Design World September 2015

www.designworldonline.com September 2015

INSIDE: SENSORS: Current industry requirements provide new direction.

PAGE 114

LINEAR MOTION: Components for linear motion systems change with the times.

PAGE 74

FASTENING & JOINING: Enable efficient structures with friction stir welding.

PAGE 106

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Insights What manufacturing can learn from Thailand Earlier this year, I was part of a journalist delegation to Thailand, the Southeast Asian country that’s probably known more for tourism than industrial engineering prowess. But after a week of touring manufacturing facilities that included such international heavyweights as Caterpillar and Nissan, I left with a new mindset for how industry needs to succeed in today’s global economy.

And here are three key areas where I found that Thailand seems to be getting it right:

1. Get government buy-in. Thailand’s government has been active in promoting investment in the private sector for decades. The Board of Investment, founded in 1966, actively works with manufacturers to encourage them to build factories in the country. There’s a liberal investment policy, with 100% foreign ownership allowed, no export requirements and no restrictions on foreign currency. Corporate tax exemptions are granted for up to eight years.

2. Education has to focus on emerging technology. Automation is here on the factory floor, so it’s best to embrace it. I toured the Institute of FIeld roBOtics (FIBO) at King Mongkut’s University of Technology, and it was refreshing to see such a variety of developments happening.

Researchers and students were looking at the entire spectrum of robotics, from industrial to medical to entertainment. Thai universities know that there is a huge need for qualified engineers in this growing industrial space in their country, and they’re actively answering the call.

3. The right kind of training for blue collar workers is critical. We hear so much about the skills gap in the U.S., so I was really impressed upon visiting the Thai-German Institute, a joint initiative of those two countries. Founded two decades ago to be a conduit for transferring hightech industrial knowledge into the country, it’s blossomed into a training center for advanced manufacturing technology. They conduct short, medium and long term training in a realistic actual factory setting. More than 300 courses are offered on subjects including fluid power, predictive maintenance, PLCs, motors and drives, mechatronics, robotics, testing, welding and CAD. There’s a fantastic 12:1 student to teacher ratio, and you’ll generally find one student per machine, so this is truly hands-on learning.

Thailand’s industrial sector still has challenges, for sure. Leaders clearly want more R&D type investment, and that may be a difficult road. It’s one thing for foreign companies like Caterpillar or Nissan to build plants there, but the tougher push is trying to break past the assembly side of manufacturing. Higher incentives are in place for R&D type ventures, and it will be interesting to see if that gamble pays off.

What do you think manufacturers need to do now to improve their bottom lines?

Pa ul J. Heney - Edi tor i al D i re ctor pheney@wtwhme di a.com

Comment on Paul’s blog on Pneumatic Tips, www.pneumatictips.com/blog

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Insights 9-15_Vs3.LL.MD.indd 4

DESIGN WORLD

September 2015

On Twitter @ DW—Editor

9/2/15 3:31 PM

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

My “big data” nightmare I have had a vision of what “big data” will look like on the factory floor. And it is scary. Really scary.

Big data, of course, refers to the use of predictive analytics to extract value from data, usually lots of data. Big data is thought to hold a lot of promise for improving industrial operations and making them more productive. In a perfect world, big data techniques will help predict when complicated production equipment will breakdown well before there are obvious signs of trouble. They will also eliminate minute variations in manufacturing processes that degrade product quality.

In reality, most manufacturers could experience big data as an expensive exercise in chasing your own tail. To understand the reason why, consider what goes on at a National Science Foundation facility in Cincinnati called the IMS Center for Intelligent Maintenance Systems. The IMS Center directs a lot of highpowered research at eliminating “fix and fail” maintenance, replacing it with “predict and prevent” efforts where production machines will never go down and the products coming off manufacturing lines never have variations.

Big data is the heart and soul of the Center’s efforts. It’s not unusual for production machines the Center studies to each generate a terabyte of data every day.

The IMS Center had a meeting a while back that makes clear the kind of intellectual horsepower it takes to profit from big data coming out of factories. The meeting was basically a room full of super-sharp Ph.D. candidates. One applied something called Mahalanobis-Taguchi methods to predict the health of rolling element bearings on a CNC machine spindle. The math got pretty deep pretty fast. He looked at a virtual sea of sensor readings while using a “Mahalanobis distance” to gauge the abnormality of patterns within them, then applied Taguchi methods to evaluate the accuracy of machine health predictions.

Another researcher predicted defect levels in semiconductor wafers using sensor data massaged with autoregressive moving averages and ensemble methods. Ensemble methods are basically machine learning techniques

using arcane numerical methods such as Bayes optimal classifiers, bootstrap aggregation and Bayesian parameter averaging.

If you get the idea these big-data projects involved a lot of rocket-science calculations, you’d be right.

Trouble is, most industrial concerns are likely to apply big data without having the insights of the IMS Center. Here’s the scene that could unfold: The people who will try to make sense of data coming from production-line machines will be engineers, not data scientists. These engineers all have had a basic statistics class in school. They have never heard of MahalanobisTaguchi or Bayesian parameter averaging. So they may just assume all the sensor readings they see follow bell curve distributions.

Real data scientists, like those at the IMS Center, would look at the bell curves and basic statistics going to these efforts and realize they are just too simplistic to ever work. But the people on the shop floor are unlikely to see the problem. The sinister thing about this scenario is that the underlying behavior models will be wrong but will occasionally lead to random correct predictions about machine behavior. The engineers involved will believe that they are just a few tweaks away from a system that works wonderfully. In reality, they will be spinning their wheels guided by a model filled with unknown unknowns.

Until expectations catch up with the reality of the resources it takes to mount a successful effort in factories, big data will be a big disappointment and possibly an expensive nightmare. DW

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

On Twitter @ DW—LeeTeschler 6

DESIGN WORLD

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September 2015

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EDITORIAL

GRAPHICS

Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor

Director, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics

Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3DPrinting

Visual Design Manager Matthew Claney mclaney@wtwhmedia.com @wtwh_designer

Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_LeeTeschler

Graphic Designer/Production Coordinator Margaret Schneider mschneider@wtwhmedia.com @wtwh_Meg

Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_Motion Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_LisaEitel Associate Editor Mike Santora msantora@wtwhmedia.com @wtwh_Michael Assistant Editor Michelle DiFrangia mdifrangia@wtwhmedia.com @wtwh_Michelle

2011, 2012, 2013, 2014

Traffic Manager Mary Heideloff mheideloff@wtwhmedia.com Graphic Design Intern Erin Cawthorne ecawthorne@wtwhmedia.com

NEW MEDIA/WEB/ BUSINESS DEVELOPMENT Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave Web Development Specialist Patrick Amigo pamigo@wtwhmedia.com @amigo_patrick Video Manager John Hansel jhansel@wtwhmedia.com @wtwh_jhansel

Business Development Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick Online Coordinator Jennifer Calhoon jcalhoon@wtwhmedia.com @wtwh_jennifer MARKETING Marketing Team Leader Stacy Combest scombest@wtwhmedia.com @wtwh_Stacy Marketing Coordinator Carli Evilsizer cevilsizer@wtwhmedia.com @wtwh_Carli Marketing and Events Coordinator Nicole Loepp nloepp@wtwhmedia.com @wtwh_Nicole Marketing and Events Coordinator Jen Kolasky jkolasky@wtwhmedia.com @wtwh_jen Content Associate Lexi Korsok lkorsok@wtwhmedia.com @medtech_lexi

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WORLD A DESIGN WORLD RESOURCE

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September 2015

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NATHAN XAVIER

l Contributors Spotlight Work with stronger joints and lighter materials

MARY C. GANNON Senior Editor Design World

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Consulting Engineer Rittal Corp.

84

IEC devices and busbars take down control-panel costs

Nathan Xavier has been with Rittal since 2007. He holds a B.S. in Mechanical Engineering and provides customer-specific applications support relating to Rittal industrial enclosure and power distribution solutions.

Mary primarily covers fluid power and interconnect technologies. She has been working as a technical editor for 10 years. She earned her B.S. in Journalism at Boston University in 1998, and has worked as a business reporter, public relations associate and now technical editor.

Linear Evolution

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MILES BUDIMIR Senior Editor Design World

1. How do you think the world will change in the next 20 years?

I think we’ll be more connected, with continually faster and faster technologies changing how we live and do business daily. I think our society will be more reliant on technology.

Miles has been in the publishing world for 15 years, more than six of which have been spent with WTWH Media. He holds a BSEE and M.A. in Philosophy. He previously worked as an engineer for a small controls company. Miles has also taught electronics courses at local tech colleges and has been teaching philosophy part time (adjunct) for about 10 years.

2. What technology do you find the most frustrating?

Wearable tech. Not only are most of these devices not that accurate or where they will probably be in the next five years, I do find them to be almost confining as we are constantly needing to check our smart watches and Fitbits. … [Even though] we clearly know we’re walking ourselves, if we’re not tracking it, it somehow doesn’t count. And that’s absurd when you think about it.

1. What part of society do you see being most affected by advances in engineering over the next decade? Computing and internet technology have changed practically every aspect of society and continue to do so every day. But also, it looks like robotics and AI, as well as medicine, will also experience revolutionary changes.

96 How IIoT is being used now

LESLIE LANGNAU Managing Editor Design World

2. What first attracted you to the world of media/publishing? Maybe it was my love of the printed word. As far back as I can remember, I’ve always been surrounded by printed matter, and my parents were big readers as well, so it probably rubbed off on me in some mysterious way.

Leslie has been an editor for more than 28 years. She has been covering the 3D printing/ additive manufacturing industry, among other subjects, since joining with Design World more than 8 years ago. She has a B.S. degree in Mechanical Engineering from Michigan State University.

1. What trend or new technology would you like to see emerge over the next five years?

I would like to see better ways to ensure/encrypt your data for security. I know a big part of the problem is users just don’t change factory settings. That’s an easy fix—prevent the device from working until they change the setting. But I for one will not buy IoT devices for the home. I simply don’t trust that any of these devices will have strong enough security levels.

2. What do you think is the biggest issue editors face today? Getting noticed in the right way. You want people to read your work and value the information and explanations you deliver. But it’s unfortunate that we have to play the “click-bait” game to get attention. …

My colleagues know I don’t like headlines such as “3D print an organ!” It’s technically not possible yet, and may never be. … Accuracy is compromised in favor of popularity.

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July 2015

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Te c h n o lo gy Fo r wa rd

Additive manufacturing moves beyond the “cool” phase Change is a constant with additive manufacturing (AM), also known as 3D printing. The next trend you’ll find is the growth of additive services. Part of this growth is driven by customer need, part by the frequent acquisitions made by the larger vendors.

Customer need turns out to be an interesting driver.

SMS Research Advisors conducted a survey on AM. The majority of the 700 respondents are familiar with additive and it’s benefits: 79% know AM gives users access to more complex design capabilities, 79% know it reduces lead time for product development and 42% see AM improving manufacturing efficiency.

But only 20% see AM improving product quality and enabling more integrated products. Still, knowledge and understanding about AM is fairly strong.

The respondent makeup was 47% engineer, 15% designer, 14% executive, 13% other and 9% project manager.

What was more interesting from this survey was the view about the choice between in-house versus outsourcing additive projects. About 73% of the respondents see service bureaus as giving them access to advanced equipment. 60% see less of an investment risk by using service bureaus (versus purchasing a machine). 53% said service bureaus are a way to produce parts that cannot be internally manufactured. And 47% said service bureaus offer access to additive expertise.

Selling AM machines to end users may no longer be the main goal of vendors in this industry. Instead, a trend may be developing where vendors offer AM production services for users.

Survey respondents noted several challenges with AM machines: 63% said current costs were an issue, while 58% felt that future costs won’t be as much of an issue. Post-processing and material availability were seen as challenges now and in the future, with the future coming in at 34% and 46% respectively.

Noted Joe Allison, CEO of Stratasys Direct Manufacturing, such challenges indicate that the industry should change the conversation from one of emphasizing AM’s technical benefits to that of AM’s overall business value.

I recently had the opportunity to visit the fairly new Stratasys Direct Manufacturing company at its Austin plant. This company emerged from the acquisitions of Solid Concept, RedEye and Harvest Technologies. It is one of the largest service bureaus in the U.S. In the past 12 to 18 months, it has tripled its capacity to prototype and build customer parts, with much of that growth coming in metals.

Imagine a company with the following machines: 13 Polyjet, 42 stereolithography, 43 laser sintering, 97 extrusion, 14 direct metal laser sintering, 23 CNCs and 13 injection molding systems. Yeah, impressive.

In addition to these technologies, the company also offers urethane casting, tooling and finishing services. Several of the laser-sintering machines are DTM versions before that company was bought by 3D Systems.

Stratasys Direct Manufacturing is additive technology agnostic. Most of the direct metal lasersintering machines come from EOS. Metal additive projects are more likely to be outsourced to a service bureau than done in house. Many of the reasons have already been mentioned—access to advanced equipment, less risk and the ability to manufacture parts not possible internally.

The survey indicates that AM is moving to the next phase. First, it changed how prototypes were made.

Now it’s changing how production parts are made.

The survey also indicates that many engineers and designers are optimistic about using AM. They generally believe it will play an important role in manufacturing in the future. DW

Le sli e La n g n a u - M a n ag i n g Edi to r lla ng na u r@wtwh m edi a .co m

On Twitter @ DW—3Dprinting 12

DESIGN WORLD

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Co nten t s |

September 2015 • vol 10 no 9

|

designworldonline.com

F E AT U R E S MOTION 74 LINEAR Linear Evolution From nanometer resolution to high-force actuation, components for linear motion systems are changing with the times.

114

SENSORS Industrial sensing evolves to address the IoT Current industry requirements are providing new direction for industrial sensors

84 ELECTRONICS

Busbars and IEC devices take down control-panel costs More North American engineers than ever use IEC devices instead of NEMA components— especially with modular busbars to replace

126

MACHINE VISION Image dimension measurement system makes tolerance checks faster When a French manufacturer required precise measurement of medical parts, a new imaging system brought the flexibility to accurately measure 99 points in mere seconds.

traditional wiring for controls.

ETHERNET 96 INDUSTRIAL How IIot is being used now The latest development of industrial Ethernet is how it will be a part of the Industrial Internet of Things (IIoT).

& JOINING 106 FASTENING Work with stronger joints and lighter materials

ON THE COVER

Enable consistent, strong and more efficient structures with friction stir welding.

Busbars and standardized IEC devices let integrators build systems less expensively than ever.

Image courtesy of Rittal

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CONTENTS SEPTEMBER 2015_first page_Vs3.LL.indd 14

2015

2015

2015 O N LIN E

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D E PA R T M E N T S 4 Insights 6 Teschler on Topic

11 Contributors 12 Technology Forward

18 Green Engineering

40

22 Engineering Exchange 24 Design For Industry 40 Design Notes

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50 Coupling Notes 54 CAE Solutions 62 Internet of Things 131 Product World

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Contents SEPTEMBER_second page_Vs1.indd 16

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» Gree n E n g i n e e ri n g

Energy storage solutions for solar-powered devices n By: Sol Jacobs • VP and General Manager • Tadiran Batteries Energy harvesting is seeing dramatic growth, especially for wireless devices that use small photovoltaic systems to draw energy from sunlight. The energy storage solutions being used in photovoltaic systems are also applicable to similar devices that harvest energy from vibration/ motion, heat differential and RF/EM signals.

There are five basic components to an energy harvesting device: sensors, transducer, energy processor, microcontroller and optional radio link. The sensors detect and measure environmental parameters such as motion, proximity, temperature, humidity, pressure, light, strain vibration and pH. The transducer and energy processor work in tandem to convert, collect and store the electrical energy in either a rechargeable lithium battery or a supercapacitor.

The microcontroller collects and processes the data. The radio link communicates with a host receiver or data collection point using RF or cell phone technology, typically in conjunction with low-power communications protocols such as ZigBee, Green Power, Bluetooth LE and 6LowPan, which all operate within a peak power range of 10 µW to 100 mW. The power available through energy harvesting is sometimes limited and variable, so design engineers need to find ways to conserve energy wherever possible. This is possible through power-efficient microprocessor and component design, as well as by programming the device to remain in a dormant state that draws little or no energy, then to periodically query the data, awakening only if certain thresholds have been exceeded.

To determine if a remote wireless application is well suited for energy harvesting, several factors need to be considered, including the reliability of the device and its energy source, the expected operating life of the device, environmental requirements, size and weight considerations, and total cost of ownership. Remote wireless applications characterized by a processor that awakens periodically often draw a big, brief pulse of current at periodic intervals. The current pulse arises when the processor awakens and transmits its data. The current levels can be on the order of hundreds of milliamps or more for time periods ranging from fractions of a second to several seconds.

These sorts of power levels necessitate some form of energy storage capability using either a rechargeable Lithium-ion (Li-ion) battery or a supercapacitor.

Supercapacitors, also known as ultracapacitors or Electric Double Layer Capacitors (EDLCs), are often used to backup memory in mobile phones, laptops, digital cameras and other consumer devices. Supercapacitors work by storing energy in an electrostatic field rather than in a chemical state.

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» Gree n E n g i n e e ri n g Generally speaking, supercapacitors are not well suited for long-term deployment in industrial wireless devices. They excel

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Additionally, their energy density is low and they have a high self-discharge (up to 60% per year).

Supercapacitors linked in series also require balancing circuits. As a result, supercapitors are much bulkier than comparable industrial grade Liion batteries.

Certain energy harvesting applications may be well suited for standard consumer-grade Li-ion cells that are relatively inexpensive and widely available. However, consumer grade LI-ion batteries have notable limitations. These limitations include a life expectancy of less than five years and 500 recharge cycles, and a temperature range of only 0 to 60° C. Industrial-grade Li-ion batteries are probably a better bet if the wireless device is intended for use in remote, inaccessible locations where battery replacement is difficult or impossible, or in extreme environmental conditions. These ruggedized batteries can deliver up to 20 years of operating life with 5,000 full recharge cycles, along with an expanded temperature range of -40 to 85° C. They can also provide high-current pulses (5A for a AA-size cell) common in remote energy harvesting uses. Industrial grade Li-ion cells also feature glass-to-metal hermetic seals, whereas consumer rechargeable Li-ion batteries use crimped seals that may leak.

Industrial grade Li-ion batteries are generally recommended for applications that involve extreme temperatures and remote, inaccessible locations, where the labor to replace a battery can often far exceed the cost of the battery itself. Industrial grade Li-ion batteries also make sense for use in large-scale projects, where their 20-year operating life can eliminate multiple rounds of scheduled battery change-outs, while also reducing the potential risk of compromised data and lost revenue due to battery failure. All these factors should be considered when estimating the total cost of ownership, an important yardstick when choosing between consumer grade and industrial grade Liion batteries. DW

20

DESIGN WORLD

September 2015

9/2/15 4:12 PM

Your Catalyst to Innovative Motion Control Solutions A single resource for integrated mechanical, electronics, drives and software, with experienced customer support for the development of simple-to-sophisticated automation systems.

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At Catalyst Motion Group We are able to accomplish this through coordinated utilization of our extensive engineering resources and vertically integrated manufacturing resources.

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And, with our engineering capability, if we don't have it ...we can develop it!

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www.designworldonline.com September 2015

INSIDE: SENSORS: Current industry requirements provide new direction.

PAGE 114

LINEAR MOTION: Components for linear motion systems change with the times.

PAGE 74

FASTENING & JOINING: Enable efficient structures with friction stir welding.

PAGE 106

Modular

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military/aerospace

1

0

» Design for Industry

machine tool

Encoder for machines with loose mechanical motion

Some machines have a significant amount of flexure near the area requiring motion feedback. The MSA 37x series linear motion feedback encoder system was designed for machines with loose mechanical motion during operation. These encoders suit motion applications such as press brake and metal forming/ bending machines.

The encoders include a bearing set internally for guiding the scanning optics, and a bearing set externally for the attachment of a coupling rod that affixes to the machine, thereby allowing for measurement of the moving elements of the machine.

Digital TTL resolutions of 5 and 1 µ are possible, with accuracies up to ±10 µ. The encoders also have magnetic limit switches that can be used to send end of travel signals to the control. Reference marks can be in the center, on either end of travel, or every 50 mm. The encoders are designed to handle large shock and vibrations, and the series is ROHS compliant. DW

WHAT DO YOU THINK?

RSF Elektronik rsf.at/en Connect and discuss this and other design engineering issues with thousands of professionals online

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Your CatalystPRECISION to Innovative SURGICAL Motion Control Solutions RE-DEFINED A single resource for integrated mechanical, electronics, drives and ® Haydon Kerk Motion Solutions software, with experienced customer support for the development Micro Series Lead Screw Technology of simple-to-sophisticated automation systems.

For extreme control in medical applications including infusion pumps, intravenous therapies, surgical robotics, radiology, opthalmic instruments, microscopes, and other instruments that require ultra-precise motion control in confined spaces.

2 mm (5/64-in) diameter Micro Series Standard Lead Screw Assembly C

Micro Series BFWB Barrel Nut Assemblies

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Micro Series BFWR Rectangular Nut Assemblies

At Catalyst Motion Haydon KerkGroup Motion Solutions Micro Series lead screw products enable a whole new range of micro-solutions that facilitate

big advances in medical technology. The Micro Series provides precise control, reduced power consumption, and weight reduction without sacrificing performance or reliability. Prototype kits are now available in our online store and shipments can We are able to accomplish this through coordinated utilization of our extensive engineering resources and vertically integrated manufacturing resources. be made in 24 hours.

We put it all together – customized motion systems that include stepper motors, brush and brushless DC motors, linear mechanics, drives, electronics and an For custom, application-specific needs,Our Haydon Kerk and offers in-housein-house engineering and manufacturing machining, extensive array of peripheral system components. considerable wide-ranging manufacturing capabilities allowincluding us full control of the entire process, making,ofand injection molding capabilities, strategically frommold development prototypes to delivery of fully tested production units. integrated to satisfy your needs for a hundred, a thousand, orwith a million assemblies.

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military/aerospace

Two gallium nitride (GaN) high electron mobility transistors (HEMT) promise to solve several long-standing issues for radar systems using traditional travelling wave tube (TWT) amplifiers. GaN-based solid-state amplifiers operating at 50 V are not prone to the failures seen with high voltage (kV) TWT power supplies, and thus have longer lifetimes. Also, these transisters have near instant on capability—with no warm up—and have longer detection ranges and improved target discrimination.

Conceived to enable these benefits, these two GaN RF transistors were engineered to deliver high power and efficiency in a small package size. The first device, a 350-W/50-Ί fully matched GaN HEMT is the highest power C-Band transistor available on the market. The second, a 500-W/50-Ί GaN HEMT, is the highest power S-Band transistor fully matched to 50 Ί in a single-ended package of its size.

According to the manufacturer, the C- and S-Band products break power records for GaN power and efficiency performance housed in a small 50-Ί package. This efficient power enables the economical combination of transistors to achieve multi-kilowatt power amplifiers required for defense, weather and air traffic control radar.

Offering pulsed saturated power performance typically greater than 400 W, the CGHV59350 is most often used in ground-based defense and Doppler weather radar systems. The 50-Ί, fully matched GaN HEMT operates over a 5.2 to 5.9 GHz bandwidth, exhibits 60% typical drain efficiency, and is packaged in an industry standard 0.7 x 0.9 in. ceramic/metal flange package.

Delivering 700 W of typical saturated RF pulsed power, the CGHV31500F is offered for air traffic control radar systems. The 50-Ί, fully matched GaN HEMT operates over a 2.7 to 3.1 GHz bandwidth, exhibits 12 dB power gain, and is packaged in an industry standard 0.7 x 0.9 in. ceramic/metal flange package. DW

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DESIGN WORLD

RETAINING DEVICES & maintenance & assembly tools

High power RD devices solve TWT radar issues

September 2015

POWER TRANSMISSION

 

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9/2/15 1:14 PM

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packaging

» Design for Industry

Motors key to fast arm pallet wrapper The engineers at Technowrapp had an idea that, if successfully executed, would result in the world’s fastest arm pallet wrapper. But they also wanted to ensure their Runner Arm would be simple to operate and easy to maintain.

In the Runner Arm automatic rotary arm pallet wrapper, the engineers created a device that can wrap 136 pallets/hour with 10 turns per pallet, stabilizing a pallet with just 76 g of stretch wrap film (value achieved with 15 μm film).

The rotary arm with centripetal contrast ring contains and guides the arm as it moves and makes it possible to reach 45 rpm, combining this with low structural stress. The cutting and welding pliers operate on the moving load, contributing to the increase in speed and efficiency of the work cycle.

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DFI 9-15_Vs6.LL.MD.indd 28

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September 2015

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3/6/14 4:12 PM

9/3/15 4:44 PM

Power Review

Altra Industrial Motion Vol. 4 | No. 3 | 2015

The Power Brands in Power Transmission

BOSTON GEAR Original “Domed Crown” Stainless Steel 700 Series Reducer

Featured in this Edition...

Boston Gear Original “Domed Crown” Stainless Steel Reducer Formsprag Rebuild and Overhaul Service Twiflex USA Brake Calipers TB Wood’s Sure-Flex® Plus Huco Oldham Couplings Warner Linear Programmable S-Track Linear Actuator

®

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Find Altra Industrial Motion on:

Altra Industrial Motion Ameridrives Couplings Ameridrives Power Transmission Bauer Gear Motor Bibby Turboflex Boston Gear

Altra Industrial_#1_9-15.indd 29

The Power Of Experience

Delroyd Worm Gear Formsprag Clutch Guardian Couplings Huco Dynatork Industrial Clutch Inertia Dynamics

Kilian Manufacturing Lamiflex Couplings Marland Clutch Matrix International Nuttall Gear Stieber Clutch

Svendborg Brakes TB Wood’s Twiflex Limited Warner Electric Warner Linear Wichita Clutch

For more information contact us at: info@altramotion.com or visit www.altramotion.com

Scan to download the interactive version of the Power Review

9/2/15 3:50 PM

Boston Gear Original “Domed Crown” Stainless Steel 700 Series The Boston Gear 700 Series Worm Gear Speed Reducer has been a foundation in food and beverage applications for decades. As a leader in worm gear technology, Boston Gear continues to improve product performance by developing innovative designs to meet more stringent demands and anticipated tightening of federal regulations in the food and beverage industry.

Utilizing the often imitated but never equaled 700 series worm gearing combined with new exterior designs, the new stainless steel 700 series performance has been optimized to withstand the harshest washdown conditions! The new line incorporates features that were designed with the input of some of the food processing industries’ leading players to maintain optimal performance in the toughest caustic environments.

The Stainless Speed Reducer is NSF International certified and the Stainless Gearmotor is UL / ULc Certified.

Boston Gear Stainless Gear Drives Enhance Food Safety The Clean Product Advantage • NSF Certified • Sealed motor flange Certified • Electropolished exterior finish • Covered hardware P-7756-BG • Maintenance friendly features Process improvements have yielded the BEST standard leadtime for stainless worm gear reducers. ®

The Boston Gear Service Advantage • Standard 2 day delivery on any cataloged SS700 Series product • Same day break down service • After hours/holiday hotline • Stocked at local and regional distribution centers

For more information download P-1998-BG & P-7756-BG from www.AltraLiterature.com or visit www.BostonGear.com

Laser marked nameplate provides worry-free part identification while maintaining a smooth, unetched surface. Rounded housing prevents foreign matter adherence and fluid accumulation.

Formsprag Rebuild and Overhaul Service Send Formsprag your old clutches to make them like new again. The difference is not just cosmetic.

All internal components – sprags, energized springs, retainer, bearings, seal and hardware are refurbished or replaced to new performance standards. The inner and outer races are ground to specifications noted below so that no wear patterns remain.

• Sprag Surface is hardened to 58-62 Rc • Sprag Surface finish is 15-25 microinches • Sprag Surface taper limit is 0.0002 inch per inch Consider these advantages: - Price – A guaranteed savings of at least 30% or more versus new product - Speed – Clutches are received, inspected and rebuilt in the shortest possible time frame

- Warranty – 1 year on labor and materials, same as new clutches - Emergency Breakdown Program – All products that are air freighted into the

Warren plant are processed immediately and, in most cases, are able to be rebuilt within a 24-hour period.

For more information download Application Guide P-1465-FC from www.AltraLiterature.com

Altra Industrial_#2_9-15.indd 30

9/2/15 3:51 PM

Twiflex USA Brake Calipers Twiflex offers the largest range of industrial disc brake calipers in the world. Spring applied units may be retracted pneumatically, hydraulically or electrically (depending on caliper design) while most direct acting brakes have some form of positive retraction device.

Pneumatically Applied Brakes are best suited for light to medium stopping duties and for tensioning applications where a high degree of control is required.

Hydraulically Applied Brakes address higher torque requirements, while spring applied calipers are essential where braking must be maintained in the event of supply system failure Mechanically Applied Units are suitable for light tensioning duties or where no external power is available; they may also be specified when designers wish to use their own means of actuation.

For more information download P-1648-TF from www.AltraLiterature.com

Call Twiflex Toll-Free: 844.723.3483

Sure-Flex® Plus: A New Standard for Performance For over 50 years, TB Wood’s has led the coupling industry with the original TB Wood’s Sure-Flex design. And we haven’t stopped innovating: this industry favorite just got even better.

Our new Sure-Flex Plus EPDM and Neoprene sleeves are best-in-class for coupling performance and value. Here’s why: High Torque Rating 30% Increased Torque Rating Provides longer service life in demanding applications, reducing required maintenance and associated replacement cost.

Longer Life Sure-Flex Plus Lasts Over 3X Longer than the Competition Extensive testing shows our sleeves outlast the imitators. More uptime means less costly downtime.

Better Value Save Money Using a Smaller Coupling The increased rating of the Sure-Flex Plus sleeves lets the user choose a one-size-smaller coupling for over 50% of common applications. This lowers the cost of both initial purchase and future sleeve replacement.

TB Wood’s Incorporated

Interchangeable Retrofits to Existing Flanges No need to replace the full coupling – The Sure-Flex Plus sleeve design is 100% compatible with the current industry standard that TB Wood’s created over 50 years ago.

For more information download P-7819-TBW from www.AltraLiterature.com or visit www.TBWoods.com

Proven Oldham Couplings 25% Higher Torque Just introduced, the Oldham lateral offset couplings are designed to handle 25% higher torque than their forerunners.

Previously, a peak torque rating of 44Nm was the highest available.

Now, 55.36Nm is possible using a specially designed larger diameter disc.

The Oldham is precision engineered throughout and comprises two hubs with inward facing tenons. These engage with matching slots spaced at 90° in a central lightweight torque disc. A hard, low friction facing on the working surface guarantees long, trouble-free operation.

Typical applications range from the incremental control of fluid valves to positional systems in machinery, robots and slide tables. They can also be applied to microstepper and closed loop servo systems and, to a lesser extent, half and full step motor drives.

Altra Industrial_#3_9-15.indd 31

Programmable S-Track Linear Actuator Warner Linear has expanded the S-Track linear actuator product line with the addition of a new programmable model.

An easy-to-use integrated keypad allows operators to set and reset end of travel positions as well as two intermediate stops.

New S-Track electric actuators are designed for better control and quieter operation in general duty applications including medical, industrial, turf & garden and recreational vehicles.

For more information download catalog P-1581-WL from www.AltraLiterature.com or visit www.WarnerLinear.com

9/2/15 3:53 PM

Warner Electric www.warnerelectric.com

Matrix International www.matrix-international.com

Inertia Dynamics www.idicb.com

Warner Linear www.warnerlinear.com

Altra Industrial_#4_9-15.indd 32

Altra Electric Clutch Brake brands offer the largest selection of clutches, brakes and linear actuators available from a single source...worldwide.

Warner Electric, Matrix International, Warner Linear and Inertia Dynamics have over 60 years combined experience designing and manufacturing technically-advanced, cost-effective braking and positioning systems.

State-of-the-art Altra clutch and brake solutions are utilized on drivetrains in an array of global markets including material handling, packaging machinery, food & beverage, elevator & escalator, turf & garden, agriculture and off-highway, forklift and medical.

www.AltraMotion.com

9/2/15 3:54 PM

packaging

To achieve these speeds, the engineers used Bonfiglioli’s C, W, and BE/BN motor series for the pallet and vertical carriage movement as well as the ring rotation and the servo-assisted tensioning systems.

The motors were used for the tensioning, feeder, and plier carriages, as well as for the presser and linear roller.

The carriage system is equipped with Bonfiglioli’s W63 and BN_FD Motors with a motor power of 0.75 kW. In addition, the tensioning and plier carriage are also equipped with W63 and BN_FD Motors, with motor powers of 0.55 kW for the tensioning carriage and 0.37 kW for the plier carriage; the tensioning carriage also uses a W86/BE motor with a motor power of 1.1 kW.

The arm rotation uses Bonfiglioli’s W110/BN_FD motor series with 4 kW of motor while the presser uses a W63 BN_FD motor with 0.55 kW of motor power. The linear roller uses the C22 BE series with 0.75 kW of power. These various motor solutions have helped the Runner Arm achieve high speeds while maintaining low structural stress. DW

WHAT DO YOU THINK?

Bonfiglioli bonfiglioli.com

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

Bring Your Machine To Life With Custom Drives

rol Al

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Aerotech can accommodate your custom automation controller needs by using our plug-in architecture for specific algorithms such as 2D bar code, interfaces to non-standard sensors, signal outputs synchronized to servo sample time, and more. If you have a need for custom hardware or firmware in your drive package, contact Aerotech today.

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In our concept machine at right, Aerotech’s drive packaging can be customized to fit into the wasp body with special algorithms developed at the firmware layer for flight control.

ed C

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Contact our Control Systems Group at 412-967-6839 or sales@aerotech.com to discuss your application today, or see go.aerotech.com/csg46 AH0315C-CSG

Dedicated to the Science of Motion

AH0315C-CSG-WASP-Custom Drives-8_5x4_75.indd 1

8/5/2015 9:13:38 AM

September 2015

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DESIGN WORLD

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9/3/15 4:45 PM

4

0

» Design for Industry

packaging

Gearmotors deliver efficiency in packaging applications In packaging, the demand for smaller, lighter, reliable and energy-efficient power transmission components is constant. A new entrant into the efficient power transmission market is the ie3 premium efficiency gearmotors, which offer increased efficiency over standard IE1 models throughout the speed range and initiate less mechanical stress, which directly translates into long-term energy savings. The ie3 gearmotors run cooler and with less noise and, as they are sealed for life and require practically no maintenance, significantly reduce costly downtime. Two key factors enhance the durability of these gearmotors: ultralong-lasting e-coat paint and lubrication through premium H1 food-grade grease.

Key attributes of these gearmotors include: • light, reliable and compact in size • high torque at low speed • sealed for life for maximum efficiency and reduced labor • standard high-grade grease for lifetime lubrication and reduced maintenance/downtime • high-quality, durable, e-coat paint to withstand the toughest environments • hypoid gearing for efficiency DW

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

Brother Gearmotors brother-usa.com/gearmotors 34

DESIGN WORLD

DFI 9-15_Vs6.LL.MD.indd 34

September 2015

WHAT DO YOU THINK?

www.designworldonline.com

9/2/15 1:16 PM

Graybar 7-15.indd 35

9/2/15 3:59 PM

4

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» Design for Industry

energy

Capacitors for high temperature applications Military and commercial markets continue to demand capacitors capable of high-reliability, long lifetime performance at operating temperatures in excess of the current 125° C. The AT Series MLCCs offer two new case sizes (0603 and 0805), two new voltage ratings (16 V VHT 250° C and 25 V VHT 200° C), and new C0G and VHT temperature coefficients that differentiate the 200° C parts from the industryleading 250° C parts.

These high temperature MLCC capacitors reliably test data at 250° C, and are rated at both 250° C and 200° C for de-rating schemes. The series

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3/6/2015 11:34:56 AM 9/4/15 9:12 AM

# Zero-Max_full_pgs_r10_Design World 2/12/10 4:02 PM Page 1

Your ball screw Your servomotor Our coupling

Together a winning combination for today’s servomotor applications.

Our ServoClass® couplings have been recently redesigned to enable your actuator to go even faster and achieve the positional accuracy that will take your designs to the next level. Our couplings will do all this with low bearing loads.

3 New sizes now available.

Now, size, select and see the right ServoClass® coupling solution for your application with Zero-Max 3D CAD files.

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Personal CNC Prototyping - Product Design - R&D - Engineering Eisertech, a medical device company in San Diego, CA, designs and manufactures spinal implants and surgical instruments with the help of their Tormach PCNC 1100. What started out as garage shop prototypes has grown into a successful medical device product line.

To read more about this story, and to see what others are doing with their PCNC mills, visit www.tormach.com/design.

PCNC 1100 Series 3

Titanium bone screws and surgical spinal implants manufactured by Eisertech LLC.

exhibits high current-handling capabilities, high volumetric efficiency, high insulation resistance, and extremely low ESR and ESL, in addition to high frequency performance and capacity retention with frequency, and low parasitics and dc leakage for circuit stability and efficiency.

Now available in an extended range of sizes (0603 to 2225), values (100 pF to 1 ÂľF), voltages (16 to 50 V), and dielectrics (C0G and VHT), AT capacitors perform in demanding automotive, avionics, aerospace and energy applications.

They are suitable for: automotive applications, including under hood power, engine control units, and hybrid electric and plug-in electric vehicles (HEVs and PEVs); avionics and aerospace applications, including transducers, engine controls, spacecraft, and flap and brake controls; and energy applications, including downhole oil exploration, logging while drilling, geophysical and geothermal probes, seismic sensors, and solar and wind energy conversion.

The series can also be used as decoupling and bypass capacitors and for dc filtering in motor drives and high frequency ripple currents, and is also well suited for use in sensors and timing circuits, high-pulsed current circuitry, dc/dc power conditioning converters, dc current sensing and subsystems, ac/dc converters, and dc/ ac inverters.

AVX Corp. avx.com

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PCNC 770 Series 3 PCNC mills shown here with optional stand and accessories.

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DFI 9-15_Vs6.LL.MD.indd 38

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September 2015

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With superior performance and rugged durability, the Q4X provides reliable detection when other sensors can’t. An FDA-grade stainless steel housing means the Q4X stands up in the most aggressive washdown procedures. The Q4X is the right choice for your most challenging applications. Š 2015 Banner Engineering Corp., Mpls, MN USA

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» D e s i g n N o te s

Mike Santora • Associate Editor

By using vario

us

machines and a PCNC 1100 m ill from Tormac h, the NASA team can quickly prototyp e and develop diffe rent versions of unique compone nts. “We’re mak ing parts for flight pr ojects, high-alt itu de balloons, and pr ototyping things for an eventual sate llite mission,” sa id Alan Kogut.

Personal CNC mill helps NASA boldly go...

Both the costs and risks of spaceflight are always high. So what do you do when you don’t have the time, budget and room for error to outsource the machining of ever-evolving prototypes?

NASA Goddard Spaceflight Center uses an array of manufacturing and engineering tools to develop their one-off, highly customized technologies. In fact, they use a shop that is connected to their labs, which houses an array of manual milling, CNC and production machines.

According to Alan Kogut, an astrophysicist at the center, without their attached shop they would be relegated to outsourcing the creation of various components and instruments. By using various manual machines and a PCNC 1100 mill from Tormach, the team can quickly prototype and develop different iterations of unique components. “We’re making parts for flight projects, high-altitude balloons, and prototyping things for an eventual satellite mission,” he said.

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The Goddard Spaceflight Center is producing projects like PIPER (the Primordial Inflation Polarization Explorer) to measure the linear polarization of the cosmic microwave background. The satellite instrument looks for the signal from primordial gravity waves excited during an inflationary epoch shortly after the Big Bang.

They fly these telescopes in containers of liquid helium, which keeps the temperatures near absolute zero (about 1.5 K). The cold temperatures keep the telescopes’ heat radiation from interfering with the radiation the researchers are trying to see, which is limited to a few parts per billion.

For PIPER’s precision sensors and instrumentation to operate correctly at such low temperatures, the team needs to compensate for differential contraction of components in their designs. Brackets and fixtures holding sensitive instruments for getting data back to Earth are housed in these icy temperatures. If the differential contraction is not compensated for in the design, signals and www.designworldonline.com

9/2/15 1:32 PM

have at Goddard The teams ch mill with their Torma ed iz m o st cu inding. ure for wire-w a unique fixt

measurements could be lost in the vastness of outer space. This is where it’s advantageous to have a machine shop so close—faster, less expensive prototypes and flight-ready final components.

The teams at Goddard have also customized their Tormach mill with a unique fixture for wire-winding. According to Kogut, they have to wrap a couple miles of thin wire—about 1⁄3 as thick as a human hair—in an extremely uniform manner for the satellites. “You take a couple miles of this wire and you wrap it around to make a whole bunch of parallel strands over large distances,” he said. This creates a grid that is about 2 ft across.

The strands have to be held to a plane so they form a flat surface (to a few millionths of a meter) and the wires have to be spaced accurately to about 4 or 5 µm, which is where the need for CNC comes into play. “We are able to use the mill to both cut the fixture that the wires get wound onto, and then use it to put the wires in place,” said Kogut.

Using a high-accuracy CNC machine is vital to the proper operation of a component like this. As the maker movement has emerged, both manual and automated machines have become more n tion Polarizatio Primordial Infla he (t e ER th IP P of n The atio the linear polariz s re su ea m ru), st er in Explor tellite ckground. The sa ba e av w ro ic m ity cosmic primordial grav the signal from . ment looks for ng g Ba ortly after the Bi waves excited sh ainers of liquid nt co in lescopes te e es th fly ey Th ar absolute temperatures ne e th g in ep ke , scopes’ helium ld keeps the tele co e Th .

K) 1.5 n zero (about ith the radiatio om interfering w fr n io to at d di ite ra lim at is he which e trying to see, ar s er ch ar se re the billion. a few parts per

Design Notes 9-15_Vs6.LL.MD.indd 41

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» D e s i g n N o te s

readily available and less expensive. It has also ushered in prosumer-style machines, which are capable of production-quality work, but available on a budget and in a footprint that small businesses and consumers can handle.

NASA has been able to circumvent traditional manufacturing within this facility, allowing them to prototype, produce and innovate faster and on a tighter budget.

“These projects are not high-budget projects, but they still involve a lot of parts that are sort of custom-made to fit,” Kogut said.

“Rather than going to all the trouble of figuring out exactly what we want, making up shop

drawings, sending it out to a shop, getting a quote, and then getting the part produced, we decided to just get our own machine that we could make our own brackets and fixtures with a much faster turnaround.”

Though they don’t use many exotic materials—mostly aluminum, stainless steel, copper and the occasional block of titanium— NASA has to keep their tolerances tight and their budgets even tighter. DW Tormach tormach.com

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Edited by: Mike Santora • Associate Editor

» D esi gn Notes

Negative-stiffness isolators a plus for CMM system gativeK BM-8 ne The Minus tor provides bration isola l, stiffness vi ance vertica tion perform la o is y z ll H ta .5 0 ng a to orizontal, usi and 0.5 Hz h no air or e ical syst m— n a ch e m e passiv quired. electricity re

Manufacturers need to control processes to produce a consistent, reliable product. Where precision surface engineering is required, surface measurement is a key part of maintaining control of the process.

Laser interferometers are widely used in industry for the measurement of small displacements, refractive index changes and surface irregularities. When built into inspection equipment, like a coordinate measuring machine (CMM), a laser interferometer system reports the surface condition of a product with more accuracy than any other method. These CMM laser interferometry surface measurement systems, however, can be negatively affected by plant low-frequency vibrations, which can distort the interferometry measurements and deliver inaccurate readings.

One specific CMM system, designed and manufactured by Arnold Gauge Company, has directly addressed the vibration issue. The company’s CMM system maintains its throughput by integrating a compact negative-stiffness vibration isolation platform.

“Every second, the laser in the CMM is generating about 2,000 readings,” said Michael Bruins, president of Arnold Gauge Company.

“These readings, taken at the micron level, are displayed on a chart and plotted against the pre-engineered ideal surface. Due to these

» Transmissibility for negative-stiffness isolator versus an air table

Schematic of negative-stiffness isolator Top Plate

Vertical

Upper Column Plate Negative-Stiffness

Flexures

Rigid Support Beam-Column

Support Tube (Threaded) Base Leveling Screw

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Design Notes 9-15_Vs6.LL.MD.indd 44

micro-tolerances, any vibrations on the plant floor, such as from forklifts, are going to be detected in the readings. To counteract these vibrations, we selected negative-stiffness vibration isolation.”

Negative-stiffness vibration isolation systems enable vibration-sensitive instruments, such as laser interferometers, to operate in harsh conditions and severe vibration environments.

Negative-stiffness isolators, engineered

by Minus K Technology, use a completely mechanical concept in low-frequency vibration isolation; they do not require electricity or compressed air. There are no motors, pumps or chambers, and no maintenance because there is nothing to wear out. They operate purely in a passive mechanical mode.

In this vibration isolation system, verticalmotion isolation is provided by a stiff spring that supports a weight load, combined with a negative-stiffness mechanism. The net vertical stiffness is made low without affecting the static load-supporting capability of the spring.

Beam-columns connected in series with the vertical-motion isolator provide horizontalmotion isolation. A beam-column behaves as a spring combined with a negative-stiffness mechanism.

The isolator provides 0.5 Hz isolation performance vertical, and 0.5 Hz horizontal, using a totally passive mechanical system.

For an isolation system with a 0.5 Hz natural frequency, isolation begins at about 0.7 Hz and improves with increase in the vibration frequency. The natural frequency is more commonly used to describe the system performance.

Negative-stiffness isolators resonate at 0.5 Hz. At this frequency, there is almost no energy present. It would be rare to find a significant vibration at 0.5 Hz. Vibrations with frequencies 44

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above 0.7 Hz (where negative-stiffness isolators begin isolating) are rapidly attenuated with increase in frequency.

Also, transmissibility with Negative-stiffness isolators is substantially improved over air systems. Transmissibility is a measure of the vibrations that are transmitted through the isolator relative to the input vibrations. The negative-stiffness isolators, when adjusted to 0.5 Hz, achieve 93% isolation efficiency at 2 Hz, 99% at 5 Hz, and 99.7% at 10 Hz. DW Minus K Technology minusk.com

September 2015

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Edited by: Mike Santora • Associate Editor

» D esi gn Notes

Tips for maximizing slip ring lifecycle and performance Do your slip rings run trouble free for their expected lifecycle? If you answered “no,” you’re not alone. Many engineers who work with rotating machines experience slip ring problems or downtime at some point. The good news is you can easily keep your slip rings running smoothly for the long haul by following just three simple steps. All you need to do is configure, install and maintain the slip rings properly.

do not always consider the actual Unfortunately, even experienced operating conditions when setting engineers sometimes configure slip maintenance expectations, causing rings without paying enough attention them to overstate or understate to how the device will be installed on service intervals. The bottom line is the machine. It turns out that different that slip ring maintenance starts on mounting orientations call for different the drawing board, not on the factory slip ring configurations. And if you get floor. the configuration wrong, the slip ring Here are some simple design may suffer from recurring signal loss strategies that will help you ensure problems and a shortened working life. the longest possible life and lowest Maintenance isn’t always possible maintenance for the slip straightforward either. It’s easy to lay rings used on packaging and other the blame for poor maintenance on industrial machines. end-users, but the truth is some slip One of the first steps is to eliminate ring designs are inherently difficult configuration errors. To maximize to maintain. What’s more, engineers

gnal channels Keeping the si the an awareness of on top requires nging ha al ic ation. Vert mounting orient icular rt ientations in pa and standing or to nt configurations will need differe remain signal channels ensure that the th seals above the labyrin

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» D e s i g n N o tes

design flexibility and minimize size, s enance interval modern slip rings typically have a Nominal maint gh if you plan on modular design. Modularity lets users may not be enou nal g at high rotatio running a slip rin freely combine power and signal s re tu ed tempera speeds, at elevat channels to meet their exact application ts nmen . aminated enviro nt co in or every additional 100 million revolutions or requirements. s ating condition Aggressive oper or yearly. n For example, the SR085 slip ring io at degrad n lead to signal ca The maintenance regimen itself is from Kübler lets users configure up to l failures. even mechanica simple: Just vacuum out any dust that has 20 channels divided between load and accumulated on the slip ring load and signal signal. Each additional module adds just contacts. The slip rings used in most packaging 10 mm to the slip ring’s base axial length of 64.5 mm. or industrial applications don’t even require But even with all the design flexibility of modular channels remain above the labyrinth seals. any oil on the contacts. slip rings, there are still common configuration With horizontally mounted slip rings, gravity While it’s true that engineers have little mistakes. Often, engineers will configure a slip ring doesn’t help or hurt the dust situation much. control over whether end-users will ultimately without regard for its mounting orientation.

You can locate the signal and load channels adhere to the recommended maintenance The reason orientation matters is that the signal in any order that makes sense for your intervals, there are a couple of key upfront channels are more susceptible to contamination from application. dust and other particulate than the load channels.

Another threat to smooth slip ring operations design factors related to maintenance: Duty cycle. Nominal maintenance Accumulated dust can degrade the signal integrity is a disregard for recommended maintenance and shorten the maintenance intervals and lifecycle intervals. We recommend the first maintenance intervals may not be enough if you plan on running a slip ring at high rotational speeds, of the slip ring. at 50 million revolutions or after one year of at elevated temperatures or in contaminated That’s why it’s important to configure slip rings operation, whichever comes first. Subsequent environments. These aggressive operating with the signal channels above other modules—such maintenance intervals should be scheduled as those for power and labyrinth seals. As long as the signal channels are on top of the slip ring, gravity will With horizontally mounted work in your favor and minimize the amount of dust slip rings, gravity doesn’t help that falls onto signal channels. or hurt the dust situation Keeping the signal channels on top requires an much. You can locate the awareness of the mounting orientation. Vertical signal and load channels in hanging and standing orientations in particular will any order that makes sense need different configurations to ensure that the signal for your application.

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conditions can lead to signal degradation or even mechanical failures without an equally aggressive maintenance regime.

Easy access. All slip rings require some routine maintenance, but not all slip ring designs make maintenance quick and easy. It’s important to look for designs that have ready access to the power and signal contacts without requiring disassembly of the slip ring.

Slip rings are so common nowadays that engineers tend to take their performance for granted. And in general, modern slip rings are reliable enough to tolerate some neglect. However, if you really want to get the most out of a slip ring, a little extra attention to mounting orientation and ease-of-maintenance will go a long way. DW

Better prevent than cure.

GAM900S – Acceleration precisely measured and safely monitored.

Kübler kuebler.com

e signal ring with th ip sl e th g n n only Configuri d channels ca a lo e f th ve o le buildup o channel ab the inevitab t, n ve re 5 p 8 t o SRI0 minimize, n on Kübler’s technology w e upling n e co h e T iv . ct st du ess indu -l ct ta n co a s for use slip ring use . Developed ta a d d n a l a gn slip to transfer si achines, this ackaging m p d e worry e p y n -s a h t on hig withou ty ri g te in l a sign ring ensures contacts. y st u about d

GAM900S series acceleration sensors provide permanent, safe monitoring of vibration, shock and swing on e.g. wind turbines.

More preventive information available at: www.baumer.com/us/gam

September 2015

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» D e s i g n N o tes

Edited by: Mike Santora • Associate Editor

Ball drive actuator stabilizes world’s fastest motorcycle

Motion System

s Corp

oration’s 1,000-lb-rated Model 85199 ba ll drive actuator ha s high efficiency and requires less energy to move the same amount of load.

Ballscrews and ball drive actuators are normally associated with machine tools.

Every so often though, engineers get the chance to go pit their knowledge about these components in unusual applications, such as a motorcycle built be beat land speed records.

When engineer Mike Akatiff and the rest of the team behind the Top 1 Ack Attack Streamliner Motorcycle set out to defend their land speed record title, everything had to be precise. Since the Ack Attack team first broke the motorcycle land speed record in 2006, they have been planning to be the first bike to blast through the 400 mph speed barrier. Attempting to top your own record of 376.363 mph offers little room for error. Records are meant to be broken, not bike parts and spirits.

That’s why the safety features needed for the bike were crucial. The “training 48

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wheels” for the start and end of the runs and rear stabilizing flaps during the coast down period at the end of the run were critical safety considerations. To handle the specific mechanics involved for these safety components, Akatiff and his team chose Motion Systems Corporation’s 1,000-lbrated Model 85199 ball drive actuator. Ball drive type actuators have better efficiency

ck

Since the Top 1 A

er Attack Streamlin broke Motorcycle first

nd the motorcycle la 06, 20 in rd speed reco to ed ct it’s been expe ke bi become the first the to blast through barrier. d ee sp 400 mph

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compared to acme screw type units and require less energy to move the same amount of load. This helps reduce the power supply size and weight making the device far more user and environment friendly. This type of actuator also has better speed and a custom stroke.

The actuator has a diameter of 0.979 in. and integral freewheeling at stroke ends to eliminate limit switches. This freewheeling feature prevents over travel at the end of stroke. A ball cage within the nut ID cams up against stop pins at each end of travel to initiate freewheeling and linear advance stops. The stop pins are mounted in the screw thread and are factory installed for the specified stroke. This design generally eliminates the need for externally mounted P114 8.5 x 4.75 HORIZONTAL TL ad.pdf

1

There are a number of design considerations when building components for projects as unique as the Ack Attack Streamliner. Unlike actuators used in normal conditions, the G-forces in both acceleration and deceleration are extreme. limit switches. All elements (screw, nut and ball cage) are heat treated alloy steel with bearing surfaces for long wear characteristics.

The nut is provided with a 19⁄16 thread for attachment of the translating tube on the 85199 actuator.

With the demands of the motorcycle’s parts being so rigorous, some elements of the 85199 actuator had to be modified.

There are a number of design considerations when building components for projects as unique as the Ack Attack Streamliner. Unlike actuators used in normal conditions, the 4/18/14

G-forces in both acceleration and deceleration are extreme. Additional means of ensuring the actuators remain functional and intact under these loads was a challenge for the design team. Every mechanical design element was directly responsible for keeping a person safe. “The human element regarding safety is paramount. Our ability to modify base line actuators into custom one-off units makes Motion Systems the choice of world class competitors,” said Erik Wolf, president, Motion Systems Corporation. DW Motion Systems Corporation actuator.com

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»»

» Co u p li n g N o tes

Advantages of Zero-Max’s composite disc couplings include absorbing shock and vibration, misalignment capacity, electrical isolation and elimination of fatigue and fretting.

A quick look at special couplings Special environments and applications require couplings that handle the usual torque transmission and misalignment, but with a few extra features.

Edited by: Mike Santora • Associate Editor

Most disc couplings use a metal

and fretting. Metal disc couplings may be less expensive initially, but overall cost of composite disc couplings is usually lower because they are maintenance free and rated for long life.

Accommodating misalignment is a critical aspect of a flexible disc coupling.

Misalignment between coupled shafts often exists due to manufacturing tolerances,

disc-pack. However, Zero-Max’s composite disc coupling uses a uniquely shaped discpack that is constructed of a composite material rather than metal. This composite material offers an alternative to metal disc couplings. Advantages include absorbing shock and vibration, misalignment capacity, electrical isolation and elimination of fatigue 50

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improper installation or from loads on the system. Engineers should regularly examine lateral, angular and axial misalignment between shafts to see if the coupling selected is up to the task. It is important to know a coupling’s misalignment rating as well as the stiffness rating. The stiffer a coupling, the higher the reaction load misalignment will transmit to the coupled items. These reaction

9/2/15 1:44 PM

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» Couplin g Note s

Cylindrical bushings allow the attachment of hollow shaft gear reducers and other hollow shaft connections to any metric and inch size solid shaft diameter.

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loads will have a negative effect on the life of the system. To limit these reaction loads, the Zero-Max composite disc couplings are less radially stiff than metal disc couplings.

Therefore, they transmit lower reaction loads on the coupled equipment, increasing the life of connected components.

How much misalignment a system can handle determines the selection between a single-flex (one flexible disc-pack) and a double-flex (two flexible disc-pack) coupling.

While more compact in size than the doubleflex variety, a single-flex coupling will have lower misalignment capacity and higher reaction loads. A common misconception is that single-flex disc couplings cannot accommodate lateral misalignment. Although this is true for metal disc couplings, the design of the disc-pack used in the ZeroMax CD coupling allows the single-flex CD coupling to accommodate limited lateral misalignment. This permits designers to use a single-flex disc coupling in designs that may not have space for a double-flex coupling.

Gear couplings are a type of mechanical device designed to transmit torque between 52

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two shafts that are not collinear. The coupling typically consists of two flexible joints, one fixed to each shaft. These joints are often connected by a third shaft called the spindle.

Most joints consists of a 1:1 gear ratio internal/external gear pair. The tooth flanks and outer diameter of the external gear are crowned to allow for angular displacement between the two gears. Mechanically, the gears are equivalent to rotating splines with modified profiles. They are called gears because of the relatively large size of the teeth. Gear couplings are generally limited to angular misalignments of 4 to 5°.

Gear couplings ordinarily come in two variations: flanged sleeve and continuous sleeve. Flanged gear couplings consist of short sleeves surrounded by a perpendicular flange. One sleeve is placed on each shaft so the two flanges line up face to face. A series of screws or bolts in the flanges hold them together.

Continuous-sleeve gear couplings use shaft ends coupled together and abutted against each other, which are then enveloped by a sleeve. Often made of metal, these sleeves

September 2015

9/2/15 1:49 PM

»» When Size and Performance Matters Medical-Industrial Actual Micro-Coax cable bundle diameter compared to a penny.

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can also be made of Nylon.

Single-joint gear couplings are used to connect two nominally coaxial shafts. In this application, the device is called a geartype flexible, or flexible coupling. The single joint allows for minor misalignments such as installation errors and changes in shaft alignment due to operating conditions. These types of gear couplings are generally limited to angular misalignments of 1⁄4 to 1⁄2°.

Magnetic couplings transfer torque without a physical mechanical connection.

This makes them suitable for fluid pumping applications because the connection can be made through thin barriers, helping maintain a hermetically sealed rotary feed through.

Because none of the coupling parts are in contact, wear is virtually nonexistent and the use of permanent magnets means no external power source is needed. Magnetic couplings also have a built-in safety feature where, in the event of an overload on the coupling, it will shift to the next position and keep going.

Magnetic couplings can typically only handle light torque loads and applications with either gradual starts, or low rotational inertia of the driven side of the system. They www.designworldonline.com

Coupling Notes 9-15_Vs3.LL.MD.indd 53

are also rather large in diameter, considering their relatively light torque load. The couplings also have moderate radial loads on support bearings. DW 19000

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Manchester, New Hampshire , USA Tel: +1.603.669.4347 www.hca.hitachi-cable.com

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»»

» CA E Solu t i o n s

Design optimization: Topology and much more

Topology optimization.

Source: solidThinking

Optimization with Tosca Structure done on a vehicle model that has been developed by The National Crash Analysis Center (NCAC) of The George Washington University under a contract with the FHWA and NHTSA of the U.S. Dept. of Transportation.

Source: SIMULIA

Bruce Jenkins • President • Ora Research

54

Topology optimization and its seductive biomorphic shapes are what many think of when they hear the word “optimization” in engineering design. But topology optimization is just one kind of structural optimization—and that, in turn, is only one of five broad classes of optimization technology available to engineers today.

Equally if not more valuable, depending on the nature of the design problem, are parameter optimization, multidisciplinary optimization (MDO), multi-objective or Pareto optimization, and robustness-andreliability optimization.

The power of all these numerical methods is their ability to rationally and rapidly search through design alternatives for the best possible design(s). Parameters in a design that can be varied to search for a “best” design are called design variables. Given these variables, design can be structured as a process of finding the minimum or maximum of some attribute, which is termed the objective function. For a design to be acceptable, it must also satisfy certain requirements, or design constraints. Optimization is the process of automatically changing the design variables to identify the minimum or maximum of the objective function while satisfying the design constraints.

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ACEAD_S

» CAE Solu t i ons

Multi-objective (Pareto) optimization.

Source: Noesis Solutions

Here’s how these methods work, and what kinds of problems they help engineers solve:

shape of a 2D or 3D solid to minimize volume while satisfying stress and displacement constraints (generically termed a cost functional).

Structural optimization is optimization of a Size optimization consists of modifying sizestructure’s shape, size, topology, topometry or related properties of structural elements, such as topography to satisfy operating limits imposed shell thickness, beam cross-sectional properties, on the response of the structure, and by spring stiffness and mass, to solve the optimization further limits on the values that the structural problem. parameters can assume. Structural optimization Topology optimization denotes optimizing methods apply optimization algorithms to solve material layout within a given physical design structural problems by means of finite element volume, for a given set of loads and boundary analysis. conditions, so that the resulting layout meets Shape optimization means optimizing prescribed performance targets. This is often used structural shapes by adjusting the surface to identify a conceptual design that best meets

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specified design requirements, which is then refined for performance and manufacturability.

It frequently yields biomorphic-appearing shapes best suited to additive manufacturing methods, before being modified for production by conventional subtractive manufacturing.

Topometry optimization is similar to topology optimization but applied to 2D elements, with the variables restricted to the element-wise thicknesses.

Topography optimization, like topometry optimization, is applicable only to 2D or shell elements, and aims at finding the optimum bead pattern in a component.

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» CA E Solu t i o n s

Here are some of the many optimization software choices available today:

Robust design optimization. Source: OptiY Parameter optimization, in some respects a more generalized version of structural optimization, is a procedure for finding values for any parameter(s) in a design—not just structural parameters—that are optimal in some defined respect, such as minimization of a specified objective function over a defined data set.

Multidisciplinary optimization (MDO) incorporates all relevant disciplines—structural (linear or nonlinear, static or dynamic, bulk materials or composites), fluid, thermal, acoustic, NVH, multibody dynamics, or any combination— simultaneously in an optimization problem. By exploiting interactions among disciplines, MDO can identify design solutions that are superior to those arrived at by optimizing each discipline sequentially, with substantially less expenditure of engineering time and labor.

Multi-objective or Pareto optimization is a method for numerically addressing the fact that real-world optimization problems usually have more than one objective, and these objectives often conflict or compete with one another. For example, in optimizing a structural design, the desired design will be both lightweight and rigid. Because these two objectives conflict, a tradeoff must be made: there will be one design that is lightest, another design that is stiffest, and an infinite number of possible designs that are some compromise of weight and stiffness. The set of tradeoff designs that cannot be improved on according to one criterion without harming another criterion is called the Pareto set, and the curve plotting the Pareto set is called the Pareto frontier.

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Once the Pareto frontier has been identified, the action of comparing these various Paretooptimal solutions with one another to choose the preferred solution is based on exogenous factors (outside the computer model), and is carried out by human decision-makers.

Robustness and reliability optimization are methods for managing the fact that product designs are nominal, while manufacturing and operating conditions are real world. Finite geometric tolerances, variations in material properties, uncertainty in loading conditions, and other variances encountered by a product either in production or in service can cause it to perform slightly differently from its nominal, as-designed values. Therefore, robustness and reliability as design objectives beyond the nominal design are often desirable. Performance of robust and reliable designs is less affected by these expected variations, and remains at or above specified acceptable levels in all conditions. To evaluate the robustness and reliability of a design during simulation, its variables and system inputs are made stochastic by being defined in terms of both mean value and a statistical distribution function. The resulting system performance characteristics are then measured in terms of a mean value and its variance. DW

Altair HyperStudy, OptiStruct, solidThinking Inspire ANSYS Adjoint Solver, Optimetrics Autodesk Optimization for Inventor CD-adapco STAR-CCM+ /Enabling Optimate+ Cenaero Minamo Collier Research HyperSizer COMSOL Multiphysics Optimization Concepts NREC TurboOPT II DATADVANCE MACROS, pSeven DecisionVis ExplorerDV Dynamic Design Solutions FEMtools Optimization Dynardo optiSLang ESI Group Virtual Performance Solution Optimization ESTECO modeFRONTIER Exa PowerFLOW Optimization Solution FEA-Opt SmartDO FRIENDSHIP SYSTEMS CAESES/FRIENDSHIPFramework FunctionBay RecurDyn/AutoDesign iChrome Nexus LIONlab LIONsolver LSTC LS-OPT MSC Nastran Design Optimization NISA Software CSIL NISAOPT Noesis Solutions Optimus Optimal Solutions Sculptor OptiY GmbH OptiY Phoenix Integration ModelCenter PIDOTECH PIAnO PTC Creo BMX (Behavioral Modeling Extension) Quint OPTISHAPE-TS RBF Morph Red Cedar Technology (a CD-adapco company) HEEDS MDO, HEEDS NP Siemens PLM NX Nastran Optimization, Femap with NX Nastran Optimization, LMS Virtual.Lab Optimization Sigma Tech IOSO SIMULIA Isight, SEE, Tosca SolidWorks Simulation Structural Optimization Vanderplaats R&D GENESIS, DOT, BIGDOT, VisualDOC Virtualpyxis Virtual.PYXIS Within Technologies (an Autodesk company) Enhance

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» CA E »Solu CA Et iSo onlut s ions

Additional midsurface extraction options are applicable to symmetric or asymmetric, planar or curved, and uniform or tapered cross sections.

Easier CAD prep for CAE The MSC Apex is a next generation computer-aided engineering (CAE) platform. It introduces a CAE Specific direct modeling and meshing solution, MSC Apex Modeler, that streamlines CAD clean up, simplification and meshing workflow.

In this release is Smart Midsurface technology, a workflow to expedite the creation of finite element models for thin structures composed of metals, plastics and composites.

MSC Apex Structures is an add-on to MSC Apex Modeler that expands MSC Apex to an integrated and generative structural analysis solution.

Other features include: • Incremental Midsurface Workflow—a semiautomatic, incremental workflow to create midsurface geometry and expedite the process up to 10 times. The incremental midsurface workflow involves the creation and pre-configuration of pairs that act as guides for subsequent midsurface extraction and creation.

• Midsurface Extraction Methods—midsurface extraction methods are available for a larger range of thin structures composed of injection molded plastics, metals and composite materials.

Midsurfaces may now be extracted for variable thickness sections, whether they are tapered, curved, symmetric or asymmetric.

• Rapid Development of Simulation Model Definitions—the process of meshing midsurface geometry and defining material and section properties was a key focus of this release. New features enable analysts to rapidly construct surface and solid element meshes, now supporting hex meshing and mesh seed point constraints. MSC Apex can also automatically

Thickness and offset properties are automatically generated for both uniform and nonuniform sections common in injection molded plastics.

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map hundreds of 3D geometry thickness and offset onto shell element properties in seconds and has been documented to be up to 24 times faster than manual methods.

This capability has been expanded to support thin sections that are non-uniform and further expands the scope of designs that can be modeled.

MSC Apex Structures offers users a fully integrated simulation environment for structural analysis.

• Regenerative Analysis Readiness has been enhanced so that analysis readiness checks are now done automatically as users work on their model. Any change in the mesh, the loads, boundary conditions or thickness properties will automatically regenerate analysis readiness results. This reduces trial and error and speeds up the “modeling to validation” process so that users can make faster decisions during virtual testing. DW MSC Software mscsoftware.com

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For engineers, file and document management has a few requirements: (1) viewing 2D and 3D designs in a browser; (2) automatic file synchronization across desktop, web and mobile platforms; (3) version and permission control across project teams; and (4) an ability to lock files for editing to name a few. Two packaged solutions offer easy to use file and document management and address these requirements of engineering use-cases and workflows often missing from consumer based cloud storage and file sharing tools.

These packaged solutions come in two versions, free or paid. The Kenesto Drive—a virtual cloud drive—is included in both versions. Kenesto Drive automatically maintains desktop files and documents synchronized with Kenesto’s web browser app. Users always have access to the latest version of their documents and files, reducing the risk of working on an older version of a document.

The free version lets users view and share 2D and 3D engineering documents, keep team members up-to-date with most current versions, and access version history. The paid version is an annual subscription that offers additional value and capabilities for those users that want to take control of the engineering workflow and design process with collaboration, task and workflow management tools.

Kenesto users can now benefit from simple document management, sharing and collaboration that provides improved control and visibility of the engineering process. DW

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» CA E Solu t i o n s

CFD for accurate thermo-fluid system design

The newest version of Flowmaster 1D computational fluid dynamics (CFD) software is for fast and accurate thermo-fluid systems design. This software features several key and enhanced functions including an improved multi-arm tank component, and integration with complementary 1D pipe stress products, such as CAESAR II and CAEPIPE for pipe fluid-force predictions.

The physical modeling capabilities in version 7.9.4 include: • Multi-Arm tank component. Users choose between two distinct heat transfer models: poly-tropic and full heat transfer.

This is a feature of particular applicability to the aerospace market.

• Enhanced Experiments. Users can easily modify key system parameters and observe the impact immediately and from one place in the software. A persistent “run” dialog provides direct access to start simulations.

• Bookmarks. This feature enables automatic updates of charts upon completion of a design iteration allowing

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users to compare the effects of a given modification. Multiple bookmark plots can be used concurrently to create a detailed understanding of the system across multiple iterations.

In addition, the Flowmaster product offers integration with leading pipe stress computer-aided engineering (CAE) tools. The hydro-dynamic force generated by a fluid transient event can be calculated, and the resulting force-history can be exported to both SST CAEPIPE and Intergraph CAESAR II for pipe stress analysis, which suits process, utility and energy markets. These seamless interfaces in the Flowmaster product facilitate

geometry and data transfer between these two leading CAE tools. Users will attain complete system performance results under transient conditions early in the design process by using this feature. DW Mentor Graphics mentor.com

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» I nternet of Things

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10 IoT will power a range of intelligent connected devices from smaller equipment, such as gateways or mobile point-of-sale units, to industrial devices, like robots and specialty medical equipment.

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PROGRAMMABLE INCREMENTAL ENCODERS

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Designed to connect through the Microsoft Azure IoT services, Windows 10 IoT offers enterprise-grade security along with native connectivity for machine-to-machine and machine-to-cloud scenarios.

Azure IoT Suite is an integrated offering that takes advantage of all relevant Azure capabilities to connect devices and other assets, capture the diverse and voluminous data they generate, integrate and orchestrate the flow of that data, and manage, analyze and present it as usable information. The offering, while customizable to fit the unique needs of organizations, will also provide finished applications to speed deployment

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Large Variety of Mechanical Designs

of common scenarios seen across many industries, such as remote monitoring, asset management and predictive maintenance, while providing the ability to grow and scale solutions to cover millions of “things.”

Within proprietary Windows 10 IoT networks, establishing communication is done with AllJoyn. AllJoyn is an open source software framework and set of services for interoperability among connected devices, regardless of the underlying proprietary technology of communication protocol.

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assistant, which has been present on its phone operating system for a while now, is accessible directly from the desktop with either a click or voice command. It can serve as a handy helper when you need to get things done.

• Microsoft Edge—Edge is slated to become the new default web browser for Advantech Corporation, Industrial Automation Group Windows 10, with Internet Explorer consigned to the background to support legacy software. advantech.com/ea.

Edge features a host of built-in features such as a screen grab tool with touchscreen doodling ability, a note pad and reading mode.

• Virtual desktops—A key tweak has been made to one of the most important features of Windows 10, as far as desktop users are concerned, which is virtual WHAT DO desktops. On previous builds, the apps you YOU THINK? had open on any desktop where shown on every desktops taskbar, making it cluttered.

No so with Windows 10.

• Task View for multi-tasking—This Connect and discuss this and other feature makes multi-tasking more useful. design engineering issues with thousands of professionals online Sitting on the taskbar across the bottom of the screen, when launched, it will display all of your currently opened apps.

• Multiple desktops—When you launch Task View, Windows 10 will support the ability to view multiple desktops. You can switch between different desktops where multiple apps run. Using the “Snap Assist” feature, you will also be able to grab apps from those different desktops.

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Advantech offers diverse platforms with Windows 10 IoT pre-installed, including boards, systems and gateways. A WISE-PaaS platform fully supports Windows 10 IoT with core, mobile and industry versions through the Universal Windows Apps structure to offer Cloud services. By adopting it, developers can rapidly build and deploy applications with greater speed, flexibility and agility. It enables developers to easily and effectively construct IoT Cloud solutions. DW

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... ... ... ... ... ..

SMART

.......................................... ................................ ........................ ................... .............. ........... ........

Dual axis EtherCAT ...... .... .. servo drive

Intelligent Motion Control

These PWM (pulse width modulation) servo drives include a dual axis EtherCAT drive. The NPMPM Series of EtherCAT servo drive modules provide motion performance previously only achievable using linear drives, without the drawbacks of such linear drives. These drives are significantly smaller, more efficient, produce less heat dissipation, are better protected and lower in cost.

When used with the optional 10 MHz laser encoder interface and the control algorithm, positioning systems can:

• achieve speeds above 2 m/sec

• have sub-nanometer jitter values

• have nanometer velocity tracking errors

• exhibit extremely low settling time

• exhibit system robustness with minimal sensitivity to disturbances and load changes.

The NPMPM is a slave that runs under any ACS EtherCAT masters. The NanoPWM type of drives suit applications in wafer metrology and inspection, FPD inspection, and ultraprecision machining for processing of optical components. DW

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» I n te rn e t of Th i n gs Security management system The current approach to security management for IoT devices is to repurpose legacy security management systems. While this approach may work for some IoT gateways and large IoT devices, it does not scale to the smallest IoT devices, especially small battery-powered edge devices and sensor solutions.

Floodgate Security Manager is designed to provide the management services required by all IoT devices, including small, battery-powered, and mobile devices, without the overhead and complexity of traditional enterprise security management systems. This software suite helps protect IoT and embedded devices against cyber attacks. It can be operated as either an on premise or a cloud-based security manager.

It provides device status monitoring, security policy management, command audit logging, and security event logging and reporting for devices running Icon Labs’ Floodgate Agent or other lightweight IoT management protocols such as COAP

and MQTT. Floodgate Security Manager provides comprehensive reporting and auditing capabilities to help achieve EDSA Certification, ISA/IEC 62443 Compliance, and/or compliance with the NIST Cybersecurity framework.

“With the IoT growing dramatically, it’s only a matter of time before hackers turn more attention toward embedded systems with limited onboard security resources,” said Steve Hoffenberg, a director at industry analyst firm VDC Research.

“New security technologies are needed not only to protect IoT device functionality and data, but also to protect conventional IT and the cloud assets to which the embedded systems are connected.” DW

Icon Laboratories iconlabs.com

Rotary encoder with EtherCAT option PSE and PHE 900 series of rotary encoders suit heavy duty applications commonly found in the steel, mining and energy industries and are now available with an EtherCAT interface option. The 900 series is available as solid shaft and hollow-shaft absolute sets.

The EtherCAT implementation provides angular position value on its machine, while advanced signal processing inside the encoder delivers velocity, acceleration, alarms and warnings to the control system, providing multi-variable feedback for sophisticated control algorithms with cycle times as short as 31.25 µsec. DW HEIDENHAIN heidenhain.com

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.......................................... ................................ ........................ ................... ..............

Ethernet based router ........... ........ ...... .... ..

The C6 Router, when partnered with COMBIVIS

Connect software, provides everything needed to connect remotely to machines in the field for commissioning, program adjustment and troubleshooting using KEB’s secure VPN connection to networked servers around the world.

The Ethernet-based C6 Router comes with WAN, LAN, USB and serial interfaces, and standard digital I/Os. For hard-to-access installations, like wastewater treatment facilities, oil and gas, and wind turbines, a cellular network option is available.

These models include standard 2G/3G/3G+ EDGE/

HSPA quadriband capable of speeds of up to 5 Mbps up/14 Mbps down. They come with one push-pin type SIM card and SMAStecker antenna, with the option of adding an auxiliary Diversity antenna.

In addition, the C6 Router handles harsh environments.

The unit is housed in a stainless-steel enclosure and is ready for DIN rail or wall mount. There are no fans or moving parts to maintain and an extended temperature option is available for extreme environments (-20 to 70° C). DW KEB kebamerica.com

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ADDITIVE MANUFACTURING CNC MACHINING INJECTION MOLDING

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... ... ... ... ... ..

» I n te rn e t of Th i n gs POSITAL uses IoT for smart manufacturing Some manufacturers on the forefront of Industry 4.0 established cloud-connected processes years ago. Consider POSITAL FRABA, which uses the IoT to leverage Cloud-backed production of rotary encoders, inclinometers and linear position sensors. Billed mass customization, the Cloud-based data system lets Posital build custom components at low cost through automated product interfaces (APIs, not to be confused with application program interfaces in GUIs for motion and control software).

Why IoT here? Posital’s encoders and sensors support motion control in industrial robots, packaging systems, medical equipment and the heavy-duty machinery used in construction, mining and energy production. These applications have different needs with respect to housings, seals, shock and vibration mitigation and dynamic response, not to mention different connection technologies (including analog, digital serial, fieldbus or industrial Ethernet).

Posital’s mass customization helps systematically satisfy these disparate requirements. With an enormous range of mechanical variants and several programmable features, the company can offer more than one million unique product configurations.

“Before mass customization, our manufacturing could accommodate lots of options, but distributor’s stock was limited and lead times could be lengthy. But optimized, Cloud-based production means that we can build to order and still have very quick short delivery,” said Christian Leeser, president of Fraba, owner of Posital.

Modular components and interchangeable sub-assemblies let engineers build hundreds of thousands of design variations. Assembly personnel scan work-order barcodes to download graphical (Ikea-like) manufacturing instructions to their PC in real time. “So the factory system deploys to countries with different languages.

Plus there’s no chance that someone gets old manufacturing instructions and does something

in an outdated or flawed way,” said Leeser. Posital’s system also stores each product’s design and sale details, including QA and test records.

Posital’s Product Finder tool lets the company’s 120 international distribution partners specify sensors to customer requirements from a menu of features—a multi-turn absolute rotary encoder with a stainless-steel housing rated for IP67level environmental protection, with an 8-mm diameter shaft, a CANopen data interface and an M12 5-pin connector, for example.

The web-based product finder confirms the configuration is feasible and provides a part number. The distributor can then order the part, usually receiving it within a week.

The latest Posital tool to enable Industry 4.0 is UBIFAST programming (to let distributors and large customers complete final configuration onsite). A small unit plugs into the sensor through a standard cable, while a built-in WiFi hotspot gives users access to a configuration interface through a standard web-browser window (on a PC, tablet or smartphone). Years later, a customer needing a replacement can contact Posital with the original serial number and a full record of the device’s configuration history will be available. DW POSITAL posital.com

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.......................................... ................................ ........................ ................... ..............

Bridge ensures ........... ........ wireless uptime ...... .... ..

In industrial networking applications,

such as communications between offshore oil platforms or train-to-ground communications, a reliable wireless bridge is essential to minimize system downtime and maximize availability. The AWK-3131A wireless AP/bridge/client delivers fast, reliable wireless performance in industrial settings by supporting IEEE 802.11n technology with a maximum net data rate of 300 Mbps, plus AeroLink Protection redundancy to prevent a single point of failure from bringing down an entire network.

With AeroLink Protection, a network has two or more protected wireless client nodes connected to one access point. One serves as the active node, while the others are passive backup nodes. If the active node stops sending or receiving data for any reason, AeroLink Protection restores the communication link within 300 msec by bringing backup nodes online.

Due to overcrowding on the 2.4 GHz frequency band and the introduction of 802.11ac, many industrial networks have already begun migrating to 5 GHz. Engineered for flexible deployment, the AWK-3131A can operate on either the 2.4 or 5 GHz bands and is backward-compatible with existing 802.11a/b/g applications to future-proof wireless investments.

Seamless roaming offered by the AWK-3131A’s Turbo Roaming technology reduces handover time to the millisecond level and provides the benefits of seamless transmission and control. To avoid packet loss, the AWK-3131A actively searches for APs with a stronger signal without waiting for a

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complete disconnection. Turbo Roaming is useful in the control and monitoring of mobile vehicles such as the unmanned AGVs and shuttles commonly implemented in factory automation.

Power and radio frequency disturbances are the two most common causes of wireless communications failure in industrial computing applications. The AWK-3131A is designed with integrated dual isolation protection to mitigate both. First, Integrated RF Isolation provides 500-V insulation protection and level 4 ESD protection without loss of the RF signal. Next, Integrated Power Isolation provides 500-V insulation protection and stabilizes system voltage.

The AWK-3131A is compliant with industrial standards and approvals covering operating temperature, power input voltage, surge, ESD and vibration to assure performance in harsh industrial environments such as oil refineries, water treatment centers and offshore platforms. DW

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Âť I n te rn e t of Th i n gs

Controller enables IoT connectivity

The VersaGateway controller is an enhanced communications controller for translating between various protocols and enabling Cloud Communications with the Divelbiss VersaCloud M2M platform.

Programmed using the EZ Ladder Toolkit in Ladder Diagram, Function Block and Structured Text, and based on P-Series PLC on a Chip technology, the controller delivers flexibility when translating between different serial bus protocols, logging system data to the full size SD card, or adding IoT capability to existing systems.

The controller supports communications through several ports. Two serial ports are user configurable as RS232 or RS485, and support MODBUS RTU/ASCII protocols as either a Master or Slave device. The serial ports are also directly programmable through 70

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the Structured Text programming language, allowing the implementation of custom protocols suitable for communicating to bar code scanners, RFID readers or other serial devices.

Two CAN ports are available, one of which is isolated and configurable for NMEA2000 bus power. Both CAN ports support the SAE 1939 and NMEA2000 protocols. Ethernet and WiFi ports can be used for MODBUS TCP Server and Client communications, as well as IoT communications with the VersaCloud M2M platform. The VersaGateway has optional cellular capability for communicating with the VersaCloud M2M platform. A GPS option is also available.

For applications that require data logging, the controller has a real-time clock, 512 K of battery backed SRAM, and a full size SD

card. These features give the user ultimate flexibility and options for implementing data buffering and logging. When used with the VersaCloud M2M platform, the controller can communicate data to VersaCloud, where it is date/time stamped and stored in the Cloud database for later viewing, analysis and export. The controller supports supply voltages from 9 to 32 Vdc and has an operating temperature range of -40 to 80° C, for use in applications with extreme environmental requirements. DW Divelbiss Corporation divelbiss.com

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9/2/15 2:39 PM

Smarter Embedded Designs, Faster Deployment

The combination of NI LabVIEW system design software and reconfigurable I/O (RIO) hardware helps small design teams with varied expertise develop demanding embedded applications in less time. Using this graphical system design approach, you can take advantage of the same integrated platform to program embedded processors and FPGAs for faster application development in industries ranging from energy to transportation, manufacturing, and life sciences.

LabVIEW system design software offers ultimate flexibility through FPGA programming, simplifies code reuse, and helps you program the way you think–graphically.

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800 453-6202 Š2013 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments.

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analytics. This platform-as-a-service (PaaS) will capture and analyze the volume, velocity and variety of machine data within a secure, industrial-strength cloud environment. It will enable developers to rapidly create, deploy and manage applications and services for industry.

Predix Cloud will enable operators to use machine data faster and more efficiently.

By combining GE’s expertise in information technology (IT) and operational technology (OT), this service will deliver tools like asset connectivity, machine data support and industrial-grade security and compliance.

The Industrial Internet is generating data twice as quickly as any other sector.

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Linear Miles Budimir Senior Editor

From nanometer

the demands of new applications and industries. New demand in areas like medi-

actuation, components

cal devices, for instance, calls for more nimble, smaller components adaptable to

for linear motion

new environments and performance standards.

systems are

This calls for more precise resolution of positioning systems, for encoders with nanometer resolution, or linear actuators capable of making small, precise moves with little force or on the other end of the spectrum high-force alternatives to more traditional technologies like hydraulic actuation.

But it’s also a different world that engineers are designing in. More designers are looking to source pre-engineered or integrated systems. Whether due to shortened design cycles, limited budgets or fewer engineering staff on hand, these factors are causing engineers to consider pre-engineered systems. And motion component manufacturers are aligning themselves to give designers more options by partnering with companies to simplify component sourcing and system design.

changing with the times.

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Linear motion components like encoders and actuators are evolving to meet

resolution to high-force

DESIGN WORLD

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Low-profile linear guides, such as the Compact Series from PBC Linear, feature 23 mm standard heights and can be configured with a range of options including different leadscrew diameters, nuts and integrated motors.

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Li n e a r M ot io n Encoder innovation For applications where space is at a premium, encoders like NUMERIK JENA’s LIK 41 kit-style optical linear encoder is a suitable option. The scanning unit has a low height profile and the graduation carrier has two ways of mounting and is offered in various lengths. This flat linear encoder is a good fit for multiple industries, including semiconductor, medical, metrology and automation.

The encoder scales have a graduation of 20 µm with lengths up to 30 m.

There are two ways of mounting the scale: singleflex and doubleflex. Singleflex is mounted directly to the machine axis with a specially engineered adhesive on the back. Doubleflex is the preferred method to mount a scale when high accuracy is required. A base metal layer is affixed to

Some linear encoders, such as the LIK 41 series from NUMERIK JENA, are a good fit for applications where space is at a premium, and can offer resolutions in the nanometer range.

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the axis of motion by a pin on the left side of the scale; an oil film and another metal layer with the graduation imprinted rests on top of the base metal tape. The thin oil film allows for free thermal growth with low friction, yet the top metal layer does not fall away from the base tape due to a recommended fixing point at one location.

Accuracies to ±1 µm are achievable with the doubleflex mounting arrangement.

Reference marks are also imprinted on the scales in the middle, or every 50 mm, or by specific application requirements.

The scanning units on the LIK 41 are small with a height of 6 mm. They contain an electrical shielding scheme so they can be mounted close to motors in the application. The scanning units can be programmed once installed to the linear scale to maximize the signal quality and build

3/27/2015 4:00 PM 9/3/15 9:08 AM

We take linear motion solutions personally.

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Li n e a r M ot io n The MSA 37x series of encoders from RSK Elektronik, is designed for machines with loose mechanical motion.

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in signal margin for long life of the machine operation. The scanning units output to either a 1-V peak-to-peak analog or TTL interface with resolutions down to 50 nm possible with the TTL (RS 422) versions.

Precision may not be the only important criteria for all applications. Case in point: RSF Elektronik offers a linear motion feedback encoder system designed for machines with loose mechanical motion during operation.

The MSA 37x series encoders are well suited for motion applications such as press brake and metal forming/bending machines, or similar types of machines that have significant flexure near the area requiring motion feedback.

The encoders feature a design that includes a bearing set internally for guiding the scanning optics, and a bearing set externally for the attachment of a coupling rod that affixes to the machine, thereby allowing for measurement of the moving elements of the machine.

Digital TTL resolutions of 5 and 1 µm are possible, with accuracies up to ±10 µm on the MSA 37x series. The encoders also have magnetic limit switches that can be used to send end-of-travel signals to a controller. Reference marks can be in the center, on either end of travel, or every 50 mm. The encoders can also handle large shock and vibrations.

Linear actuation Linear actuators are also evolving. From higher force options that continue to challenge traditional hydraulic and pneumatic systems to novel technologies such as single devices capable of producing both linear and rotary motion, designers have a lot more choices available to them.

For instance, the new XFC Series electric cylinder from Parker’s Electromechanical Automation Division features maximum thrusts to 80,000 lb. The secret of the XFC lies in the integrated roller screw technology, which uses planetary rollers in place of the ball bearings used in ballscrew products. The advantage 78

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What’s Your Move?

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Design and performance in any of these four areas can significantly enhance — or diminish — the overall performance of the machine. This performance directly translates to competitive advantage and reduced cost of ownership.

WITTENSTEIN is the preferred choice for quality gearheads, actuators, linear systems and specialty motors that excel in these requirements. Our holistic expertise of motion systems combined with the integrity of our product optimizes machine performance.

See how we can enhance your moves—visit us at Pack Expo 2015 in Las Vegas.

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High-force electric cylinders from Parker feature maximum thrust to 80,000 lb, speeds to 40 in./sec, max acceleration to 2 g and frame sizes from 75 to 190 mm.

of planetary rollers is that they provide a greater number of contact surfaces between the thread of the screw and the internal threads of the roller nut. This equates to higher overall load capacities, higher speeds, and shock loading capabilities.

The high thrust capability coupled with the all-steel frame based on standard metric hydraulic cylinder construction provides a seamless migration from hydraulic to full electromechanical motion and delivers a cleaner and more energyefficient solution overall with increased levels of control.

On the motor front, an innovative motor concept combines linear and rotary

motion into one compact package.

The PR01 Series of linear-rotary motors from LinMot can be used to implement a range of combinations of linear and rotary motions. The housing contains both an electromagnetic linear drive and a rotary direct drive, each controlled by a servo drive. This means that the upper-level controller can implement dynamic linear-rotary motion sequences that can be programmed to be either synchronous or completely independent of each other.

Currently two sizes are available that differ in the maximum available torques for the rotary motors and the linear forces for the linear motors.

Other options include variations with gearboxes, hollow shafts and stainlesssteel components.

“One constant in engineering design, besides concerns with costs and timing, is the quest to simplify the design process. �

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For a full list of available enclosures and participating dealers, please visit www.rittalenclosures.com Terms and conditions subject to change.

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Tolomatic MXE and MXB rodless electro-mechanical actuators are available in both screw- and belt-drive designs with a variety of bearing styles and options.

When it comes to applications where space is at a premium, such as many medical applications, component manufacturers are responding with designs that fit in smaller tighter spaces, weigh less, yet don’t sacrifice precision or accuracy.

One example comes from PBC Linear in their low-profile linear guide system called the Compact Series. This addition to the company’s Mechatronics Enabled initiative is designed to provide smooth, accurate and

repeatable linear motion in tight spaces.

With a 23-mm standard height and the flexibility to be configured to adapt to the demands of a given application, the linear guide system is a good fit for applications in lab automation, medical, automated delivery systems, dispensing robotics and electronic board manufacturing.

The product line offers options including bearings, leadscrew diameters, nut types such as standard fixed nuts or

anti-backlash nuts and different motor frame sizes such as NEMA 17 or 23 stepper motors.

Simplifying design One constant in engineering design, besides concerns with costs and timing, is the quest to simplify the design process. In other words, engineers welcome anything that makes their jobs easier. One strategy that some companies are adopting is to work more closely together, forming strategic

Rittal durability and pricing beat our competition once again You’ve known Rittal quality in Wallmount Enclosures for years. Now you can get the industry’s highest-quality enclosures at a price so low Hoffman and Saginaw can’t bear for you to see.

And, with our manufacturing plant located in the USA, local availability means you won’t have to wait for the perfect Rittal Wallmount enclosure you need for your facility today.

• Available in more than 100 standard sizes in both carbon and stainless steel • UL Listed with foamed-in-place gasket, flange trough collar and secure locking system

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partnerships to offer designers one-stop shops for sourcing components.

For example, engineers can specify Tolomatic electric rod actuators and rodless electro-mechanical actuators using Rockwell Automation’s Motion Analyzer web-based software, making it easier for engineering teams to specify, design and validate complete motion control systems that use Allen Bradley controls.

The Rockwell Automation mechatronic design tool is a cloud-based architecture that aims to help mechanical, electrical and controls engineers collaborate more efficiently and effectively to create prototype machines.

The interdisciplinary design approach can help decrease time to market and reduce engineering costs. DW LinMot linmot.com NUMERIK JENA numerikjena.de

Del-Tron’s

Ball & Crossed Roller Linear Slides carry loads up to 779 lbs! These light weight slides offer engineers and designers the flexibility to choose the right linear slide technology for their application. Manufactured in the USA, our ball and crossed roller slides offer several levels of precision ranging from a straight line accuracy of 0.0005” per inch of travel in our standard precision slides to 0.0000040” per inch of travel in our high precision slides. Available with inch or metric holes and hole locations these factory preloaded, low friction slides are ready for installation right out of the box!

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DESIGN WORLD

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Galil Motion Control

ALL THE RIGHT MOVES...

...for Ultimate Precision Galil Motion Controllers handle virtually any application Between our flexible product offering and our affordable custom solutions, we can accomodate all of your motion and I/O needs. Select one through eight axes. Choose internal multi-axis servo or stepper drives. Increase the number of axes and I/O by daisy-chaining through built-in Ethernet ports. Guaranteed low price per axis with driver included.

Galil products are easy to program and use, backed by unparalleled technical support and both ISO 9000 and ISO 13485 certification.

• Process commands in as little as 31 microseconds • Handle all modes of motion, simple to complex • Handle ultra-high resolution systems • Support closed loop stepper motors • Up and running in minutes • Use virtually any encoder • EtherCAT master available

galil.com 1.800.377.6329

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E l e c t r o n i c s

Busbars and IEC devices

take down control-panel costs Nathan Xavier Consulting Engineer • Rittal

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More North American engineers than ever use IEC devices instead of NEMA components— especially with modular busbars to replace traditional wiring for controls.

Busbars and standardized IEC devices simplify integration and enhance safety, and now new combinations and kits are letting control-panel integrators complete systems less expensively than ever. Spurring this trend is global acceptance of IEC components and modular busbar systems with universal certifications for worldwide installation.

Why busbars?

At their core, busbar systems are meant to replace all line-side wiring and associated accessories in an electrical panel. Usually after the main feed (and the main overcurrent-protection device) high-amperage cables run to power distribution blocks (PDBs). These PDBs split large cables into smaller low-amperage cables, which then run in trays to individual devices.

Busbars can replace these parts and more. Except Busbars include copper busbar and splice connectors, supports, covers, adapters, cable clamps, plate clamps, circuit-breaker and fuse base adapters. Modularity simplifies setup.

www.designworldonline.com

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Modular busbar systems can simplify bills of materials (BOMs). For instance, a modular busbar support can work with copper busbars of different cross-sectional areas; component adapters attach to busbars with different crosssections; a single circuit-breaker adapter can work with as many as ten different breakers.

Such modularity lets engineers revise or create new BOMs with minimal part changes.

for rare main-lug-only (MLO) applications, most control panels have a main overcurrent protective device (OCPD) within the cabinet.

This can be a circuit breaker or a fused disconnect.

In most installations, the main OCPD mounts in the panel with the controls and control wiring (including line-side wiring, distribution blocks and wire duct) under it. But if the main OCPD is small enough (generally 600 A or less), it can often mount directly onto the bus (and be on the same row as the control devices).

If the OCPD is too large or otherwise incapable of mounting directly to the busbar

Traditional motor circuit

(with an adapter), the design must energize the bus with feed cables. Such larger installations usually require multiple cables per phase. Insulated flexible busbar can replace these cables with a single conductor.

Here, flexible busbar carries all necessary certifications and ratings to facilitate an easy transition from standard round cable.

Featuring a wire bend radius as little as 0.125 in., flexible busbar saves panel space and eliminates the need to cut and strip multiple cables. Elimination of line-side wiring, PDBs and wire tray can help offset most of the busbar’s cost. Smaller enclosure size or (for larger systems) total elimination of the

Group motor circuit

Fuse or CB

NEMA versus IEC The National Electrical Manufacturers Association (NEMA) establishes standards for electrical components in North America. Industrial control and systems equipment must meet NEMA ICS 2, Standard for Industrial Control and Systems; they’re usually certified by a third party under UL 508, Industrial Control Equipment. The equivalent global standard is the International Electrotechnical Commission (IEC)—IEC 60947, Standards for Low-Voltage Switchgear and Controlgear.

Type E/F motor circuit

Fused disconnect (or circuit breaker)

Non-fused disconnect

enclosure also saves money—a benefit passed down from designer to integrator to end-user.

Non-fused disconnect

MMP

Contactor (optional)

Contactor

Thermal overload

Motor

Motor

Type E CMC

Type F CMC

Contactor (optional)

Motor

Group motor installations don’t require short-circuit protection for individual motor circuits. IEC equipment excels in such setups.

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UL 508, the primary industry standard to which devices are certified in the U.S., is now harmonizing with IEC 60947 to become UL 60947. Effective 2017, UL 60947 will further cement IEC devices as the industry standard.

So within the U.S., IEC devices are becoming the first choice for many designers in automation.

Here’s a comparison of IEC and NEMA equipment to show why.

NEMA standards are more general, so NEMA components form robust controls that address myriad applications. With just a few parameters to consider, design work is easier. NEMA devices meet standard size ratings (00, 0, 1, 2 … 9) so last longer, too. But NEMA devices are often overbuilt for their application. For example, a NEMA Size 0 contactor is rated 5 hp at 460 V for full-load current (FLC) of 8 A. This contactor has a continuous current rating of 18 A, more than double the full-load current.

In contrast, IEC standards are more specific, so components are more customizable. IEC components are rated by continuous-current ratings much closer to their switching capacity. So an IEC contactor equivalent to the NEMA size 0 is rated 5 hp at 460 V (with 8 A FLC) but with a continuous current rating of only 9 A. This tighter tolerance means IEC controls come in twice the number of sizes as NEMA counterparts.

IEC motor controls under 100 A (more than 80% of the market) are also 30 to 70% smaller and less costly than equivalent NEMA controls. That’s mostly because of compact arc suppression. Every time a contactor closes or opens, an arc forms that slowly degrades the metal contacts.

NEMA contactors have large conducting surfaces to address this; both the rated mechanical and electrical operations are higher than equivalent IEC units. But better arc suppression in IEC contactors means they need less material, so are smaller. IEC also classifies machines into different “usage categories” that define contactor and relay electrical load and duty cycles, so designers can pick units with just the right capacity.

Over time, predictive maintenance provides the lowest cost of ownership.

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Series KG Impact Sensor

The KG Impact Sensor is used on industrial actuators and other moving parts as an easy-to-use early warning device.When stopping impact exceeds the set parameters, the KG Sensor signals the PLC as the LED changes from green to red. Just-In-Time Maintenance dramatically increases productivity and is easy to accomplish with the KG Impact Sensor.

Motor protection circuit breakers Overload relays and contactors for motor control don’t protect against short circuits. In NEMA panels, branch short-circuit protection is through fuses or molded-case circuit breakers (MCCBs). In contrast, IEC panels use motor-protection circuit breakers (MPCBs) for disconnecting and short-circuit protection with instantaneous magnetic trips (plus manual motor control and overload protection with thermal trips).

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May 2014 DESIGN WORLD DESIGN 8WORLD 7

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There’s no NEMA equivalent to an IEC MPCB and the devices can’t replace a UL 489 MCCB or as a UL 98 disconnect switch per the NEC. So, UL simply classifies these products as manual motor controllers. Also known as manual motor protectors or motor-starter protectors, these often go in group-motor installations.

Such setups don’t need short-circuit protection for each individual motor circuit. There are restrictions, but NEC Article 430 (Motors, Motor Circuits, & Controllers) and UL 508A (Industrial Control Panels) allows several motor loads on one branch.

IEC motor-protection circuit breakers also satisfy UL 508 as combination motor controllers (CMCs).

These work as branch circuit protectors for motor loads, eliminating the need for a UL 489 MCCB or fuses. These CMCs are Type E Manual Self-Protected Combination Motor Controllers—self-protected so they work after a short circuit, something even UL 489 MCCBs don’t do.

The contactor for remote motor control creates a Type F CMC that works in circuits similar to group-motor installations but without restrictions.

Replacing single-function devices with manual motor protectors or CMCs can save panel space, wiring labor and money.

Standardized metric sizing and installation There’s a bit more design work to configure IEC components, but it’s offset by how fast IEC panels set up. IEC components have standardized widths, so a two-pole miniature circuit breaker is twice the width of a one-pole; a three-pole version is triple the width.

Most motor starters rated 37 A and below are 45 mm wide; those rated between 40 and 55 A are 54 mm wide; and 60 to 100 A are 72 mm wide. In addition, most accessories like auxiliary contacts work with devices regardless of rating or size. This standardization lets designers easily configure panel layouts, even with devices from different manufacturers.

Like NEMA devices, IEC controls can panel mount with two or four mounting holes. But unlike some NEMA devices, almost all IEC controls also mount to standard 35-mm DIN rail—so a panel integrator can install an entire row of IEC devices with just a few screws to mount the DIN rail.

About 30% of all motor failures are from overloads. Most IEC overload relays are Class 10 units with a 10-sec tripping time. Typical NEMA relays are Class 20 units with a 20-sec tripping time, overbuilt for

Booth C-1847

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IEC motor controls are readily available throughout the world and typically carry a CE mark for the European market and a UL mark for the North American market. Global manufacturers (as those in the automotive industry, for example) benefit most from this common machinery platform.

It ensures easy parts sourcing and conformation to local electrical codes.

general-purpose use. So one largely unfounded concern about IEC devices is the threat of nuisance tripping (when the relay trips the motor during peak current draw, usually startup). Most modern motors reach operating speed before the 10-sec tripping time, and special applications that require more time can incorporate Class 20 overload relays.

About 15% of all motor failures are from single phasing, usually when an upstream single-phase load causes imbalance in a downstream three-phase load. Here, bimetallic IEC overload relays can address phase-loss sensitivity. During electrical imbalance, a

differential tripping mechanism makes the overload relay more sensitive by lowering the trip point. But damage can still happen, especially after extensive single phasing of a motor with a load not high enough to trip the relay. Engineers concerned with true phase-loss protection should invest in solid-state (electronic) overload relays or

separate phase monitors.

Motor temperature depends on heat from magnetic and current effects of normal operation and ambient temperature. Overload relays must prevent motor overheating even under extreme heat and cold. But relays often have their own temperature-dependent characteristics different from that of the

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IEC components are rated by continuous-current ratings

so some overload relays trip more slowly when it’s cool, for example. Temperature compensation isn’t available for most NEMA equipment.

In contrast, IEC devices use mechanical means to reduce temperature effects and maintain consistent trip times. For safety, some IEC devices feature IP20-rated bodies, so objects bigger than 12.5 mm (0.5 in.) can’t contact the live terminals.

There’s no such NEMA standard, although some manufacturers design NEMA equipment with comparable features. In addition, IEC 60947 outlines differences between devices allowed to show damage after short circuits and those that aren’t. Type 1 coordination devices can show damage and aren’t for reuse. Type 2 coordination devices can’t show damage and are reusable after a short-circuit fault. Type 2 devices enhance safety by eliminating arc-flash risk, plus reduce downtime.

close to their switching capacity. IEC motor controls under 100 A are also 30 to 70% smaller and less costly than equivalent NEMA controls.

Busbar misperceptions In the past, busbars only unified single-use systems for specific applications. Even today, only a few manufacturers make standardized busbar systems for control-panel use. Still, misperceptions persist due to lack of knowledge about these systems.

Misperception: Busbar systems are more dangerous due to difficulty making touch-safe installations. Traditional busbar installations such as load centers and MCCs offer touch safety with dead front panels that only let personnel access power connections from the enclosure’s rear. New modular systems for use with control panels incorporate

touch-safe terminals and covers. They also eliminate terminal blocks so are safer than many typical power-distribution block-andcable installations.

Misperception: Busbar systems involve complex fabrication and integration. In the past, many switchgear installations using busbar required bending, drilling and tapping of the copper bus. But newer busbar systems eliminate this, so installers can just cut it to length. Even cutting the bus to length is sometimes unnecessary. Connections to the bus are through adapters held in place with setscrews or spring clamps.

Shown here is traditional wiring (left) and the simpler wiring of a busbar system (right).

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Easier integration with busbars Much of the physical integration of controls is labor intensive. Here, busbars make it easier to terminate wires and connect equipment.

Plus busbars reduce the amount of enclosure drilling and tapping for setup. It’s true that such work is easy for facilities with CNC machines, but it’s a monumental task for those without. Even plants with CNC machine access benefit from reduced tooling wear and turnaround time.

Power distribution blocks: PDBs usually install with at least two mounting screws per phase. This means a typical three-phase application needs at least six drilled and tapped holes in the mounting panel. Plus, each end of the feed cables must terminate into the block and OCPD. This constrains wire sizes and room for future expansion.

Line-side wiring: Completing a control panel’s line-side wiring takes considerable time. For example, a typical three-phase 300A application with 12 motor starters could mean 36 cables for these devices, plus another three for the feed. Each of these cables must be measured, cut, stripped, routed, labeled (identified) and terminated on both the line and load sides.

Wire duct: All line and load wiring typically routs along wire duct. The wire duct

E l e c t r o n i c s

must be measured and cut to size. The panel is then drilled and tapped to receive the wire duct fastening screws or just drilled to accept rivets. A typical mounting interval is 4 in., so each row in a 32-in.-wide enclosure with a 28-in.-wide mounting panel may need as many as eight holes. Here, installers must use extra caution, because the installation must accommodate the duct’s wire-fill capacity as well as the cable’s wire-bend radius. No busbar system can replace all wiring duct, but most can eliminate line-side wiring duct.

Main overcurrent protective device: This also requires mounting screws into the mounting panel. But some installations mount the main OCPD directly to the bus, to do away with screws and save panel space.

Miscellaneous control devices: Typical IEC control devices 100-A and less install on standard 35-mm DIN rail. This DIN rail must fasten to the panel with drilling and tapping of the mounting panel. Screw intervals are generally 4 to 8 in., so (as mentioned) as many as eight holes must be made for every row of controls in a typical enclosure. Each MCCB requires at least two of their four holes (three-pole) for direct panel mounting.

Eliminating these holes reduces labor costs.

Note that busbar systems for control panels fall under the new standard IEC

In some industries, NEMA devices that have long dominated the North American motor-control landscape are giving way to IEC-approved equipment shown here.

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61439 (Low Voltage Switchgear and Controlgear Assemblies). The components must pass requisite tests in a process known as design verification (formerly called type testing).

Like the IEC devices with which they work, busbar assemblies come with requisite third-party listing (not recognition) to this standard. So, UL panel integrators can use all the parts without having to describe them (as they would need to do recognized products).

Busbar benefits for end users Power distribution blocks aren’t touch-safe, and sometimes cause dangerous arc flashes.

Modular busbar systems for control panels address this issue with myriad touch-safe covers for adapters, terminals and the bus itself.

These make the busbar setup 100% touchsafe, even if stray fasteners, dropped tools or body parts contact the bus.

Traditional control panels constrain wire sizes, so there’s little or no room for future expansion.

Even if expansion is possible, it’s often only with extensive drilling and tapping. In contrast, personnel can update modular busbars for machinery expansion without machining. Plus, control panels using busbars easily accept extensive retrofits.

None of the devices screw into the panel, so all come out to make way for new hardware as needed. Even if the enclosure needs replacing, it’s possible to repurpose the busbar into the new enclosure—a change considerably easier than that for a traditional block and cable design.

Maintenance and troubleshooting busbar designs are also efficient. Line side wiring needs no tracing, and plant personnel can replace components from their adapters. DW

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Nobilia uses PC control from Beckhoff universally throughout its manufacturing plants for the universal transparency of the parts and production data needed to allow its individual kitchen kits to be supplied flexibly and efficiently in a lot size of 1.

photo: istockphoto.com

The latest development of industrial Ethernet is how it will be a part of the Industrial Internet of Things (IIoT).

Variations of Ethernet still abound, yet some of the conversation is moving toward accepting the open Ethernet standard, a variation developed by Mellanox Technologies. Open Ethernet is targeted more at IT use, and is being evaluated by IT departments in many companies. It is not widely used in industrial applications yet.

Ten years ago, many industrial companies had Ethernet connectivity and distributed intelligence. “The infrastructure was in place,” said John Kowal, director, business development at B&R Automation. “What we will see now, with IIoT as a strategic business imperative, is an expansion of demand and of commercialized applications to make use of all this connected, distributed intelligence.”

For many suppliers of industrial HMI devices and controllers, web servers have long been a standard feature.

But some companies are now realizing that these features enable IIoT, and they are beginning to use this capability.

“Ten years ago we didn’t have the level of secure communications commercially available,” continued Kowal. “But otherwise, we had all the Internet protocols, the mainstream, non-proprietary processors coming from the likes of Intel and AMD, and Industrial Ethernet-to-Internet connectivity.

“There were smart sensors back then too, but users didn’t want to add $100 to a photo-eye that they expected to get hit by a lift

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on a 24/7 basis. The AutomationDirect C-more HMI product was chosen for this application. It has a built-in FTP server to serve production statistics out to the Web in real time. It can also send HMI screen captures. It enabled management to look at a predefined set of operator screens as well as a full set of production statistics from anywhere in the world. Said Gary Marchuk, director of business development at AutomationiDrect, “As technologies continue to drive data to the Cloud, we see the need for these types of applications growing at a more rapid pace.”

This application was made possible through the use of standard Ethernet as the communication medium for the HMI and PLC.

With IIoT capability, operators can use smartphones and tablets to remotely monitor variable frequency drives and adjust motor speed based on the quality of the product they see coming off the processing equipment, such as that shown here from Opto 22.

truck. Now, distributed intelligence is cheaper, more accessible, and therefore going into devices like vision sensors, I/O slices and stepper drives in remote I/O form factor, whereas in the past the cost justification stopped at the high end servo drive level,” he said.

The IIoT is an evolution of the connectivity efforts started years ago. As Daymon Thompson, TwinCAT product specialist, Beckhoff Automation, noted, it is a concept that will only be fully implemented in the coming 10 to 20 years.

Even so, manufacturing operations are taking advantage of the evolution of Ethernet into the IIoT. Here are a few examples.

Packaging AutomationDirect was instrumental in helping a packaging manufacturer develop a control and data collection system in its plants. A key requirement was to have plant information and statistics available to management from anywhere in the world

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Simpler sensor connection Noted Shishir Rege, marketing manager networking and safety, Balluff, implementing a smart device was a time consuming, expensive and cryptic operation.

“Maintaining such installations was a nightmare.”

With the advent of industrial Ethernet and device communication standards like IOLink, integration of smart devices becomes simple. Parameterization, predictive diagnostics and overall functionality of sensors got a big boost. Now, instead of finding the cheat-sheets of parameters to configure a smart sensor in the middle of the night, it now becomes a matter of finding the replacement sensor and simply plugging it in. The control systems incorporating industrial Ethernet technologies with IOLink automatically configure the device to the correct parameter setting.

Lot sizes of 1 Nobilia manufactures an enormous number of kitchens per year, with over 580,000 produced in the two manufacturing plants located in Verl in East Westphalia, Germany.

Around 2,600 custom kitted kitchens leave Nobilia’s two production plants every day.

PC-based control from Beckhoff is the foundation for the universal transparency of the parts and production data needed to

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Manufacturers of Power Transmission and Motion Control Components

The IIoT enables operators and engineers to view data from just about any smart human interface device, such as smart tablets.

Photo courtesy of Opto 22

allow individual kitchens to be supplied flexibly and efficiently in a lot size of 1, which is entirely in keeping with the ideals of Industry 4.0. Modern Industry 4.0 concepts, and the higher flexibility in production that is attainable with them, are not possible without ensuring transparency of all machine and parts data.

Real-time tracking capability over the entire process is the fundamental requirement. For Nobilia, it starts by applying a barcode label that contains all necessary information about a piece of furniture. The barcode of a drawer front, for example, contains the configuration of the entire drawer, including its width and depth, the height of the rear wall and the type of handle. The production facility supplies all required parts, initiates the correct processing sequences, and ensures that the desired drawer is placed in a logistic train “just in sequence.” The latter then drives to the assembly area, where the finished body of the cabinet is married to the drawer and other elements, such as sidehung doors.

Through real-time tracking, anyone can learn where each part is in the production process at any time. Beckhoff control technology and an Oracle Works database www.designworldonline.com

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developed in cooperation with Nobilia resulted in a central, closely meshing link between ERP and design software.

Nobilia uses PC control from Beckhoff universally throughout both of its manufacturing plants, from the EtherCAT I/O system and motion control through to the Control Cabinet Industrial PCs (IPCs) and Control Panels with TwinCAT PLC/NC. Even the few older machines with conventional PLC technology can be integrated with PC-based control.

It’s possible to achieve a homogeneous data flow despite the heterogeneous machine pool. The data are held in the central database.

Special high-level language applications developed by Beckhoff are implemented in the production plants to communicate with this database and supply the respective plant controllers with adapted information.

According to Nobilia, this capability has been the key to the continuous improvement of efficiency in production.

RFID and RTLS (real-time locating systems) are used with the goal of making the identification of the furniture pieces more variable in comparison with the barcode system and also to deliver all necessary information.

These approaches will benefit from TwinCAT 3 and the multi-core IPC technology.

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At the Rexroth plant in Homburg, Germany, RFID and Bluetooth technology enable the assembly machinery, the work piece and the worker to communicate with each other for flexible and efficient production of custom products.

Analyzing production efficiency While almost everything that is being done with the IIoT could have been done 10 years ago, the difference is the technology has become affordable and easier to use.

For one of Bimba’s customers, the problem was a high-speed cylinder that tended to slow down during production runs, creating large amounts of scrap before this level of performance was detected. The recommendation was to use an IntelliSense sensor to monitor the cylinder. By connecting the actuator to the IntelliSense Data Gateway, Bimba engineers were able to remotely access the equipment and monitor the cylinder performance.

The engineers identified anomalies in the performance and linked them to other components in the system. They were able to determine, for example, that the mufflers used on the exhaust port were limiting cylinder speed. Replacing the mufflers with higher flow models improved the performance of the actuator, increasing its life. The engineers also identified an oscillation in the actuator’s stroke that was

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generating excess heat causing premature wear. They made modifications to the cylinder design to reduce the impact of this oscillation and increase its life.

Efficient production of custom products At the Rexroth plant in Homburg, Germany, an assembly line that is integrated into the Bosch Production System (BPS) enables semi-automatic production of hydraulic valves for tractors, in six basic types with more than 200 variations.

RFID and Bluetooth technology enable the assembly machinery, the work piece and the worker to communicate with each other for flexible and efficient production of custom products. Intelligent tool carriers are equipped with RFID tags to detect the required product variation and communicate the necessary materials and processes to the line. Each assembly station reads these tags and displays the relevant information to the operator through a

monitor screen to reduce throughput time and enable optimum use of resources.

The individual workplaces automatically adapt to the needs of the operators. This adaptation is done using Bluetooth tags with a user profile, which are carried by each employee and read out by the assembly station. In this way, the illumination of the station or the font size and language on the monitor are adapted accordingly.

Even the depth of information on the monitor screen automatically adjusts to the qualification of the particular user. All tools, such as the Rexroth wireless Nexo nutrunners, are connected to the data and can be accessed on the touch screen.

A digital CIP board shows production data in real time, which allows operators to rapidly identify weak points, react to malfunctions and optimize production. A Rexroth “activeCockpit” system collects, filters and continually displays production data, providing a communication platform for operators and decision-makers. This is critical in reducing downtime and increasing productivity.

A change in behavior Cisco has a customer that is using locationbased services (LBS) to drive behavior changes. Currently this customer has location-based wages depending on skill sets, and when employees move from work cell to work cell, they are expected to clock out of the one location into the other. But in reality, workers clock into the “highest wage area,” and then continue their day. By using LBS, the company can automatically update where the employees are, as well as the appropriate billing. This model was built on top of LBS for safety reasons and adds an immediate ROI for the new use case.

Mobile data Motivated in part by the cost and availability of labor, industries that benefit from remote monitoring and control use Opto 22 components in IIoT applications. A seed processing facility in Canada wanted a mobile operator interface that “could be used anywhere,” specifically requesting mobile control, monitoring and live video.

Operators now use smartphones and tablets

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to remotely monitor variable frequency drives (VFDs) and adjust motor speed based on the quality of the product they see coming off the processing equipment.

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Monitoring processes Rittal provides enclosures and climate-control products for industrial applications and data centers. This is especially useful when an application causes the two worlds to overlap, which was the case recently when Rittal was asked to partner with Colorado-based Palmer Drives Control Systems (Palmer DCS) to provide control panels for an application that monitors the efficiency of flames in steelmaking kilns.

As a provider of turnkey solutions for codecompliant control panels, many of which are found in hazardous locations, Palmer DCS must meet specific and varied requirements. The control panels monitor flame efficiency in the kilns. Features of the Rittal cabinets were important to their selection: flexibility and modularity, increased capacity and a cost savings of about 35%.

The cabinet is placed next to a kiln, so it must withstand 2,800° F temperatures nearby. The internal cabinet, however, must be kept much cooler. The water-cooled heat exchanger/air conditioner (which is externally mounted to the side of the control cabinet) must provide adequate amounts of cool air and proper flow. The maximum cooling water temperature is 80° F. Remote control Alexander Dodds, a woodworking OEM, built an innovative machine with several Schneider Electric products, including Magelis STU HMI and Vijeo Designs Air app, which allow remote control of the machine from an iPad or Android smartphone or tablet.

According to the company, this app has been a big selling point for them when one of its customers had an employee break an old HMI screen and lost $8,000 in revenue because the machine was down for two days. If they’d had the latest dovetailing machine with the Magelis HMI, they could have been up and running again in five minutes using a tablet or smartphone while the screen was being replaced.

In addition, embedded Ethernet in the MachineStruxure PLCs allows faster transmission rates between the controllers and the touch screen HMIs. One of Dodds’ customers using a dovetailing machine reported the ability to produce an additional 100 cabinet drawers per day because of the performance of the new controller.

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I nd ustrial Ethernet Distributing control “With traditional device networks, distributing control was not as prominent or as convenient as it is today in the IIoT, nor were the field devices able to provide the information necessary to easily execute such an architecture,” said Randy Durick, VP, Network and Interface Div., TURCK. With Ethernet-enabled devices, these networks and the information supplied can be visible outside the immediate application; data can be sent directly to the cloud, available on a LAN or WAN. In a device-level network, such as DeviceNet or similar network, the network simply isn’t as easily accessible (or in some instances, simply isn’t accessible outside of the local controller). In this network, data is more localized. DW AutomationDirect automationdirect.com Balluff balluff.com Bimba bimba.com Bosch Rexroth boschrexroth.com/en/us B&R Automation br-automation.com Beckhoff Automation beckhoff.com Cisco cisco.com Opto 22 opto22.com Rittal rittal.com/us-en

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Work with

stronger joints and lighter materials Enable consistent, strong and more efficient structures with friction stir welding.

Mary C. Gannon • Senior Editor

Traditionally, joining two separate pieces of metal requires a filler material, usually an alloy different from the base metal. For example, MIG and TIG welding is most common in the aluminum extrusion industry, but in some cases, adding this different alloy can cause miniature stresses as well as corrosion problems down the line.

Friction stir welding (FSW), still a relatively new technology, has seen an increase over the last several years in its end-use application, said Jason Weber, the director of business development for energy and industrial products of SAPA Extrusions North America.

Invented in 1991 by the Welding Institute of Cambridge, it is mostly used in the aerospace and defense industry, but continues to broaden its range of end use applications, such as in the rail, marine and energy sectors, said Steve Jackson, business development manager for thermal management at Sapa North America. www.designworldonline.com

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FSW is a method of joining two pieces of metal with no filler metal involved at all, subjecting components to heavy plastic deformation at high temperatures. “The key point here is [the process] is lower than the melting point. The process itself uses a rotating tool that is plunged into the components and friction is generated,” said Jackson. “It really is that simple. The tool produces a severe plastic deformation under high pressure, which welds the two materials together.”

How it works Jackson said that the weld probe and fixturing is critical in FSW. When joining two pieces of aluminum, the weld probe generates heat through friction, creating a homogenous structure.

“Because aluminum has naturally high thermal properties, the heat actually is naturally pulled away from the weld probe so you get the fine microstructure,” Jackson said.

Additionally, friction stir welding offers reduced thermal distortion and shrinkage because the material never gets to the melting point. It also provides improved repeatability and is suitable for automation.

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Unlike the mostly handheld manual MIG and TIG applications, FSW is always done by a machine that provides a consistent, high-quality finished product.

One of the biggest questions is why use FSW in the first place? FSW can transform small extrusions into wide extrusions. The typical aluminum extrusion press in the U.S., as well as worldwide, has a 7-in. circle size. Some companies are fortunate enough to have larger presses ranging up to 24 in. in diameter; however, the bigger the circle size, the higher the 108

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Fastening & Joining

Example of FSW used for cold plate manufacturing.

costs. The typical maximum width is 48 in.; however, the same technology is used to weld train frames together creating the body, which can have a 20-ft radius.

Why it’s better When performing MIG or TIG welding, you need to use an inert gas to prevent contaminants from entering the weld. As the weld melts and reaches its boiling point, you need to ensure that no contaminants get into the weld. Contaminants lead to porosity, which then cause problems from a thermal management and stress point of view. This is not a problem with FSW, because porosity is not an issue, so leaks and areas where miniature cracks can develop are eliminated.

Additionally, FSW offers reduced thermal distortion and shrinkage because the material never gets to the melting point.

It also provides improved repeatability and is suitable for automation. And, if an application requires two different alloys— for example, brass and aluminum—they still can be welded together.

Example of FSW to create wide heat sink.

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Example of FSW used in the manufacture of trains.

Modular versus bonded fin heat sinks FSW of aluminum extrusions is being used more and more to take advantage of the excellent thermal properties of aluminum.

Aluminum is used worldwide in large heat sinks because it offers high thermal efficiency and no porosity. It is also easy to manufacture aluminum into custom shapes, is lightweight and has low material costs. Although copper may have better thermal properties, its inconsistent price points inhibit its wider use. In addition, copper is heavier than aluminum and cannot be extruded.

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An example of a modular heat sink manufactured with FSW.

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Extruded aluminum offers a mix of advantages and disadvantages. For example, said Jackson, extrusions are superior to castings and bonded fin heat sinks and is available for total lower cost. The challenge comes, however, because typically in North America, aluminum extruders go up to about 4:1 ratio or even 10:1 ratios. Just a handful of aluminum extruders, SAPA included, can extrude fin ratios up to 16:1 and occasionally 19:1. Previously, this met most thermal applications; however, as electronics continued to get hotter, the thermal management industry developed bonded fin heat sinks. Bonded fin heat sinks can reach ratios of 40:1; however, this process is labor intensive and requires products to be “superglued� together with thermal epoxy.

To reduce labor costs, SAPA developed its own modular heat sinks that offer ratios up to 60:1. Through testing, the company was able to prove that FSW module heat sinks are 8% thermally more efficient than bonded heat sinks because there is no filler material, like the thermal epoxy.

Cold plates are yet another example of advanced thermal technology using FSW, especially in vehicles. Previously, cast cold plates were used, however porosity on large castings proved to be expensive. FSW is used to weld end caps on the extruded cold plate.

Recent tests showed the product withstood pressure testing up to 2,700 psi.

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Jackson stresses the importance of working closely with the design engineers at your extruder or thermal management company early because thorough and proper extrusion design can reduce the weight, while increasing function and operation.

“You want to really make sure you’re using the best practices for manufacturing. You want to design the extrusion so that it can be friction stir welded as fast and as easily as possible,” he said. “Regarding a thermal performance, make sure you’re using the correct alloy as well as the fin design and the heat sink orientation. When you put all of this together, you can get an efficient, cost-effective solution.”

Conclusion In conclusion, FSW is an alternative to other welding and mechanically joining methods used to join both aluminum extrusions and other alloys together. The automated process can be applied to aluminum extrusions as well as for joining extrusions to other materials. The result is a product stronger and thermally more efficient than MIG, TIG or bonded fin heat sinks. DW SAPA Extrusions North America sapagroup.com

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Industrial sensing evolves to address the IoT Randy Frank • Contributing Editor

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Current industry requirements are providing new direction for industrial sensors

Unlike consumer or even automotive applications for sensors, industrial clients have different driving forces that shape what they must accomplish or improve. Traditionally, these forces have not changed significantly at the highest level for decades. But Industry 4.0, also known as the Internet of Things (IoT) has become a major driving force for sensors and networks.

Industry 4.0 promises to deliver more and better actionable knowledge that should improve the performance of all types of industrial devices, equipment and systems in a range of areas:

Figure 1. The SICK CLV630 bar code scanner provides sensor health information.

 

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S e ns o r s

Figure 2. The MEMSIC MFC2030 flow sensor measures bi-directional flow with increased flow range as well as low power consumption.

Product health. Today, a simple go or no-go, yes or no response from a sensor provides insufficient data. Users want to know not only that the information comes from a reliable sensor, but also the health status of the sensor and whether or not it is near the end of its useful life.

“In the past couple of years, this has intensified quite a bit,” said Mark Langridge, director, sales and marketing for Packaging, Food, Beverage and Consumer Goods of SICK. “Whether they use a product from SICK or from one of our competitors, the expectation of it working in the application is just a given.”

Machine performance. Langridge cites three specific areas currently being addressed: analyzing/predicting machine bearing life, scanner input and bar code information. One aspect that puts greater emphasis on these and other inputs is IO-Link.

Providing sensor information to a programmable logic controller (PLC), power management software and enterprise resource planning (ERP) systems, IO-Link is the first standard IO technology worldwide (IEC 61131-9) for communicating with sensors and actuators. With IO-Link, the industry can get more information from even the simplest products. While IO-Link has existed for several years, it just surpassed 1 million links in 2012.

”With Industry 4.0 and the smart factory, (IO-Link) is just an enabler of all that information down to a level that you could never get to before,” he said.

Web-based systems. “Many inquiries for web-based systems are coming in the wake of Industry 4.0,” said Jens Kautzor, CEO of Hoffman + Krippner, a manufacturer of standard as well as custom LVDT, load cells, displacement, force and ultrasonic sensors and other products.

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S e ns o r s

Figure 3. All Sensors’ DLV Series Low Voltage Digital Pressure Sensor addresses smaller package size and other industrial requirements.

Smaller sensors. Daniel DeFalco, marketing manager at All Sensors, a manufacturer of microelectromechanical systems (MEMS) piezoresistive pressure sensors notes another sensor change resulting from the IoT and Industry 4.0.

“One of the requests we have received over the years with the Internet of Things becoming more popular is a smaller package size,” he said.

It seems there is never enough space, especially when more technology is being crammed into an enclosure. Kautzor agrees with the need for smaller size and adds two more customer requests.

“In recent years we have seen increased requirements in regard to size, quality and availability,” he said.

Other factors There are other forces in play that put a higher emphasis on items one and four in Table 1 (see page 122).

“In general, our industrial customers are trying to improve the consistency and quality of the products they ship out the door and lower their cost of production,” said Aaron Biggar, a senior applications engineer at Banner Engineering.

Globalization—Dale Deering, program director for 1D Vision Product Development at Teledyne DALSA, identified four different change areas, one unique to the imaging industry and one tied to Industry 4.0.

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S e nso rs

Figure 4. Banner Engineering’s QM42VT1 wireless vibration and temperature sensor is designed to work with the company’s 1-Wire Serial Interface Node models, MultiHop M-H6 radios and the Wireless Q45 Sensor Node.

traditional regions into Indo-China, South America and other emerging markets, resulting in price pressure and the need for further innovation,” he said.

Efficiency and ease of use—“Industrial customers continue to seek improvements in efficiency, cost and imaging innovation,” said Deering. “IoT is perhaps growing faster in the consumer market than the industrial market, but interconnectivity is certainly important.”

Ease of use is increasingly important to industrial sensor users. “As the imaging industry matures, work that has traditionally been done by skilled OEM labor moves down market,” Deering continued. “End users now expect to implement smart cameras and imaging systems with limited engineer skill.”

Figure 5. The KMM65 force sensor has a measurement range from 1 to 500 kN.

In the flow—Even industrial flow sensing applications are undergoing change. For many years, industrial customers ranging from gas meter makers, automation, medical and more have used diaphragm, Coriolis, capillary tubes and other mechanical gauge meters for measuring air and gas flow. Recently, these users have started to adopt solid-state based solutions and they are affected by Industry 4.0.

“The size of the solution, the battery power, ruggedness and other issues including remote sensing and monitoring are driving many market segments to solid-state flow sensors,” said Chris Winkler, senior marketing manager for MEMSIC, a manufacturer of MEMS sensors.

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S e ns o r s Table 1. Five areas that drive change in the industrial market Improve economics

Improve safety Meet/address government regulations

Incorporate/cope with new technology

Respond to changing customer requirements

Reduce cost

Operators

Improve security

Quality

Increase throughput

Equipment

Price

Reduce rejects

Facilites

Lower energy consumption

Also incorporate standards

Improve quality

Implement advanced robotics

Reduce energy consumption of a process

Replace old or obsolete technology

Delivery End consumer input

Reduce downtime Identify need for maintenance/repairs prior to failure

Industrial driving forces In general, classifications of industrial activities and changes seem to fall into four buckets: (1) improve economics; (2) improve safety; (3) meet/address government regulations; and (4) incorporate/cope with new technology. Table 1 shows the types of activities that could be included in these different areas. Many of the newest items in these categories are technology driven.

In some instances, the activities could be placed into more than one bucket.

“A fifth bucket that I would include would be responding to new customer requirements, as customer demands for quality, price and/or delivery can frequently change,” said Aaron Biggar, Banner

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Engineering. (Column 5 added thanks to Biggar.)

“For my industry, the driver is consumer input and consumer buying behaviors,” said Mark Langridge, SICK, “because that’s changed significantly over the past 10 to 15 years.”

Today, smaller packages, such as individual or snack portions are increasingly preferred over the bulk buying behavior of the past. The changing package sizes have a significant impact in a packaging facility and on its sensing requirements.

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S e ns o r s Suppliers respond to industrial requirements “The one thing that we have tapped into is a low supply voltage sensor,” said All Sensors’ DeFalco. “Since some of the remote sensing is battery operated, the consumption of power has become an issue.”

All Sensors recently introduced the DLVR, a low-voltage pressure sensor family that can operate in a hand-held sensing environment. It uses a 3.3- or 5-V supply voltage, interfaces with I2C or SPI bus and has better than 0.5% accuracy (typical) over temperature.

For MEMS-based sensor suppliers, size, ease of interface and low-voltage operation are all important. MEMSIC’s MFC2030 BiDirectional Flow Sensor is another example.

“Our device easily interfaces to microprocessors and can be powered from battery or conventional 2.7 to 5.5 V supply,” said MEMSIC’s Winkler.

For flow sensors, dynamic range is another key factor. The MFC2030 offers improved performance and dynamic range on the order of 100:1.

To provide more information about contamination and the environment of the scanner itself, SICK introduced the S3000 scanner. This is just one of SICK’s responses to Industry 4.0 requirements.

Bar code readers offer another example of added information. The CLV630 bar code scanner has integrated function keys for starting auto-setup or evaluating reading quality including the ink on the ink-jet printer head and other diagnostic features.

“This provides more information about the condition of the detection or the reading,” said SICK’s Langridge.

Whether it is lowering the cost of existing items that the customer buys or incorporating new technologies to improve productivity and quality, anything that can be done to save money and time is significant to industrial customers, according to Banner Engineering’s Biggar.

“Increasingly, we are focused on areas where our traditional customers commonly have pain,” he said.

Machine vibration is often a symptom of a number of serious potential problems. To address them in a timely manner, engineers at Banner developed the wireless vibration and temperature sensor to help maintenance engineers identify these problems and correct them before they lead to machine failure or other serious problems.

For Teledyne DALSA, new product requirements for imaging include ease of use, interconnectivity, more robustness to handle less well-controlled environments, and many new features to make them more flexible and easier to use. New designs are also smaller and more power efficient. This has led to increased use of CMOS imaging.

“CCDs have, for the most part, been replaced by CMOS imagers in new products,” according to Teledyne DALSA’s Deering.

Figure 6. Teledyne DALSA’s new Linea line scan family exclusively uses CMOS technology.

By partnering with Altmann, Inelta and PIL, Hoffmann + Krippner added high-precision potentiometers, LVDT and load cells and ultrasonic sensors to its sensor offerings. This simplifies customers sensor design-in activity in many areas. The KMM65 standard force cell is one example of a new portfolio product.

While many of the driving forces seem familiar, many changes could occur in the industrial market as it increasingly embraces even greater connectivity of the IoT and Industry 4.0—but not at the same time. DW

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Machine Vision

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Image dimension measurement system makes tolerance checks faster Lisi Medical’s plant in Miribel, France, specializes in the outsourcing of surgical implants and ancillary items. Consisting primarily of plates and screws, these parts require precision manufacturing and are inspected by the plant’s metrology department. The typical tolerances allowed range from 0.1 to 0.05 mm.

“We measure around thirty points on each part. We perform these measurements either on entire production runs or randomly selected parts. Inspecting a part with a conventional system consisting of a profile projector, micrometers and calipers takes around 20 minutes on average. With the IM measurement system, these inspections take only four to five minutes,” said François Lyannaz, metrology manager.

The IM Series image dimension measurement system in question is the second one Lisi has acquired for its metrology laboratory. This new type of dimension analysis system combines the speed and flexibility of a vision system with the accuracy of a double telecentric lens, making it possible to obtain high-accuracy, reliable measurements in a minimum amount of time.

A user simply places a target on the stage and presses the button. Up to 99 points are measured in a matter of seconds—with a repeatability of 0.5 µm.

The Intelligent Pattern Analysis Search System (iPASS) determines the position and orientation of targets and compares their shapes against those of recorded targets.

The large, 100-mm dual telecentric lens captures entire targets in a single image for simultaneous measurement of all points. This technology allows pixels to be captured as if the lens were vertically positioned. As a result, measurements are not affected by distortions or distance. In addition, measurement data can be saved and exported as reports or to statistical packages. Anything can be measured, from inside diameters, circular pitches and angles to more complex dimensions.

“The other major advantage to the system is its repeatability,” said Lyannaz.

“It automatically finds and measures targets, reduces the risk of error and eliminates the risk of measurements being affected by variations in operator

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Machine Vision

skill levels. It gives a single standard for measuring our parts.”

Measurement stability is an essential aspect of the IM Series.

Adjustment by the least-squares method ensures stable edge detection, even if a sequence of edge points is misaligned due to noise or other factors.

Another way the IM-6000 Series enables stable edge detection is by ignoring abnormal edge points, even in situations where a target has burrs or chips that lead to errors during the least-squares adjustment. With an accuracy of one-hundredth of a pixel, Keyence’s sub-pixel processing system detects edge positions more accurately than conventional systems.

When edges are extracted manually

with the naked eye, discrepancies between operators are virtually impossible to avoid.

Furthermore, the system measures dimensions without moving the XY stage, thus eliminating vibration-induced errors.

“The system comes ready to use. Its simplicity and Keyence’s technical support enabled us to use it to its full potential almost immediately,” said Lyannaz. DW

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

Stepper motors Kollmorgen Kollmorgen.com LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

The PMX series of stepper motors now has 8, 11 and 14 frame sizes in addition to the traditional 17, 23 and 34 sizes, each with several stack length and winding options available.

Also available are options for 1.8 and 0.9°

KA Type Linear Actuator / SAR Ballscrew or belt driven, exible design.

step angles. The motors are CE, RoHS and REACH compliant.

Thermoplastic rack

KK Type Linear Actuator / SAR Ballscrew driven, high accuracy and reliability.

Nexen Group Nexengroup.com Made of self-lubricating polymer, the Versa Rack can run at full speed without additional lubrication. It can easily

KS Type Linear Actuator / SAR Ballscrew driven for clean room applications.

withstand washdown and outdoors operation (even in coastal climates with salty air). The Versa Rack features backlash less than 3.2 µm and positional accuracy of ±580 µm, depending on the pinion selected.

AC Servo Motors.

It also withstands loads of 500 to 1,200 N depending on pinion size. The speed rating of value pinions and thermoplastic racks is 480 to 750 rpm and 2 m/sec.

Hiwin D1 and D2 Servo Drives for Servo Motors, Torque Motors and Linear Stages.

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Pro duc t World Motorized leadscrews Thomson Industries Thomsonlinear.com Thomson Motorized Leadscrews are available in two motor configurations: Rotating Screw (RS) and Rotating Nut (RN). They come in standard and high precision variants and have a wide range of standard options to give designers flexibility and ensure a close match to the application. NEMA frame sizes between 11 and 23 can be selected with various leadscrews available in metric and imperial sizes. Stepper resolutions range from 0.00016 in. (0.00398 mm) to 0.005 in. (0.127 mm) and the NEMA 23 variant delivers a maximum axial thrust of up to 200 lb (890 N). Single and double stack configurations are also available where more load capacity is required.

Encoder solutions that just make sense.

Contact us today and find out how EPC’s advanced optics, sensors, and robust housing designs are the sensible solution for your motion control feedback challenge.

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CELEBRATING

HERRMANN ULTRASONICS WELDING TECHNOLOGY

Herrmann Ultrasonics, Inc. 路 1261 Hardt Circle 路 Bartlett, IL 60103, USA 路 www.herrmannultrasonics.com

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Pro duc t World Fastening system

Flexible RFID system

Penn Engineering Pemnet.com

Balluff Balluff.com

The PEM VariMount fastening system (Type VM) uses self-clinching technology

The BIS V is capable of reading three

paired with a round steel or stainless-steel base plate to offer a clean and

different frequencies of RFID tags. With

ready-made assembly for mounting into any rigid material or panel, including

four dedicated RFID ports and one

composites, plastics and metals.

IO-Link master port, RFID can now be

Multiple radial holes in the base

mixed with sensors, hubs, actuators and

plate and a “generous� footprint

even SmartLight tower lights all in one

combine for effective mounting of

processor. Since it has an IP65 rating, the

the assembly, whether the method

BIS V processor can be mounted directly

is mold-in or laminate with layers,

on the production line instead of making

adhesives, standard fasteners or spot

long runs back to a control cabinet.

welding. Mounting can be performed either on the front or through the back of a panel.

Industrial gas springs Ace Controls acecontrols.com Available in cylinder sizes from 15 to 40 mm, the NEWTON line of gas springs offers strokes from 20 to 1,000 mm and forces from 40 to 5,000 N. The springs also feature new slide bushings and seals that reduce friction and wear, large gas passages and an extended piston rod guide that accommodates high off-axis forces.

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SALES

Ad In dex Aerotech. Inc. ..................................................33 All Motion ...........................................................4 Allied Electronics, Inc. ....................Cover,3,130 Altech Corp. .....................................................15 Altra Industrial Motion Corp. .........29,30,31,32 American Control Electronics ........................55 AMETEK Catalyst Motion Group ....................21 AMETEK PMC/Dynamic Fluid Solutions .......17 AMETEK PMC/Dynamic Fluid Solutions .......23 Anderson Metals Corp., Inc. .........................113 Applied Motion Products, Inc. .......................13 Aurora Bearing Co. ..........................................16 AutomationDirect .......................................... 26 Baldor Electric Co. ....................................... 105 Balluff GmbH .................................................. 36 Banner Engineering Corp. .............................39 Baumer ............................................................47 Beckhoff Automation ...................................101 BEI Sensors ...................................................123 Bellowstech, LLC ............................................78 Bimba Manufacturing Co. ................................2 Bird Precision ................................................. 90 Bishop-Wisecarver Corp. .............................. 93 Bison Gear & Engineering Corp. ...................IBC CADENAS PARTsolutions ............................. 134 Canfield Connector ........................................ 44 CGI, Inc. ............................................................61 COMSOL ...........................................................73 Crouzet Motors .........................................64,65 CS Hyde Co. .......................................................8 Custom Machine & Tool Co., Inc. .................. 99 Del-Tron Precision, Inc. ...................................82 Design-2-Parts Shows .................................139 Deublin Co. ..................................................... 42 DIEQUA Corporation ....................................... 95 Dorner ............................................................. 88 Dunkermotoren, part of AMETEK .................19 Encoder Products Company ...................... 136 EXAIR Corp. ........................................................5 EZAutomation ...................................................1 Fabco-Air, Inc. ............................................... 103 Fixtureworks .................................................. 90 Galil Motion Control ........................................83 Graybar ............................................................35 HARTING, Inc. of North America .....................72 Haydon Kerk or PITTMAN ...............................25 Helical Products Co. .........................................7 HELUKABEL USA ............................................ 94

Herrmann Ultrasonic ...................................137 Hitachi Cable America Inc. .............................53 HIWIN Corp. .....................................131,133,135 igus, Inc. ....................................................... 109 Interpower Corp. .............................................62 ITT Enidine .................................................Insert J.W. Winco, Inc. ...............................................16 Keystone Electronics Corp. ...........................51 Lee Spring Co. ...............................................125 Lenze Americas ............................................116 Master Bond, Inc. ........................................... 42 Methode Inc. ................................................128 Miki Pulley USA ...............................................69 Moog Components Group ................................9 Nason .............................................................. 28 National Instruments Corp. ...........................71 NB Corp. of America ....................................... 89 Newcomb Spring Corp. ..................................52 NOOK Industries, Inc. .....................................77 Novotechnik U.S. Inc. .................................. 104 OMEGA Engineering Inc. ................................59 Omron ............................................................120 PBC Linear........................................................91 Peninsular Cylinder Co. .................................76 PennEngineering ......................................... 102 PHD Inc. ...........................................................87 Posital-Fraba ...................................................63 Proto Labs, Inc. ..........................................57,67 QA1 ................................................................ 104 R+W America ................................................ 108 Rittal GmbH & Co. ....................................80,81 ROSS Controls Inc. ....................................... 111 Rotor Clip Company, Inc. ......................117,119 SAB North America .......................................132 Servometer .....................................................78 Setco ..............................................................112 SEW Eurodrive ................................................BC SIKO Products Inc. .......................................129 Smalley Steel Ring Co. ...................................10 THK America, Inc. .......................................... IFC Tompkins Industries, Inc. ........................... 118 Tormach, Inc. .................................................. 38 TRIM-LOK, Inc. .................................................49 U.S. Tsubaki Power Transmission, LLC ........ 20 Whittet-Higgins Company .............................27 WITTENSTEIN holding Corp. ...........................79 ZERO-MAX, Inc. ................................................37

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THE BEST JUST GOT BETTER...

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