Design World September 2017 by WTWH Media LLC

www.designworldonline.com September 2017

INSIDE:

MOTION CONTROL: Hybrid servos vs. standard servos: how do they stack up? PAGE 66

ELECTRONICS The IoT and motion control fuels a rising tide of Raspberry PI, BeagleBoard, and Arduino boards PAGE 88

INDUSTRIAL ETHERNET How IIoT enhances management tools. PAGE 96

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I n s i g ht s

Another look at reshoring Politicians’ claims to the contrary, there are certain manufacturing jobs that are simply not returning to the United States—some production is simply much less expensive in other countries, and some jobs are being replaced not by foreign workers but by robotics and automation efficiencies. One area where we can look to make some small gains is in reshoring. While not a cureall, it’s a strategy that certainly makes sense in some industries. The Reshoring Initiative was founded in 2010 to help facilitate understanding of the costs of offshoring. Those costs, which aren’t always realized until it’s too late, include inventory carrying costs; intellectual property risks; travel expenses to find, interview and check up on suppliers; shipping expenses; and opportunity costs due to long product pipelines. Some recent commentary from the Reshoring Initiative’s president, Harry Moser and John Stoneback, president of Fairport Harbor, Ohio-based JM Performance Products brought some of these issues into focus. The key driving variable to offshore was low labor costs in overseas markets like China. Moser said that when companies first began to offshore to China, wages were so low that the price differential was 30-40%. “But now that the Chinese wages have come up, that price gap might only be 10 or 15%,” he said. “As a result, even China is outsourcing to Malaysia for cheaper labor.” Stoneback explained that three key benefits to reshoring he’s seen are cost, time, and insurance, with inventory and space logistics being a potential fourth factor. He said that those factors are so small if a company is manufacturing domestically that the math can be done in your head—it is a simple cost analysis. “There’s more control as the ability to guarantee delivery within five days or so, even by truck, anywhere in the U.S. is reasonable—therefore it’s easier to keep the supply going smoothly without any overseas delays or surprises,” he said. “Even the weather is a factor in delivering from overseas. The fact is, in overseas production you can anticipate having delays, spreading out money over time, multi-line invoicing, and increased insurance−plus you may have to over-produce to anticipate needed demand.” Stoneback postulates that a manufacturer can anticipate four to five times the shipping cost variance in bringing products in from China versus making them here. And that’s not factoring in any importer’s mark-up, which could be 15% or so. The Reshoring Initiative has an interesting “Total Cost of Ownership Estimator” on its website, at reshorenow.org/TCO_Estimator.cfm. This tool calculates 30 cost factors for each source—and may be a helpful tool for any manufacturers wrestling with the issue of whether to offshore or not. DW

Pa ul J. He n ey - Edi tor i al D i re ctor phe ney@wtwhme di a.com

On Twitter @ DW—Editor

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

Trust me -- My spreadsheets are perfect I recently heard an application engineer describe a new spreadsheet calculator his Tier Two automotive employer had devised. The spreadsheet helped calculate several technical parameters that went into sizing and selecting a new high-tech automotive component. Meant to be filled out by design engineers at Tier One suppliers, it would be used in the specification of engineered parts valued in the millions, if not tens of millions, of dollars. I only had one question for the engineer: Who had verified the accuracy and logic of that spreadsheet that was destined to be responsible for so much of the firm’s sales? The answer: “The engineer who wrote it verified it himself….probably.” For that company’s sake, I hope its spreadsheet is correct. But you’d have to say they have a lot of confidence in a key spreadsheet that no one but the spreadsheet creator has ever examined. It turns out that this scenario isn’t out of the ordinary, even for researchers with a technical background. So says a couple of computer scientists from the UK. In a paper available from the arXiv.org open-access

library maintained by Cornell University, they describe a study of neuroscience researchers who regularly use spreadsheets to tabulate and manipulate data. The majority of the study participants said they didn’t show their spreadsheets to anyone else for a sanity check. Only about 20% did an accuracy check by asking one of their peers to look at their work. Also interesting was that nearly a third of the researchers in the study didn’t bother documenting their spreadsheets as to the inputs, computations, output, and data point entries. And researchers tend to be self-taught when it comes to spreadsheet skills. None of those in the study had taken a training course in how to create spreadsheets. The majority had picked up what they needed to know on the job while about a quarter of them had some tutoring from their peers. The irony was that though a minority of the researchers in the study had ever seen the inside of a class room devoted to spreadsheet work, almost three quarters of them rated their own proficiency in Exel as being in the intermediate range. The scientists running the study point out that this reply smacks of overconfidence. They point to a previous study of spreadsheet use in which nine highly experienced

spreadsheet developers all were found to have made at least one error, and 63% of the spreadsheets they created overall had errors. Yet when asked about how confident they were in their work, the median reply was “very confident.” I’d have to say the results these scientists report has the ring of truth. I also have to admit it’s been a long time since I had anyone check a spreadsheet I made. Ditto for anyone asking me to check a spreadsheet they’d created. I suspect that the experience of most technical professionals mirrors my own. Getting back to the automotive Tier Two supplier, the engineer with whom I spoke did, in fact, have a way ensuring accuracy in spreadsheets. “I once created a huge spreadsheet for a thermal analysis while I had a 103⁰ fever,” he said. “I knew I was sick so I focused intently on my work. When I went back and checked, I had made errors in only two cells, both of which held complicated equations.” Oddly, creating a spreadsheet while feverish was not one of the practices the UK scientists mentioned. DW

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

On Twitter @ DW—LeeTeschler

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Te c h n o lo gy Fo r wa rd

Is that all there is? The Internet of Things burst onto the scene in a big, splashy way in 2014. It promised to help you design better because you would have better knowledge about how components interact, and thus, could tweak designs to deliver products that generated greater productivity. It’s now 2017. The main uses of the IoT are preventive downtime, predictive maintenance, and a lot of companies offering you services on downtime and maintenance. What has the IoT shown that it does differently than earlier methods of downtime prevention and predictive maintenance? As a refresher, since 1982 when the first attempts at connecting industrial automation equipment were made, most data gathering approaches for industry involved adding sensors onto various components that would register every micro-inch of movement, every pound of over or under weight, every motion in or out of range, and so on. These data were then sent over a network, usually some Ethernet

derivation, where an automation engineer or expert would look at them and determine what could be tweaked to improve the production process. What’s changed since then? Those early attempts were about reducing downtime, predicting when maintenance could head off an unexpected line stop, and just maybe make a process run a bit better. What’s changed with the introduction of the IoT? Presently, the IoT is about installing lots of sensors onto just about anything you can—resulting in tons of data. Sensor technology has vastly improved since 1982. The IoT has definitely been a boon to this industry. Now the IoT is about establishing communication between and among all kinds of devices—more devices than previously connectable—to gather the data from those sensors. Well, we all still use Ethernet or some derivation. So we essentially are still transmitting all the data in the same way we have done for decades. One of the main promises of the IoT is that it will give you better data to improve automation processes. So how is that going? Analytical software is arriving. Some success stories are being told. But the IoT, after three years,

seems to be primarily about eliminating unplanned downtime. You hear great statistics announcing that, “unplanned downtime can be reduced as much as 70% through sensorbased monitoring.” How is this different from what’s been evolving since 1982? Many of the “success” stories of IoT are really about a plant that did not automate over the last several decades, and finally has done so, and has seen good results. Well, of course. But are those results any better than those obtained by the early automation adopters? Maybe it’s early yet and data analytics, arguably the real key to IoT, still need to develop and become easy to use. But if IoT does not offer any more than preventive downtime and predictive maintenance, you can’t be blamed for thinking, “Is that all there is?*” DW *Title of the famous 1969 song sung by Peggy Lee

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

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G u e s t

E d i t o r i a l

Manufacturing—the best career choice for problem solvers Pamela Kan • President of Bishop-Wisecarver Group

hile we clearly enjoy the technological advances of living in the 21st century, many Americans’ thoughts on the manufacturing industry haven’t moved past the Industrial Revolution. Comments about dark, grimy, repetitive, dangerous work conditions persist today, but are far from the reality. Manufacturing in 2017 means technologically advanced machinery, modern buildings, use of robotics, 3D printing, artificial intelligence, virtual reality, augmented reality, and the Internet of Things, just to name a few. Perception vs. reality This perception vs. reality viewpoint is causing short-term and long-term problems for manufacturers. In the 2015 public perception report by Deloitte and The Manufacturing Institute, Americans are reluctant to choose careers in manufacturing, and thus, they aren’t encouraging the next generation to pursue these jobs either. This is one reason we have more than two million manufacturing jobs expected to go unfulfilled in the next decade. However, Generation Y respondents with some personal experience or familiarity with manufacturing ranked it as a higher option. This is an important data point showing up repeatedly – when students have some knowledge with manufacturing, their interest in pursuing it as a career rises exponentially. Programs that work STEM-related programs at school and through companies are making a difference in introducing students to the realities of manufacturing. These programs, including FIRST Robotics and ASTRA STEAM Summit, take time and commitment from teachers, businesses and mentors, but they are providing numerous proof points of success. In addition, there is national Manufacturing Day, where students and their parents/teachers can come on site to manufacturers around the U.S. to see what we really do. These are just a few of the successful programs where manufacturers can participate. As part of these programs, we have the opportunity to showcase the benefits of manufacturing that matter to the younger generation: technology, innovation, environmentally friendly and strong salaries and benefits. Technology Millennials have been raised with technology as part of every aspect of their lives and understanding it plays an important role in manufacturing will help them see this as a more viable career option. From hardware to software and everything in between, the technology advancements in manufacturing are constant and require workers who can keep adapting. 12

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Innovation Manufacturing needs great problem solvers who can work to meet current customers’ needs, while also developing new innovations for future concerns. The Deloitte/The Manufacturing Institute report mentioned above, found that 78 percent of millennials said their decision to work at a company was influenced by how innovative they considered the company to be. Manufacturing is all about innovation – it’s what we do all day, every day. This same group said they value opportunities for personal development and a chance to make a difference. Engineers in manufacturing will say they love taking their education and making a difference by creating something new to solve a customer’s problem. Environmentally responsible Most students don’t realize that manufacturing companies are looking for ways to innovate and solve problems in new ways, while also saving money, time and the planet. Companies like mine are often conflict-free certified and green certified where we commit to going over and beyond the required to conserve resources, prevent pollution, reduce waste and shrink our carbon footprint. Manufacturing facts to share In addition to the reasons above, manufacturing also provides strong salaries, benefits and long-term stability and growth opportunities. The National Association of Manufacturers (NAM) Top 20 Facts list should be shared everywhere. It includes the economic factors that surprise many and help showcase the benefits of working in this industry. As manufacturers, we must show the next generation (and their parents) the realities that manufacturing is an economic leader providing technologically advanced, environmentally concerned, innovative career choices allowing people to make a difference in their community and world. It will take consistent effort, but the facts and reality are on our side. Let’s communicate, engage and help change the view of manufacturing to the benefit of us all. DW

September 2017

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Co ntent s |

September 2017 • vol 12 no 9

designworldonline.com

F E AT U R E S

MOTION CONTROL

LINEAR MOTION

82 88

Hybrid servos vs. standard servos: how do they stack up? A new type of integrated hybrid servo motor is finding use in direct-drive applications where it offers lower cost, smaller size, and higher efficiency than conventional servo motors.

Defining the compliance of electromechanical linear actuators Modern motion controllers with built-in frequency analyzers allow direct identification of electromechanical actuators ... under load … subject to real-word conditions. That in turn may help designers improve stiffness and actuator performance — even to the point of getting higher servo bandwidth.

102

MATERIALS

INDUSTRIAL ETHERNET How IIoT enhances asset management tools Many operators of industrial sites are challenged with making their plants more competitive. The challenges are significant, but taking on these issues is now less daunting and more cost effective thanks to new Industrial Internet of Things (IIoT) capabilities.

FASTENING & JOINING Special adhesives bring clarity to optic applications Fiber optic, opto-electronic and photonic applications must have superior transparency, requiring optically clear epoxies, polysulfides, and silicones that exhibit excellent light transmission.

Plastic bearings step up to the plate Polymer bearings can be a long-lasting and cost-effective alternative to metal bearings—and may reduce costs by up to 40%

ELECTRONICS

ON THE COVER

The IoT and motion control fuels a rising tide of Raspberry PI, BeagleBoard, and Arduino boards The internet of things has created a big market for inexpensive computer boards, so much so that standard open-source designs now have their own clones.

DESIGN WORLD

CONTENTS SEPT 2017_first page_Vs3.LL.indd 14

Correction: A few lines of text were inadvertently truncated from the July article, “Lens sees clearly even through shock and vibration.” A corrected version is on the July Design World Digital Edition.

September 2017

Photo: istockphoto

A | S | B | P|E

ON THE COVER

American Society of Business Publication Editors

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F R E E C ATA L O G & B R O C H U R E

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12 Guest Editorial 18 Green Engineering 20 Design For Industry

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32 Design Notes 42 Coupling Notes 46 CAE Solutions 56 Internet of Things 110 Product World 128 Ad Index

Contents SEPT 2017_second page_Vs1.indd 16

DESIGN WORLD

September 2017

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Follow the whole team on twitter @DesignWorld EDITORIAL

DESIGN & PRODUCTION SERVICES

Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler

Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

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September 2017

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9/11/17 9:14 AM

» Gree n E n g i n e e ri n g

Adjustable frequency drives help steel plant reduce its energy costs n Paul J. Heney • Editorial Director

ArcelorMittal is the world’s largest steel producer, producing an annual crude steel production of 93.1 million metric tons in 2014. The company has active operations across 60 countries. Its second largest facility in the United States, Burns Harbor, is a fully integrated steelmaking facility located in Northwest Indiana. This plant is capable of producing five million tons of raw steel annually to serve many leading customers in the automotive industry, as well as other key markets like construction, shipbuilding and rail. Burns Harbor uses a hot rolling process to reheat semi-finished steel slabs nearly to their melting point before reaching 13 successive rolling mill stands driven by motors, and finally coiling up the lengthened steel sheet for transport to the next process. After exiting the finishing mills, the steel is carried down a succession of more than 300 individually-driven rolls through ten banks of low-pressure, high-volume water sprays that cool the red-hot strip to a specified coiling temperature between 1000° and 1250° F and into one of three downcoilers. 18

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September 2017

The cooling system was reliant on many antiquated electrical starters for control of the pumps powering the process. These devices did not provide intelligent load management and operated 24/7—regardless of necessity. This constant operation led to energy waste that could easily be prevented through the application of a responsive control solution capable of reducing or completely stopping motor operation during times of lower demand. The plant identified the benefits of adjustable frequency drives, which are designed to adjust a motor’s speed to closely match output requirements, resulting in typical energy savings of 10 to 50%. Following the recommendation of a trusted systems integrator, the company began to explore using Eaton’s power management solutions— and learned about the benefits of the SC9000 EP drive when applied in a process application. The company had the opportunity to see the Eaton drives in action within a controlled test chamber and knew the solution would provide

www.designworldonline.com

9/12/17 2:03 PM

» Gre e n Engi neeri ng

robust, reliable control along with the energy efficiency benefits. As a result, the company decided to move forward with five 4160 V, 400 hp medium-voltage drives from Eaton. “It was invaluable to see the Eaton drives operating in an environment that perfectly mirrored our plant conditions,” said Melecio Magallon, an engineering project manager at ArcelorMittal. “We were able to address details that might have otherwise not arisen until installation, which helped us save time and greatly reduce complexity before the solution was even shipped.” The SC9000 EP drives feature a powerpole inverter with heat pipe technology to provide a high power density in a compact footprint, while enabling the drive to withstand harsh environmental conditions. This technology offered the benefit of the smallest physical footprint of all equipment proposals, meeting the stringent space requirements for the application.

Further, by incorporating a 3-level neutral point clamped (NPC) inverter topology, the drive reduces the number of power switching devices in the inverter, improving reliability by reducing the overall component count. Following manufacturing and delivery, the customer’s engineering team was able to seamlessly integrate the SC9000 EP drives into their existing control room. Eaton’s service engineers then helped with commissioning to ensure seamless start-up, while the systems integrator managed project programming and communications. After applying the drives to the new runout table system, ArcelorMittal was able to improve the efficiency of operations and make progress toward securing valuable incentive from the local utility, with estimated annual energy savings of more than $500,000.

The steel manufacturer is reaping several added benefits from the drives: • Improved uptime due to the industry’s lowest inverter part count and simplified maintenance with a modular powerpole design, roll-in/roll-out inverter • Encapsulated power pole inverter with heat pipe technology helping increase power density, reduce overall equipment size and protect sensitive electronic components in harsh environments • Common bus design allowing five drives to be connected to three upstream breakers with one set of three-phase cables for every pair of drives to greatly reduce installation time and complexity • Ability to view key operating variables directly from the drives via an integrated keypad system DW Eaton Corp. | eaton.com/SC9000

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September 2017

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9/11/17 12:30 PM

Design for Industry | a e r o s p a c e / m i l i t a r y

Inspection system accurately inspects carbon composites

The Carbon Composite Inspection System automates the manual visual inspection process of carbon composites for the aerospace and other industries. It is based on Apodius 3D technology and features advanced inspection and analysis of lightweight carbon-fiber components that operates at an unprecedented level of speed and detail. The system is comprised of a portable ROMER Absolute Arm with Integrated Scanner, the HP-C-V3D Apodius Vision Sensor camera-based scanning hardware, and the custombuilt Apodius Explorer 3D real-time software package. The ROMER Absolute Arm SI acts as a global reference system for data collected by the Composite Inspection System, addressing a range of industries including aerospace, automotive, transportation, marine, electronics, infrastructure and more.

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September 2017

This solution delivers high-definition fiber orientation and geometry measurement, as well as complete three-dimensional model creation and analysis. Operators can perform actual-totarget value comparison and detect, document and classify previously difficult to define composite production errors. The new product is compatible with all ROMER Absolute Arm SI models. DW Hexagon Manufacturing Intelligence | HexagonMI.com

WHAT DO YOU THINK?

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D e s i g n f o r I n d u s t r y | food and beverage

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Enhancements to the EPIC ULTRA rectangular connector housings include new covers and models aimed at the food and beverage industry or any other application that requires electrical connectors with high levels of corrosion resistance. The connectors include EPIC ULTRA H-A ¾ and EPIC ULTRA H-B Cover. The corrosion-resistant HA ¾ family of housing is UL-50 Type 4, 4x and 12 rated and IP-65 approved. Its die-cast zinc and nickel-plated surface creates a conductive shell around the housing that virtually eliminates all EMC. The housings are available in several styles, including top and side entry hood, panel mount base, cable coupler, 90-degree surface mount base and 90-degree panel mount base with stainless steel screws for inserts. Used with EPIC ULTRA bases and hoods, these durable covers are made out of an FDA-approved, corrosion-resistant material and feature stainless steel levers and bolts. These covers are available in several sizes and surface mounts, | fo including single lever and double lever, and their blue color provides excellent visibility. These rectangular connector housings feature a nickel-plated zinc housing, nickel-plated brass body and stainless steel hardware. Together, these corrosionresistant materials make the connector a good fit for applications that would simply be too harsh for traditional aluminum connectors. These applications include wind turbines, washdown machinery, offshore equipment, chemical processing lines, telecommunication installations and many other heavy industrial equipment. EPIC ULTRA’s housing also enhances electrical shielding performance and resists damage. DW

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September 2017

9/11/17 9:46 AM

Power Review

Altra Industrial Motion Vol. 6 | No. 3 | 2017

The Power Brands in Power Transmission

Featured in this Edition...

Learn with Altra!

Learning with Altra: Utilize resources to stay informed about Altra products and services

Learn from the leading brands in the Power Transmission Industry

Altra How-To Video Series on YouTube Altra Webinar Series and OnDemand Webinars

Find Altra Industrial Motion on:

Altra Industrial Motion Ameridrives Bauer Gear Motor Bibby Turboflex Boston Gear Delroyd Worm Gear Formsprag Clutch

Altra Industrial_#1_9-17.indd 23

The Power Of Experience

Guardian Couplings Huco Industrial Clutch Inertia Dynamics Kilian Lamiflex Couplings

Marland Clutch Matrix Nuttall Gear Stieber Clutch Stromag Svendborg Brakes

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

Scan to download the interactive version of the Power Review

9/11/17 9:23 AM

Altra’s How-To Video Series on YouTube Visit Altra Industrial Motion on YouTube to see our newest videos including our instructional How-To Video Series. HOW-TO VIDEO SERIES: The How-To Video Series offers helpful how-to videos on a variety of industrial applications. New videos are uploaded routinely, so check back often! • Warner Electric | Clutch & Brake Electrical Troubleshooting • Warner Electric | Normal Wear Patterns for Friction Clutches and Brakes

SHARE VIDEOS

• Warner Electric | Cover Kits for EM or UM Clutches and Brake

Share your favorite videos via email or various other social media sites. Videos can also be added to custom playlists or saved to a “Watch Later” list.

• Boston Gear | Avoiding Gearbox Damage by Proper Motor Installation • Boston Gear | 700 Series Gearbox Lubrication • TB Wood’s | Sure-Flex® Plus Installation • TB Wood’s | Dura-Flex® Couplings Installation Instructions • Warner Linear | How to Adjust the Limit Switches for a K2 or K2X Actuator w/External Limit Switches • Warner Linear | Actuator Basic Selection • Warner Electric | Heavy Duty Clutch or Brake Autogap Installation and Settings • Warner Electric | UniModule Airgap Adjustment • Warner Electric | Normal Duty Clutch or Brake Autogap Installation and Settings • TB Wood’s | L-Jaw Couplings Installation • Warner Electric | Normal Duty ER Brake Installation • Warner Electric | ER and FB Type Brakes Troubleshooting • Warner Electric | Installing the Autogaps for a Normal Duty Clutch or Brake Sizes 475 to 650 • Warner Electric | Heavy Duty or Spline Drive ER Brake Installation • Warner Electric | Setting the Autogap for a Heavy Duty Clutch Coupling or Brake in sizes 500 and 650 • Warner Linear | Proper Steps and Best Practices for Mounting of Warner Linear Electric Actuators

• Boston Gear | Adding & Replacing Lubrication on a Boston Gear 700 Series Right Angle Single Reduction Worm Gearbox

Scan to visit the How-To Video Playlist on YouTube

www.YouTube.com/AltraMotion

Altra Industrial_#2_9-17.indd 24

9/11/17 9:23 AM

Altra Webinar Series and OnDemand Webinars

The Altra Webinar Series is open to the public and are held on the first Wednesday of each month at 10 AM (CST). They will also be posted to the websites for access. For more information, please contact altra-webinar@altramotion.com.

Webinar Schedule SEPTEMBER 6, 10 AM (CST) FACTORS TO CONSIDER WHEN SELECTING OVERRUNNING CLUTCHES SYNOPSIS: Altra Industrial Motion offers a wide range of Overrunning clutch solutions. Our goal for this webinar is to provide guidance as to why you might select one over others. OCTOBER 4, 10 AM (CST) CENTRIFUGAL CLUTCHES: APPLICATIONS AND SELECTION SYNOPSIS: Centrifugal clutches provide a simple, mechanical solution for applications needing a soft engagement of high inertia loads. Our goal for this webinar will be to review common applications for Centrifugal clutches and the data needed for their proper selection.

View upcoming Webinars by visiting www.AltraWebinars.com

All Altra Webinar Series presentations are accessible after the live presentation for those who are unable to attend the live session and will be posted to our websites for access. For more information, please contact altra-webinar@altramotion.com. Please see a sampling below of available OnDemand Webinars.

OnDemand Webinars: • Factors to Consider in Linear Actuator Selection • Load Holding Brakes Solutions | Small To Moderate Sizes • Load Holding Brakes Solutions | High Capacity Systems • Factors to Consider In Coupling Selection • Proper Torque Arm Use • Factors to Consider When Selecting a Clutch, Brake, or Clutch/Brake • Warner Linear New Product Launch – Introduction to H-Track • High Capacity Gearboxes & Overrunning Clutches: To Rebuild or Replace • Factors to Consider in Right Angle Worm Gearbox Selection • Factors to Consider When Selecting a V-Belt • Altra Industrial Motion | Beyond Friction Faces • Form-Flex Couplings: Applications Beyond the Energy Sector • Helping Us Help You: Product Identification

the launch We are pleased to announce of our OnDemand Webinars!

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VIEW

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- Watch Now!

View all OnDemand Webinars by visiting www.AltraWebinars.com Altra Industrial_#3_9-17.indd 25

9/11/17 9:24 AM

Power Transmission and Motion Control Solutions for Industrial Applications

Heavy Duty Clutches and Brakes

Electric Clutches and Brakes

Gear Motors

Overrunning Clutches

Gear Drives

Engineered Couplings & Universal Joints

Power Transmission Components Linear Actuators & Controls

Engineered Bearing Assemblies

Air Motors

Belted Drives & Sheaves

Geared Cam Limit Switches

The Power Brands in Power Transmission Ameridrives Couplings Bauer Gear Motor Bibby Turboflex Boston Gear Delroyd Worm Gear Formsprag Clutch

Guardian Couplings Huco Industrial Clutch Inertia Dynamics Kilian Lamiflex Couplings

Marland Clutch Matrix Nuttall Gear Stieber Clutch Stromag Svendborg Brakes

TB Woodâ&#x20AC;&#x2122;s Twiflex Limited Warner Electric Warner Linear Wichita Clutch

www.altramotion.com Altra Industrial_#4_9-17.indd 26

9/11/17 9:25 AM

3 POWER TRANSMISSION

Design for Industry

RETAINING DEVICES & maintenance & assembly tools

Smart condition monitoring aims to end downtime

BEARLOK

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Predictive maintenance is the best answer to minimizing the risks of equipment failure, however, monitoring practices in the past have been expensive, problematic or simply unreliable. The Smart Condition Monitoring promises to provide plant-wide 24-7 monitoring. With the Smart Condition Monitoring (SCM) system, operators can gain access to the status of rotating equipment. The system can raise the alarm to predict failures in advance and provide information on recommended actions to take, avoiding unplanned production downtime events and the associated excess maintenance costs. For example: If a mixer or a refrigeration unit fails in a food or beverage processing plant the drop in productivity can cost thousands of dollars per hour, which is often compounded by the cost of wastage and unplanned maintenance. Preserving the efficiency of these primary assets is therefore paramount to meeting KPIs and ultimately achieving profitability. Traditional methods of condition monitoring have involved highly trained personnel running sophisticated algorithms on vibration pattern recordings to identify if a machine is due for maintenance or a defect is present. IR cameras can also be used to reveal hot-spots where excess vibration or friction creates an abnormal heat signature. Other, less sophisticated methods have involved listening devices or even holding a screwdriver to the machine to sense the vibration. With recent developments in modern sensor technology, businesses can now engage in ongoing monitoring activity in a reliable and cost effective manner. As a result, it has never been easier to avoid the catastrophe of unplanned downtime - the nightmare of production and maintenance teams across the food and beverage industry. Smart Condition Monitoring relies primarily on developments in sensor function, networking and the use of smart controllers to provide continuous monitoring. September 2017

DFI 9-17_Vs3.LL.indd 27

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9/12/17 2:18 PM

Design for Industry | f o o d a n d b e v e r a g e

With advances in technology, a range of factors can be automatically monitored and cross referenced by an SCM, including vibration characteristics, operating temperatures, drawn current and shifts in operating parameters. The system uses multiple smart sensors, physically attached to the asset (using glued, screwed or magnetic fixings), which feed back information through Ethernet to an advanced sensor controller that incorporates a Mitsubishi Electric PLC. The solution can be used as a self-contained, stand-alone device (idea for feasibility studies or trials) or as a fully integrated system, allowing information to be transmitted across the factory for easy access with HMIs on the shop floor, to PCs connected to higher level data systems, or to mobile devices over local Wi-Fi, the internet or mobile networks. The crucial data analysis is performed on board the PLC, so the system can be relied upon to transmit simple but accurate overviews or warnings to operators in real-time prior to any significant asset failure. An intuitive graphical interface, as with many of the latest automation technologies, is vital for operators to diagnose potential issues without expert knowledge. Using the installation of HMIs configured to display basic parameters, the system can automatically create conditions and alarms with an associated text description. Diagnostics can be configured to display all data regarding an asset, or a general overview that can be simplified into a traffic light alert system displaying overall condition for ease of assessment. Thanks to an associated App, operators can also use a mobile device to monitor the status of equipment while on the go. Once in operation, a Smart Condition Monitoring system can detect a wide range of potential issues. These include bearing defects from races or balls and rollers, motor imbalance, misalignment, instability, resonant frequencies, breakages, blockages and low levels of lubricant, temperature 28

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September 2017

fluctuations and phase failure in power components. From these faults, the system can offer suggestions for future operation, more precise error identification and trend analysis. By spreading sensors around the plant and including information from other automation systems, the reach of an SCM goes far beyond the more traditional methods that would typically concentrate on a specific power transmission component. This means that many smaller ancillary systems can also be connected economically, reaching out from primary assets to take into account a more holistic and therefore far more effective, encompassing view of the production facility itself. The importance of such systems has increased as production managers are now required to attain a reliable ‘future’ plant, with new approaches needed to allow for increased digitisation and ensuring the adaptability of processes for future technological development. These trends have seen the demand for condition monitoring systems increase over the last few years, which is not likely to slow down - given a number of market sources are predicting the industry will undergo compound annual growth (CAG) up to 7% for the period to 2020. The cost to the industry of not adopting an SCM approach is equally daunting: a report from international business analysts Dunn & Bradstreet indicates that 49% of Fortune 500 companies experience at least 1.6 hours of downtime per week, which is the equivalent of two working weeks a year. Downtime cost estimates for food producers vary wildly from hundreds of Euros per hour to tens of thousands, depending on the size and nature of the process, so, cumulatively it’s clear the cost to the industry is huge. As global competitiveness increases those with an advantage are likely to take the spoils. By using a smart approach with regards to condition monitoring, proactive maintenance can become part of the plant system architecture, providing continuous access to the diagnostic information that operators require to safeguard assets. Maintenance policies can be safely amended to increase productivity, for example, relaxing set lubrication schedules and using the monitoring system to signal on-demand maintenance for whichever asset requires attention instead. Through unparalleled access to diagnostic information, resources can be effectively channeled to improve efficiency. With total access available via a combination of smart devices, networking and the use of “smart manufacturing” principles - responses to alarm conditions can be faster, with both production and maintenance teams referring to accurate, predictive ‘live’ information. For the food and beverage industry where profits or stock can be severely affected by unplanned downtime, an SCM system allows not only full condition monitoring to avoid failure but also the automation IT framework to synergize the use of maintenance resources in a cost effective and efficient manner. DW Mitsubishi Electric | MitsubishiElectric.com www.designworldonline.com

9/11/17 9:47 AM

Let’s solve this. Together. Having a linear motion automation issue? Not sure what products to select for your packaging application? You’re not alone. For more than 45 years, Nook Industries has helped solve some of the smallest and biggest linear motion problems, and we can help solve yours. With production and engineering in Northeast Ohio, and support available across the country, we’re close by and ready to partner with you.

together.nookinfo.com 800•321•7800 Nook Industries, Cleveland, OH USA

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9/11/17 9:41 AM

Design for Industry | p a c k a g i n g

Rise to greater heights with helix conveyor Need to move product up or down in a tight space? The SmartFlex Helix Conveyor features a proprietary flexible chain. The SmartFlex Helix can operate in a footprint as small as a 10 ft x 10 ft, and is ideal for product handling applications where product needs to travel up or down in a confined space. The conveyor’s compact design allows for five feet of elevation change in 10 ft (incline angle of up to 12°), giving users more freedom and flexibility in designing a material handling system with multiple layouts using a single conveyor. The SmartFlex Helix comes in three belt widths: 85 mm, 180 mm, and 260 mm. Additionally, it does not require lubrication. DW Dorner | dornerconveyors.com

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9/11/17 9:47 AM

a c i r e m 4. A n i e d nce 193 a m Y i s R E V

Energy efficient motors for fixed and variable speed applications Known as electronically commutated motors, this line of brushless dc electric gearmotors are ideal for environments requiring virtually maintenance-free operation and accurate speed control as well as operation over a wide speed range. They are also desirable for settings where brush dust contamination is to be avoided or brush contact arcing could affect electronically sensitive equipment. Brushless dc gearmotors are cost-effective, compact and long lasting, and offer several advantages over brushed dc motors, including: • Virtually maintenance free; lubricated and sealed for life • Extremely configurable; several shaft configurations and custom options available • High efficiency, further enhanced with quiet helical and hypoid gearing • Safe 12-48 Vdc motors with a wide speed control range The brushless motors work with an OEM’s own design drive or standard brushless drives from Brother with features such as adjustable acceleration, deceleration, open or closed loop operation, current limiting and other performance and safety features. Key attributes of the gearmotors include: • Light, reliable and compact in size • Wide power range, with 50, 100, 200 and 400 W versions available • Sealed for life with standard high-grade grease for lifetime lubrication and reduced maintenance/downtime • High-quality, durable, e-coat finish to withstand the toughest environments • Significantly more efficient than worm gearboxes as a result of unique hardened hypoid gear geometry and processing DW

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DFI 9-17_Vs2.LL.indd 31

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9/11/17 9:47 AM

Âť D e s i g n N o te s

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

Racing wheelchair gets re-engineered for design competition down, terial costs To keep ma am used press the design te ction metal constru braked sheet r the etal tubing fo rather than m ged n a ame, and ch wheelchair fr l om a manua the process fr an ng process to manufacturi ne. automated o

When Houston area schools needed support for students that wanted to race wheelchairs, the University of Houstonâ&#x20AC;&#x2122;s Dr. Michael Cottingham, founder of the UH Adaptive Sports Program, approached HELIOS Ontrack Racing Company with an idea. As part of an International Design Competition, a team of Industrial Design students set out to design a racing wheelchair. Model Solution, a Laird company, became involved with the students in the competition, and built a prototype model of the racing wheelchair. Then the real work began. The goal was to supply the Houston metro middle and high schools with 150 racing wheelchairs featuring an adjustable frame and a retail price under $800. No small task. The UH team and MS engineers had to meet design requirements ensuring that the design would work for all athletes. Even more complex issues arose with the machining process. The original design called for a relatively thin rear wheel compared to its large diameter, 32

DESIGN WORLD

Design Notes 9-17_Vs.3.LL.indd 32

September 2017

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9/12/17 1:19 PM

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Using 5052 A luminum shee t metal versus tu bing for the frame resulted in a cost reduction of 60 % (from $2,500 to $1,000).

making machining difficult. Second, some of the fine features in the design were small relative to the large wheel size, also adding to the machining difficulties. Finally, the thin wheels were often bent during the machining process, and needed to be repaired during the assembly stage. The UH students had difficulty modifying the CAD data to make the part easier to machine and assemble. The Model Solution engineering team made several modifications for the student to review and accept. To keep material costs down, the team designed a process that used press braked sheet metal construction rather than metal tubing for the wheelchair frame, and changed the process from a manual manufacturing process to an automated one. The process for developing the prototype model included design modifications, CNC machining, wet sanding and finishing of the frame, fabric wrapping, and final assembly. The model used an aluminum frame, with ABS, urethane and fabric for the interior features. Ultimately, using 5052 Aluminum sheet metal versus tubing for the frame resulted in a cost reduction of 60% (from $2,500 to $1,000). However, for 150 frames, the cost per frame came down by 82% (from $1,667 per frame to $300 per frame). In order to make entering and exiting the racing wheelchair safer, an anti-tip stand was integrated into the design as well. DW

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WHAT DO YOU THINK?

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Design Notes 9-17_Vs.2.LL.indd 35

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» D e s ig n N o tes

Crimpers add new capacity for hydraulic and industrial hose Edited by: Mike Santora • Associate Editor

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The FP175 is a suitable choice when the operation re quires crimping of very large hose s or reduction of bi g pipes. It is suita ble for connectin g parts requiring high forces.

By 2013, Powertrack, a company specializing in hydraulic and industrial hose and fittings products, was looking to increase its market position in the oil and gas industry – and fracking was a major consideration in this segment. The Powertrack Long Beach facility has seven employees in a 15,000-square-foot facility, with a 14,000-sqare-foot yard for testing. Handling the demands of catering to the oil and gas industry required some upgrades to make the facility competitive. “One thing that separates us from a lot of companies is the large FinnPower crimper and the ability for us to pressure test each assembly that comes off our production,” says Keith Richards, vice president of sales September 2017

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» D e s i g n N o tes

& marketing at Powertrack’s Long Beach, CA facility. “We test and certify all of our hoses. Since we cater so much to the refineries in the oil and gas industry, a failure could be catastrophic not only in injury but also environmental cleanup.” This led Powertrack to search for a crimper that could handle the larger diameter hose. In 2013, Powertrack invested in two FP175UC Finn-Power crimping machines for its Pittsburgh and Long Beach facility. In 2015, the company also purchased an FP175UC for its Houston location. “We purchased the Finn-Power crimpers to expand our capability

The FP175 is a suitable choice when the operation re quires crimping of very large hose s or reduction of big pipes. It is suita ble for connectin g parts requiring high forces.

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to crimp large bore oilfield and gas drilling hoses and hydraulic hose assemblies,” explains Richards. “We believe that the additional capacity to crimp these large bore oil and gas hoses will improve our ability to assist energy exploration companies in the extraction and production of crude oil and natural gases.” On the importance of fracking in in the oil and gas space Richards explained, “This meant increased large diameter water suction and discharge hose. The swaging process was taking too long and wasn’t very accurate. We were also increasing our position in the rotary hose market. These were previously produced on swagers. Today with the new style of shorter fittings, we can now crimp and make it a more flexible hose, an easier hose to handle because we aren’t working on this big, bulky fitting that we have to swage. Now we can crimp the smaller fitting.” The FP175 is a suitable choice when the operation requires crimping of very large hoses or reduction of big pipes. It is suitable for connecting parts requiring high forces. FP175 is one of the largest crimping machines on the market using a non-wearing lubricated guide system for accuracy and durability.

Higher Productivity “In the industrial market, everything is based for crimping purposes on the OD of the hose,” concludes Richards. “With the Finn-Power crimper, we can easily adjust the crimp specs to accommodate the hose. On a swager you cannot. If the die does not meet the criteria of the ultimate spec, you have to change the die out again. Your inventory of swage dies is 2 -3 times the amount the inventory of crimping dies.” It’s easier to change the crimper’s setting than to disassemble a swage die and install a new swage die. Swaging process doubles or triples our production time. We can produce at least 30+ hose assemblies with the FP175 in the time it takes to swage 15 assemblies.” DW

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Design Notes 9-17_Vs.2.LL.indd 39

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» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

Adhesive tape helps medical devices stick with it When patients requiring heart-rate monitors

kept asking doctors if there a better way to make the monitors stick, 3M chose to accept the challenge. The company that makes everything from Post-it Notes to the structural adhesives that hold airplanes together, also makes medical adhesives. One of the core challenges of adhesive science is dealing with a substrate like skin; it’s trickier than most would think. “Sticking to skin presents a major challenge to the medical device industry,” said Diana Eitzman, Ph.D., director of agile commercialization, 3M Critical and Chronic Care Solutions Division. 4076 Extended Wear Medical Tape gives medical device manufacturers and engineers a long-term wear, acrylic-based adhesive solution designed to increase patient comfort with a strong and reliable bond in challenging applications. The non-sensitizing adhesive was developed for long-term wear, providing a bond that is firm yet comfortable so patients may not even realize they are

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wearing a device. This allows engineers and manufacturers to focus solely on their device’s design and application, spurring innovation while ensuring their timeline and budget requirements are met. Compliant with ISO:10993 and ISO:10993-10, medical industry regulations assessing a product’s potential to produce irritation and skin sensitization, 4076 Extended Wear Medical Tape is approved for use on intact skin. The tape is part of a product line designed for the medical device manufacturing, design and supply industries. DW

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» Co u p li n g N o tes

Coupling installation overview Edited by: Mike Santora • Associate Editor

Even if a coupling is properly selected, poor installation can cause failures; staying within the recommended misalignment ratings of a coupling at installation is critical. Here, we will cover several coupling types and what to be careful of during installation. Always be sure the coupling is used within the manufacturer’s ratings. Use a torque wrench for proper screw seating torque. The first, and arguably most common tool for installation is the torque wrench. It’s important to use a torque wrench when your tightening screws on couplings. It’s an overlooked piece of information; over-torquing or under-torquing the screws on a coupling is going to vastly affect how well they clamp and, ultimately, how long they last. Next is the shim stock or feeler gauge and shaft alignment measurement tools such as a dial indicator system or laser alignment

system. With rigid couplings, for example, be sure to install screws starting with the inside two or four depending on the style. When we have a 4 screw version, the way this coupling should be installed is the two inner screws should be tightened to 50% of the total torque. Then, go out to the outer screws, bring those up to 50% of the torque and go back and bring the two inside screws up to 100%. Lastly, go to the outside screws and bring them up to 100%. This tightening sequence is critical.

In jaw coupling applications, it’s important not to attempt to press standoffs into the balance holes. Insert jaws of the second hub into spider openings until standoffs contact the second hub.

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September 2017

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For beam couplings, tighten first and before tightening the second, rotate the coupling by hand to allow it to reach its free length. Certain couplings are prone to be installed either compressed or extended. Beam couplings and bellow couplings will have the biggest issue with this; it’s important not to install these couplings either compressed or extended. It drastically reduces the service life of a coupling if it’s not installed at the correct length. When installing an Oldham coupling, slide hubs onto the shafts with tenons at 90° before inserting the center disc but do not tighten. Place one disc on one hub and center by hand, use a shim the thickness of the coupling’s axial misalignment rating and slide the second hub into the groove

It is critical that bellows couplings are not installed under compression or extension, but at the proper length. Tighten one hub first and before tightening the second, rotate the coupling by hand to allow it to reach its free length and then tighten the second hub.

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»» until the tenons touch the shim. Tighten both hubs and remove the shim. Oldham couplings have a disc and that disc actually moves up and down. There needs to be a gap or space to allow the disc to move, if we were to assemble this and squeeze the hubs together and tighten the hubs down we have trapped the disc at that point. This is why we talk about shimming and leaving a gap between the face of the Oldham disc and the tenons on the coupling hub. Disc or bellows couplings: It is critical that these types of couplings are not installed under compression, not extended either, but at the proper length. Tighten one hub first and before tightening the second, rotate the coupling by hand to allow it to reach its free length and then tighten the second hub. Jaw couplings. For small sizes, slide hubs onto shafts with tenons facing each other. Fully tighten screws on one hub. Do not attempt to press standoffs into the balance holes. Insert jaws of the second hub into spider openings until standoffs contact the second hub. It may require some force to press the second hub into the spider, this is common. DW

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» CA E S o lut i o n s

Pawan Soami • Product Manager, Multibody Dynamics, COMSOL

Modeling vibration and noise in a gearbox

Figure 1: Left: von Mises stress distribution in a gear pair. Right: Variation of gear mesh stiffness with shaft rotation.

A gearbox, used to transfer power from the engine to the wheels, radiates noise for two reasons. First, the gears, which transmit power from one shaft to another, exert undesired lateral and axial forces on bearings and the housing. Second, the flexibility of the different components of the gearbox, including bearings and housing, can result in vibration. In a gearbox, varying gear mesh stiffness causes sustained vibration that is transmitted to its housing, which in turn vibrates and transmits energy to the surrounding fluid, such as gearbox oil, resulting in the radiation of acoustic waves. To accurately model and simulate this coupled phenomena, a contact analysis, multibody dynamics analysis, and acoustic analysis should be performed. The gearbox considered in this analysis has a drive shaft connected to the counter shaft and five pairs of helical gears. The gears are different sizes but are made of the same material: a structural steel.

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September 2017

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9/11/17 3:06 PM

Figure 2: Top: von Mises stress distribution in the housing. Bottom: Normal acceleration of the housing. Contact analysis of the gear mesh The mesh of gears, which is assumed to be elastic, is a source of sustained vibration. As such, the stiffness of the gears must be evaluated at different positions. As gear teeth deform during operation, a stationary parametric analysis is performed to determine the stiffness variation over a gear mesh cycle. A penalty contact method is used

THIN ENOUGH?

and constraints are defined to account for the twisting of gears leading to contact forces. Simulation results showing the distribution of von Mises stress in a gear pair indicate high stress values at contact points as well as at roots of the teeth (Figure 1). Using simulation, it is possible to see the variation of gear mesh stiffness with shaft rotation, as shown in Figure 1.

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Figure 3: Normal acceleration at the top of the housing. Left: Time history. Right: Frequency spectrum.

September 2017

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» CA E Solu t i o n s

Figure 6: Sound pressure level at 1500 Hz. Left: Housing surface. Right: Near-field region. Multibody analysis of shafts, gears, and housing The multibody analysis is performed in the time domain for one full revolution of the drive shaft using the gear mesh stiffness predicted by the contact analysis. This analysis is needed to compute the dynamics of gears and the resulting vibrations of the housing. In this case,

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Figure 5: Air domain enclosing the gearbox used for the acoustic analysis.

The von Mises stress distribution in the housing due to the forces transmitted by the drive shaft and the counter shaft can be seen in Figure 2. The normal acceleration of the vibrating housing, which is responsible for the noise radiation, is also shown in Figure 2. Figure 3 shows the time history and frequency spectrum of the normal acceleration at the top of the housing. The dominant frequencies at which the housing is vibrating are between 1500 Hz and 2000 Hz. The housing deformation is shown in Figure 4.

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Acoustic analysis of noise radiating from the housing The normal acceleration experienced by the housing and predicted by the multibody analysis is used as the noise source in the acoustic analysis. The simulation, performed in the frequency domain, predicts the sound pressure

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DESIGN WORLD

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Figure 7: Far-field SPL (dB) in the x-y, x-z, and y-z planes, respectively, at a distance of 1 m at 1500 Hz. level outside the gearbox. As the normal acceleration values are in the time domain, a forward FFT (fast Fourier transform) is used to convert them to the frequency domain. An air domain encloses the gearbox where the acoustic pressure is computed (Figure 5). To reduce the size of the computational domain without affecting the accuracy of the results, a spherical wave radiation condition is applied on the exterior boundaries of the air domain to

allow outgoing acoustic waves to leave the modeling domain with minimal reflections. The sound pressure level (SPL) on the housing surface and in the near field are shown in Figure 6. SPL can also be plotted in the far-field, as shown in Figure 7. Far-field plots in different planes and at a distance of 1 m give an idea of the dominant directions of noise radiation at the selected frequency.

For simulating the vibration and noise generated, a multibody-acoustic interaction modeling approach is adopted. This technique can be used early in the design process of the gearbox, thus improving the design in such a way that the noise radiation is minimized for different operating conditions. DW Comsol | Comsol.com

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» CA E S o lut i o n s

Software simplifies robotic machining

A new function creates nonoverlapping shifted surfaces at defined angles from any curves – this is useful for separating part surfaces in mold manufacturing as well as for trim steel and trim line surfaces in draw die manufacturing.

Release 4 of Version 4.0 of Tebis software creates area curves during part comparison to enable better detection and limitation of modified areas. Design measures can be quickly implemented or new NC programs can be quickly calculated for modified areas. The new function creates non-overlapping shifted surfaces from any curves at defined angles. All overlaps within parts that would result especially at sharp edges and small radii of curvature are automatically filtered out and smoothed. These surfaces suit separating part surfaces in mold manufacturing as well as trim steel and trim line surfaces in draw die manufacturing. The lengths and angles of surfaces can be conveniently and interactively adjusted using drag arrows. Parts can be automatically morphed with the most complex trimming curves in surface morphing. The geometry of the original curves is fully retained and color properties are transferred 1:1. Curves can also be included in surface morphing. This results in benefits in draw die manufacturing, for example. If the active surfaces must be morphed to compensate for springback of the sheet, all trimming curves can be morphed, as well, to yield the geometries for a correctly trimmed sheet metal part in a single step.

DESIGN WORLD

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Tebis Version 4.0 Release 4 simplifies automated deep-hole drilling based on bore information stored in the part.

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The Price Alternative

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Deep-hole drilling in the CAM area has been better oriented to support automated calculation and machining. There is also a new tool type with an extended set of cutting data and special speeds, feed rates, cooling types and depth sections needed for deep-hole drilling. These values can be separately managed for each individual tool. There is a new machining function that manages the special requirements of deep-hole drilling such as threading, intersections of bores or acceleration ramps. This further simplifies automated deep-hole drilling based on the drilling information stored in the part. The definition of toolpaths has been further simplified in 5-axis milling and operating convenience of the functions has been improved. Options have been included for fast vector smoothing and for tilt-optimized calculation of toolpaths even without manual definition of vectors. When using barrel cutters, the tool contact point can be controlled according to the respective part situation. For these tools, which suit machining cavities, it is often better to first start with a slightly greater slope with a tool contact point that is closer to the cutter tip. The slope can then be reduced to optimize tool wear. The slope can be increased at the bottom of the pocket until the cutter tip (ball) exactly contacts the fillet between the flank and bottom. This removes the residual stock at the end of the flank. Tebis Version 4.0 Release 4 offers new possibilities for robotic machining. For example, additional axes in robot cells can be controlled as simultaneous NC axes if the robot is mounted on a positioning unit. It is important to permanently position the robot with the linear axes so that the arm is used within the optimal working area. With the new part-driven robotic machining, the robot can now guide a workpiece past a tool that is in a fixed position in the robot cell. Tebis now supports laser hardening and laser weld cladding affording an even larger range of applications. DW Tebis America | tebis.com

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Scalability IIoT platforms and middleware need to be optimized to support tens of thousands of devices, all trying to exchange not just information with a central hub server or application but with each of the other devices in the application. Addressing, configuring, and managing thousands—even tens of thousands—of devices must be accounted for.

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Edge computing Centralized intelligence and control topologies are being reevaluated in favor of distributed architectures, with intelligence pushed into each edge device or data endpoint. IIoT applications involve thousands of devices intercommunicating, often with the requirement for near real- time communication and control between devices. Edge computing uses intelligence at the edge of the network to decrease network latency, deliver real-time control and monitoring, and offer report by exception to reduce data volume. 56

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..... Efficient communication architectures

In the long run, it is likely that OT devices will adopt IT protocols and communication standards, as they’ve already adopted Ethernet and TCP/IP as the main bus and data transmission protocols.

Many IIoT applications will be deployed in areas with unreliable and low-bandwidth networks. As a result, a more efficient network and communication architecture will be required. Protocols like MQTT (Message Queue Telemetry Transport) that use a publish/subscribe architecture and low overhead packets can reduce network latency and improve real-time communication speed between devices and endpoints.

Cognitive computing The key value-add of IIoT applications is predictive analytics. Knowing when a part is going to fail before it actually fails can bring almost immeasurable value to IIoT applications through reduced truck rolls, safety improvements, and optimizing overall equipment efficiency (OEE). The basis of predictive analytics is cognitive computing— essentially, computers that mimic the way the human brain works. For IIoT platforms to perform predictive analytics, they’ll need support for cognitive computing. Today and for some years to come, IIoT applications will require connecting legacy systems and devices to cutting-edge IT systems.

Protocol support Combining OT and IT technologies requires wide support of different OT and IT protocols. At least in the short run, both OT and IT protocols need to be translated through middleware, so that OT devices can communicate with IT devices and software.

32-Bit MCU Family with ARM Cortex M0 M0+ M3

Top Applications: • • • • • • • • •

Part Numer M0 Z32F06423AKE Z32F06423AEE M0+ Z32F03233QYE Z32F03233RBE Z32F03233AKE Z32F03233AEE Z32F06433AEE Z32F06433ARE Z32F06433TKE M3 Z32F06410AES Z32F06410AKS Z32F12811ARS Z32F12811ATS Z32F38412ALS Z32F38412ATS

Wearables Robotics Identity and tracking Smart lighting Medical instrumentation Automotive control systems Building automation Domestic household appliances IoT

All major development tool environments supported including: • • • •

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Core

Flash

SRAM

Max. Freq.

ADC Resolution

ADC Speed

Timers

UART

SPI

12C

MPWM

ADC

I/O Ports

Pkg.

LCD Driver

Cortex-M0 Cortex-M0

64KB 64KB

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40MHz 40MHz

12-bit x 1 unit 12-bit x 1 unit

1MS/s 1MS/s

4-16bit+1 FRT 4-16bit+1 FRT

2 2

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30 44

32 LQFP 48 LQFP

Cortex-M0+ Cortex-M0+ Cortex-M0+ Cortex-M0+ Cortex-M0+ Cortex-M0+ Cortex-M0+

32KB 32KB 32KB 32KB 64KB 64KB 64KB

4KB 4KB 4KB 4KB 6KB 6KB 6KB

40MHz 40MHz 40MHz 40MHz 40MHz 40MHz 40MHz

12 bit x 1 unit 12 bit x 1 unit 12 bit x 1 unit 12 bit x 1 unit 12 bit x 1 unit 12 bit x 1 unit 12 bit x 1 unit

50KS/S 50KS/S 50KS/S 50KS/S 50KS/S 50KS/S 50KS/S

3-16bit+2-32bit 3-16bit+2-32bit 3-16bit+2-32bit 3-16bit+2-32bit 3-16bit+2 32bit 5-16bit+2 32bit 7-16bit+2 32bit

1 1 2 2 2 2 2

1 (USART) 1(USART) 2(USART) 2(USART) 2(usart) 3(usart) 4(usart)

2 2 2 2 2 3 3

1 1 1 1 1 1 1

4 5 5 11 1-unit 11ch 1-unit 14ch 1-unit 14ch

21 25 29 45 45 61 77

24 QFN 28 TSSOP 32 LQFP 48 LQFP 48 LQFP 64 LQFP 80 LQFP

11Seg/8Com 12Seg/8Com 18Seg/8Com 23Seg/8Com 26seg/8Com 30seg/8Com 38seg/8Com

Cortex-M3 Cortex-M3 Cortex-M3 Cortex-M3 Cortex-M3 Cortex-M3

64KB 64KB 128KB 128KB 384KB 384KB

8KB 8KB 12KB 12KB 16KB 16KB

48MHz 48MHz 72MHz 72MHz 72MHz 72MHz

12-bit x 2-unit 12-bit x 2-unit 12-bit x 3-unit 12-bit x 3-unit 12-bit x 2-unit 12-bit x 2-unit

1.5MS/s 1.5MS/s 1.5MS/s 1.5MS/s 1.5MS/s 1.5MS/s

6-16bit 6-16bit 6-16bit 6-16bit 10-16bit + FRT 10-16bit + FRT

2 2 2 4 4 4

1 1 2 2 2 2

2-unit 11 ch 2-unit 8 ch 3-unit 16 ch 3-unit 16 ch 2-unit 16 ch 2-unit 16 ch

44 28 48 64 86 64

48 LQFP 32 LQFP 64 LQFP 80 LQFP 100 LQFP 80 LQFP

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Internet of Thi ng s

And a massive gap exists in technology, communication protocols, and standards between equipment designed several decades ago and the equipment shipping today. That’s the gap IoT middleware is trying to fill. Until that day arrives, here are the major IIoT platforms in the market today, their key strengths, and their potential weaknesses.

utilities, oil and gas, transportation, mining, and the public sector.

Key Strengths: Cisco has a strong background and support for IIoT applications at layers 1 through 4 and potentially 5 of the OSI model of interconnectivity. This is a wide product offering for general networking and Internet connectivity.

Potential Weakness: It lacks direct support for legacy endpoint devices including sensors, instrumentation, and other OT-specific assets. The core function of the Cisco IoT Cloud appears to be network connectivity, with OT integration needs being a lower priority.

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Predix uses a platform as a service (PaaS) model and is a cloud-based operating system designed for IIoT applications. According to GE, Predix is built on Cloud Foundry, an opensource platform, and is optimized for secure connectivity and analytics at scale, both in the cloud and on the edge. Key Strengths: Predix targets system- wide optimization. Rather than making one piece of equipment better, the software aims to create a detailed model that spans the entire system. The view created by this model allows both improved optimization of each part of the system and optimization of the entire system. Potential Weakness: Predix in its current form is fairly new to the market, having been released in February 2016. Reports have surfaced claiming that core parts of GE’s Predix software rely on partnerships with other companies, including PTC.

Cisco IoT Cloud

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Cisco’s offering is designed around six pillars of technology: network connectivity, fog computing, data analytics, security (cyber and physical), management and automation, and application enablement. The Cisco IoT Cloud addresses challenges across a variety of industries, including manufacturing, 58

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IBM Watson IoT Another platform as a service based on open standards (Cloud Foundry, Docker, OpenStack), Watson IoT Platform should simplify cognitive IoT development. The platform connects sensors to cloud applications using IBM Bluemix, which includes the Node-RED development environment (an open-source tool for wiring together hardware devices, APIs, and online services).

Key Strengths: IBM Watson IoT leverages both open technologies, such as RESTful API architecture, and inhouse- built advanced cognitive computing and artificial intelligence capabilities.

Potential Weakness: Constant internal IBM development cycles can slow down users during application development; current documentation can be missing or hard to find.

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..... PTC ThingWorx

0 90

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PTC Thingworx has three pillars of technology: core application enablement, connection services with device and cloud adopters, and edge connectivity using the Edge MicroServer and Edge “Always On” SDK. Key Strengths: The platform architecture takes a holistic approach to connectivity, from end data points and devices all the way to the cloud. Thingworx integrates with cloud providers such as AWS IoT Service, Microsoft Azure IoT Hub, Salesforce IoT Cloud, and others and has vast OT protocol support through recent acquisition of Kepware Technologies.

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Potential Weakness: Core features include software tools and products acquired through company acquisitions; internal technology integration pitfalls are a potential concern.

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Material for this article was excerpted from “2017: State of the IIoT, Key Trends and Predictions for the Industrial Internet of Things, by Opto 22. DW

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I nter net of Things

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

Microsoft technology and Rockwell Automation’s manufacturing analytics solution enables Great Lakes Brewing

staff to identify and address equipment challenges in real time.

Manufacturing analytics help brewery meet demand Craft beer is booming business in the United States, and even seasoned breweries are finding themselves looking for creative ways to keep up with thirsty consumers. Cleveland-based Great Lakes Brewing Company (GLBC), an independent craft brewery founded in 1988, recently tapped into manufacturing analytics technology that helps scale production without sacrificing product quality. GLBC deployed the FactoryTalk Analytics for Devices from Rockwell Automation to bring the power of the Internet of Things (IoT) and analytics to its floor. The technology gives GLBC greater insight into the health of its beer-brewing machinery to help increase efficiency, improve quality and minimize downtime. “From day one, Great Lakes Brewing Company has been committed to good beer, which means we are relentlessly focused on quality – from the ingredients we use to our production process and beyond,” said John Blystone, electrical and control supervisor, Great Lakes Brewing Company. “Adding advanced analytics and hardware diagnostics to our equipment allows us to continue fulfilling our 60

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quality commitment by giving us more meaningful insight into our production processes.” The solution provides health and diagnostic analytics from devices at the brewery. Inside the FactoryTalk Analytics there is a bot called “Shelby” that can interact with production staff using natural language processing. This technology is based on the Microsoft Bot Framework and trained with Microsoft Cognitive Services to help enable brewery staff to easily identify and address equipment challenges in real time. “Shelby has been instrumental in our move to a more connected plant-floor environment, allowing us to tap into a wealth of existing data to solve problems very quickly,” Blystone said. The Analytics is one component of a joint technology collaboration between Rockwell Automation and Microsoft designed to help companies make the most of digital transformation. DW Rockwell Automation Inc. | Rockwellautomation.com

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GE Digital announced a new service model for customers of its Industrial Software solutions. The Acceleration Plans model drives faster time to outcomes and return on software investment by providing subscribers with the support, education and adoption tools needed to quickly and accurately gain insights into critical assets and operations. Depending on specific objectives, each tier gives users access to world-class support expertise, maintenance, training, and adoption and managed services capabilities. Acceleration Plans ensure users realize value from their digital investment immediately, and achieve the outcomes that are most critical to their business. Acceleration Plans offer three tiers of increasing value depending on customer needs. These tiers provide the necessary tools and guidance to make new software installation and adoption successful, and help maximize return on investment. Average time for ROI is within eight months. GE Digital | Ge.com/digital/services

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I nternet of Things

........................................ .............................. ...................... ................. ............ OPC UA companion standard ......... ...... .... .. for Sercos released The OPC Foundation and Sercos International announced that the

Sercos OPC UA Companion Specification Release is available. This specification describes the mapping of the Sercos device model and the Sercos device profiles to OPC UA, so that functions and parameters of Sercos devices are accessible with OPC UA in a vendor-independent manner. This initiative aims to simplify the communication between machine periphery and supervisory IT systems and to support the requirements of Industry 4.0 regarding semantic interoperability. The Sercos OPC UA Companion Specification enables machine-to-machine interoperability, and machine integration with the cloud-based applications at a minimum. Sercos suppliers will now be able to take advantage of the service oriented architecture of OPC UA. The mapping rules specified by Sercos can be used for different implementation approaches. On the one hand, the OPC UA server function can be implemented in a Sercos master device, such as a CNC or PLC. On the other hand, it is possible to transfer this functionality to a Sercos slave device. In the latter case, the OPC UA accesses are executed in parallel to the Sercos real-time

Inclusion of OPC UA in the Sercos system architecture.

communication or even without any Sercos real-time communication. Thus, a consistent communication with OPC UA down to the field level is possible without abandoning the hard-real-time communication of the Sercos automation bus. DW Sercos | Sercos.org

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NEWS: CC-Link IE acquires Chinese national standards The CC-Link Partner Association (CLPA) has strengthened its position in the Asian market with the announcement of an additional GB/T Chinese national standard. GB/T 33537.1 ∼.3-2017 is related to industrial communications networks and establishes CC-Link IE as a recommended standard in the Chinese market. This means that companies adopting the use of CC-Link IE in their machines and systems could gain a significant competitive advantage in this market. CC-Link IE is currently the only open gigabit Ethernet for automation and a de-facto technology leader in the Asian market, where it has seen widespread use in the automotive and consumer electronics industries. IE’s gigabit bandwidth supports the demands of Industry 4.0 applications. This new certification means that it will also be a choice for companies participating in the “Made in China 2025” initiative. DW

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M o t i o n

C o n t r o l

Hybrid servos vs. standard servos: how do they stack up?

A new type of integrated hybrid servo motor is finding use in direct-drive applications where it offers lower cost, smaller size, and higher efficiency than conventional servo motors. Donald Labriola P.E. | QuickSilver Controls, Inc.

No single motor type has advantages in every application. Direct-drive applications favor so-called hybrid servos while high-speed geared-down applications tend to favor conventional servo motors. Misapplication of a conventional servo into a direct-drive application may result in as much as a third less efficiency and provide only 40 % of the continuous power at a typical application speed. This leads to 160 to 450 % more heat being dissipated by the conventional integrated servo motor as compared to a similarly sized NEMA 23 frame (4 in. long) integrated hybrid servo motor. There are several types of integrated servo motors; traditional low pole count ac brushless, and hybrid servos which use high pole count ac brushless motors, with the latter being used open loop as step motors. The integrated hybrid servo motors, as used in this comparison, are operated as true servo motors using vector drives. These comparisons do not hold for step-loss prevention mode step motor drives, even though the same style of motor may be in use. This closed loop versus open loop performance difference is also true of low pole count motors; the same motor performs significantly better when using a full servo control than when the same motor is driven by a variable speed drive.

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The SilverMax X-Series from QuickSilver is a fully integrated hybrid servomotor with feedback, a controller/indexer, and a digital driver all in one.

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M o t i o n

C o n t r o l

Torque Vs Speed 1.5 1.25 1

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The torque-speed curve compares torque for the hybrid servomotor and a conventional servomotor, showing that the hybrid motor has more continuous torque at lower speeds. Fundamental motor differences Hybrid servo motors are based on high pole count (typically 100 pole) motors typically called step motors when operated open loop. Traditional servo motors typically use lower pole count (typically 4 to 16 pole) motors. Given the other motor factors being the same, the torque constant (Nm/A) for a motor increases with the number of poles, and the speed goes down by the same ratio. The torque constant (if losses are accounted for separately) equals the voltage constant when expressed as volts/radian/sec. In this example comparison â&#x20AC;&#x153;Aâ&#x20AC;? brand integrated servo motor lists the voltage constant as 6.6

V/1,000 RPM which corresponds to 0.06 V/ Radian/sec which also equals 0.06 Nm/A, and a winding resistance of 1.1 ohm. The Integrated Hybrid servo from QuickSilver has a measured voltage constant of 0.227 V/Radian/Sec, and a winding resistance of 0.66 ohms. This means that the conventional servo requires more than 3.5 times as much current to produce the same torque at the shaft as does the hybrid servo. Power loss is calculated in the copper windings by Ploss = I2R. This corresponds to more than 20 times the power dissipated just to hold the same torque when the motors are stopped. Thus, a high torque constant is beneficial at low to

This graph of output power

Mech. Power- W

available constant power at lower speeds, making it more suitable for direct-drive applications.

Curve comparison Looking at the torque curves for the two motor types indicates a number of things. The curves show that the hybrid servo has

Output Power vs. Speed

300

versus speed shows more

medium speeds. However, the high torque constant also causes a higher motor backEMF for a given speed, which reduces the voltage available to the drive current into the motor at higher speeds. This condition limits the top speed of the motor. These differences make the hybrid servo motor useful for many direct-drive applications, but limits their use in high speed applications where the lower pole count motor wins out.

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M o t i o n

C o n t r o l

Total Eﬃciency

Motor+Driver Eﬃciency DC in to Sha> out

A graph of efficiency versus speed reveals that the hybrid

0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0

servomotor and controller are significantly more efficient than the conventional servomotor up to about 3,200 RPM. 0

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more continuous torque up to approximately 2,000 RPM, and more continuous torque than the “A” motor has peak torque up until approximately 1,500 RPM. These are important speeds for direct- drive applications; that is, with the motor directly driving the load without a gearhead. A typical lead screw (¼ in.,

24 in. long, both ends secured with a single bearing) has a critical speed of approximately 1,600 RPM, while extending the leadscrew to 36 in. drops the critical speed to just over 700 RPM. A typical direct drive belt drive (1-in. diameter pulley = 3.14 in./rev) moves at 52 in./sec while rotating at 1,000 RPM.

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M o t i o n

The chart of output power versus speed shows that the hybrid servo has approximately constant power from 700 RPM up to nearly 1,500 RPM, which again covers the directdrive requirements. This means that the speed can be chosen within this range and will still be fully using the motor capabilities. The conventional servo data shows power out through 7,000 RPM, but has been truncated to fit the graph. While the continuous power of the “A” motor does extend up to 226 W at higher speeds, the continuous power at 1,000 RPM is just 35 W compared to 90 W for the QCI-X23C-3 Hybrid Servo. So determining the preferred motor type definitely depends upon the application in which the motor is being used.

“The high continuous torque provided by the high pole count motor allows the motor to actually reach its maximum power capability in many directdrive applications without needing a gear head to match the motor speed to the application speed.” The motor efficiency for the QuickSilver Hybrid servo was directly measured, while the efficiency for the traditional servo was approximated based on the torque and the I2R losses and estimated speed related losses, as well as the input current of 6.6 A at 48 V producing 0.33 Nm at 6, 500 RPM (226 W out, 318 W in, some 92 W dissipated as heat). With the continuous torque curve stated as based on an 85˚C case temperature, the power being September 2017

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M o t i o n

C o n t r o l

dissipated by the motor has been taken as approximately continuous across the speed range for these calculations. What is readily apparent is that the hybrid servo motor and controller are significantly more efficient than the conventional servo motor up to about 3,200 RPM. At 1,000 RPM, midrange for many direct-drive applications, the hybrid servo is some 225 % as efficient than the continuous operation of the conventional servo motor, and some 300 % as efficient when compared to the peak torque curve of the conventional low pole count motor (which is still only producing about 64 % of the hybrid servo torque). Again, there is a wide speed range of high efficiency operation for the hybrid servo motor. Here, the curve has been somewhat truncated to show the direct drive range of speeds; the â&#x20AC;&#x153;Aâ&#x20AC;? system eventually reaches an efficiency of 71 % at the nominal continuous power point of

6,500 RPM. While this may be useful for applications that actually need this speed, it is not accessible for most direct-drive applications. Although both motor types have an efficiency of zero at zero speed, the Hybrid Servo system takes only some 20 W to hold a 1.2 Nm load when stopped, compared to an estimated 90 W needed to hold the conventional servo at 0.31 Nm, and an estimated 250 W for the peak holding torque of 0.56 Nm when stopped. This difference is important in gluing fixtures, grippers, vertical loads, clamps, and similar loads which spend a significant portion of their time stopped with torque present. Typical direct-drive applications Many direct-drive applications require motor speeds between 250 and 2,000 RPM. For example, piston direct displacement pumps for precision delivery are usually in the 250 to 500 RPM range, while belt

drives are 200 to 1,000 RPM. Lead screws typically range from 500 to 1,500 RPM for a wide range of applications, with the speed not only limited by the critical speed (first resonance) of the lead screw, but also by the lead nut speed rating, which can often limit the speed of even short lead screws. The motors used for the hybrid servos are based on the step motors. The designs use a significantly smaller amount of magnetic materials, and the usually single magnet (with a long 3 stack motor having 3 magnets) is axially aligned with the rotor, making for easy installation which does not require careful alignment and grinding. Although the pole count is high, the single magnet is shared between all of the rotor poles by a clever homopolar design. These motors are also internal permanent magnet motors (IPM), which is a technology just starting to be used for higher end servos and high efficiency motors. The use of the IPM design allows for field weakening methods

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M o t i o n to be used which allows the peak power and efficiency speed ranges to be extended. The field weakening methods also allow the ultimate motor speed (albeit at a reduced torque) to be extended beyond that which would normally stall the motor due to the back EMF exceeding the drive voltage. Due to the higher pole count, the commutation frequency for these motors is significantly higher than for the low pole count motors, but the speed increase in digital signal processors (DSP) has made this less of a problem. The high continuous torque provided by the high pole count motor allows the motor to actually reach its maximum power capability in many direct-drive applications without needing a gear head to match the motor speed to the application speed. This means that the actual rated power can be used at the needed speed. Using a higher speed rated motor in a typical direct-drive application means buying a 200-W motor and driver and then only being able to get 30 or 40 W into the application, or adding a gearhead (which with its added size and cost and reduced reliability, really changes the comparison). Proper matching of the motor speed characteristics to the load requirements significantly reduces power usage and the resulting wasted heat. This result may be counter intuitive when considering that a traditional servo is expected to have high efficiency, but this high efficiency is only available in the narrow range near its optimal operating speed; the efficiency is much lower when operating below that speed. Also remember, for positioning applications, the holding power requirements may actually dominate the total heating. DW QuickSilver Controls, Inc. | www.QuickSilvercontrols.com

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Defining the compliance

FREQUENCY ANALYZER

of electromechanical linear actuators BODE/ NYQU Modern motion controllers with built-in frequency analyzers allow direct identification of electromechanical actuators ... under load … subject to real-word conditions. That in turn may help designers improve stiffness and actuator performance — even to the point of getting higher servo bandwidth. Leonid Gannel, Ph.D. • Servo engineer • Jabil Shemer Motion

| Background image: istockphoto.com

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on motion controllers let engineers identify electromechanical actuators — even subject to real-world conditions. These tools allow analysis of linear actuators as multi-mass models defined by masses of bodies linked by compliant couplings that contribute to system resonances. Defining the couplings lets designers boost actuator stiffness — in turn boosting actuator performance by increasing its servo bandwidth. Modeling a motion design with a perfectly stiff plant for the servo design is unrealistic. Motion-design researchers describe the modeling problem it causes as the inertial reduction instability phenomenon. More specifically, this describes how increasing the amplitude of the plant’s Bode with each resonance may lead to low gain (or phase) margin or even loss of stability for velocity (or position) loops. Now let’s go through an example identification method for defining a three-body actuator — an approach that works for systems modeled with four and more bodies as well. In fact, this method is also valid for actuators with rotating motors. The only difference is that masses and forces must be replaced by rotational inertia (moments of inertia) and moments.

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PLANT STRUCTURE FOR FREQUENCY-DOMAIN ANALYSES

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Shown here is the basic motion-system model for frequency-domain analysis.

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Profiling electromechanical servo actuators — with analysis right at the loaded actuator in a test setup replicating real operating conditions — is the most effective way of quantifying that actuator’s structural features and other characteristics. The mathematical model an engineer gets from this analysis can be used for both velocity and position-loop design and verification of analytical modeling.

FREQUENCY ANALYZER

Motion controllers with frequency analyzers Controllers from ACS Motion Control, Elmo, Galil, and others include built-in accurate frequency analyzers that are user friendly. Along with the wide bandwidth of these modern PWM and linear current amplifiers — bandwidths to at least 1 to 2 kHz — the frequency analyzers are indispensable in the study of multi-mass electromechanical actuators. The presence of resonances due to compliant coupling between motor and load degrades the performance of robot manipulators, CNC machine tools, and X-Y

This is a Bode plot of the plant of a gantry stage consisting of linear-electromechanical actuators carrying load in the X direction.

coordinate tables. Vibrations in the low and middle-frequency range limit servo-actuator performance most significantly. Representing the actuator as a set of compliantly coupled bodies helps design engineers identify locations of compliant (low-stiffness) linkages. That in turn may help designers improve the coupling stiffness ... and boost actuator

performance — even to the point of getting higher servo bandwidth in some cases.

BODE/ NYQUIST PLOTS Electromechanical actuator compliance example The first step of actuator investigation is to analyze plant behavior. Here, the plant is part of the velocity loop from current command to

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Increments of the amplitude Bode are defined by mismatch ratios. Comparison of the first-body Bode for the structure here with the experimental Bode in the screen-capture from the SPiiPLUS FRF Analyzer confirms that the former is valid to use as a model.

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ν 1 (s), ν 2 (s), and ν 3 (s) = Linear velocities of 1st (motor) body and 2nd and 3rd (load) bodies S 3 (s) = Linear position of 3rd body F (s) = Motor force F 12 (s), F 23 (s) = Compliant forces m 1 , m 2 , and m 3 = Masses of 1st, 2nd, and 3rd bodies M = m 1 + m 2 + m 3 = Total mass c 1 , c 2 = Couplings' stiffness The transfer function H 1 (s) of 1st body is defined by resonances R 1 and R 2 ...

BODE/ NYQUIST PLOTS the motor/load/velocity/position. It includes the current amplifier, the motor with linked load, and the position sensor (which in this case is an encoder). The disturbance (with a harmonic shape, as a rule) is that excited by a current reference signal compared with velocity/ position over defined frequency range. Plant frequency response plotted in a Bode presentation has a logarithmic scale on the horizontal axis with the input signal frequency in Hertz. The ratio of the output position amplitudes (phases) to input motor current in decibels is plotted on the vertical axis. Consider the specific case of a gantry stage driven by linear electromechanical actuators on its axes. The mathematical description of the actual electromechanical actuator is rather complicated. The actuator has a few resonance phenomena. Each is represented by pairs of anti-resonance (AR) and resonance (R) frequencies with a phase rate up to +180° between them. For the Bode plots of our example gantry stage, let us choose two resonances for the sake of simplification. Here we must distinguish the three-bodies model 78

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for further identification. But because the key resonances are far enough apart, we can apply the superposition principle. Recall from systems theory that the superposition principle for linear systems states that the net response at a given place and time from two or more inputs is the sum of responses caused by each separate input. So for our exercise, application of the superposition principle allows simplification of the three-bodies actuator model as a coupled two-body models. Let’s now use that well-known two-body compliant model to represent the actuator design. For simplification, let’s also ignore internal viscous friction of masses as well as any viscous friction between masses. Refer to the block diagram of linear three-bodies model presented in this piece, as well as the transfer function H1(s) of first body defined by R1 and R2 resonances. The lower-frequency first resonance R1 is represented by stiffly coupled first and second bodies with mass m12 = m1 + m2 linked with stiffness c2 to the third body with having m3 mass. The higher-frequency second resonance R2 is represented with first and second bodies only linked with c1 stiffness. The third body

is switched off for frequencies higher than resonance R1 frequency. So that means for transfer functions H1(s) the T2AR1 = m3 · c2(-1) — so the period of AR-frequency of the three-body system is equal to the naturaloscillations period of the third body stiffly coupled to the first and second bodies: T2AR2 = m2 · c1(-1) — the period of AR frequency equal to natural-oscillations period of the second mass with stiff coupling to the first mass and the third mass switched off. The R-frequency period of the three-bodies model is: T2R1 = (m1 + m2 )m3 c2(-1) / (m1 + m2 + m3). The R-frequency period of the twomass model is T2R2 = m1m2 c1(-1) / (m1 + m2) including first and second masses only. Now consider the Bode plot presented in the figure titled, “Asymptotical Bode plots of first and third-body linear models” of the first body according to transfer functions H1(s) where a slope of (-2) is equivalent to (-40) dB/decade. In addition, the slope of the plantamplitude Bode before the first resonance

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These calculations show compliant coupling causes lower-frequency resonance between the body with mass of 452 kg and the third 158-kg body. Compliant coupling causing the higher-frequency resonance is between the first 161-kg body and the second of 291 kg.

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is defined by total mass M after the first resonance by the sum of first (motor) and second masses — (m12 = m1 + m2) and after second resonance by the first mass m1 only. That explains the increasing Bode slope by L1 after the first resonance … and by L2 after the second resonance. Let’s use commonly accepted mismatch definitions for second and third bodies so that Y2 = m2 / m1 … and Y3 = m3 / m1. That means that increments of the amplitude Bode L=L1+L2 are defined by mismatch ratios as:

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L1 = 20lg[(1 + Y2 + Y3) / (1 + Y2 )] and L2 = 20lg(1 + Y2). Comparison of the first-body Bode for the structure (refer to the figure titled, “Asymptotical Bode plots of first and third-body linear models”) with the experimental Bode in the screen-capture from the SPiiPLUS FRF Analyzer (from ACS Motion Control for analysis of frequency response functions) confirms that the former is valid to use as a model for further identification. Calculation of actuator-model parameters The above equations for periods of anti-resonance with index AR and resonance with index R can be rewritten:

Note that the ratio of frequencies fR1 to fAR1 is equal to the square root of the ratio (1 + Y2 + Y3) to (1 + Y2). What’s more, the ratio of fR2 to fAR2 is equal to the square root of (1+Y2). Both AR and R frequencies maybe determined more accurately from the experimental phase Bode but not from the amplitude Bode — especially in situations with low mismatches. Except for AR and R frequencies, the total actuator mass M can also be calculated from the experimental Bode. Here, the total Plant Gain 20log KP is found from the amplitude Bode at the angular frequency of 1 rad/sec. In fact, we can find three things from motor data sheets and the ACS Motion Control controller we use to explore our example gantry setup: 1) Gains of plant components as current amplifier KA in Apk/bit 2) The motor force constant KF in N/Apk 3) Position resolution KE in counts/m

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So total mass M in kg is:

Case in point: Specifics on our gantry-table example As an example, consider the axis on our XY gantry table. Assume it sports a linear ironcore motor and linear position encoder controlled from motion controller — the ACS SPiiPlusCM with an internal three-phase sinusoidal PWM power amplifier. As can be seen from the experimental plant Bode (shown in the Bode-plat figure) the actuator has two highly pronounced resonances. That means that the three-bodies model work for further identification. Note that we ran our experiments with nonzero velocity to avoid registering the effects of friction at low-frequency ranges. Let’s determine the parameters of the model according to the proposed method. Refer to the figure titled, “Gantry case-study calculations” for initial data as well as the data derived from the experimental Bode. These calculations indicate that the compliant coupling leading to the first lower-frequency resonance is between the body with mass m1 + m2 = 452 kg and the third body with mass m3 = 158 kg. In addition, compliant coupling leading to second higher-frequency resonance is between the first body with mass body m1 = 161 kg and the second with m2 = 291 kg. What does this all mean? Essentially it indicates that the source of the first resonance is radial compliance in the Y linear bearing. The source of the second resonance is axial compliance in the X linear bearing. In some such cases, design engineers can work with linearsystems manufacturers to address such compliant behavior — for example, by increasing preload on the linear assembly. DW

Jabil Shemer Motion | www.shemer.com ACS Motion Control | acsmotioncontrol.com

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Polymer bearings can be a longlasting and cost-effective alternative to metal bearings—and may reduce costs by up to 40%

Plastic bearings

step up to the plate Edited by Paul J. Heney • Editorial Director

High-performance plastics have been around in everyday life for years—we commonly see them used in kitchen appliances, bicycles or cars—but they are finding new life in more industrial environments today. Applications are many, and can include machine tools, filling machines, and pneumatic cylinders. One company using plastics to its advantage is Cologne, Germany-based manufacturer igus. These lubrication-free and maintenance-free Tribo polymers have numerous advantages. Referred to as motion plastics, they resist rain, salt and extreme temperatures, are impervious to oil and chemicals, are lighter and more energy-efficient than comparable metal solutions, and are also cost-effective. As a result, the company’s plastic bearings are increasingly being put up against metal solutions. The ability to withstand stationary stress says little about a bearing’s performance capability. The degree of wear-resistance of a bearing— and how low its coefficient of friction is—do not become apparent until it is used in moving applications, where wear is unavoidable.

FAT16-R1-2_testlab: Plastic bearings are developed and tested in igus’ massive simulation laboratory; more than 135 billion test movements are executed each year. 82

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FAT16-R1-4_bearing: Plastic bearings are impervious to oil and chemicals, are lighter and more energy-efficient than comparable metal solutions, and are cost-effective.

Testing For more than three decades, igus has been developing and producing polymer bearings, under the brand name iglidur. The materials are developed and tested in the industry’s largest test laboratory: 2,750 square meters. More than 135 billion test movements are executed each year in the center. As a result of the research and development, approximately 50 materials are currently available, including 16 full-range materials. Many materials available in the form of bar stock, liners or, for 3D printing, filament or SLS powder. Polymers enable a great deal of design freedom: with little effort, even extremely complex parts can be made or their characteristics can be significantly influenced by means of specific additives. The individual components of the compounds are mixed homogeneously during the injection-molding process. Fibers and filling materials increase the bearing’s load-carrying capacity. In addition, solid lubricants have been included in the material. All the components work together and result in good sliding and abrasion properties. In contrast, rolled metal bearings have a layered structure. The inner layer is thin and, in the event of high loads, edge pressure or vibrations, can easily be stripped off or damaged by dust particles. Moreover, the sliding layer represents a limit to the degree of possible wear. The homogeneous composition of the plastic compounds, in contrast, is considerably more 84

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robust as the wall thickness of the bearing acts as a wear zone. Bearings made of metal alloys have to be permanently lubricated, a disadvantage that is cost-intensive and time-consuming. What’s more, lubrication with grease or oil is becoming increasingly unpopular for hygienic and ecological reasons. Sinter bearings have oil lubrication incorporated, and are therefore not dryoperating bearings. The same applies to rolling bearings, which—especially in the case of needle bearings—are often replaced with plastic bearings for technical and economic reasons. Today’s research is focusing in the area of shaft materials and surface treatment. Continuous tests that react to shaft changes and are aimed at a perfect matching of shafts and bearings are absolutely critical. Plastic bearings can be used on very different shafts—including the cost-effective “soft shafts”—which is a clear advantage over many other types of bearings. In addition to the cost benefits associated with plastic bearings, designers can use a non-hardened shaft and thus reduce costs even more. As a result of this R&D program, engineers have been able to calculate service life for given applications. Designers can receive this type of insight when ordering, and also have the ability to choose their requirements, such as: longest service life with dry operation, dirt-resistant, vibration-dampening, resistant to chemicals, and ability to withstand edge pressure.

Applications In agricultural engineering, components must be able to cope with stress and be resistant to dirt. This industry is a good example of the potential of bearing technology in different markets. Bearings used in agricultural machinery must be resistant to wear and cope with high surface and edge pressures. Fertilizers, slurry or fuels can affect improperly chosen bearings. The machines must perform reliably, even after being out of use for long periods of time. Especially in agricultural environments—where machines can be exposed to extreme amounts of dirt—plastic bearings can provide optimum functionality and long operating times. igus has developed special materials in the form of iglidur Q2 and Q290, which are especially suitable for the slow pivoting applications that involve high loads and are typical in the agricultural sector. Bearings made of the low-cost material are also insensitive to dust and dirt, a key need here. In the food and packaging industry, the absence of lubrication plays an important role in view of the strict hygienic and safety standards in these sectors. According to Food and Drug Administration regulations, products cannot be contaminated by lubricants or other substances. As a consequence, only plastics that are FDA-compliant and suitable for use with food are used in these sectors. In contrast to metals, plastics are always noncorrosive due to their organic structure and are also resistant to anorganic media, including acids, lyes and aqueous salt solutions. “All interior and exterior areas must be able to withstand wet conditions and cleaning chemicals. It must be ensured that, during ongoing operation, malfunctions or unintended shutdowns do not occur under any circumstances,” said Dieter Koller, design engineer at Singer & Sohn GmbH. The company makes special machines for the food industry. To avoid dirt and contamination in this industry, iglidur products are used in a sausage-separating machine instead of the work being done manually. “We used to install needle bearings. But they proved to be unsuccessful in the face of the rough everyday stress associated with opera-

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M a t e r i a l s Baumaschine_Grau: Motion plastics can find applications even in heavy-duty applications such as construction equipment.

tion and cleaning. They are very sensitive in that the bearings had to be replaced as soon as a few drops of water penetrated through the seal during cleaning. This was too costly in the long run. The plastic machine elements, on the contrary, are characterized by a low level of water absorption and are resistant to chemicals,” said Koller. Several industries also show a lot of promise for plastic bearings. In the sterile environment of medical and laboratory equipment, for example, devices must not only be free of oil and grease but must also be anti-bacterial. Other sectors demand materials that are insensitive to air-borne dust particles and fibers—in the textile industry, antistatic

plastics that are electrostatically dissipative are used to ensure that statically charged bearings do not attract any lint or dust. Other uses include underwater, high-load applications, medical technology, and the automotive industry. Materials of the future 3D printing is opening up new possibilities for plastic bearings—two modern technologies that complement each other perfectly have now been brought together. In combination, they guarantee a high degree of freedom in engineering design and, at the same time, a high level of wear-resistance for the components manufactured in this way. To achieve

this, igus is researching and developing new 3D materials that are specially designed for moving applications. Since the first iglidur Tribo filament was introduced in 2014, the range of products has been expanded—six Tribo filaments are now available; bearings or more complex designs can not only be manufactured, but can also be used directly in industrial applications. With 3D printing, the company can also make customer-specific injection molds made of high-performance plastics in a very short time. With the SLS process, the corresponding tools can be produced in quickly and used in a standard injection-molding machine. DW igus | igus.com

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anagement tools enable ce

The IoT

and motion control fuels a rising tide of Raspberry PI, BeagleBoard, and Arduino boards Leland Teschler â&#x20AC;¢ Executive Editor

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Electronics

The internet of things has created a big market for inexpensive computer boards, so much so that standard open-source designs now have their own clones.

If you eyeball crowd-funding sites such as Indiegogo or Kickstarter you will find several projects aimed at creating computer boards in the format of the Raspberry Pi, BeagleBone Black, or other inexpensive open-source devices. There have been over 11 million Raspberry Pi boards sold since the computer’s release in 2012. The somewhat more expensive BeagleBoard has been around since 2010 and several hundred thousand seem to have sold so far. And there seem to be well over one million Arduino microcontrollers in circulation as well. All these boards originally targeted educational uses but have increasingly been applied in a variety of practical applications. Much of the open-spec embedded industry has standardized on the interface format for one of these three boards. There are numerous add-on boards available that will work on Raspberry Pi’s 40-pin expansion interface. Ditto for the Linux-ready BeagleBone Black from BeagleBoard.org, containing dual 46-pin connectors. The Arduino layout is also widely used and is a bit notorious because its 14 digital I/O reside on two connectors, so there is an irregular offset between I/O pins seven and eight where one connector ends and the other starts.

The Pi Desktop computer kit from Element14 includes a case and an expansion board that can let a Raspberry Pi become a kind of desktop PC. We assembled the Pi Desktop and took it out for a spin. The Pi Desktop contains an intelligent on/off button so named because it puts the Pi through a controlled shut down when you turn the device off. This worked as advertised. All in all, the assembly of the Pi Desktop and its operation, though brief for us, came off without any glitches.

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E lect ro ni cs The enhanced version of the BeagleBone Black developed by San Cloud in the UK includes extra USB ports, double the amount of DDR3 RAM as on the normal BeagleBone Black, and an optional six-axis gyro and accelerometer.

O E M P R E S S U R E T R A N S M IT T E RS

All these boards have gone through several revs over the years. The more recent versions have typically added wireless networking schemes of one kind or another, mainly because of the internet-of-things movement. Most clones emerging today also contain numerous wireless radios, but the usual reason for cloning one of these boards isn’t for better wireless facilities. Instead, the goal is to either beef up the ability to handle complicated tasks with more memory and specialized processing abilities, or to enhance the I/O capabilities in ways oriented toward specific applications. For example, one clone of the BeagleBone Black board comes from SanCloud in the UK. Its version of the BeagleBone Black SBC launched on Indiegogo and starts at $52. Improvements include double the amount of DDR3 RAM found on the original BeagleBone Black. Also on the board are extra USB ports, optional barometer and six-axis gyro, and Gigabit Ethernet. Over on Kickstarter, there were ten active computer board projects when we recently checked, all aimed at building Raspberry Pi or BeagleBone clones. One such project is a Pi clone developed by UP in the Netherlands. Where the original Pi uses a Broadcom SoC with a quad-core ARM processor, the UP version contains an Intel quad-core Atom processor. The Intel processor lets the UP device run Windows 10 – a feat not possible with any of the ARM versions of the board. Several other boards and open-source products in this area have debuted in recent months. Interestingly, many them incorporate features that are helpful in applications involved with motors and motion control. Here are a few we found particularly noteworthy. Board basics Though the Raspberry Pi has been around for more than five years, new versions still emerge. One of the latest comes from the electronic distributor Premier Farnell Ltd. via its Element14 online community. Element14’s Pi 3 Model B board includes the standard Broadcom BCM2837 64-bit quad-core processor. But the clock speed has been boosted to 1.2 GHz. The board also reflects the recent trend toward wireless connectivity: It 90

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Elect ronics

contains both WiFi and Bluetooth LE facilities, as well as the usual Ethernet port. Storage facilities consist of the usual 400 MHz 1-GB SDRAM and MicroSD card. The Model B also reflects another trend in Pi boards: It’s power consumption has risen to 2.5 A from a 5-V source. Slower Pi boards lacking WiFi and BLE generally have drawn about 1.8 A. Peripherals aimed at Pi boards continue to expand as well. A significant number of Pi applications turn the Pi into a kind of desktop computing device, so add-ons have emerged that simplify this task. One is the Pi Desktop computer kit based on Raspberry Pi 2 and 3. Also from Element14, it includes a case and an expansion board that can let a Raspberry Pi become a kind of desktop PC. The kit provides an intelligent and safe power controller, a real- time clock, an intelligent on/off switch and an mSATA SSD socket for up to 1 TB of on-board storage. Additional hardware includes a heat sink and various fasteners, spacers, and USB Micro-type A adapter. One advantage of obtaining peripherals like the Pi Desktop through an entity like Element14 is the relatively extensive online forums surrounding products. Comments posted there about the Pi Desktop, for example, reveal a couple of interesting facts: Lots of Pi users don’t notice the higher current requirements of the newer versions. They power the boards from older supplies and wimpy cables that aren’t up to the new specs, and they experience hard-to-track-down issues as a result. Also, users sometimes have issues with the Pi Desktop because they haven’t flashed the Pi SD card with the latest version of the Debian Linux operating system that runs the Pi. (As of this writing the latest version is “Jessie.”) As with the continual upgrades of the Raspberry Pi, board makers have extended the BeagleBoard format from its initial mission statement. Recent additions tend to be helpful in application areas focused on robotics and machine control. One version, called the BeagleBone Blue, is built around the same 1-GHz Texas Instruments AM335 processor as BeagleBone Black and carries the same 4 GB for onboard Flash storage and 512 MB of RAM. But it is geared toward motion control thanks to an integrated power management system that lets the board natively host eight 6-V servo controls, four 4-A dc motor outputs, and four encoder inputs. The board also comes equipped with a nine-axis inertial measurement unit and a barometer. Dedicated headers are provided for UART, SPI, DSM2 radio, and even GPS.

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WARNING

An integrated Power Management system on the Beaglebone Blue lets the board host eight 6-V servo controls, four dc motor outputs, and four encoder inputs that come in handy for motion control tasks.

The board has a standard USB 2.0 host and client port, useful because there is no dedicated camera or display interface. It is also possible to connect a TFT display via SPI. As with the Raspberry Pi, operating systems load via a MicroSD card. The board supports the Unix-like Debian operating system and the Linux Ubuntu Snappy distributions, as well as robotic-specific OSs and languages like ROS, ArduPilot, and Machinekit. Similarly, versions of the Arduino microcontroller board now sport features

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

that come in handy for motion control. The current basic Arduino board is called the UNO. It is based on the ATmega328 processor from Atmel and carries 14 digital input/output pins (of which six can serve as PWM outputs), six analog inputs, an ICSP (in-circuit serial programming) header, and a reset button. The Uno differs from older Arduino boards in that it includes an Atmega16U2 programmed as a USB-to-serial converter. One of the more recent Arduino boards is dubbed the Arduino 101. The most

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The Arduino 101 runs an intel Curie module and adds BLE as well as a six-axis accelerometer/gyro to what is present on more basic Arduino boards. The additional features open up possible applications in motion sensing and remote control via Bluetooth facilities in smart phones.

September 2017

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Adafruit’s Feather Huzzah holds an ESP8266 WiFi microcontroller running at 80 MHz which contains a Tensilica chip core as well as a full WiFi stack. Users can program the microcontroller using the Arduino IDE.

notable thing about it is the substitution of an Intel Curie processor for the traditional Atmel device. There are two tiny cores, an x86 (Quark) and a 32-bit ARC architecture core, both clocked at 32 MHz. The Intel toolchain compiles Arduino programs (called sketches in Arduino parlance) so they distribute optimally across both cores. The processor runs a Real-Time Operating System (RTOS) and framework developed by Intel that is open sourced. The Arduino core communicates with the RTOS to accomplish such tasks as performing PWM. The 101 includes Bluetooth LE and a six-axis accelerometer/gyro. The board operating voltage and I/O is 3.3 V, but all pins are protected against 5-V overvoltage. Max current draw is 1.5 A. The board can be powered either from the USB connector or an external source. Finally, there is a chip that is compatible with the Arduino which frequently serves as the basis for simple internet-of-things devices. The chip is the ESP8266 made by Espressif Systems in China. It is basically a WiFi chip but has a microcontroller built in. The CPU is a 32-bit design from Tensilica in the U.S. which runs at 80 MHz. The ESP8266 also contains 16 GPIO pins and interfaces for SPI, I2C, I2S, and a UART. The ESP8266 CPU and its Wi-Fi components can be programmed like any other Arduino device. One widely used board built on this CPU is called the Feather Huzzah and is made by Adafruit in NYC. This small (2x0.9x0.28-in) board comes with 4 MB of 32-Mbit Flash, 9 GPIO pins, a built-in lithium-polymer battery charger, and a 3.3-V regulator with a 500-mA peak current output. The board works with an Arduino IDE (or NodeMCU firmware with the Lua scripting language) via a USB interface.

The Huzzah is part of Adafruit’s Feather board series. So it can be expanded by combining it with other boards in that series. They include boards for BLE, packet radio, relay controlled power, GPS, stepper and dc motor control, and numerous other functions. DW

Not suitable for repairing crummy sensors

Adafruit Feather Huzzah ESP8266, https:// learn.adafruit.com/adafruit-feather-huzzahesp8266/overview

(or your reputation).

Element14 Raspberry Pi 3, https://www. element14.com/community/community/ raspberry-pi Element14 Raspberry Pi Desktop, https://www. element14.com/PiDesktop

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Arduino 101, https://store.arduino.cc/usa/ arduino-101

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BeagleBone Blue, https://www.arrow.com/en/ research-and-events/articles/introducing-thebeaglebone-blue

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UP, http://www.up-board.org/upcore/ Libre Computer Le Potato, Raspberry Pi form factor, https://www.kickstarter.com/projects/ librecomputer/libre-computer-board-next-gen4k-sbc-dev-board-for?ref=nav_search

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SanCloud BeagleBone Enhanced, https:// beagleboard.org/enhanced ocontroller using the Arduino IDE.

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WARNING

References

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I n d u s t r i a l

E t h e r n e t

| istockphoto.com

How lloT enhances asset management tools

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www.designworldonline.com

9/11/17 2:03 PM

Jack Creamer

Market Segment Manager Pumping Equipment

Schneider Electric

any operators of industrial sites are challenged

with making their plants more competitive. Issues such as energy waste, unanticipated downtime and inefficient processes all emerge as top of mind. Although these challenges are significant, taking on these issues is now less daunting and more cost effective thanks to new Industrial Internet of Things (IIoT) capabilities. The area of asset management provides a prime example of how IIoT data exchange and smart machine concepts can be applied to business problems. When aligning business processes to enable data capture and analysis it all starts with the individual assets. As more individual assets are enabled, site-wide processes become more efficient and productive. Assets can be described at traditional factory floor applications and remote process applications. An example of traditional factory floor applications would be the machines and equipment you would find in food and beverage processes. The applications for this type of industry enable users to centralize inputs to one location, while enabling machine level analysis for periodic monitoring. With remote process applications, the monitoring equipment is typically installed in rural locations. Thus, benefits are centered around maintenance enhancement but include maintenance cost reduction and improved process uptime. A critical success factor for remaining competitive is the ability to gather greater volumes of data, to analyze that data in new and different ways, and to utilize the results of that analysis to drive quick decisions. Thus, in addition to sensors, engineers will need to connect various smart devices such as PLCs, smart HMIs and smart VFDs that can gather the data and send it to remote locations via web servers or other digital means.

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I nd ustrial E t h e r n e t Design choices will involve:

1 An understanding of the key operating parameters to measure to insure optimal uptime. 2 Understanding how to monitor these parameters – use of sensors, and so on. 3 Understanding the measures and when to act. 4 Technology used to gather the data – local and remote. Asset performance management tools enable predictive maintenance Some of the new asset management tools are now available as a cloud-based service. In the past, asset management centered around either reactive (if it breaks, get it fixed as soon as possible) or scheduled maintenance. Now a more cost-effective model has emerged: predictive maintenance. That is, replacement of worn components at exactly the right

time, just prior to end-of-life or prior to unanticipated downtime. To enable predictive maintenance, devices must be capable of communicating their status. Then, that data must be analyzed. Advanced asset performance monitoring is built on these three layers of analysis: Gather the data. The first layer • uses asset specific algorithms, rules and thresholds (derived from many data points gathered over time across many sites) to gauge the performance of the assets (for example, how long that motor will last, or whether warning signs are being detected).

• Interpret the data. The second layer

consists of a Service Bureau, which is manned by a team to determine if the event the system has detected is a normal condition, or whether it requires additional investigation.

layer, engaging a remote expert, is employed If more investigation is required. The expert analyzes the data, determines the root cause, and develops a detailed event report.

• Analyzing the exceptions. The third

The cloud-based asset management model is scalable. An industrial site can start small and only be billed for the amount of monitoring that is required (4 or 5 pumps for example or, if the electrical system is being monitored, the main breakers). Then, as time goes on, more assets can be easily added until site-wide or multiple site monitoring is in place. Once it is determined through monitoring that maintenance needs to be performed, the world of the on-location service person is also made simpler. A service engineer, in front of a machine, can pick up an iPad and point the built-in camera at the equipment. The iPad will then pop up a visualization of the equipment inside the cabinet. It tells the service engineer, “Here is drive A, there is actuator B.” The engineer taps the piece of equipment on his screen and the relevant data he needs appears. That information could be the history of that www.designworldonline.com

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I nd ustrial E t h e r n e t particular drive, with information regarding how it’s been behaving over the last 14 days. On the screen, he sees a visual model of the equipment and, although he’s never seen this machine before, he knows how to repair it. See an example of this live augmented reality end user solution deployment. This scenario presents two key business benefits. The first is the avoidance of unnecessary and costly machine downtime (by being able to open cabinet doors virtually, without disruption to the ongoing process). The second is to address maintenance challenges faster and more accurately by providing instant access to relevant maintenance information and support materials (like user manuals, instructions and diagrams). DW Schneider Electric | www.schneiderelectric.com

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F a s t e n i n g

J o i n i n g

Special

adhesives

bring clarity to optic applications Fiber optic, opto-electronic and photonic applications must have superior transparency, requiring optically clear epoxies, polysulfides, and silicones that exhibit excellent light transmission. Rohit Ramnath • Senior Product Engineer, Master Bond

ptical transmission, the ability for light to be channeled through a material, is particularly important for fiber optic, opto-electronic and photonic applications. As a result, superior transparency is an essential characteristic of an optical adhesive. Optical transmission is measured from 0 to 100% on a wavelength scale of approximately 200 to 3100 nanometers (nm). Another common and interchangeable measurement of wavelength is microns, μm. Ultra violet (UV) light typically falls in the 200-400 nm range. From approximately 400700 nm (0.4-0.7 microns), there is “visible light.” After that, from about 700 nm to 1 mm, you have “infrared light,” (IR) which can be further broken down into near infrared (0.75-2 μm), middle infrared (2-15 μm), and far infrared 15 μm to 1 mm. Most optically clear epoxies, polysulfides, and silicones exhibit excellent light transmission across the visible, and near IR ranges, with some specialty systems providing a high transmission in the UV and in the middle IR wavelength ranges.

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Figure 1. Optical transmission test results for EP30, MasterSil 151, MB600 UV15 Optical transmission is required in numerous applications. For example, a manufacturer of IR lasers would inquire about epoxies with a transmission capability in the wavelengths between 800 and 1500 nm range. Other applications include LED lights, display panels, and optical lens coupling, which might need optically clear adhesives, sealants, and encapsulants which transmit in the visible range. There are even rare cases where a manufacturer of night vision goggles may need to block UV light. To help engineers meet specific requirements for a wide variety of optical related applications, Master Bond has tested several epoxies through independent laboratories, as well as various research organizations at universities over the years. To measure the optical transmission of an epoxy, a cured film, usually about 0.002 to 0.004 in. (2 to 4 mils) in thickness, is prepared. This specimen would then be put through a UV-Vis and IR spectrophotometers to obtain the transmission curve.

“To help engineers meet specific requirements for a wide variety of optical related applications, Master Bond has tested several epoxies through independent laboratories, as well as various research organizations at universities over the years. ”

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Fastening & Jo in i n g Table 1: Optical Transmission Test Results

Product

UV Transmission (200-400 nm)

Visible Light Transmission (400 – 700 nm)

IR Transmission (700 nm-2000 nm)

EP30

350-400 nm: > 95%

>95%

MasterSil 151

200 -225 nm:<80% 225-400 nm: >90%

>95%

MB600

200 -250 nm:<90% 250-400 nm: >95%

>90%

UV15

Absorbs UV light

>95%

Some of the products that Master Bond sent out for independent testing include EP30, EP30-2LB, MasterSil 151, MB600, and UV15. The results and conclusions are reported in the accompanying table* and graphs below. *Disclaimer: Note that the percentages in the table are estimates based on the chart produced by the spectrometer. The graph in Figure 1 shows the results of EP30-2LB, MasterSil 151 and MB600. EP30-2LB is a two-component room temperature curing, optically clear epoxy. Test results showed that this epoxy transmits

well from 450 to 900 nm and above. However, it has the unique capability to block UV light completely from 200 to 400 nm, and is widely used in applications where UV blocking is critical, yet transmission is needed in the visible wavelengths. MasterSil 151 is noteworthy for its low index of refraction and its ability to transmit light very well from 225-2500 nanometers. It is a silicone compound that combines flexibility, high-temperature resistance, strong electrical insulation, and optical clarity. These properties enable it to be

Figure 2. Optical transmission test results for EP302LB, MasterSil 151, MB600, and UV15

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Faste ni ng & Joining

used for coating, sealing, and potting applications involving sensitive optical and opto-electronic type applications. MB600 retains its optical clarity after curing and has very special light transmission properties, particularly in the UV range of 200-350 nm. It is a one part, aqueous based sodium silicate system widely used for coating applications requiring excessively high temperature resistance, since it is serviceable up to 1,500°F. The graph in Figure 2 highlights the results of wavelengths ranging from 400 to 3000 nm for these adhesives: EP30, MasterSil 151, MB600, and UV15. EP30 shows very good optical clarity with superior light transmission when compared to many other epoxies. It is a low viscosity, two-part epoxy, widely used for bonding, coating, sealing and casting applications. UV15 is a UV curable epoxy based system, which provides excellent optical clarity and light transmission properties. To meet ever increasing industrial demands, Master Bond continues to develop advanced systems with unparalleled optical transmittance.

PEM® Brand Fasteners Strong attachments in thin sheets.

PEM® brand fasteners keep loose parts to a minimum since the fastener becomes permanently attached to the host (panel) material. These fasteners offer a wide selection of product types, styles, sizes and mounting types to meet most application requirements.

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Produ ct Wo rl d Brushless dc motor with integrated drive Allied Motion alliedmotion.com The KinetiMax 42 EB is a 42-mm diameter outer rotor, brushless dc motor with an integrated drive. The KinetiMax 42 has a robust bearing system capable of handling high side loads. It has a minimum operating

life of 20,000 hours. The KinetiMax has an integrated speed control loop with speed set input to adjust motor speed from 150 to 5000

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Lubricating and assembly paste Klüber klubersolutions.com Klüberpaste UH1 84-201 is a white lubricating and assembly paste that is formulated for the food-processing and pharmaceutical industries. Klüberpaste UH1 84-201 offers corrosion protection and can be used as either an assembly paste for transitions and loose fits, or as a long-term lubricant for low-speed guide rails, hinges, rollers and chains. Additionally, the paste provides adhesion for friction points, even when subjected to humidity due to its water-resistant properties. As an ISO 21469-certified lubricant, Klüberpaste UH1 84-201 supports the compliance to the hygienic requirements for production in hygienically sensitive environments.

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Configurator.

Control operates with gestures Heidenhain heidenhain.us The TNC 620 control with touch screen is operated by gestures, similar to smartphones or tablet PCs. The operator can navigate quickly through long lists, programs, tables and other content by what is known as

Now you can configure Fabco-Air products anywhere. On the shop floor. At the airport. At a remote job site. And you can do it with almost any device. Even your smart phone! The Fabco-Air configurator is the most comprehensive, user-friendly, and dynamic program in the industry. It generates everything you need from one location.

kinetic scrolling.

A slow, brief swiping movement

results in scrolling over a few lines; a longer and quick movement leads to dynamic scrolling over many lines. With a short tap, the user can stop the dynamic scrolling at any time. That makes it possible to easily find, for example, an NC block or a tool in long NC programs or tool tables. In the 3-D test mode, zooming in and out as well as moving and rotating objects is particularly helpful. Further, a pop-up keyboard appears for text input.

The new MC 8410 main computer with touch screen technology in the TNC 620

corresponds to the MC 7410 in the prior solution with this functionality.

A few clicks instantly give you: • Product Part Numbers • List Prices • Lead Times • CAD Files • Seal Part No's & Prices • Repair Kit Part No's & Prices • Mounting Hardware • Accessories & Attachments • Switches/Sensors

Off-the-shelf tapped or threaded shafts NB nbcorporation.com These new off-the-shelf tapped or threaded shaft

Additionally, the program includes an unprecedented DECONSTRUCTION feature. Simply input a valid Fabco-Air part number to display all relevant information. DECONSTRUCTION can also be used to re-configure a basic part number for different mounting, stroke, added options, etc.

lines are produced in the U.S.A., never annealed, and have outer diameters that are ultra-precise. Tapped shaft can be ordered with one or both ends tapped in either case-hardened carbon steel or stainless steel. Threaded shaft can also be ordered with one or both ends threaded but only in case-hardened carbon steel. Diameters range from ¼ to 1-1/2 in. Travel lengths sections available from 6 in. to 36 in.

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Decentralized servo drive system Kollmorgen kollmorgen.com The AKD-N Decentralized Servo System design allows the drive to be positioned close to the motor and uses a single hybrid cable for power, safety, and fieldbus communication. This patented design reduces cabling by more than 80%, allowing for faster setup and smaller cabinet size and may remove the need to cool the cabinet.

The AKD-N is also IP67 rated and can withstand wet environments not typically considered

‘drive safe’. This eliminates the need for protective enclosures, allowing for a smaller, more easily integrated switch cabinet. Without the need to oversize the motor and de-rate it, the motor is optimized for the application and the footprint on the machine is kept small.

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The MUI30 has 85 to 264 Vac universal input range, 47 to 63 Hz input frequency and low leakage current under 100 microamps. For applications up to 30 watts, it has efficiency to 95% and an operating temperature range of -40 to +85ºC. It integrates 2 MOPP insulation, 4000 Vac reinforced isolation and 5,000 m operating altitude. The MUI30 meets medical safety standards, including IEC/EN/ANSI/AAMI ES60601-1 and IEC/EN/UL 60950-1. It is available in a 2.89 x 1.50 x 1.00-in. pin-type package.

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Prod uc t World Two-in-one, current transformer and voltage tap WAGO wago.us Power Tap allows for both current transformation and voltage tapping in one device. The Power Tap is designed to work in conjunction with the 285 Series feed through terminal blocks, adding current and energy measurement to its features. Equipped with the POWER CAGE CLAMP and Push-in CAGE CLAMP connection technology, wiring the Power Tap is tool-free and reliable. • Primary to secondary current ratio of ' 250 A / 1 A   • Accuracy class of 0.5 according to EN 61869   • Compact 25 mm width   • Color coded terminals to prevent miswiring. The 855 Series Power Tap coupled with the 285 Series terminal block offers an economical and complete system solution.

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One component elastomeric primer/adhesive system

more drop-in interchanges

Master Bond masterbond.com Developed for priming and bonding polyolefinic substrates, X21Med is a single component elastomeric compound that passes ISO 10993-5 tests for cytotoxicity.

X21Med is easy to use, either

as an adhesive or a primer. It has a viscosity of less than 250 cps and cures at ambient temperatures or more rapidly with heat.

As a primer, it is applied in a thin layer to the surface and the solvent is allowed to evaporate.

When used as an adhesive, X21Med should be applied to both substrates and then mated. The maximum area of bonding effectiveness is about 1 square inch. Once cured, this clear to light amber colored product is tough and not rigid. It is a reliable electrical insulator and has a volume resistivity exceeding 1014 ohm-cm. X21Med is serviceable from -60°F to +200°F [-51°C to +93°C].

Integrated servo motor and drive Tolomatic tolomatic.com The Tolomatic ACSI integrated servo/motor/controller is now available with PROFINET Industrial Ethernet protocol. The integrated package is suitable for replacing pneumatic cylinders

from the air cylinder source

and automating any simple axis of motion with Siemens or other PROFINET enabled PLCs.

Available in two sizes (NEMA 23 and 34), with peak torques up to 1.35 N-m (12 in.-lb), the

ACSI features standard M12 connectors, an IP65 rating, dual Ethernet ports with LED indicators

FABCO-AIR

for easy troubleshooting and a USB microprogramming port. All models of ACSI come equipped with 24 Vdc digital I/O (4 in / 2 out) and 0-10 Vdc / 4-20ma analog I/O (1 in / 1 out) for distributed sensors and logic to expand the network. The dual Ethernet ports with integrated

Phone (352) 373-3578 • Fax (352) 375-8024

managed switch allow many axes of ACSI to be daisy-chained without affecting network

www.fabco-air.com E-Mail service@fabco-air.com

performance.

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Forming the Future

LEADING THE

Produ ct World

INDUSTRY

LARGEST WAFIOS FMU IN THE USA For more than a century Newcomb Spring has been recognized as the industry leader, with unmatched capabilities and expert services. Our precision manufacturing processes produce the highest quality custom springs, stampings and wire forms with:

• • • • •

The best spring calculator - the Springulator® The largest Wafios FMU in the USA CNC forming up to .625” wire diameter 9 facilities in the USA and Canada An Innovation Department that develops custom software & equipment

Direct drive servos Yaskawa yaskawa.com The SGM7F line of direct drive servo motors delivers 4 to 35 Nm of torque in a device as small as 2.1-in. high and 5.3-in. in diameter (53 x 135 mm). This size advantage makes it possible to apply the mechanical benefits of a direct coupling between a servo motor and a load in tighter spaces than ever before. Machine designers can use SGM7F to make automated machinery more compact, freeing up valuable space on crowded plant floors. Additional Features: • An open core design that adapts easily to shaft mounting and allows wiring to pass through easily • 24-bit encoding for precise motion control • A self-cooled design that generates a low level of heat • A design that is ideal for applications which require downsizing and shorter cycle time

newcombspring.com Product World_9-17_Vs4.LL.indd 116

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Fully Integrated Display

Compact IPCs Advantech www.advantech.com/ea This new series of rackmount IPCs features short-depth, self-diagnosis, remote manageability, and modularized design. These IPCs easily integrate in an equipment enclosure, leaving more space for cable routing and internal devices. Once installed, the IPCs report their status to a remote administrator before failure occurs. Maintenance can quickly swap key modularized parts, minimizing maintenance time.

The ACP-2020 and ACP-4020 both feature short-depth

(400/350mm), a built-in intelligent system module that checks IPC fan speed and temperature and proactively reports any abnormal condition. The front-accessible system fan, hot-swap drive bay, and redundant power module facilitate quick maintenance.

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

Standard Parts. Winco.

Thermally conductive epoxy EpoxySet www.epoxysetinc.com EP-207 is a thermally conductive epoxy potting and encapsulating compound for electronics and heat dissipating devices. This room temperature curing system is UL-94V0 yellow card listed

JW Winco, Inc. offers a comprehensive line of tube connection components, including inch and metric close tolerance tubing, as part of its immense offering of standard machine components for industry. Explore our full line on our website www.jwwinco.com or contact us with your application requirements. Sales@jwwinco.com Phone: 800-877-8351 Fax: 800-472-0670

with electrical insulating properties and a high dielectric strength. It is low viscosity and will create strong seals to metals, ceramics, glass and many engineered plastics. The EP-207 is suitable for thermal cycling applications from -55 to125Â°C. It has a slight degree of flexibility making it the best choice for resistance to mechanical and vibrational shock. This low cure shrinkage epoxy will not damage intricate circuits and components during cure. September 2017

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Order by 10 p.m. ET for same-day shipping. Order by 8 p.m. ET for next-day delivery.

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Self-clinching flush-head studs PennEngineering pemnet.com Ballscrews & Rollerscrews

These self-clinching flush-head studs have a lowdisplacement head design enabling close-to-edge installation of the fasteners in thin metal sheets. The studs provide suitable attachment solutions compared with weld studs and other conventional hardware. Since

Industrial Robots

the studs install permanently, they will never loosen or fall out over time.

The studs are manufactured from steel (FHL) or

stainless steel (FHLS) and will mount successfully in steel or aluminum sheets with thickness of .040-in. / 1mm and Linear Motors

greater. Thread sizes to accept mating nuts range from #2-56 / M2.5 through #10-32 / M5. A variety of lengths can be supplied.

Linear Actuators

Cartridge Check Valves

Linear Guideways

Designed for Installation into Plastics

Linear Encoders / Positioning Measurement Systems

• 100% Performance Tested • Simple Press-In Installation • Wide Range of Cracking Pressures • 2.5, 5.5, and 8 mm Sizes • All Stainless Steel

AC Servo Motors

For more information, contact The Lee Company

Innovation in Miniature

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

Hiwin D1 and D2 Servo Drives

For more information visit

www.hiwin.com

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Prod uc t World Motion controller adds larger base modules and more Delta deltamotion.com Delta Computer Systems now has more Base Modules and Power Supply options for its RMC200 motion controller to serve larger manufacturing processes and multi-function testing equipment. The new B11 and B15 Base Modules support applications from 13 to 32 axes in user defined increments, and the new 56-Watt PS6D power supply will handle any possible configuration. These items supplement the B7 base module and 35-Watt PS4D power supply.

The RMC200 uses the same RMCTools software as the other Delta controllers—

the RMC75 (can control 1 or 2 axes) and the RMC150 (can control up to 8 axes). These RMCs have special capabilities for synchronizing the motion of multiple axes, enabling the construction of machines with scalable performance and quick production changeovers. All of the controllers provide built-in dual loop support for controlling pressure/force/torque as well as position/velocity/ acceleration. The controller can transition smoothly between these control modes, enabling smooth, reliable motion.

Low Backlash

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

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

Hollow Shaft

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Rotary actuators and pneumatic object grippers AutomationDirect automationdirect.com NITRA rotary actuators are available in

WE Series Linear Guideway Wide Series Ball Type.

four body sizes with or without shock absorbers. All are double acting and have an adjustable travel range from zero to 190 degrees. Anodized aluminum bodies include integral mounting slots for position switches and a ball bearing hub and integrated piston magnets are standard. The compact design of the NITRA rotary actuators is suitable for general material handling and other industrial applications such as conveying, clamping, transferring parts, positioning, and controlling valves.

PG Series Linear Guideway Integrated Magnetic Encoder.

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HG / EG / RG Series Linear Guideways Ball and Roller Type.

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OCTOBER 16-18, 2017

Minneapolis, Minnesota USA

You’ll Get the Latest Innovations, Techniques and Best Practices Learn directly from trusted industry instructors covering important topics in motion control, motors and automation technologies MCMA TechCon, now in its 26th year, gives you: • High Quality Education • Networking Opportunities • Access to Industry Leading Suppliers • Real-world Solutions to Advance Your Projects

PLAN TO ATTEND! REGISTER TODAY!

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Prod uc t Wor l d Remote access HMI WEINTEK weintekusa.com LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

The cMT3090 HMI operates as a conventional HMI with increased data/graphic processing from it’s dual-core CPU. Additionally, it works as a server allowing remote access from anywhere. Remote access through the cMT Viewer application

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

(or EasyAccess 2.0 and OPC-UA and MQTT compatibility) provides unlimited control and monitoring capabilities.

The cMT3090 HMI contains a 1GHz dual-core CPU, 4GB flash, 1GB Ram, a 9.7-in.

Hi-Res display (1024x768) and Dual Ethernet. It supports IIoT standard communication protocol (MQTT and OPC UA client/server).

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

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

AC Servo Motors.

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

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The Industry Leader in Test Point Technology for More Than 70 Years Components Corporation’s signature line of printed circuit board test points delivers top-fight performance and cost-efciency. • Cost-efective, time-saving solution for PCB test applications. • Mission critical performance in the harshest of test environments. • Broad range of product oferings for specifc design requirements. • RoHs/Reach/Confict Materials compliant. DesIgneD for VaLue. VaLueD for PerforMance.

Produ c t Wo rl d Self-learning 40 hp soft starters Carlo Gavazzi GavazziOnline.com The 45 mm wide RSGD Series Soft Starter is a softstarter for 3-phase induction ac motors, needing just three settings. The self-learning algorithm adjusts the soft starter parameters to work with different applications and varying load conditions. It is active at every start to ensure that the motor always starts with the optimal settings. New current balancing algorithm keeps the current unbalance to less than 15%. The RSGD Series has an option for Class 10 electronic overload, providing advanced motor protection and

COMPONENTS CORPORATION

6 Kinsey Place, Denville, NJ 07834-2692 866-426-6726 www.componentscorp.com

resulting in further space savings in the electrical panel. Phase sequence protection can be enabled and disabled easily through the integrated push button, simplifying

Motor Feedback Systems for linear and rotative drives

installation in applications that require reversing. Torque controlled ramp-down results in much smoother deceleration of motors. All these features are offered in one of the most compact soft starters on the market.

Absolute and incremental magnetic measurement ■ ■ ■ ■ ■

Contactless and completely wear-free and maintenance-free Extremely precise, even if the scale is covered with dirt Flexible dimensioning of measurement lengths and diameters Easy handling, high accuracy of position for highly dynamic processes Safety SIL2 certified (optional)

SIKO Products Inc., Phone +1 (734) 426-3476, www.siko-global.com

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Linear roller bearings for high contamination environments IKO Ikont.com The new MX series of linear roller bearings now includes special features for environments sensitive to metal chips, dust, and other contaminants.

A dust protective C-Wiper can be mounted to the outside of the end seal,

ensuring operation in environments where metal chips are spattering. After 1,000 km of operation, the C-Wiper prevented foreign substances from entering the slide unit with no damage to the end seal.

The MX specification uses a proprietary C-Lube lubrication system. As the

cylindrical rollers circulate, lubricant is distributed to the loading area through the rollers along the track rail. Lubrication is properly maintained in the loading area for over 12,500 miles.

High load capacity. The MX models utilize rows of cylindrical rollers to provide a greater contact area than slides that use steel

balls. They also maintain high rigidity in every direction. As a result, bearings deliver high load capacities––up to 674 kN for dynamic loads and 1,300 kN for static loads.

It’s About Time Time to Save Time is money. Switching to EPLAN Electric P8 from CAD software typically reduces project time by 40% or more right out of the box - as much as 80% when using the feature-rich EPLAN portfolio to its fullest.

Time to Automate EPLAN automates time-consuming data creation and verification functions CAD users must perform manually - often repetitively - like device tagging, generating wiring, parts and connection lists, performing cross-referencing and error-checking.

Time to Plan Ahead EPLAN has virtually unlimited scalability for managing the increasing electrical content designing for the IIoT/Smart Factory environment. The bigger the assignment, the more EPLAN excels. CAD can’t do that.

Time to Switch EPLAN is the future of engineering. It’s freedom to concentrate on what matters most – engineering – so you or your team can quickly create high-quality plant and machinery designs and documentation. For more information or for a free 30-day trial, contact us at

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MASTER BOND

Machine

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Key Bellevilles, Inc. LARGEST MANUFACTURER OF DISC SPRINGS IN THE WORLD Live Load with Belleville Disc Springs LARGEST STOCK OF STAINLESS STEEL AND INCONEL SPRINGS IN THE WORLD HIGH TEMPERATURE FLANGE BOLT

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SALES

Ad I n dex Accumold .....................................................98 Aerotech ...................................................... 85 Aignep USA ............................................ 35,49 All Motion ....................................................... 4 Allied Electronics .......................Cover,21,118 Allied Moulded Products, Inc. ....................86 Altech Corporation ..................Gatefold,37,39 Altra Industrial Motion .............. 23,24,25,26 AMETEK DFS ................................................ 61 Anchor Fluid Power ................................... 101 Anderson Metals ...................................... 114 Applied Motion Products ............................ 45 Aurora Bearing Company ........................110 AutomationDirect ......................................... 3 Baldor Electric .............................................34 Bimba Manufacturing Company ............... 11 Bird Precision ............................................110 Bishop-Wisecarver ..................................... 69 Bison Gear .................................................. IBC Bokerâ&#x20AC;&#x2122;s Inc. .................................................. 16 Canfield Connector ................................... 123 Carlo Gavazzi ..............................................44 Century Spring Corp. ................................104 CGI ................................................................53 Components Corporation ......................... 124 CS Hyde Company ......................................56 Data Image Corporation ........................... 117 Del-Tron Precision, Inc. ............................... 71 Design-2-Part Shows ...............................126 DieQua ................................................. 30,120 Digi-Key Electronics ................................... 15 Dunkermotoren .......................................... 63 Eagle Stainless Tube ............................ 58,59 Elesa USA Corporation .............................107 Encoder Products Company .....................48 Endress+Hauser ........................................49 EPLAN ........................................................ 125 EXAIR ............................................................. 5 EZAutomation ............................................. 13 Fabco-Air ......................................111,113,115 Helical Products Company .......................... 7 Hiwin Corporation .......................119,121,123 igus Inc. ....................................................... 64 Indium Corporation .................................... 31 Interpower ...................................................22 ITT Enidine ............................................. Insert IXYS .............................................................. 57 J.W. Winco, Inc. ......................................... 117

Keller America Inc ......................................90 Key Bellevilles Inc. ................................... 127 Keystone Electronics Corp. ...................... 77 Lauren Manufacturing ...............................70 LEMO USA, Inc. ............................................80 Lenze Americas .......................................... 87 Magnet Applications .................................. 73 Maryland Precision Spring ......................100 Master Bond .........................................35,127 Memory Protection Devices, Inc. .............. 33 Miki Pulley US ............................................. 47 Mohawk Spring ........................................... 79 Motion Control & Motor Association .......122 Motion Industries / Eaton .......................... 51 Nason ...........................................................38 Neugart ..................................................... 112 Newcomb Spring Corp ............................. 116 Nook Industries .......................................... 29 Novotechnik ................................................ 43 OKW USA ...................................................... 17 OPTO 22 ....................................................... 62 PBC Linear ............................................. 40,41 Penn Engineering .....................................109 phd Inc. ........................................................ 54 Proto Labs ..................................................... 9 Pyramid Inc. .............................................. 121 QA1 ............................................................... 16 R+W America ............................................... 91 Rollon Corporation ....................................108 Rotor Clip Company, Inc. .........................105 SEW-EURODRIVE ......................................... BC SIKO Products ........................................... 124 Smalley Steel Rings ................................... 10 Smart Products USA, Inc. ........................106 Sunstone Circuits .....................................103 The Lee Company ..................................... 119 THK America, Inc. ......................................... 1 Tolomatic, Inc. ............................................. 19 Tompkins Industries ..................................94 Tormach ....................................................... 65 Trim Lok ....................................................... 72 Turck Inc. ............................................... 93,95 Visumatics Industrial Products ................50 Weintek USA ................................................36 Whittet-Higgins ........................................... 27 Wittenstein ..................................................92 Yaskawa America, Inc. ............................... 55 Zero-Max, Inc. ................................................ 2

Mike Caruso mcaruso@wtwhmedia.com 469.855.7344 Garrett Cona gcona@wtwhmedia.com 213.219.5663 @WTWH_gcona Jessica East jeast@wtwhmedia.com 330.319.1253 @wtwh_MsMedia Michael Ference mference@wtwhmedia.com 408.769.1188 @mrference

Tom Lazar tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom Jim Powers jpowers@wtwhmedia.com 312.925.7793 @jpowers_media Courtney Seel cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

LEADERSHIP TEAM

Michelle Flando mflando@wtwhmedia.com 440.670.4772 @mflando

Publisher Mike Emich memich@wtwhmedia.com 508.446.1823 @wtwh_memich

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EVP Marshall Matheson mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

Follow the whole team on twitter @DesignWorld

DESIGN WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. DESIGN WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care. DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. CopyrightÂŠ 2017 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher. Subscription Rates: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only. Subscriber Services: To order a subscription or change your address, please email: designworld@halldata.com, or visit our web site at www.designworldonline.com DESIGN WORLD (ISSN 1941-7217) is published monthly by: WTWH Media, LLC; 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103. Periodicals postage paid at Cleveland, OH & additional mailing offices. POSTMASTER: Send address changes to: Design World, 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

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