DESIGN WORLD SEPTEMBER 2019 by WTWH Media LLC

www.designworldonline.com

September 2019

inside: Motion Control: What really limits gains

in a servo system

p. 62

Internet of Things:

How to better integrate IoT devicesâ&#x20AC;&#x201D;use apps

p. 84

Sensors: Applying the right

position sensor

p. 90

Compare

roller-screw to ball-screw actuators page 72

COVER_SEPT 2019_FINAL.indd 1

8/30/19 9:15 AM

INTRODUCING AIROS

Bimba’s Air Preparation Product Line Beyond actuation, Bimba now offers a complete family of high quality air preparation equipment that meets the needs of every pneumatic circuit.

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Celebrating more engineering creativity Last year, we launched the LEAP Awards, a competition to honor the best engineered components across the mechanical and electrical engineering spaces. Not sure what to expect with a first year’s awards program, we kept things rather simple … and were pleasantly surprised when we received well over 100 entries, making it perhaps one of the best awards launches in the engineering community’s history. The 2019 edition of LEAP is well underway, and you can expect to read about the judging panel, as well as the category finalists and the winners in the coming months. But we’re also expanding the program a bit. In addition to a new category for software, we’ll be awarding more honors. Instead of naming one winner and several honorable mentions in each of our 14 categories, this year, we’ll have three winners. These winners will be awarded Gold, Silver and Bronze titles for first, second and third place, respectively. There will still be several honorable mentions awarded in each category, based on the judging scores/feedback as well as the category size. I’m happy that we’ll be spotlighting more of the excellent engineering design work that’s being done across the world, because that’s really what’s at the heart of this publication. Every day, our editorial team is working hard to find and curate the best engineering information for our readers — whether that’s through feature articles, product roundups, technical reports, or application stories that illustrate the design possibilities. LEAP gives us a new and exciting way to cut through the clutter of news releases to let you know what technologies and products are truly innovative and worth your attention. I look forward to bringing you complete information about all of the winners in the coming months, both here in the print version Design World, as well as on our website, designworldonline.com. DW

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

(510) 471-4000

On Twitter @ DW—Editor

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September 2019 www.designworldonline.com DESIGN WORLD

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Teschler on Topic

Four years of college and poor

numerical skills

One of my college classmates during my sophomore year was a guy who majored in aerospace engineering. He consistently got poor grades in his engineering classes mainly because he had trouble with the math that was involved. I later heard that he’d transferred out of the engineering college to major in political science. This move let him go from perennially being on academic probation to maintaining nearly an A average. I recalled his transformation recently when stumbling over the results of a survey by the Center for Global Assessment, an organization within the Educational Testing Service. CGA research shows that a significant number of adults with bachelor’s degrees or higher have poor skills in literacy and in working with numbers. The analysis comes from a study called the Programme for the International Assessment of Adult Competencies. This study gave participants questions that required numerical reasoning and comprehending what they read. Test takers hailed from 24 countries that included the U.S., Canada, several European and Scandinavian countries, Japan, and the Russian Federation. The questions on the skills test aren’t what you’d call stumpers. One shows an advertisement for a product carrying a regular price and a discounted price during a sale. Test takers have to calculate the percent of the discount. Another question shows a table of performance measures you might see in a Consumer Reports product comparison and asks test takers to identify the product that earned the highest rating in one of the categories. When answering questions like these, U.S. adults overall ranked below average in numerical, literary, and problem-solving skills. (Interestingly, Scandinavian countries placed near the top in all three categories – perhaps a motivation for the idea of the U.S. buying Greenland?) But the study also revealed substantial variations in performance among educated adults, with as many as a quarter of those holding college degrees scoring less than the top quarter of those who stopped at high school. It also turns out that college grads in several other countries score better than U.S. college grads in numerical and literary reasoning. For example, college grads in Switzerland, Norway, and even Bermuda scored higher than U.S. college grads on average when it came to numeracy; Canadian and U.S. college grads were about the same. For literary reasoning, Bermuda and Norway bested U.S. college grads, though the U.S. average was higher than that of Canada, Switzerland, and Italy. Researchers also parsed their results by the age of the test takers. This led them to see that the predictive capacity of education diminishes over time – some older adults gain skills while many others lose them regardless of educational background. That may be true, but I can’t help but think of my math-impaired political science-major friend. Apparently, you don’t have to know much about math to be a political scientist, but perhaps you should. DW

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

September 2019

Lee Teschler Column 9-19_V1.indd 6

DESIGN WORLD

8/27/19 7:48 AM

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Technology Forward

Is 3D printing dead? “Many say that 3D printing is dead, but can those who disagree offer evidence to the contrary?” I was recently asked this question in an email. Given that this is the 35th year anniversary of the introduction of the first 3D printer, I was a bit surprised by it. Chuck Hull came out with the first stereolithography system 35 years ago. Scott Crump invented fused deposition modeling around 1989. And new ways to make parts layer by layer have emerged nearly every year for the past five years now. So, I do disagree with the statement that 3D printing is dead, and I can offer evidence. Today, 3D printers are used to make dental implants, medical implants of all types, machine tooling and fixtures, even green habitats, parts that fly on airplanes and ride in cars; houses, electronic printed circuit boards, basic prosthetics, various types of gears and bearings, guitars, clothes, rocket nozzles, models of every human organ, drones and drone parts, furniture, … the list is nearly endless. Perhaps the person asking the question is only familiar with consumer style 3D printers. Or maybe those printers that cost less than $500. That lower price end does appear to be inactive. What is emerging are 3D printers in the $5000 range that are more rugged, have better print accuracy, and are a bit more capable.

This category of desktop 3D printers is thriving. Recent news includes: The Makerbot launch of the Method X manufacturing workstation. With a measurable dimensional accuracy of ± 0.2 mm (± 0.007 in.) and a part build size is 6 x 7.5 x 7.75 in.; it’s a desktop unit that works with real ABS, but in a production capacity. Then we have all the recent news of “desktop” 3D printing vendors opening new facilities or obtaining funding for expansion—certainly not a sign of a dying industry. Some of the recent news includes Markforged opening a new, 2000 sq ft R&D center. Desktop Metal installing a number of its metal 3D printers in various educational institutions, such as the University of Sheffield in the UK. And the professional 3D printing market, also known as the additive manufacturing market, is seeing strong growth. Carbon recently announced it raised more than $260 million in growth funding. This latest round brought its total fundraising to more than $680 million. HP recently opened a Digital Manufacturing Center of Excellence in Spain. The center is about the size of three football fields and will be used to help transform the way engineers design and manufacture products. GE Additive Print Services will support General Dynamics with part qualification, production, post processing and inspection of additively

manufactured components. The two companies are working together to identify applications in which additive manufacturing can provide value through weight reduction, performance optimization, and lead time reduction. Digital manufacturing is the new arena for the additive industry as a number of technologies and corporate partnerships converge to speed products to market. Siemens and HP will expand their integrated additive manufacturing offering, incorporating new systems and software including overall product lifecycle management (PLM), AM factory optimization, industrial 3D printing and data intelligence, manufacturing execution, and performance analytics. And finally, the GE Additive Education Program’s (AEP) will grant polymer 3D printing packages to 982 primary and secondary schools and reach 793,000 primary and secondary school students in 23 countries. Since its foundation in 2017, over 1,296,000 students and 2,000 schools in 36 countries have benefitted from the AEP. So, in this 35th year of additive manufacturing, the industry is doing just fine. Paraphrasing a quote attributed to Mark Twain, reports of this industry’s death are quite premature. DW

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

September 2019 www.designworldonline.com

Tech Forward 9-19_Vs2.LL.indd 8

DESIGN WORLD

8/27/19 7:52 AM

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Green Engineering Paul J. Heney

• VP, Editorial Director

Sustainable 3D-printed habitat

shows possibilities

BigRep, a leader in large-format 3D printing, launched a fully 3D-printed urban green habitat installation using multiple, recycled plastic-based filaments — called the Genesis Eco Screen. Addressing some of the biggest environmental challenges such as plastic waste, overconsumption of energy and other resources, rapidly deteriorating biodiversity and urbanization, the installation is a prototype in urban architecture and a showcase in Additive Manufacturing (AM) of a scalable, city-developing circular economy. The installation features unprecedented innovations made possible only by using custom-made generative design algorithms and the world’s largest, serial production 3D printers (FFF). The Genesis Eco Screen features an embedded water and drainage system for plants and insect habitats, including a shelter for solitary bees. Measuring a full 4 by 4 meters, the Genesis Eco Screen is reminiscent of a massive root system, and is printed using multiple filaments — consisting of BigRep PETG and BASF Innofil3D rPET made of 100% recycled PET printed on four large-scale ONE printers. The project, set to be completed by late August, will be on display in downtown Berlin. The actual printing has been occurring at a public site, the Thaersaal at Humboldt University. Once completed, the Genesis Eco Screen will be on display at the Fiction Forum exhibition center, the site of a now-demolished East German border control station that left a gap between East and West.

DESIGN WORLD

Green Engineering 9-19_Vs3.LL.indd 11

“Disruptive technologies such as 3D printing are key to solving some of the world’s biggest problems,” said BigRep CIO and NOWLAB Managing Director Daniel Büning. “We want to deliver groundbreaking innovation to maximize the potential of AM, thereby creating entirely new applications. With this project, we are introducing a new and truly sustainable manufacturing protocol to the manufacturing of polymer objects using multiple pre-used plastic materials. The Genesis Eco Screen shows how society can develop a greener future — with circular economy solutions that are sustainable, local, modular and collaborative.” Circular economy is aimed at minimizing waste by closing the gap between resource input, waste, emissions and energy usage. This is achieved by reducing consumption and material usage. Set up at Fiction Forum as a closed loop process, the PET bottles are recycled as an input material and 3D printed for an innovative, yet hands-on, showcase for production to demonstrate this approach.

www.designworldonline.com

September 2019

8/27/19 7:54 AM

Machine Tool Components

Green Engineering The Genesis Eco Screen was created using

Spring Plungers

some of the most advanced self-generating design algorithms and agent-based modeling.

Clamps

Workholding Grippers

At the Thaersaal, the public can learn more about this closed loop process in an exhibit detailing the steps turning waste into high-tech printing material. Used PET-bottles are delivered to a collection point, cleaned and pre-processed for the Dual Axel Shredder, a machine designed by the Germany company raw paradise. It processes the plastic into printable raw material for the actual filaments that are produced with a filament extruder. The filament is a long strand, only 2.75 mm in diameter, and it looks like a cable. Coiled on filament spools, one for each printer, it is fed into the large-format ONE printers. The Genesis Eco Screen was created using some of the most advanced self-generating design algorithms and agent-based modeling. These algorithms and agents are intelligent tools, almost comparable to AI, capable of autonomously designing complex geometries with only a few pre-set parameters. For the Genesis Eco Screen, these included, for example, a data analysis of the sun exposure across

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September 2019

the installation in order to be able to optimize the diameter of the 3D-printed â&#x20AC;&#x153;branchesâ&#x20AC;? and the creation of the shading features and plant positioning accordingly. DW Fiction Forum www.kreativ-bund.de/fictionforum BigRep GmbH www.bigrep.com

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

www.designworldonline.com

DESIGN WORLD

8/27/19 7:55 AM

Automate now with low-cost, maintenance-free drylinÂŽ gantries

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8/27/19 7:40 AM

Contents 9 • 2019

•

vol 14 no 9

•

designworldonline.com

Medical www.designworldonline.com

84 62 _MOTION CONTROL

84 _INTERNET OF THINGS

What really limits gains in a servo system?

How to better integrate IoT devices—use apps

Understanding the real factors limiting servo gains, and system performance, makes it easier to devise counteracting stratagies.

72 _LINEAR MOTION How roller-screw and ball-screw actuators compare

As electric rod-style actuators overtake fluid power in a variety of high-force applications, it is important to understand how different screw technologies compare in the search for optimum performance and low life-cycle cost.

A Supplement to Design World - September 2019

Medical device innovations industrysupplier you need to know Medical Tips cover 9-19_FINAL.indd 109

8/28/19 7:39 AM

109-122

Engineering September 2019

Systems for integrating IoT devices and smart equipment can be architected in many ways, and end users will find easier access when mobile apps and FTP access are incorporated.

A supplement of Design World

Fastening technology covering nuts, bolts, rivets, screws, u-clips, eye bolts, washers and more.

COVER_FASTENER ENGINEERING 9-19_Vs1.indd 124

8/28/19 7:36 AM

124-146

90 _SENSORS Applying the right position sensor

Best practices for choosing between general-purpose and mission- specific position sensors for industrial applications.

96 _SCANNING Reverse engineering: A basic 3-step how-to

Here are tips on developing protocols and processes for reverse engineering with scanning technology.

ON THE COVER

Here a Tolomatic electric rod actuator with a ball screw drives a log-cutting operation. | Image courtesy Tolomatic Inc.

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

2019

BRONZE REGIONAL AWARD asbpe.org

September 2019 www.designworldonline.com

CONTENTS 9-19_Vs3.LL.LE.indd 14

DESIGN WORLD

9/3/19 10:10 AM

190731_AutoC_DW_US.indd 1 Digi-Key 9-19.indd 15

7/23/19 8/27/19 2:05 7:41 PM AM

9.19

• contents departments 04 Insights 06 Teschler on Topic 08 Technology Forward 11 Green Engineering 18 Design For Industry 32 Design Notes 46 Internet of Things 54 CAE Solutions 60 MC2 School 147 Product World

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CONTENTS 9-19_second page_Vs1.indd 16

September 2019

DESIGN WORLD

9/3/19 10:22 AM

DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

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

WEB DEV / DIGITAL OPERATIONS

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FINANCE

Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel

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Staff page 9-19_Vs1.indd 17

â&#x20AC;&#x192;â&#x20AC;&#x192;

September 2019

8/27/19 11:39 AM

Design for Industry Aerospace/military

Adaptable heat pipes cool hot components

When you need to manage the thermal needs of electronics, one solution is flat

and round copper heat pipes. These heat pipes provide low cost cooling forÂ cloud and edge computing, electric vehicles, aerospace, and data communicationsÂ needs, among others. The stand-alone cooling and can be combined with heat spreading devices to deliver high levels of passive or active cooling. Heat pipes transfer component heat with minimal temperature difference to dispense heat efficiently across heat spreaders. Liquid in the heat pipe turns to vapor by absorbing heat and removing thermal energy from hot component surfaces. The vapor travels to the cold end of the pipe, releases latent heat and condenses back to liquid. The liquid returns to the hot interface along an internal copper wick to provide continuous thermal management.

September 2019 www.designworldonline.com 18

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DESIGN WORLD

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These heat pipes consist of a sealed copper tube, internal copper wick structure, and distilled water as the working fluid. Round profile heat pipes come in lengths from 200-300 mm and diameters from 4.0-8.0 mm. Flat profile heat pipes range in length from 100-250 mm, widths from 8.2-10.5 mm, and heights from 2.5-4.5 mm. Weights range from 8-33 grams. They are effective in temperatures ranging from 30-120°C. Other fluids and sizes can be accommodated with custom heat pipe designs. The cold end of the copper heat pipe attaches easily to most heat sinks, providing effective cooling when a heat sink can’t be applied directly on a heat source. The finished heat pipes can be shaped by hand or machine. They can be friction fit, clamped, soldered, or adhesively attached. DW

Advanced Thermal Solutions | qats.com

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DFI 9-19 Vs4.LL.indd 19

September 2019

9/3/19 7:54 AM

Design for Industry Aerospace/military

Space saving dc contactors

Customers want designs to continue to shrink in size, while demanding

more features and capability. These hermetically sealed KILOVAC EV600 highvoltage dc contactors handle harsh environments, and are rated to handle more current than the EV200/LEV200 contactors without taking up additional space on the board. Rated for 600-amps, TE’s EV600 is the latest addition to the KILOVAC highperformance contactor line. The EV600 has a 20% higher current carry rating and switches up to 36% more current than the legacy EV200 contactors. KILOVAC EV600 contactors are designed with bi-directional switching capability in order to allow power switching in forward and reverse directions. “The new EV600 contactors are designed for high current systems in commercial and military ground vehicles; energy and battery storage systems; and power distribution and motion control applications,” said Earle Alldredge, product manager for TE’s Aerospace, Defense and Marine division. “They are a reliable option that offers excellent performance for their size and weight.” KILOVAC EV600 high voltage contactors also feature electronic, dual coil economization that facilitates low holding power. They are available with an auxiliary contact and 12- or 24-volt coils to match a wide range of power systems. DW

Higher Reliability smaller footprint New Ready-To-Use Cable Assemblies Now Available with Reverse Fixing Screw-Lok for Design Flexibility

TE Connectivity | www.te.com

- Save time and money on tooling, training and testing cables - Metal back-shells for maximum strain relief and RF shielding - Up to 45% smaller and up to 75% lighter than Micro-D - Resists extremes of shock, vibration and temperature - Excellent out-gassing properties

www.harwin.com/gecko-sl 20

September 2019

DFI 9-19 Vs4.LL.indd 20

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DESIGN WORLD

8/27/19 8:11 AM

M a c h i n e To o l

Linear transfer system precisely

positions materials and workpieces

For the highly dynamic transport and exact positioning of materials and workpieces, linear motor-driven transfer systems can be a good choice. With its modular concept and moving magnet design, the flexible transport system (FTS) can be scaled to the application and provides a high degree of freedom in the design by removing the moving cables. As a modular system based on components, the FTS can be easily integrated into systems and machines. This offers the user full flexibility, both in the size and scale in selection of motors and drives, as well as the programming of individual and synchronized motion. With its contactless drive, the intelligent system can adapt to a number of different production conditions. Refined from its original development in 2005 for particlefree transport in the solar deposition process, the proven FTS is compatible with today’s in-line manufacturing systems. Through its magnetic principle of operation, the FTS is an option to meet extreme requirements in a high vacuum, since all the electronics are located outside the vacuum. The FTS can also operate with precision in dusty and dirty environments. This makes it attractive for many applications, ranging from semiconductor and display manufacturing to battery production, where the FTS demonstrates its special handling characteristics and easily copes with a wide range of moving loads from a few grams up to 1,000 kg per carrier. Combined with highly repeatable accuracy and speeds up to 5 m/s with a velocity ripple of maximum 2% at 20 mm/s, the FTS is optimally equipped for a variety of industries. Another unique feature of the FTS is its motion control function and suitability for low-speed use, such as coating processes. Whether it’s used in a clean room, vacuum, with noble gasses, high temperatures or in chemical areas, the Rexroth FTS addresses a variety of transport and handling tasks. DW

Bosch Rexroth | www.boschrexroth-us.com

Whether in a vacuum, a clean room or in dusty and dirty environments, the linear motor-driven transfer system FTS always works with high precision.

DESIGN WORLD

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September 2019

8/27/19 8:10 AM

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

Sensor measures equipment strain

The ESR digital strain sensor monitors the structural health on equipment where

needed. It is coupled with an encoder that uses the digital interface EnDat for high signal quality, accuracy and robustness. The sensor can be mounted on any flat surface where load or mechanical forces apply to a body. Suitable applications include use on cranes, conveyor belts, bridges, wind turbine rotor blades or wherever a load or force needs to be monitored on a mechanical structure. It can also be used in harsh environments. The ESR series is a fatigue-free measurement concept providing high-resolution digital input into a system of choice. It is based on an optical encoder attached on a mechanical measuring arm which connects to the body being monitored. The applied force on the structure is calculated by the subsequent system measured as a position difference by the encoder.

Meet FDA and 3A Requirements 316 Stainless Steel Simplicity® Bearing 316 Stainless steel shaft

• Tolerates the Most Demanding Washdown Environments • Extreme Temperatures, +/- 400°F • Corrosion Resistant • Sanitary Design

DFI 9-19 Vs4.LL.indd 22

Watch the video on bearing selection: http://bit.ly/bearing-selection

9/3/19 2:25 PM

The material in the measuring arm of the sensor unit can be adapted to match the material of the measured body. The purpose is to create a passive temperature compensation and increase the overall measurement accuracy for those installations where ambient temperatures are fluctuating. Simplicity during installation and commissioning was one of the driving factors during the product development, and therefore different mounting accessories are available. The sensor can be tailored for a permanent installation or used in temporary measurement campaigns.

The sensor resolution is 0,025 μɛ (μm/m) and has a measuring range of ±5 000 μɛ. The product enclosure is IP66-rated, which means it is dust proof and has protection against powerful jets of water. It is of use in a temperature range from -40°C to +100°C. DW

Leine Linde, HEIDENHAIN CORP. www.heidenhain.us

and Upgrade Your OEE MTB Series

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DFI 9-19 Vs4.LL.indd 23

pbclinear.com 6402 E. Rockton Road, Roscoe Illinois 61073 USA • +1.800.962.8979

8/27/19 8:49 AM

Design for Industry Packaging food/beverage

Hygienic servo motors minimize

contamination risks

In food and beverage manufacturing, demand for more product varieties is creating a need for smaller, more flexible machines with the HMI located in close proximity to the process. But such products must also stand up to the rigors of contamination and cleaning. Food and pharmaceutical makers can better protect their products with hygienic industrial control hardware. The Allen-Bradley Kinetix VPH hygienic servo motors and a new stainless-steel version of the Allen-Bradley PanelView Plus 7 graphic terminal help minimize contamination during production and ease compliance. The stainless-steel PanelView terminal can be used on a machine in a “splash” or contaminant zone without the need to be covered or isolated. This helps protect product quality and simplifies the cleaning processes, while removing obstructions to the human machine interface (HMI), so operators can better monitor production. The general-purpose HMI terminal is certified by the National Sanitation Foundation (NSF). It has an ingress-protection rating of IP69K to support highpressure, high-temperature chemical wash downs. It also uses a food-grade silicone gasket with a distinct blue color to help production workers notice if it’s been damaged and needs to be replaced. The Kinetix VPH hygienic servo motors can improve machine reliability while

September 2019 www.designworldonline.com 24

DFI 9-19 Vs4.LL.indd 24

enhancing consumer safety by meeting stringent hygienic standards. The hygienic design – including high-grade stainless-steel housing and a smooth surface – can withstand wash downs and reduce the risk of contamination. The servo motors are designed per the EHEDG and 3-A sanitary standards and are IP69K rated and NSF certified. They seamlessly integrate with the Allen-Bradley Kinetix 5500 and 5700 servo drive platform, using single-cable technology to help optimize a machine’s speed and accuracy. And they’re available in a range of sizes and options to help meet a variety of application needs in food and pharmaceutical production. DW

Rockwell Automation www.rockwellautomation.com DESIGN WORLD

8/27/19 8:50 AM

Power Review

Altra Motion Vol. 8 | No. 3 | 2019

The Power Brands in Power Transmission

Featured in this Edition... Bauer Gear Motor IP68 Solutions: Energy Efficient Technology for the Wastewater Industry Warner Electric Introduces New ERX Brakes Range and the WES Contactless Sensor Stromag Introduces the New Steel Spring Coupling (SSC) Experience the TB Woodâ&#x20AC;&#x2122;s Service Difference Twiflex USA Brake Calipers Boston Gear Rapid Response Delivery

Bauer IP68 Geared Motor Solutions for the Wastewater Industry

IP68 Solutions Creating A Premier Industrial Company Ameridrives Bauer Gear Motor Bibby Turboflex Boston Gear Delevan Delroyd Worm Gear Deltran

Altra Industrial_#1_9-19.indd 25

Formsprag Clutch Guardian Couplings Huco Jacobs Vehicle Systems Kilian Kollmorgen Lamiflex Couplings

Marland Clutch Matrix Nuttall Gear Portescap Stieber Stromag Svendborg Brakes

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

Follow Altra Motion on:

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

Scan to download the interactive version of the Power Review

8/27/19 10:28 AM

Bauer Gear Motor IP68 Solutions: Energy Efficient Technology for the Wastewater Industry IP68 geared motors are most suitable where it is required to convey or transport foul, waste, river or rain water, and all types of sludge-containing waters in communal or industrial areas. They are frequently used in applications such as agitators for mixing and homogenizing, in extremely wet areas or even completely submersed under water.

IP68 Solutions

Features and Benefits: • • • •

Motor efficiencies IE2 / IE3 and IE4 IP68 submersible designs High axial and radial loading capacity ATEX certified

• • • •

Customized sealing solutions Advanced coating systems Leakage sensors and detectors Stainless steel shafts

dustr Altra In

ion ial Mot

Solutions for the Water and Wastewater Industry Tailor-made to your application

For more information, download P-7184-BGM from www.AltraLiterature.com

Scan to visit IP68 Solutions

Warner Electric Introduces New ERX Brakes Range and the WES Contactless Sensor Warner Electric has released a new range of pre-assembled electromagnetic brakes that offer superior performance for stopping and parking applications. The brakes can be specified in standard, high-torque or high-speed configurations and with a selection of accessories included. Thanks to its modular design and efficient stock holding, Warner Electric is able to offer thousands of variations with a very short lead time. Additionally, the integrality of the brakes range offered by Warner Electric is now equipped with the latest contactless sensor WES. Warner has developed this innovative technology for monitoring electromagnetic brakes in elevators and stage/theatre applications. Backwards compatible with conventional electromechanical microswitches, but with none of their inherent limitations, the patent-pending WES contactless sensor brings improved reliability to electromagnetic brake monitoring and adds the capability for predictive maintenance, eliminating unscheduled downtime. “WES” for monitoring of brake state

For more information, download P-8705-WE and P-8692-WE from www.AltraLiterature.com

Stromag Introduces the New Steel Spring Coupling (SSC) The new spring-loaded coupling, which takes the shock loading out of drive transmission, offers a robust solution that can be tailored to suit any application in the off-highway and construction sectors. Resistant to high temperature due to the application of steel and high temperature friction material, the SSC can be adapted to tailormade drive trains by utilization of various spring packs and friction materials. This compact solution is long lasting with no wear and tear of the rubber material. Benefits:

Functions:

• Customized torsional stiffness adapted to the application

• Transmission of torque

• Compact solution which fits in every installation space • 2in1: Combination of coupling and clutch • Smoothly starting due to two-stage characteristic of the torque curve

• Damping of torsional vibrations • Absorbing of high shock loads • Fail safe system for steel spring (patent applied) • Suitable up to 120°C ambient

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www.strom

P-8676-SG-

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120 Hansastraße - Germany 59425 Unna 2303 102-0 Phone: +49

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Altra Industrial_#2_9-19.indd 26

8/27/19 10:29 AM

Experience the TB Wood’s Service Difference TB Wood’s is highlighting what sets them apart in the areas of Service, Support and Strength with this quarter’s focus on SERVICE.

• Our manufacturing plants are structured to provide short lead times

SUPP O

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y the Specif Dif ference od’s TB Wo H

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ST RE NGT

Scan to watch Specify the TB Wood’s Service Difference

Twiflex USA Brake Calipers Twiflex offers the largest range of industrial disc brake calipers in the world. Spring applied units may be retracted pneumatically, hydraulically or electrically (depending on caliper design) while most direct acting brakes have some form of positive retraction device. Pneumatically Applied Brakes are best suited for light to medium stopping duties and for tensioning applications where a high degree of control is required. Hydraulically Applied Brakes address higher torque requirements, while spring applied calipers are essential where braking must be maintained in the event of supply system failure. Mechanically Applied Units are suitable for light tensioning duties or where no external power is available; they may also be specified when designers wish to use their own means of actuation. For more information, download P-1648-TF from www.AltraLiterature.com

Call Twiflex Toll-Free: 844.723.3483

Boston Gear Rapid Response Delivery A large vegetable grower and processor located in Northern California needed a double reduction speed reducer to replace a failed unit on one of its pepper processing machines. The equipment was critical to the plant’s operation, so downtime needed to be kept to a minimum. Since the original reducer was not a standard product, the Boston Gear engineering team quickly went to work to create a drawing for a custom, 700 Series double reduction speed reducer with a 1500:1 ratio. The customer then verified that the new gearbox design would fit in their application based on Boston’s specs and dimension drawing. To help the customer even further, the Boston Gear team took the time to prefill the oil so the unit was ready-to-use upon receipt. • • • • •

Custom double reduction reducer 1500:1 Gear ratio 2-Day shipment Exclusive Stainless Bost-Kleen (SBK) washdown coating Oil prefilled prior to shipment

Service

Reduction s Double 700 Serie ery onse Deliv Rapid Resp

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For more information, download P-8556-BG from www.AltraLiterature.com

Altra Industrial_#3_9-19.indd 27

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3/18

8/27/19 10:29 AM

Boston & Bauer

Washdown Gear Drives & Gear Motors for the Food & Beverage Industry The original Domed Crown™ Design

The Best Choice for Food & Beverage Safety As the leading innovators in gearing and gear motor technology, Boston Gear and Bauer Gear Motor present a full line of Stainless Steel and Aseptic products that provide sanitary protection and optimal performance in the toughest caustic environments.

Distinct Advantages of the Boston Gear and Bauer Gear Motor offering: 1. Wide Breadth of Products • Worm / Helical-Worm / Helical-Bevel or Helical / Parallel Shaft • Gear Drives (Speed Reducers)/Gear Motors/Shaft Accessories • Reductions of 3:1 thru 10,000:1 • Output Torque from 100 lbf-in thru 7,500 lbf-in Scan to watch! Boston & Bauer Washdown Video

2. Critical Product Features for Washdown Suitability & Sustainability • NSF International Certified (Worm Gear Drives) • UL/ULc Certified (Gear Motors) • IP67 / IP69K Compliance • The Original Domed CrownTM Technology • 316SS Cast Housings 3. Performance Competitive Advantages • Proven: Longer Product Life • Proven: Higher Motor Efficiency • Proven: Higher Gearing Operating Efficiency • Proven: Lower Gearing Operating Temperature • Proven: Reduced Installation Time & Maintenance Cost

For more information, visit www.BauerGears.com and www.BostonGear.com

Altra Industrial_#4_9-19.indd 28

8/27/19 10:30 AM

Design for Industry Packaging food/beverage

Accurately detect nonmetallic materials and levels of liquids and solids

The M12 series compact capacitive sensors accurately detect nonmetallic objects or materials and accurately detect levels of liquids and solids. With improved electromagnetic compatibility (EMC), and sensing faces composed of polyetheretherketone (PEEK), they resist chemicals. They are available with an IO-Link interface or with a conventional normally-open or normally-closed final stage, each with a push-pull function.

These capacitive sensors are suitable for detecting the presence of solids, but are equally good at detecting material or liquids like granulates, sugar, oil, and aqueous media through a nonmetal wall, such as packaging, glass or plastic, with a maximum thickness of 4 mm. Flush-mounted versions have a measuring range of 0.5...5 mm, while non-flush mounting versions have a measuring range of 0.5...8 mm. The IO-Link versions can use IO-Link Device Manager software to configure features like full/empty calibration, switching setpoint, and output type. Standard versions include the BAE00MN M12 teach-adapter accessory. It makes it simple to calibrate the sensor, setting the switching point sensitivity and limits, all using the adapter’s pushbutton Key features include: • Object detection of nonmetallic materials and level detection for liquids or solids • Device manager software for configuration and diagnostics window for IO-Link versions • Simple sensitivity adjustment via teach-adapter for versions without IO-Link • Extended measuring and temperature ranges • Improved electromagnetic compatibility (EMC) DW

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

Balluff www.balluff.com

DESIGN WORLD

DFI 9-19 Vs4.LL.indd 29

www.designworldonline.com

September 2019

8/27/19 8:51 AM

Design f o r I n d u s t r y Packaging food/beverage

Packaging batch size of one

The metal industry is not immune to the global

trend away from bulk annual orders toward small-batch customer orders with short lead times. To handle this type of individualized production in batch sizes as small as one, manufacturing systems must become much more flexible. This track-based transport technology has independently controlled shuttles. With rapid changeover times, it enable flexible, customer-centered manufacturing. Â The SuperTrak transport system can be scaled in one-meter increments. The independently controlled shuttles give machine designers all the flexibility they need. Â Mass customization centers around an ability to produce small batches cost-effectively. Users of track technology benefit from high transport speeds and short changeover times that make manufacturing profitable down to batch size one. DW

B&R www.br-automation.com/en/

September 2019 DESIGN WORLD

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8/30/19 1:09 PM

SUPERIOR HYGIENIC DESIGN

FIND OUT MORE NOW AT:

WWW.NEUGART.COM/EN-US

TECHNOLOGY

The first hygienic design planetary gearbox with 3-A RPSCQC certification. The stainless steel HLAE gearbox was specifically developed and constructed for use in hygiene and food applications. As the worldâ&#x20AC;&#x2DC;s first hygienic design planetary gearbox, it fulfills a need amid the stringent requirements for production in sensitive industry sectors. The HLAE planetary gearbox from Neugart is therefore an essential component in the safe and clean manufacturing of food, cosmetic and pharmaceutical products. CONTACT US | Phone: 980-299-9800 | 14325 South Lakes Drive | Charlotte | NC 28273 | Email: sales@neugartusa.com

Neugart 9-19_DW.indd 31 1 551_USA_HLAE_AZ_RZ.indd

8/27/19 07:18:39 10:32 AM 19.07.2019

Design Notes

Composite materials for transmission components reduce friction

Edited by Mike Santora • Associate Editor

Quantix 55-14 was developed based on the high-performance polymer PEEK. This material is also known as “Low Hardness PEEK” and reduces wear when it comes in contact with steel components. Engineers used the material to manufacture sealing rings that function as hydraulic rotary feedthroughs that contain the oil between the clutch and the interior of the transmission shaft in automatic transmissions.

September 2019 www.designworldonline.com

Design Notes 9-19_Vs8.LL.indd 32

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8/27/19 10:19 AM

Components made of thermoplastics are most frequently produced based on standard compounds. This also applies to high-performance plastics (HPP) such as PEEK, a polymer used in applications that produce high operating temperatures. The material developers at Freudenberg Sealing Technologies are taking a different approach and have developed PEEK compounds that are tailored to the respective application. The resulting gear seals and thrust washers are characterized by lower wear, lower friction, and lower temperature development. Off-the-shelf material solutions can offer advantages: they are standardized, readily available, and have already proven themselves in many applications. A standard range of base polymers that are processed with or without commercial fillers is available for simple plastics and technical thermoplastics as well as for HPP materials such as PEEK. Despite their availability, however, these solutions have a significant disadvantage in that material ingredients are not optimized to match specific application needs and performance can be compromised. Now, there are special filler packages for new HPP materials that focus on applications for sealing rings and thrust washers used in automatic transmissions. The new materials are based on precise knowledge of an application. To optimize the material properties, a base polymer is enriched with various ingredients. Fillers such as graphite or glass and carbon fibers, for example, can reinforce the material, reduce friction and wear, or produce conductivity. Additives such as pigments, waxes, and stabilizers influence crystallization and flow behavior, while different colors enable the correct assembly of the component. The resulting HPP materials are precisely tailored to address current and even future application challenges. One example is the new material Quantix 55-14, which was developed based on the high-performance polymer PEEK. This material is also known as “Low Hardness PEEK” and reduces wear when it comes in contact with steel components. The engineers at Freudenberg used the material to manufacture sealing rings that function as hydraulic rotary feedthroughs that contain the oil between the clutch and the

DESIGN WORLD

Design Notes 9-19_Vs8.LL.indd 33

www.designworldonline.com

interior of the transmission shaft in automatic transmissions. The lower incidence of system wear produced by Quantix 55-14 reduces hardness requirements for shafts and lowers customers’ production costs. Levitorq thrust washers also use Quantix 55-14. The flat, disc-shaped components are used in torque converters and automatic transmissions where they absorb axial forces from rotating components. Friction needs to be as low as possible in these applications. When the shaft starts to rotate, Freudenberg’s patented groove technology allows fluid to pass under the washer. This creates a hydrodynamic lubricating film that lowers friction and reduces wear in the application. If conditions prevent operation in the hydrodynamic range, the importance of the material’s very low, dry friction will increase durability. Material experts have conducted comparative wear and friction testing on thrust washers made from Quantix 55-14 and those made from readily available, standard HPP materials designed for applications that require low friction and wear. Thrust washers made from Quantix 55-14 demonstrate a 95% reduction in wear, a 55% reduction in friction, and a decrease in temperature at the interface of 35 °C. “As these examples show, grabbing a product off the shelf isn’t always the best approach,” says Dr. Christoph Klingshirn, who is responsible for global plastics development at Freudenberg Sealing Technologies. “If materials expertise is combined with application knowledge, this can lead to ever-higher performance plastics.” DW

Freudenberg Sealing Technologies www.fst.com

September 2019

8/27/19 10:20 AM

Design Notes

Here, we see a sensor repeatability testing apparatus.

The three R’s of analog position sensorbased mechanical measurements

Edited by Mike Santora • Associate Editor

Those of us old enough to remember the “good old days” recall that grade school focused on learning the 3 R’s: reading, ‘riting, and ‘rithametic. In the world of sensors, there are also 3 R’s: Repeatability, Resolution, and Response. As important as these sensor parameters are, there is often confusion about exactly what they mean and in what ways they tend to interact with each other. Repeatability is a measure of the variation between outputs of a sensor-based measuring system for repeated trials of an identical mechanical input in a constant environment. S common practice is to use at least three repeated inputs, but five or more identical inputs are considered to be an even better sample for determining this parameter. Repeatability is usually evaluated by applying an averaging process to the variations in output values observed for the multiple trials. It is typically specified as a percentage of Full-Scale Output or Full Span Output (FSO), but sometimes it is specified in absolute terms such as parts per million or fractions of the mechanical units applicable to the actual sensor-based measurement.

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A constraint on repeatability measurement is that the trial inputs have to be applied in the same way, usually from a lower value to higher value, to eliminate any effects from hysteresis. Hysteresis error is a measure of the difference in system output when the mechanical input is rising up to the desired input value from a lower value compared to an identical input coming down from a higher input value to the desired value. For most contactless position sensors, hysteresis error is smaller than repeatability error. An example demonstrating repeatability can be seen in Figure 1, which shows a spring-loaded position sensor in a typical gaging stand being calibrated with a precision gage block of 0.5000-in. dimension. The sensor delivers an output of 0 to 10 Volts DC full scale for 0 to 1-in. of probe movement. The tip of the sensor is moved inward to allow the gage block to be inserted between the tip and a flat base and then released to contact the block. In 5 trials, system outputs are 5.0012, 5.0016, 5.0013, 5.0010, and 5.0015 Volts DC. The average value is slightly over 5.0013 Volts and the maximum variance is Âą0.0003 Volts, which is equal to Âą30 ppm of FSO, or 0.003% of FSO. Resolution is a measure of the smallest change in the input to a sensor-based measuring system that will produce a measurable change in the electrical output from that system. While this may seem like a straightforward concept, it is impacted by factors external to the sensor itself, the most significant of which is the signal-to-noise ratio of the systemâ&#x20AC;&#x2122;s analog output. Electrical noise present on the systemâ&#x20AC;&#x2122;s output can reduce the effective resolution of the system by masking any small changes in the sensorâ&#x20AC;&#x2122;s output. For example, if the sensorâ&#x20AC;&#x2122;s resolution specification is 0.25 mV, but the system output noise and ripple is 2 mVp-p, clearly sensor output changes smaller than 2 mV will not be discernable within that noise. Thus, the actual system resolution is only about 12% of what the sensor resolution specification offers. Like repeatability, resolution is often specified as a percentage of Full Scale/Full Span Output (FSO) but may also be specified in absolute terms like fractions of the units of the actual sensor measurement, or, in digitally-augmented measurements, in bits, which is just a fractional measure expressed in powers of 2, as found in computers. Thus 10-bit resolution is 1 part in 1024 (210), 12-bit is 1 part in 4096 (212), etc. Response denotes a sensor-based measuring systemâ&#x20AC;&#x2122;s performance under dynamic input conditions, that is, when the systemâ&#x20AC;&#x2122;s mechanical input is changing rapidly. It is particularly important to recognize that response is a measuring system parameter, not merely a sensor parameter or specification. In practice, there are several ways to characterize response, typically based on whether the system is a first order or second order system. Traditional analog systems have used Bode plots to show frequency response and phase lag for repetitive inputs. For step function response, three times the system time constant is a typical measure of dynamic performance. In digital sampling systems, the update rate for a specified number of bits is one of the preferred measures of response. Regardless of the choice of how to specify response, the ultimate purpose is to understand how well the measuring system can respond to a changing input before the systemâ&#x20AC;&#x2122;s output becomes inaccurate, unusable, or unstable.

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Design Notes It is easy to see that a system’s repeatability could easily be affected by its resolution. If the measuring system’s resolution is inadequate, it would likely be a significant limiting factor to highlevel measurement system repeatability. In practice, sensor repeatability may be excellent, but measuring system repeatability cannot be any better than that permitted by the system’s resolution. While the interaction of repeatability with resolution in a measuring system is pretty easily understood, the interactions of resolution and response are not so straightforward. When the system’s mechanical input is changing rapidly, the effects of resolution on system output are usually masked by the more substantial effects of decreased system output due to limitations imposed by the system’s dynamic response. But if the mechanical input to a position measuring

system changes slowly or intermittently, especially in a jerky way, then the effects of stiction (static friction) come into play. Typically the effects of stiction in position measuring systems can be nonlinear and are often not very repeatable, so determining or characterizing system resolution can be much more complicated, if even possible. And because the system resolution interacts with system repeatability, as was noted above, measurement errors can increase substantially, particularly if the system is providing position feedback for closedloop control. Of course, any effects caused by stiction will also appear as non-linearity in the sensor’s output. But because stiction effects are not very repeatable, digital linearization techniques to offset the non-linear effects will not be practical. For this reason, efforts to reduce

stiction are usually necessary to minimize any measurement errors caused by stiction in very slow-moving or intermittent-motion positioning systems. These efforts can involve applying techniques such as “dither,” a low amplitude signal of high frequency that is input into the system to supplant stiction with much reduced dynamic friction, or by decreasing friction on the moving surfaces of the sensor by improving their surface finishes and by coating them with a lubricant. DW

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Design Notes

Bearings help in harsh weather Edited by Mike Santora • Associate Editor

After three months of design and testing, including comprehensive failure analyses, AST arrived at a fully functional solution: a customized 6209-2RK ball bearing with chrome steel rings, stainless balls and cage, double lip labyrinth seals, and aluminum complex grease.

A middle-market OEM that produces outdoor electrical cabinets had a problem: With many of their cabinets located near coastal areas, weather exposure, including salt from ocean spray, was compromising the integrity of its products, which incorporated bearings on the cabinet hinges. Specifically, condensation had rusted the cabinet’s ball bearings and steel cage. Historically, they had used a conventional catalog chrome steel bearing for its cabinets, which was incapable of withstanding the coast’s extreme weather variations — which often occurred on the same day. Servicing the corroded bearings was difficult, as the cabinet hinges had frozen, making it difficult to open the cabinet. The manufacturer approached AST to find a cost-effective and efficient solution. First, engineers addressed the basics: grease. While a new lubricant provided shortterm relief, it was soon apparent that this was not a long-term solution. Indeed, the internal metal components still became corroded and non-functional.

September 2019 www.designworldonline.com

Design Notes 9-19_Vs8.LL.indd 38

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Next, engineers transitioned production to full stainless-steel bearings, which provided the cabinets with the desired functionality and durability â&#x20AC;&#x201D; but at a prohibitive cost. In total, the new bearings cost at least four times more than the original bearing, which made repair and new production costs too high. The engineers went back to work, tinkering with various material options while understanding that many of the cabinets were still active (in operation near the sea), which rendered prospective design changes impractical. After an exhaustive review of their faulty bearings, the team of engineers honed in on the common damage: While grease protected the raceway surfaces of the rings, the weather had rusted the soft metal cage and the balls. Engineers considered this narrower damage and concluded that a revised stainlesssteel ball complement and assembly inside a standard chrome steel ring set would provide the necessary product improvements. After three months of design and testing, including comprehensive failure analyses, a fully functional solution was finalized: a customized 6209-2RK ball

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Design Notes 9-19_Vs8.LL.indd 39

bearing with chrome steel rings, stainless balls and cage, double lip labyrinth seals, and aluminum complex grease. The components deployed easily into existing cabinets that were already in the field, replacing their existing hardware. The setup was cost-effective, too, adding just 15% to the cost of the original. Moving forward, it became the standard setup for the company on all new cabinets that it produced, integrating seamlessly into the existing manufacturing process. Combining stainless steel balls with a chrome steel ring (rather than chrome with chrome) is unusual and certainly not obvious, which made the design process a case study in thinking outside the box. Several years after the production modification, the manufacturer continues to integrate a customized 6209-2RK setup into its cabinets. DW

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Design Notes

How to test batteries made to

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

Bobbin-type LiSOCl2 batteries, like these shown here, are designed to draw small amounts of average current (microamps). Drawing high-rate current negates the passivation effect: a naturally-occurring phenomenon whereby a thin layer of film forms on the lithium surface to prevent direct contact between the lithium anode and the thionyl chloride, thus preventing battery self-discharge.

Not all batteries are created equal. However, differentiating higher quality cells can be difficult, as short-term tests often fail to duplicate actual longterm performance. Extended battery operating life is essential to reducing the total cost of ownership of remote wireless devices, especially those deployed in remote locations and extreme environments where the expense of replacing a battery far exceeds the cost of the battery itself. Forty-year battery life is possible for bobbin-type lithium thionyl chloride (LiSOSl2) cells, proven by AMR/AMI meter transmitter units (MTUs) manufactured in the mid-1980s. While being upgraded after 28 years of operation tests on the older batteries indicated a significant amount of unused capacity even after nearly three decades in the field. Water and gas utilities depend upon these unique long-life lithium batteries to ensure robust network reliability, as any large-scale battery failure would disrupt monthly customer billing cycles and disable remote shut-off and hook-up

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capabilities. Fear of this worst-case scenario caused city officials in Springfield, MA to invest millions in replacing tens of thousands of good meter batteries annually to avoid the potential “chaos” that would have overwhelmed the city’s resources. Demand for ultra-long-life batteries crosses all industries, including manufacturing, distribution, transportation/logistic, infrastructure, energy production, environmental monitoring, healthcare, smart metering, process control, asset tracking, safety systems, machine-to-machine (M2M), and system control and data automation (SCADA), to name a few.

The challenge of long-term battery testing

Attempting to predict long-life battery performance using short-term tests can lead to false and misleading results by forcing these cells to perform in ways that were never intended. For example, bobbin-type LiSOCl2 batteries are designed to draw small amounts of average current (microamps). Drawing high rate current negates the passivation effect: a naturally-occurring phenomenon whereby a thin layer of film forms

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Design Notes on the lithium surface to prevent direct contact between the lithium anode and the thionyl chloride, thus preventing battery self-discharge — A passivation layer reforms whenever the battery becomes inactive. Short-term testing prevents passivation, thus causing unreliable test results. Passivation layers must be designed so that there is enough to prevent selfdischarge but still allow proper power output. Too thick a passivation layer will prevent the battery from operating.

Bobbin-type LiSOCl2 batteries feature the widest possible temperature range (-55° to +125°C), allowing electronic toll collection tags to endure extreme heat soak in summer (up to 112°C according to SAE), followed by rapid cooling. In winter, the opposite occurs: extreme cold soak, followed by rapid warming.

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Design Notes 2. Accelerated testing – Arrhenius testing typically results in a two-fold increase of reaction rate for every 10°C rise in temperature. Arrhenius tests should be run at 72°C (equivalent to 32 lifetimes compared to operation at 22°C) and must be properly interpreted, as poorly made cells with excessive passivation can demonstrate a false-positive result. Cells should be stored at 72°C before performing the test, while also testing cells during storage at 72°C. Cells are then tested at Resensys SenSpot wireless sensors 72°C for one (1) month with enough current being drawn to monitor structural stress and vibration fully deplete the battery after one (1) month. The same test is performed after two (2) months with available capacity being to buildings, cranes, platforms, and depleted after two (2) months. Similar tests are run after 3, 4, machinery. These deployments are often 5 and 6 months, 1 year, and 90 months. inaccessible, making battery replacement After one and two months of testing, a Tadiran XOL cell difficult and expensive. Long-life will exhibit low capacity output because it’s not designed to bobbin-type LiSOCl2 batteries provide a be depleted so quickly, as a lithium battery can deliver a high usage rate or a low self-discharge rate, not both. By contrast, durable, low-cost solution. a Tadiran IXTRA cell and certain competitors will exhibit higher available capacity at such rapid discharge rates. However, their self-discharge rate will be higher in other tests. Starting with the three-month test at 72°C (the equivalent of 8 years of operation at 22°C) a superior quality cell will begin to exhibit higher available capacity due to lower self-discharge. The longer this test is performed, the difference between superior and inferior quality batteries will become more apparent, resulting from the method of manufacturing, the quality and purity of raw materials, and the ability to beneficially apply the passivation effect. Bobbin-type LiSOCl2 cells can survive Arrhenius testing for 90 months at 72°C, equivalent to hundreds of years of continuous operation. 3. Calorimeter testing – Calorimeters measure temperature rises to liquid surrounding the battery caused by self-discharge. Before undergoing calorimeter testing, batteries should be stabilized for one year to ensure reliable results.

Bobbin-type LiSOCl2 batteries are overwhelmingly preferred for AMR/AMI metering applications. Often deployed in underground pits (shown here) or building exteriors, these ultra-long-life batteries provide a robust and reliable solution that reduces the risk of a costly and disruptive wide-scale battery failure.

SenSpot sensors offer a technology for real-time and long-term structural health monitoring. SenSpot strain gauges use proprietary sensing, scheduling and ultra-low power synchronization technology. SenSpot is designed to operate maintenance-free for more than a decade.

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Design Notes 9-19_Vs8.LL.indd 44

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4. Lithium titration – Where historical data is not commonly available (i.e. extreme temperature, prolonged high current pulses, short lifetime applications, etc.) titration can be used to measure the amount of lithium remaining in the anode. After several months of operation under elevated temperatures and at various discharge currents, cells are dissected. The higher the self-discharge rate, the less lithium will remain in the cell. 5. Field results –Tadiran receives customersupplied samples from virtually every product application, then performs lithium titration and other tests to measure in-field battery performance. Another useful tool is measuring the number of FITs (Failures In Time) in billions of device operating hours. Performing comparable tests on competing batteries forms a useful basis of comparison. Testing should begin after one year to ensure that all batteries are properly stabilized to limit the influence of any impurities in the electrolyte. Tadiran has been tested competing bobbintype LiSOCl₂ batteries for decades, measuring key variables such as OC voltage, voltage under load, and self-discharge rates under different temperatures and load sizes. With over 100,000 application test points across the equivalent of over 10,000 operating years in the lab, and by double-checking these test results against actual field data, highly accurate predictive models based on application-specific requirements can be generated. Bobbin-type LiSOCl2 batteries are not created equal. For example, a superior quality cell can feature a self-discharge rate of just 0.7% per year, retaining over 70% of its available capacity after 40 years. By contrast, an inferior made battery can have an annual self-discharge rate of up to 3% per year, depleting 30% of its available capacity every 10 years, making 40-year battery life impossible. Specifying a superior quality battery can reduce your long-term cost of ownership, which is especially important for wireless devices being deployed at remote sites and extreme environments. DW

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Internet of Things

To prepare for Industry 4.0 and the Industrial Internet of Things, a new standard was advanced to create ASi-5. With increased data transmission rates, the capacity to communicate more data and the ability to handle IO-Link data, sensors and actuators are connected to the control system and the cloud, all while maintaining downward compatibility to existing field I/O.

A closer look at Asi-5

The AS-Interface is known as a field level automation network, a network consisting of

actuators and sensors connected through a single two-conductor cable, bringing power and communication to field devices. This feature alone enables AS-Interface – or ASi for short – to reduce large, installation-intense cable trees to one inexpensive, easy manageable cable. Actuators and sensors used in basically every field of automated manufacturing are installed by simply piercing into the two-conductor cable. Devices are instantaneously powered without the need to prepare and configure cord sets, and communication from the sensor to a Gateway initiates instantly. ASi allows sensors and actuators to be added, removed and moved easily. Planning and installation are further simplified because ASi — a topology-free network layout – follows the function of the machine. It does not force engineering to design to a specific layout and network topology. With many field devices designed to be used in situations where IP69k is required, system design and implementation becomes easy.

September 2019 www.designworldonline.com

Internet of Things_9-19_Vs3.LL(1).indd 46

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Standard Parts. Winco. Since the inception of ASi, vendors have developed devises like motor starters, control valves, stack lights, push buttons, digital and analog input and output modules to name a few. Currently, roughly 350 companies world-wide serve the AS-Interface automation market. Entering a new era of automation. AS-Interface needed to be ready for Industry 4.0 and the Industrial Internet of Things. Hence, the standard was advanced to create ASi-5. With increased data transmission rates, the capacity to communicate more data and the ability to handle IO-Link data, sensors and actuators are connected to the control system and the cloud, all while maintaining downward compatibility to existing field I/O. The new ASi-5 standard offers more design options, supports larger installations, and further reduces overhead costs. This is how ASi-5 compares to the earlier ASInterface generations: • Deterministic cycle times are four times shorter with 1.2 ms for 24 connected devices • Data width was increased from 16 bits to 32 bytes per device • Twice the network segment length (200 m) • Up to 96 connected devices up from 62 • New diagnostics channel • Easy and cost-efficient integration of IO-Link or other systems, for instance HART

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Internet of Things

• Is ASi-5 a replacement for buses like CAN and others? The ASi-5 is a field level automation network consisting of actuators and sensors connected through a single two-conductor cable, bringing power and communication to field devices.

the transmission quality enables fast and detailed diagnostics. In addition to single device addressing, devices can be addressed easily and quickly through the ASi-5 master even after installation, all while preventing duplicate address assignment. Here are common questions designers have about working with ASi:

• Since ASi-5 uses one cable, how does it differ from PoE?

PoE addresses one of the main problems of Ethernet installations by allowing data and power to be run through the same cable. In contrast to AS-Interface and ASi-5, Ethernet still requires switches to assure the collision free domains required for deterministic control systems. PoE installations also require power injection for each segment. Most PoE installations address this by using PoE switches with integrated injectors, serving multiple ports. The challenge can be with long,

mainly linear configurations that are typically found in material handling applications and process automation systems.

• How does ASi-5 work with

higher level fieldbuses or Ethernet versions? What impact does such an arrangement have on overall communication performance?

Due to its increased data width and communication speed, ASi-5 is suited to be a partner network for Ethernet fieldbus systems. Connectivity to upper level Ethernet systems is handled by centrally located gateways. Upper level connectivity is limitless, since the only device that changes from one to another upper level Ethernet system is the gateway. All engineering work at the field level transfers over without modifications. Overall system performance is increased since the gateway consolidates the data from a number of field devices.

September 2019 www.designworldonline.com

Internet of Things_9-19_Vs3.LL(1).indd 48

AS-Interface has not been designed to replace upper level communication systems but was rather conceived to enhance their performance and to address inherent disadvantages. Even though the AS-Interface cable is one part of a solution, it is central to the cost advantages and installation flexibility. While one of the many industrial Ethernet protocols is dominating upper level communication to the PLC, AS-Interface gateways connect to virtually any of these and therefore underline the strength of the joint solution.

• How does ASi-5 handle safety?

Due to its full backward compatibility ASi-5 allows any existing AS-Interface safety device to be used. This means e-stops, door interlocks, light curtains and other devices with safe contacts or OSSDs can still be used. Additionally, new safety devices will be developed by the solutions providers, taking advantage of the increased data width and reduced cycle time. While safety was an add-on solution to AS- Interface, safety has been designed into ASi-5 from the start. This tighter integration offers better diagnostics, taking full advantage of the enhanced diagnostic channel of ASi-5. Users can expect to use ASi-5 in applications requiring SIL3/PL e according to EN ISO 13849 as well as safe integration directly into the safe Ethernet solution of the PLC. DW

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Internet of Things Gateway connects Modbus to MQTT

The STRIDE MQTT gateway connects industrial Modbus devices to an MQTT cloud-based data logging solution. MQTT (Message Queuing Telemetry Transport) is a machine-to-machine â&#x20AC;&#x153;Internet of Thingsâ&#x20AC;? connectivity protocol that provides low power usage, minimized data packets, and efficient distribution of information to one or many receivers. The gateway provides easy hardware setup to add Modbus RTU/TCP devices to an existing MQTT cloud data collection platform. The MQTT gateway interfaces with up to 32 Modbus devices; wired and Wi-Fi gateway models are available. The gateway is the hardware component only of an MQTT cloud-based data logging solution. The user must have an existing cloud computing service account from a cloud services provider. DW

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At Mazda, from system design, harness design and verification down to manufacturing and service documentation, outputs of each process have been generated in its natural language, requiring designers to translate between processes and fill in the missing pieces using their talents and skills. “To remove ambiguity while maintaining the diversity of expressions that are characteristics of these natural languages, we applied formal methods to eliminate the loss in information transfer and set a goal to build a development environment that is consistent and connected all the way through the manufacturing phase,” said Kazuichi Fujisaka, Technical Leader, Mazda Motor Corporation. “Furthermore, we also aim to shift to a development methodology that allows us to optimize the vehicle as a whole, with all possible variations being considered in the early development stage. To make this happen, we needed a development environment to visualize the entire vehicle circuitry and standardize our language, tools, and processes without compromise, creating standard models across the company. Mentor’s Capital technologies provide this environment and make Mazda’s electric development much more efficient.” In addition to the Capital Electrical Design Software suite, Mazda also uses Siemens’ NX software and Teamcenter portfolio for enterprise collaboration. DW

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

Servo drives Lisa Eitel

Servo systems consist of four main components — motor, drive,

controller, and feedback. The controller determines what the motor must do and then triggers the drive to send the necessary electrical energy to the motor to make the required move happen. In other words, the controller is responsible for calculating the path or trajectory required and sending low-voltage command signals to the drive. The drive then sends the necessary voltage and current to the motor to achieve the required motion. Servo drives can control torque, velocity, or position ... although in servo systems, the most common parameter to be controlled is torque. There are several types of servo drives. A common variation is the torquemode amplifier. These convert the command signal from the controller into a specific amount of current to the motor. Because current is directly proportional to torque, the drive is controlling the amount of torque that the motor produces. In contrast, a linear drive (in which current is proportional to force) directly controls the force output of the motor. One of the most important tools for sizing a servo motor is its torquespeed curve. But often, the torque-speed curve is specific to a certain motordrive combination. This is because the continuous and peak torque capabilities of the motor are affected by the thermal properties of both the motor and of the drive. Excessive heat — typically caused by running a motor above its peak

HOW SOME SERVO DRIVES (AMPLIFIERS) INTEGRATE INTO MOTION SYSTEMS MOTION

PCB-MOUNT SERVO DRIVE

PROGRAMMING

MOTION CONTROLLER

MOTION PROFILE

FEEDBACK STANDALONE SERVO DRIVE

MOTOR

MOTION FEEDBACK

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To use an analogy ... as the brains of the system, the controller takes information from the feedback device and sends appropriate voltage signals to the drive. The drive acts as the nervous system and sends to the motor current necessary to prompt the required motion output. This reading and responding to feedback makes the system closed loop — the defining characteristic of a servo system.

torque — can demagnetize the motor’s magnets. Although the drive has no moving parts, heat can damage its power transistors. Continuous torque is the amount of torque the motor can produce indefinitely. Peak or intermittent torque is the maximum amount of torque the motor can produce ... but peak torque can only be sustained for a short amount of time before overheating occurs. Servo drives were originally standalone components, separate from the motor and controller. But in the past 15 or so years, numerous motor manufacturers have developed integrated drive-controller offerings ... as well as integrated motordrive systems ... and even complete motorfeedback-drive-controller systems. Slightly complicating matters is that these integrated designs are sometimes simply called drives for their axis-driving function. These tend to reduce wiring, make sizing and selection easier, and save considerable space and setup time. Read more on this by accessing the MC2 servo drive installment at designworldonline.com/mc2.

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M o t i o n

C o n t r o l

•• ••

what

really limits gains in a servo system? Understanding the real factors limiting servo gains, and system performance, makes it easier to devise counteracting strategies.

Curt Wilson • Vice President of Engineering and Research • Omron Delta Tau

Here’s a piece of conventional controls wisdom – if you

want to increase system performance, raise the gains. For non-specialists in industry who are trying to optimize a servo system, this is often the extent of their control theory knowledge when they start a project. But of course, in practice it’s not possible to raise the feedback gains arbitrarily high to achieve a given desired level of performance, and knowledge of control theory at just an introductory level doesn’t provide much useful guidance as to the real reasons for the practical limits on these gains.

The ideal case To understand the sources of these limits, we’ll start with an idealized case of basic “PID” feedback position control, then introduce real-world conditions that introduce limitations. Our idealized physical plant is a rigid body “lump of mass” (m) that can move in one horizontal direction without friction. (Those used to working with rotary systems can substitute rotary

September 2019 www.designworldonline.com

Motion Control 9-19_Vs5.LL.indd 62

moment of inertia J for mass m in this analysis.) This is shown in Figure 1. Our idealized controller is a delay-free continuous (“analog”) controller using feedback from a noise-free position sensor of infinite resolution and outputting a force acting on the mass. This controller has proportional (Kp), integral (Ki), and derivative (Kd) gains that act on the error between the desired and actual positions for the mass. The block diagram for this control loop is shown in Figure 2. In this idealized case, there are few limitations to increasing the gain terms to achieve any desired level of performance. The proportional gain term Kp applies a restoring force to the mass m proportional DESIGN WORLD

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•• ••

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actual position moves toward the new desired position causes the integrator to “charge up”, and this must be “discharged” by overshooting the new set point before settling. Higher values of Ki result in higher and faster overshoot and more tendency toward oscillatory behavior before settling at zero error.

Real-world limitation #1: Measurement and other noise In the idealized case, the position measurements were perfect. Of course, in reality, they fall short of this. Two key

to the magnitude of the error. The higher the value of Kp, the stiffer the system is in response to any disturbances or desired position changes. But the dynamic equations of proportional gain feedback alone are those of an undamped spring. Increasing Kp increases the frequency of oscillation ( Kp / m rad/sec) of the mass-spring system, but it doesn’t reduce the overshoot from this oscillation. The derivative gain term, Kd, provides a counteracting force proportional to the rate of change of the error. Its dynamics are those of a damper. The higher the value of Kd, the greater the damping effect. Together, the Kp and Kd terms act like the spring and shock absorber of a car’s suspension. Most users want to set Kd high enough to prevent overshoot from the Kp reaction to a step change in error. In the idealized system, this is always possible. In the idealized system as we have defined it so far, there is not even a need for

an integral gain term Ki. But if we consider a vertically moving mass instead, then with just Kp and Kd, there would be a steadystate error where the upward force from the proportional term (Kp * err) just matched the downward force from gravity (m * g). This is shown in Figure 3. The Ki term accumulates the error over time to contribute to the control force. In the case of the vertically moving mass, it would reduce the steady-state error to zero, with higher values of Ki reducing it faster. In response to a step change in desired position, the error accumulated while the

fservo

•• ••

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1) An idealized physical system, with no friction, and movement in one axis only.

September 2019

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imperfections are measurement noise (usually electrical noise), and in digital systems, “quantization noise” stemming from the limited resolution of digitization. The higher the digitized resolution, the lower the resulting quantization noise (±½ increment). When noise of either type is present, the feedback gain terms react to the noise, leading to spurious variation in the force commands. The nature of integration means that the noise cancels out over time, so there is not much effect on Ki action. However, the instantaneous nature of the Kp action means that it responds directly to the noise, and the higher the value of Kp, the greater the reaction to a given level of noise. The problem is particularly severe with the derivative gain term Kd. The differentiation of a noisy signal, whether done with analog circuitry or by digital differencing, results in a significant amplification of the noise, with higher values of Kd increasing the amplification and its contribution to the control effort. It’s common for users to fail to achieve the level of damping they want without making the control effort noisier than they can tolerate. Plots of actual system performance illustrate this point. Figure 4 shows the response (green) to a commanded position step (red) of a system with a certain feedback resolution. Response is quick, but smooth throughout. Figure 5 shows the response of the same system to an identically sized physical step command with the feedback resolution reduced by a factor of 4 (increment size 4 times larger) using the same effective PID gains (numerical values increased by a factor of 4 to have the same physical effect). Note the roughness and “hunting” action at rest. Quantization noise can also be introduced by the limited resolution of command values. In some applications, inadequate resolution of torque/force commands can be the limiting factor in control-loop performance. Quantization noise in commanded position values can also be problematic,

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Motion Control 9-19_Vs5.LL.indd 64

September 2019

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Ki /s Err

CmdPos

fservo

Ksys ms2

ActPos

Kd s

2) Block diagram of a basic PID control loop.

DESIGN WORLD

Motion Control 9-19_Vs5.LL.indd 65

Real-world limitation #3: Additional delays An introductory digital control course accounts for the effect of these sampling delays. However, at this level of analysis, it doesn’t properly account for the interaction with finite sensor resolution. In addition, the basic analysis presented in a first course implicitly assumes that the

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feedback sampling, control computation, and command effort output all occur instantaneously. In real systems, of course, these processes do not happen instantly; the required times are known as calculation and transport delays. While sampling delays have generally been decreasing in recent years, other technology trends have caused these other delays, particularly transport delays, to be actually increasing in some cases. These additional delays exacerbate the limit cycling problems mentioned earlier. Serial-data position encoders have become increasingly common recently. They can provide high resolution, and often absolute, position data to the controller with just a few wires. However, in contrast to the use of incremental quadrature encoders, where the controller’s counter value can be sampled and used with virtually no delay, it takes significant time to shift the serial data from the encoder to the controller.

fservo

=Kp *err

Real-world limitation #2: Sampling delays In the idealized case, the feedback controller could respond instantaneously. In the real world, this can’t happen. This is especially true in the case of “discrete-time” sampleddata control systems (commonly known as “digital controllers”), which constitute the vast majority of position controllers today. There are many good reasons why digital control systems predominate here, but it’s vital to understand the limitations they impose. First, they sample the feedback sensors, and possibly compute new trajectory set points, at discrete time intervals, typically called servo cycles. These values are used to compute a control effort that will be used for a full servo cycle. The ramification of this is that the control loop is on average one-half servo cycle behind in time. This delay in controller reaction reduces the stability of the closedloop response because the effort is in response to “old” data. This means that the controller can continually be overcorrecting, resulting in “limit cycling” behavior with gains that would be reasonable with lower delays.

The problem is magnified if you use data from previous samples to compute a cycle’s control effort. For example, it’s common for the derivative action in cycle n to be computed as Kd * (errn – errn-1). This estimate of the derivative is one-half cycle old, so its use in the control effort is in total a full cycle old. Advanced control techniques such as the use of state estimators to calculate the derivative states can improve performance, but these are considerably more difficult to set up, requiring accurate mathematical models of the plant for the estimator. The higher the servo update frequency, the lower these sampling delays are. The huge increase in affordable computing power over the last several decades has permitted many systems to substantially reduce the control limitations resulting from sampling delays. However, faster sampling increases the quantization noise from digital differencing, as for derivative action, for a given digitized position resolution. The resulting overall control action can be worse than with slower sampling. Recently, it’s common for people to update to a faster controller, but keep their low-resolution position sensors, and wonder why they cannot get higher performance.

even if no bigger than the quantization in the measured position values. This is particularly true if “feedforward” gains are used to improve trajectory tracking. Commonly used velocity and acceleration feedforward gain terms use the first and second derivatives, respectively, of commanded position values. If they do not start from position values with sufficient resolution (which usually means finer resolution than the feedback), then otherwise optimal gain values will introduce too much noise into the servo loop.

Zcmd err Zact

m*g

3) An idealized vertical system, with gravitational force.

September 2019

9/3/19 11:26 AM

Step Response: Resolution X

Typically, the actual sampling of the position encoder takes place one-half or a full cycle ahead of the start of the servo cycle in which it’s used. Many high-resolution serial encoders perform interpolation on internal analog sinusoidal waveforms to obtain this resolution. This calculation-intensive process adds to the delays, meaning that the encoder is often not ready even to start reporting the present position when the controller requests this – it must report an earlier processed position. It’s often difficult to get the information from the encoder provider as to how long this added delay is. Networked servo drives are also becoming more common. This trend has been driven mainly by the wiring simplicity, usually comprising a chain or ring of Ethernet cabling between the controller and drives. In these systems,

Command Position Following Error

250

Actual Position 300

200

150

100

-100

-200

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Following Error (LSBs)

C o n t r o l Command & Actual Position (LSBs)

M o t i o n

-300 0

100

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4) System step response at full resolution.

digital command values are sent serially from controller to drives across the network, and digital feedback values are serially returned the same way. But this serial transmission introduces significant delays – typically one servo cycle for command transmission, one or

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Real-world limitation #4: Compliance In the ideal system, the plant was a rigid body in which all parts moved together with perfect stiffness. In real-world systems, there is always some compliance. In many systems, the most significant compliance is in the coupling between motor and load. This compliance typically results in a “resonant” frequency and a lower “antiresonant” frequency in the control loop. The resonant frequency can be problematic because the system wants to oscillate at this frequency. The anti-resonant frequency can be an issue because it causes the system not to respond to commanded trajectory components in that frequency range. For a rotary system with a compliance of stiffness k between a motor with inertia Jm and a load with inertia Jl , the anti-resonant frequency (in rad/sec) is:

K Jl

The resonant frequency is:

ωr= 68

K +K Jm Jl

Command & Actual Position (LSBs)

two servo cycles for processing in the drive, and one servo cycle for return feedback transmission. If the central controller is closing the servo loop and transmitting force/torque commands, these times constitute transport delays inside the servo loop, which can introduce severe performance limitations. A good rule of thumb is that the servo update frequency in such network-based control must be twice that for directly connected control, which does not have these delays, in order to get equivalent performance. If instead, the drive is closing the servo loop, with the controller sending commanded position values, these transport delays are outside the servo loop and so do not compromise loop performance. However, in many network protocols, the commanded position values don’t have sufficient resolution to permit optimal feedforward gains without introducing too much quantization noise.

ωar=

Step Response: Resolution X/4

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Command Position Following Error

60 50

30 0 20 -25

10 0

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-10

-75 0

100

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Time (ms)

5) System step response at quarter resolution.

(To convert these frequencies to Hertz, divide by 2π.) If these frequencies are significantly higher than the required bandwidth frequency of the system, they often can be ignored. In high-precision systems where even slight ringing at the resonant frequency cannot be tolerated, it’s common to add a low-pass filter to the output of the servo loop so as to reduce the excitement of this frequency. But in systems where these frequencies are closer to the needed bandwidth, or especially within it, the problems are more severe. With high servo gains, the resonant frequency mode can cause significant oscillations, or even outright instability. With basic algorithms, gains must be reduced to avoid these issues. In more sophisticated algorithms, “notch” (bandreject) filters can be added to counteract the resonance. If the anti-resonant frequency is within the needed bandwidth, it will inhibit the ability of the system to track the commanded trajectory. Servo gains higher than those required for a stiffer system would be needed to improve the tracking performance, but these would often cause other problems.

Real-world limitation #5: Stick/slip friction Most systems exhibit dry running (Coulomb) friction and higher static

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Actual Position

Following Error (LSBs)

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friction. These effects can be difficult to compensate for, particularly if the static friction is substantially greater than the running friction, leading to “stick/slip” phenomena. Here, the integrator “charges up” enough to break loose from static friction, then overshoots the commanded position due to the lower running friction, eventually “sticking” on the other side, when the pattern repeats itself. Gains often have to be reduced to eliminate this action. Air bearings or hydrostatic bearings can do away with this behavior, but introduce another phenomenon. With friction virtually eliminated, its natural damping effect is lost, and this must be made up by increased derivative action from the controller. It’s easy for small corrections to cause overshoot and hunting. Highresolution feedback and high servo update rates are typically required for these systems.

Implications It’s often advantageous to select feedback resolution substantially higher than is required to achieve the requisite positioning precision. This permits the gains to be set higher, yielding better performance metrics, before getting undesirable behaviors. The cost increment for additional resolution is much less now than in earlier decades. Using servo update frequencies higher than traditionally recommended DESIGN WORLD

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can provide important performance improvements. Frequencies of 5 to 10 kHz are now commonly used, even for systems without unusually high performance requirements. While more sophisticated control algorithms can improve performance with lower resolution and frequency, it often makes sense now to “throw speed and resolution at the problem”, permitting easier and faster system setup. The additional equipment cost often can easily be offset by reduced development cost. While auto-tuning algorithms are steadily increasing in sophistication and performance, they’re still typically somewhat conservative in their settings, preferring safe sub-optimal performance to possible problems from trying to get too much performance. Many users get started

Optimize.

with auto-tuning, then try to optimize performance manually, increasing gains until one or more of the problems noted here is encountered, then backing off somewhat. These guidelines can help users understand why they reach these limits, and suggest what can be done to mitigate the issues. DW Omron Delta Tau www.deltatau.com

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How

roller-screw and ball-screw actuators compare

Daniel Schmit • Product Manager • Tolomatic Inc.

Electric-rod actuators with either roller-screw or ball-screw technology are playing an expanding role in high-force applications across many industries and applications. These solutions can provide superior performance over fluid power cylinders (typically hydraulic) in many high-force applications. Electric systems improve positional accuracy and repeatability and provide full control of motion parameters (velocity, acceleration and deceleration, and force) at any position. They are fully programmable for superior flexibility. Electric actuators also can reduce the total cost of ownership through efficient use of electricity, significantly reduced maintenance, longer life and faster machine changeover. Force capabilities of electric actuators (both ball and roller screw) have increased substantially — with the ability to deliver forces of 225.5 kN (50,000 lbf) and higher.

September 2019 www.designworldonline.com

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Here a Tolomatic electric rod actuator with ball screw replaces a hydraulic cylinder in a log-cutting operation.

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To optimize service life and performance, it’s important to match the capabilities of either ball-screw or roller-screw actuators to the specific application. In low- to moderate-force applications for positioning, ball-screw actuators offer a lower initial cost with versatile performance and lowest power consumption. In extreme high-force, high-duty-cycle applications, roller screws deliver superior performance in a compact package, longer life and reduced cost of ownership compared to ball-screw actuator and hydraulic systems. When trying to decide whether to employ ball-screw or roller-screw technology, it is best to work with an actuator supplier with expertise in both kinds of screw technologies. Doing so will make sure that the most appropriate screw technology is employed to provide the target performance at the lowest possible life-cycle costs. When properly applied, electric actuators with either roller-screw or ballscrew electric technology can improve the energy efficiency of applications ranging from low to high force, reduce environmental impact and lower life-cycle costs while optimizing performance and processes.

Brief background on linearmotion options Electric rod-style screw actuators are replacing fluid power in high-force applications throughout industry. Tasks once limited to hydraulic and pneumatic cylinders such as pressing, holding, lifting and spot welding are now being performed by electric actuators that offer lower life-cycle costs. Hydraulic and pneumatic

Electric rod actuators have numerous performance advantages in highforce applications. Shown here (clockwise from top left) are ERD, RSA, RSX, IMA, and ServoWeld electric actuators.

cylinders still have their place, but electric actuators have numerous performance advantages in high-force applications up to and exceeding 50,000 lbf. Some of these advantages include a smaller footprint; a long and more predictable life; lower life-cycle costs; greater accuracy, control and flexibility; lower maintenance; faster change-over and setup; lower energy use; and less environmental impact. In general, screw mechanisms provide the means to produce linear motion by the rotation of either the screw or nut in an assembly. The screw is a

Roller screws have high force transmission because the rollers have increased contact with screw threads … for improved distribution of force. They also deliver high speeds, are long lasting, and need little maintenance.

September 2019 www.designworldonline.com

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cylindrical element that has threads; the nut is a matching component that rides on the screw. Each component is capable of rotating independently upon the other. Linear motion occurs by restraining one element. In high-force applications, two types of screw technologies are typically used in electric rod-style actuators: ball screws and roller screws. Actuators with ball screws and roller screws are now able to reach extremely high forces, making them suitable for many applications previously dominated by fluid power devices. What’s more, the speed, accuracy and flexibility of electric actuators create the potential for increased production throughput, process and yield improvements, as well as more adaptable machines.

Ball-screw actuator operation and iterations Ball screws use a thread form that has a circular shape. The nut has a matched thread form, allowing ball bearings that fit between the grooves to transmit force and relative motion with high efficiency. Ballscrew actuators typically have efficiencies around 80%. The ball bearings are allowed to roll and recirculate through one of several circuits DESIGN WORLD

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M o t i o n

Ball screws are suitable for low-duty-cycle applications with moderate force requirements and moderate to high speeds. A ball screw’s ball bearings have fewer points of contact than roller screws, resulting in lower life expectancy.

in the nut as rotation and linear motion occurs. There are several designs of ball screw nuts that differ in the number of ball circuits and how the ball recirculation path is controlled. The ball bearing path is a critical factor in determining the maximum speed potential of the mechanism. Alternative designs, such as internal paths or end returns, offer minor advantages such as increased velocities or reduced operating noise. However, most ball nut designs function similarly. Ball screws come in a wide variety of diameters, leads, and accuracies with both metric and imperial lead designs. A grade system was defined to classify the lead accuracies of ball screws and is regulated by ISO-3408. Ball screws are now commonly available in five grades that range in accuracy from 6 mm per 300 mm (0.0002 in. per ft) to 210 mm per 300 mm (0.0080 in. per ft).

Roller-screw actuators have highest dynamic load rating A roller-screw thread form is generally triangular in shape and transmits force through a matched set of multiple threaded rollers in the nut. These rollers are allowed to rotate within the nut while contacting the thread form of the screw. The roller nut has a set number of rollers that provide significantly more contact points with the screw in the same space compared to ball nuts, resulting in very high force transmission capabilities and much longer life compared to ball screws of similar diameter. Like ball screws, roller screws have a good efficiency rating because they are

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designed with rolling elements as compared to the sliding elements of an Acme screw. Due to the increased areas of contact, actuators with roller screws typically range from 75 to 80% efficiency, which is just slightly lower than the efficiency of a ball screw. Roller screws, like ball screws, are produced within the ISO-3408 grade system so they share similar lead accuracy considerations. Standard roller screws are hardened before being precision ground, resulting in a much deeper hardness and the highest dynamic load rating (DLR) of all the roller screw types. Another type of roller screw — the inverted planetary roller screw — operates in much the same way as a standard roller screw, except the functions of the nut and screw are reversed — that is, the rollers move inside the nut.

Advantages of ball and roller screws in high-force applications Actuators with ball or roller screws share a number of advantages over fluid power in high-force applications. These include higher energy efficiency, better accuracy and repeatability, smaller overall system footprint, quiet operation, low environmental impact, reduced maintenance, lower life-cycle costs, and the potential for process improvements that can increase throughput and lower unit costs. Higher energy efficiency — Electric actuator systems typically operate in the 75 to 80% efficiency range. In comparison, pneumatic systems typically range from 10 to 25% efficiency. Hydraulic systems typically range from 40 to 55% efficiency. Many factors affect fluid power efficiencies, including temperature, seal integrity, leaks and many others. One significant factor is that electric actuators only demand current to the drive motor when it is required. When at rest, electric actuators need very little current to hold their positions. On the other hand, fluid-powered actuators need the fluid medium to be pressurized at all times by power units or compressed systems, resulting in an inefficient use of power. Over time, power savings add up.

An inverted roller screw operates much as a standard roller screw; however, the functions of the nut and screw are reversed. The rollers traverse inside the nut.

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September 2019

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THE COUPLING.

The Tolomatic IMA servo linear actuator can be specified with ball screws to forces of 30 kN (6,875 lbf).

FOR MAINTENANCE-FREE DURABILITY

A Tolomatic RSX roller-screw electric actuators in pressing applications provide a consistent, repeatable force to 40,000 lbf while eliminating the need for operator intervention during changeovers.

Better accuracy and repeatability â&#x20AC;&#x201D; In applications needing precise control

of motion and position, actuators with electric ball screws or roller screws offer significant advantages. Standard fluid actuators are good for end-to-end position applications, but mid-stroke positioning is more complicated, needing a control valve and operator assistance. More advanced servo hydraulic control systems give fluid systems greater precision and repeatability, but at a considerable increase in cost and complexity. Electric actuator systems are much less complex and, once programmed, need little intervention or maintenance.

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Quiet operation — A noisy power unit

running a fluid cylinder can be a noise polluter and hazard for operators working near the machine.

Tolomatic RSX high-force actuators with roller screws can output forces to 178 kN (40,000 lbf).

Low environmental impact — Leaks from hydraulic systems can create messes in the manufacturing environment and also present a safety hazard if someone slips on the spill. In pneumatic systems, air leaks create unwanted noise and waste energy. In addition, hydraulic leaks can cause serious contamination to key processes and products — such as food processing, pharmaceuticals, medical devices and others. Electric actuator systems share none of these drawbacks. Smaller system footprint — Not only

do electric actuator systems save energy, they also save space. Hydraulic systems need a cylinder, a power unit to provide

oil pressure, control valves, filters and many additional components. Electric systems only need the actuator itself and a control cabinet — which can usually be conveniently located near the point of use. Minimal maintenance — Electric actuators sized properly for the application typically need little or no maintenance. In more demanding performance applications, electric actuators may need maintenance such as de-greasing, but it is usually an infrequent, simple and low-cost procedure. Fluid power devices, while typically rugged and easy to deploy, need considerable maintenance as a tradeoff. Leaky seals can contaminate the work site and reduce the working forces. Additional air and oil maintenance is needed to prevent humidity or contaminants from prematurely destroying seals and other components in the system.

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Two Tolomatic RSX rodstyle electric actuators meet the peak force requirements for a metalcastings manufacturer.

Allows process improvements —

Electric actuators can cycle faster than fluid cylinders in many applications. An example would be a fluid rod actuator that goes out and back six inches. Maybe the application only needs the six inches of travel for setup purposes, and only three inches for a production run. But fluid actuators have poor positioning capability and can only move the six inches out and back, wasting time on each cycle. Electric actuators with precise position control can be programmed to do the three-inch production run, thereby saving time and speeding up throughput. Low life-cycle costs compared with fluid power — Although electric actuator

systems are twice as efficient as hydraulic systems, they can be more expensive to implement initially. However, the cost over the life of the system can be substantially less if one factor in the increased performance, system flexibility, lower maintenance, process improvements and decreased utility costs.

How ball screw design boosts performance Simpler construction — Ball screws

feature simpler construction than roller screws and, as a result, have a lower initial purchase cost.

Low life-cycle costs — Electric actuators with ball screws have lower life-cycle costs compared to fluid power systems and, depending on the life requirements of the application, may edge roller screws due to lower initial costs and slightly higher efficiency. Moderately long life — Compared to

fluid power cylinders, ball screws deliver a moderately long and predictable life in properly designed high-force applications. Life span can be several times shorter than roller screws in the same application due to fewer contact points of ball screws. High-force applications — Ball screws can reach high forces similar to roller screws, but the actuator and machine footprint will be much larger, and operating life less than a roller screw design. Lowest maintenance — Ball screws feature low maintenance requirements ... much lower than those of fluid cylinders. Periodic relubrication of the ball-nut assembly may occasionally be necessary, depending on the severity of the application.

How roller-screw design contributes to performance Large contact area — Through-

contact area. This contributes to greater force capabilities and longer service life compared to ball screws. High duty-cycles — Roller screws are tolerant of high duty-cycles (up to 100%) at moderate speeds and working forces. While maintenance is very low, high-dutycycle applications may need occasional relubrication of the roller nut. Compact design — Roller screws have the advantage of creating higher forces in a smaller package compared to ball-screws. When the size of the actuator envelope is critical to the application, roller-screw actuators have an advantage over ball screws. Longer life — Roller-screw actuators

exhibit the longest life and highest Dynamic Load Rating (DLR) in extreme high-force applications due to multiple points of contact. Low life-cycle cost — Roller-screw

actuators deliver lower operating costs than fluid power cylinders due to greater efficiency and energy savings. Depending on the application, the high DLR and longer life of a roller screw can spur a lower total cost of ownership compared to ball screws.

hardened, precision-ground threads on the rollers and lead shaft provide maximum

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Ball screw applications Saw mill — A lumber-processing equipment company needed to replace a hydraulic cylinder in a log-cutting application to eliminate the potential of hydraulic fluid leaks into the environment. The company chose an RSA64 electric ball-screw rod actuator with a 42-in. stroke to move the saw blade. Featuring an IP67 rating to protect the actuator from splashing water and debris, the actuator was also lubricated with a high/low-temperature grease for consistent performance in all weather conditions. The ball screw provides efficient, highspeed motion to reach the stroke speed needed over the entire length of the electric cylinder. Walking beam in meat packing — In a meat-packing plant, a walking beam pulls sides of pork and beef through the plant’s chilling-aging facility. The company was interested in eliminating the use of hydraulic cylinders in its walking-beam application due to concerns about leaking

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hydraulic fluid and product contamination. The company chose RSA electric actuators with ball-screw technology that exceeded the performance of the hydraulic cylinders and provided greater process repeatability. Being able to lower the total cost of ownership played a major role in the decision to convert to electric actuators.

Roller-screw applications Automotive manufacturing — An OEM

of wheel-bearing presses wanted to replace hydraulic cylinders to improve process control, reduce energy consumption and eliminate hydraulic fluid leakage. Time was being lost during wheel size changeovers, needing the operator to make multiple adjustments to dial in performance. With hydraulic cylinders, each production changeover resulted in lost production time and rework. The company selected an RSX roller-screw electric actuator to provide a consistent, repeatable force to 40,000 lbf while eliminating the need for operator intervention during changeovers. The servo-controlled RSX www.designworldonline.com

actuator allowed the OEM to create quick and easy changeover procedures to accommodate any wheel size. Metal-casting operation — A

manufacturer of high-quality metal castings needed an electric actuator to replace existing high-maintenance hydraulic actuators in a steel foundry. Pulling the hot castings out of the molds needed approximately 66 kN (15,000 lbf). However, whenever a casting was left to cool in the mold, the customer estimates it needed a peak of 177 kN (40,000 lbf) to break the casting out of the mold. The solution was two RSX rod-style electric actuators with high-capacity rollerscrew technology to meet the peak thrust requirements. What’s more, the actuator’s IP65 rating and robust design maximized the actuator’s life in the hot, dirty foundry environment. All article images from Tolomatic Inc. DW Tolomatic Inc. | tolomatic.com

September 2019

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How to better integrate IoT devices— use Apps Systems for integrating IoT devices and smart equipment can be architected in many ways, and end users will find easier access when mobile apps and FTP access are incorporated. Don Pham • Linda Htay •

Senior Product Marketing Manager Product Marketing Specialist IDEC Corporation

Industrial and commercial users realize the growing availability of intelligent devices at their sites and are investigating ways to create value from the data these devices can provide. The first step is to ascertain device status and information, and to do so the data must be accessed and displayed. There are many ways to do this, some of which can involve significant hardware and software infrastructure. End users are also familiar with personal mobile applications that let them easily and remotely check on their home thermostats, alarm systems and other smart consumer devices—so a natural thought is to look for similar apps usable with industrial smart devices. Fortunately, these types of apps are becoming more widespread in the industrial arena, providing an improved means of remote access in many applications.

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An architecture for IoT success Internet of things (IoT) devices can include something as simple as a single field sensor for detecting temperature, or more complex systems with many data points like a packaged water pumping skid. Even older hardwired devices can be incorporated through controller I/O to boost their effective intelligence. Regardless, end users are architecting their visualization and control infrastructures to take advantage of these IoT devices. An IoT-ready infrastructure often includes integration of programmable logic

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controllers (PLCs) and human-machine interfaces (HMIs) installed in the field to provide the first-line connection to IoT devices. These local PLCs and HMIs can gather the data, scale it or perform other necessary pre-processing, concentrate or arrange it as needed and then make it readily available for higher level systems. Data from the local PLCs and HMIs can be accessed by larger SCADA systems, or via web browsers if the PLCs and HMIs have built-in web server capability. However, many times end users want lightweight ways to remotely access information without

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

building in excessive layers of computing. This is where the convenient accessibility delivered by mobile apps and file transfer protocol (FTP) functions can quickly and easily deliver just what users need.

Gathering data at the source Some IoT devices can reside directly on an Ethernet Wi-Fi network, whether this is an IT-based business network or an operations plant-floor network. While this makes it possible for higher level SCADA systems to directly connect with these intelligent network-enabled devices, that

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IDEC PLCs and HMIs work with the WindEDIT Lite app to provide an easy way for users to connect, view, change and transfer data. | Courtesy of IDEC Corp.

End users are also familiar with personal mobile applications that let them easily and remotely check on their home thermostats, alarm systems and other smart consumer devicesâ&#x20AC;&#x201D;so a natural thought is to look for similar apps usable with industrial smart devices.

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isnâ&#x20AC;&#x2122;t always the best approach for a variety of reasons ranging from cybersecurity concerns to network loading issues. Instead, it often makes sense to install a field-located controller closer to the IoT devices, and then configure it to be an IoT data concentrator. For hardwired devices or those using industrial communication protocols like Modbus or BACnet, there is even more of a reason to install local PLCs or HMIs because these controllers use these connections natively and are the best way to bridge these signals to an IT network. Some PLCs and HMIs have overlapping capabilities. Traditionally the key feature of a PLC has been wired inputs and outputs (I/O), and the prominent feature of an HMI has been visualization. Today, many modern PLCs include some local visualization, while some HMIs can control and monitor a limited amount of I/O. In addition, a growing area of overlap regards the networking and communication abilities of these devices. Both PLCs and HMIs can offer Ethernet networking, support many communication protocols and provide browser-based access by serving web pages. Many sites already need PLCs to provide some level of direct control and HMIs to supply the corresponding visualization. Therefore, PLCs and HMIs may be in service and can perform additional duties by gathering IoT data. Or, if it is more convenient, www.designworldonline.com

the site can install more PLCs and HMIs dedicated to IoT and data concentration tasks.

Other data handling routes With so many options for connecting IoT devices to controllers and HMIs, and in turn for users to access the data, it might seem that nothing else is needed. However, the cost and effort involved has not yet been addressed. Large SCADA systems are expensive to license, deploy and configure. They can require extensive IT infrastructure and dedicated personnel for support. This level of effort can be warranted for large process projects or integrated systems, but it may not make sense for many sites. For small- to medium-sized sites, the ability to use a browser to access a local controller is a convenient feature when available. Some PLCs and HMIs offer builtin browser-accessible displays to provide diagnostics and even some configuration. Taking things a step further, many HMIs can replicate and serve the local functionality to a remote browser, extending the capability of the HMI to wherever the user has a portable device. A third scenario is possible if the local PLC or HMI can host and serve web pages. In this case, the user can develop the basic web pages for displaying the data of interest, and then use their browser of choice to access them. This type of connectivity avoids software

8/29/19 7:25 AM

One Device for Maintenance licensing costs, but it does require users to be comfortable with creating web pages and configuring their network to make them accessible. Some manufacturers improve this process by including easy-to-configure web page development software with their systems.

The FTP option For intermittent bulk transfers of one or more data files, there is a standard PC-based protocol called FTP. The FTP protocol has most commonly been used between client and server PCs on a network, providing a free and easy data transfer method with no software licensing costs. However, FTP is also applicable for PLCs and HMIs compatible with protocol, and it is a powerful tool because it allows users to upload and download data files to their computing device as needed. A common application is when a local PLC is logging machine or IoT data into files. Users can rapidly transfer these data files from the PLC to the destination of their choice. Although FTP is suitable in many cases, there is an even more convenient option for remotely accessing more limited amounts of data. Apps are easier Another avenue exists for remotely accessing PLC, HMI and therefore IoT

data. This is when the PLC of HMI supplier offers a native mobile app for iOS or Android devices. A native app can deliver an improved user experience because much of the behind the scenes details are already handled. Users only need to install and run the app, connect their mobile device to the target controller and choose the data to monitor or adjust. It is best if these industrial mobile apps are free or very low cost because end users will want to install them on many devices. Once installed, the first step is to gain connectivity. For users remote from the site, this access will commonly be the internet. A popular method of connectivity for local users is to use the site’s Wi-Fi connection, as long as the PLCs or HMIs are available on this network. Wi-Fi connectivity gives users the most freedom to roam about and observe plant operations in the real world and through the app. However, it may be desirable to keep such access localized with functionality best implemented with Bluetooth wireless. A limited-range Bluetooth connection lets users take advantage of the mobile app just when they are physically near the PLC. An advantage of both types of wireless technologies, and updateable apps, is that users never need to worry about having the proper cable in hand, opening a control panel or loading the right version of software or drivers. Such easy accessibility raises questions around security, as it should. Apps for connecting to PLCs or HMIs must offer role-based security, configurable for

IDEC’s WindEDIT Lite app provides convenient menu-driven mobile access to PLCs and HMIs, allowing users to easily view IoT data.

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Broadband Ultrasonic Analysis 20-100kHz Simultaneously

| Courtesy of IDEC Corp.

Large and Intuitive Touch Screen

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September 2019

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This type of app would be most useful simply to monitor key data points. These could be machine operating speeds, temperatures from local IoT transmitters or other key data points. A more advanced application might let users adjust parameters or machine options. It is easy to see how a ready-made app facilitates remote viewing and changing of data, without requiring an extensive computing infrastructure to be installed and maintained. So far, we have considered the viewing of live data or the trending of recent data. Another option used by many PLCs is to log data within the PLC or to an SD card. Not only should the app enable the user to view this type of historical data, it should allow users to email it to other users, or even push it to site- or cloud-based databases or data storage platforms. The WindEDIT Lite app even enables more advanced capabilities like data trending, uploading and downloading of data files, and updating system firmware | Courtesy of IDEC Corp. .

each user with their own username and password. With these features, the administrator can control who accesses the PLCs or HMIs, and what data they can read or write.

Developing displays Once a user has connected their device to the PLC or HMI and logged into the app with the proper credentials, the next step is to display the desired data. Whereas PLCs or HMIs with built in web servers would require users to develop graphics, that is not quite the case with an app. An app facilitates navigation through data registers, inputs, outputs, timers, counters and other typically used values. These are selected not with programming, but through simple configuration using a built-in dialog interface. Other options allow users to pre-configure listings of just those points needed, or provide the capability to configure and view trend displays.

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An App in the toolbox Apps provide easy access to PLC, HMI and IoT data, but once connected they can also be used by maintenance personnel to perform other extended operations. The most common way would be for a technician to view system inputs and outputs while troubleshooting a problem. More advanced capabilities free the tech to do their work anywhere in wireless range. They can also be used to update firmware, and to upload or download program configurations. A mobile app becomes another tool in the technician’s toolbox, much easier to cart around than a laptop and not requiring any special cables. Many end users know they have IoT devices available at their sites and want to find the simplest and most effective method to access device data. These sites are often familiar with PLCs and HMIs but they don’t have the resources to create and maintain a large computing installation. Just as mobile apps are a quick and convenient way to access consumer devices at home, the right apps combined with PLCs and HMIs can enable end users to easily access their IoT devices and smart equipment. DW IDEC Corp. | us.idec.com

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S e n s o r s

Applying

the right position sensor Best practices for choosing between generalpurpose and mission-specific position sensors for industrial applications.

Andrew Waugh | AutomationDirect

Marketing specialists are familiar with the idea of offering good, better and best products to give the consumer options, and possibly upsell them in the process. Yet many times, this concept is imprecise. We each weigh features differently, and sometimes the better product doesnâ&#x20AC;&#x2122;t simply have more features, but instead has other attributes. Industrial end users looking to select the right position sensors for their equipment face this very dilemma. There are basic general-purpose versions and enhanced mission-specific styles of industrial sensors. From an engineering standpoint, it is tempting to select the most full-featured, optimized and easy-to-use product every time â&#x20AC;&#x201D; but wise engineers understand this can add to costs. Business owners or purchasing agents, on the other hand, are likely to look for the best value, and sometimes both parties can realize their goals with the same device. Very often, the availability of more choices is better for the end user, even if they end up using just one or a few of the options. This article will examine some criteria that users should evaluate when deciding on the best position sensors for their applications, but the discussion is also valid for investigating any type of sensor.

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General-purpose versus mission-specific For most position sensors, the three fundamental technical performance criteria are: reliable sensing distance, environmental suitability and mounting requirements. All three are related to each other, and how the sensor is designed to achieve each of these goals is partly what classifies it. A simple physical limit switch may suffice — but also be susceptible to mechanical damage — while a more advanced non-contact proximity switch has barely enough sensing distance, but can survive the environment. Defining the use of the terms general-purpose and mission-specific is an important first step, because there is no industry standard for this terminology and products may not be labeled as such. General-purpose is largely associated with a basic part or product, applicable to most common applications. Mission-specific, on the other hand, implies a more highly-engineered product with additional features and unique characteristics. These enhanced elements help the product provide key functionality not available with general-purpose products.

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Most observers would say that any missionspecific product would make general-purpose seem inadequate or inferior. However, a thorough analysis must be based on fact-based performance and cost evaluations, with an attempt to consider unintended consequences. Weighing the features With these thoughts in mind, why would anyone specify general-purpose for anything? The most important and obvious reason is cost. Generalpurpose implies a simpler and more standard device, likely mass produced to take best advantage of economies of scale. Usually, any enhancements that push a sensor toward being mission-specific mean added costs, and users who don’t need those benefits would end up overpaying. However, mission-specific isn’t always better when all impacts are considered. A lesser known side effect is entirely possible whereby a mission-specific sensor could be counter-productive in a basic application

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FIgure 1: Some sensor categories, like photoelectric, offer multiple underlying technologies ranging from general-purpose to mission-specific, each suitable for certain applications. (All figures courtesy of AutomationDirect.)

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S e n s o r s

Figure 2: Economical general-purpose sensors have standard sensing ranges and basic environmental ratings but may be suitable for warehouse applications.

due to its extra features. Perhaps it is more difficult to adjust, or less reliable at certain types of detection, so it causes difficulties for technicians and operators. If it ever needs replacement, its more specialized nature might mean less commercial availability. These collateral impacts may not be noticed on the first day of operation but can add up over time. Another key user consideration is standardization. If end users could successfully select one sensor type for all applications, their personnel would become experts with that model, and they would only need to stock the one type. Many sites would gladly pay a little more for such simplicity.

For a basic application like sensing a cardboard box or other opaque object on a conveyor, any sensor type would work â&#x20AC;&#x201D; and in fact a general-purpose retro-reflective red sensor is an excellent and reliable choice, Figure 1. Residing on the other end of the degree of difficulty spectrum would be an application for sensing a clear bottle moving down an infeed conveyor on a filling line. A general-purpose red LED sensor would likely sense on/off/on as the bottle moves

Photoelectric example As a practical example, letâ&#x20AC;&#x2122;s consider photoelectric sensors. This product group is extremely large and ever-growing with respect to both underlying technologies and potential applications. There are three general forms of sensing technology: diffuse, retro-reflective and through-beam. All three types share a common philosophy of sending and receiving light, although the source may be red LED, infrared or even laser. Each technology type and light type has different advantages.

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through the sensing path because it will only trigger on the denser view through the leading and trailing edge sidewalls. This false reading could provide two pulses as a bottle moves by, instead of just the desired single pulse. In this case, the application demands a technology specifically targeted for clear glass detection, such as an optimized sensor. This type of sensor would probably work in many other applications, but it would be more expensive and suffer other constraints, such as a limited range of sensing distances or mounting options. Since many sites have varying requirements just like these examples, it is most likely that more than one sensor type must be selected to address all applications. Focus on the environment and the technology Many designers might find a cost-effective approach is using general-purpose wherever possible, and only moving to mission-specific when the environment or technology demand it. Environmental specifics are easy to understand. Industry uses IP ratings or NEMA ratings to define how well a device can withstand ingress of solids like dust and liquids like water. Higher ratings can withstand pressure washing or even submersion. Furthermore, the materials of construction must be suitable for whatever

Figure 3: At six times the price of generalpurposes sensors, mission-specific versions may look similar but can offer extended sensing ranges and IP69K ratings enabling them to withstand high temperature/pressure food and beverage washdowns and resist chemicals.

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chemicals might be in the environment. Basic sensors and accessories may use plastic or plated metal housings, and only be rated to IP65 or lower, which is suitable for warehouse or shop environments, Figure 2. However, food or pharmaceutical applications subject to chemicals and pressure washing will drive the need for stainless steel housings and a rating of IP68 or higher, Figure 3. Of course, undesirable consequences of encapsulating a sensor in SS are usually a reduced sensing range and increased cost. Other challenging environments are welding applications and tight locations, which might require specially coated sensors to resist slag buildup, or slimline right-angle style housings instead of a regular tubular type. Both add cost and are only needed for those specific cases. Technology specifics can be much more subtle. The photoelectric example is a case

where the best sensor might detect the angle of the light reflection instead of the amount of light, a technology called background suppression. This is great for ignoring the color of an object and is important when needed, but it adds cost when not required. Finally, consider the case of proximity type position sensors for which cost versus distance evaluation is important. This is a situation where more advanced factor 1 sensors, also known as k-factor=1 or K1, cost little more than traditional sensors but offer a consistent sensing range for any type of target metal. In this circumstance, the technology offers a performance advantage for new and retrofit applications, and it could easily enable an end user to consolidate stock, a valuable benefit. The right sensor for the job If designers can choose a general-purpose sensor that survives in the environment

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and gets the job done, there is no reason for them to feel they are getting anything less as compared to a mission-specific sensor. For a new and untested application, the right approach might be to start with a standard model to see if it can pass muster. For those situations truly requiring more advanced products, a myriad of options is available. Careful end users will educate themselves on the available technologies and characteristics, and they will lean on the device suppliers as required. Sensor manufacturers and distributors usually can offer some advice based on feedback of how their products are used throughout a wide range of applications. The wide range of products available to the end user is a great benefit. With some careful evaluation, designers can target just the right models necessary to deliver the right performance and value for all their applications. DW

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A Basic 3-step How-To Here are tips on developing protocols and processes for reverse engineering with scanning technology.

Greg Groth • Exact Metrology

Among the applications for scanners, one that has come back into prominence is reverse engineering. The uses of reverse engineering are many. For example, scanning a part and developing a digital file can eliminate the need for paper documentation. Or, if a part no longer has documentation, scanning can help create digital versions. Scanning can also save design time when making modifications to existing designs by enabling designers to use the existing scanned file to alter as needed. There are several simple steps to ensure you get the most out of scanning for a reserve engineering application. Step 1: Determine intent. How will this image be used?

Do you anticipate any changes? What are your tolerance requirements? All these questions are important in determining the successful path of the data output and each are mutually exclusive of one another.

Why should I care how the image will be used?

When approaching a project of any magnitude, the ideal goal is to find the cleanest, clearest path with an optimal desired result. Not knowing the intended output can send a service tech down a long, inefficient path. Here is a scenario I encounter on a regular basis. Customer: “I need to scan an entire engine for a vehicle with CAD output.” At face value, I can jump to the

conclusion that they need every nook and cranny digitally captured by any medium of my choosing and I can spend several weeks meticulously creating detailed models of starter motors, cooling lines and complex engine block castings. 99% of the time, that is not necessary. After asking that simple question, How will this be used?, a simple volumetric representation is all that is needed to determine fit and clearances. This can be accomplished quickly and efficiently using simplified scanning techniques and rapid solid modeling.

Why do I care if the customer anticipates changes?

Anticipated changes drive the method of creation. Another common question I receive from customers is, “I need a Parametric IGES or STEP file.” This is a contradiction. Parametric CAD models contain design intent, a structured combination of prismatic 3D features driven by specific dimensions. An IGES or STEP output is a stripped version of that parametric 3D CAD

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Modern scanning hardware can capture high surface detail sometimes to the detriment or advantage of the desired production process. The reason… anticipated changes.

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3D Scanning

In a sand-casting application, for example, this is a common request. Modern scanning hardware possesses the ability to capture high surface detail sometimes to the detriment or advantage of the process, depending on the previous factors mentioned above. The reason… anticipated changes. If my intent was to create new tooling and develop clean surfaces for machining, then developing it through a traditional CAD workflow makes the most sense. But, this calls for an allowance. An allowance of tolerance. That intended flat surface may not be flat anymore on the physical part. Through 3D scanning and interpreting those surfaces back to a clean CAD model, I have now taken liberties to correct that discrepancy, therefore influencing the deviation on the actual part back to its new digital CAD counterpart. On the flip side, if I am developing something to perhaps grab or hold this part and I need high precision, then back to that prior fork in the road. We can now take a different approach to the modeling output. Similar to our engine example, we can create high precision NURBS output to satisfy those exact surfaces and make certain the part is defined properly.

Portable CMM and scanning arms deliver speed and flexibility. Wider laser lines, higher hertz rates for data capture and millions of points captured in seconds. These pieces allow users to adapt quickly from a controlled lab environment to mounting it on a machine on the shop floor to resolve an issue. Data from these units are captured with laser and its ability to adapt to different surface colors and finishes has become quite advanced in recent years.

model, typically represented by that outside “skin” of the CAD surface, allowing users to share 3D data between multiple platforms that do not share a common internal language. So, knowing what changes may be needed is important. A user can design a part to make those anticipated areas easier to modify without fighting unwieldy surfaces, fillets or draft in the completed CAD model. Or, in my example involving an engine, there is no plan to modify that data, only to check what fits around it. This can be resolved with a simplified NURBS (Non-Uniform Rational B-Splines) to get a lightweight, volumetric skin to bring in to the customer’s existing CAD design. Tolerances? The final deliverable should be perfect, right? Wrong. Do you

really need this sand casting within 0.001 in.? Are you sure you want to see every imperfection in that part? Let’s apply the brakes at this point and back up a bit. Reverse engineering, as mentioned above, is a path. A path with many twists and forks. This is one of those forks. During the process, tolerances can be managed through use of the correct hardware and software in the hands of a skilled tradesman. Expectations, on the other hand, are still a bit of a slippery slope.

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Step 2: Acquisition. Now with guidelines

established for intent, let’s examine options based on those choices. Structured light is cleaner. Portable arm-based laser scanning is fast and accurate, plus the time-of-flight and phase shift (long range) scanners can scan further distances with substantially higher precision. Metrology grade 3D CT (X-Ray) scanners are becoming more powerful and financially feasible. Why structured light? Because it’s clean. Clean data yield a cleaner result. Structured light is typically a two-camera, stereo system. The system uses a digital projector to project a fringe pattern onto the surface of the part, thus displacement of the fringe pattern along the part is correlated back into 3D data. These sheets of lights bounced off the part

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provide a clean and highly accurate digital representation of the part. This clarity is regarded as a high standard in comparison to counterparts mentioned below. Its only real limitations are translucency/transparency and deep colors opposing the light spectrum of the projected light. Also, both cameras need to see the geometry being captured. Why Portable CMM/Scanning Arms? Speed and flexibility. I think one

of the largest improvements has been in the portable CMM industry. Wider laser lines, higher hertz rates for data capture and millions of points captured in seconds. These pieces allow users to adapt quickly from a controlled lab environment to mounting it on a machine on the shop floor to resolve an issue. Data from these units are captured with laser and its ability to adapt to different surface colors and finishes has become quite advanced in recent years.

One of the key steps in reverse engineering is to determine the intent of the scan. How will this image be used? Will there be any changes? What are the tolerance requirements? All these questions are paramount in determining the successful path of the data output and each are mutually exclusive of one another.

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Chrome and deep blacks were always the nemesis, but those days are fading away. Quickly. With tolerances getting close to matching those to structured light, they are taking a good hold on the market and are becoming a dominant force and a valuable tool in reverse engineering. Current limitations are set only by the length of the portable arm, with multiple setups being required for part sizes beyond the arm’s reach. Why long range? Do you need to map out a building? Do you need to reverse engineer the outside of a 747? If so, this is the perfect tool. With the ability to scan geometry hundreds of meters away within a reasonable tolerance, long range scanning is the right application. These tools are sending out a laser beam with high precision and recording the surface it bounces off back into digital 3D data. That data can be combined with high-res imagery to provide 3D visualization of the objects, areas or spaces being scanned. Why CT (X-Ray)? Visualizing internal data is typically lumped into the category of inspection. But with 3D X-Ray machines becoming more powerful to see inside of dense materials such as steel, extracting those internals can prove valuable. Internal passages that were created with a complex network of sand cores in a foundry process can be seen to correctly validate clearances when recreating a new part. CT also eliminates blind spots, allowing designers to model complex sculptural surfaces with precision and assumptions in filling in missing geometry from conventional scanning methods. Step 3: Processing. Now we know what the intention is and how we are acquiring data, so what do we do with it? Today’s processing is a bit of

a broad spectrum, but I would like to highlight some guidelines to once again lead us down a clear path. Garbage in, garbage out. With the variety of scanners mentioned above comes a bit of responsibility. Know your hardware. Know its capabilities, know its limitations. At this point, we know how it’s being used, how accurate it needs to be and what methods we need to use to get there. Taking small short cuts in the scanning process leads to timeconsuming editing when processing 3D data. For instance, not taking an additional scan to capture the bottom of a groove or hole leads to assumptions when interpreting the scan data into a polygonal mesh. One additional 5-second scan could save hours of work. Clean data input streamlines the processing. 3D point cloud, now what? I now have millions of points that cleanly represent the part, so let’s go to

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3D Scanning the next step. The common next step is converting the XYZ 3D data points into a polygon model. Simply put, the software connects the dots with a series of triangles to create a representative skin. There are various tools that can accomplish this goal. Most hardware suppliers provide this direct output from their scanners, others rely on third party software to run the calculations. From here, the world is your oyster, so to speak. There are many software packages that allow you to manipulate the data, including smoothing out imperfections, closing small or even absurdly large holes within a reasonable assumed precision. The ability to quickly edit out pesky clamps or fixtures holding the parts during scanning is amazing. This step sets the pace for the next round of modeling.

“Most users that bought into plastics-based AM did it for prototyping. We envisioned a number of opportunities for functional, end-use components.” Conversion. My polygon data, commonly referred to as an STL, is ready to go. Intent? Check! Now let’s convert this to a useable format with the necessary parameters to get what we need out of it. Here, we come to our final fork in the road, as defined earlier by our intent. This is also another part of the process that has improved in the last 10 years. The ability to get from physical part to 3D data is 5:1, maybe more. Gone are the days of scanning a part, bringing a low-resolution version into a CAD package, cutting cross sections, converting those to complex sketches and then generating 3D features off those sketches. Today, there are software packages that can handle scanning directly into their software, converting large data sets to high-resolution mesh data and generating native parametric CAD features, all in one package, thereby shaving days off the

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process and achieving a better result. Also, the ability to generate NURBS or “As-Is” surface data with extremely high precision has been a dramatic improvement. With complex algorithms able to solve data sets with complex surface geometry with a single button push, the process continues to get faster and faster, as well as more accurate. The best of both worlds. Validation. Now that we have two pieces, 3D scan data and the intended CAD model, let’s wrap up the process. Before I throw this over the wall to manufacturing or whatever downstream process required, I need to check my work. Another improvement that continues to excel is the ability to validate data. Validation, used here, is the ability to show deviation of the scanned object back to the CAD model under development. This deviation is represented typically by a color map, with each color representing the 3D distance each point varies from its CAD model counterpart. Once this evaluation is complete and meets the expectations determined, the CAD model is ready to be delivered. DW

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M e d i c a l

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MicroCare Medical has earned success selling its Swellex silicone swelling fluid to companies assembling medical tubing. Here’s how it works. Chris Newmarker Managing Editor Medical Design & Outsourcing

MicroCare Medical (New Britain, Conn.) over the past decade has found that its Swellex silicone swelling fluid is a popular product for medical tubing manufacturers. “That’s because the swelling fluid helps workers reduce the amount of force needed to insert a tube onto a barb or other type of connector,” David A. Ferguson, senior market and technical manager at MicroCare, told Medical Design & Outsourcing. Whether the manufacturing involves assembling IV tubes and bags, drainage catheters, dialysis machine tubing or a host of other products with tubing, companies are avoiding having to throw out tubing because of stress cracks, according to Ferguson. Swellex is also helping employees avoid carpal tunnel, wrist problems and other workplace-related injuries. LEFT: Swellex temporarily softens and swells the inner diameter of a silicone rubber tube so that it can be easily attached to a barb or other connecter, as David Ferguson from MicroCare Medical demonstrated at MD&M West in February.

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RIGHT: A worker can soak a tube in Swellex for 10 to 15 minutes – until the inner diameter of the tube softens and swells enough that it can be easily attached. Images by editor Chris Newmarker

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“Since you don’t want to introduce heat, glue or anything else that can affect the integrity of the tubing or has to be qualified with the FDA, tubing is typically assembled by hand. Swellex helps make it easier,” said Ferguson, who spoke with MDO during MD&M West early this year. A worker can soak a dozen tubes in Swellex for 10 to 15 minutes – until the inner diameters of the tubes soften and swell enough that they can be easily attached, Ferguson said. The tubes then contract to their original shape, size and strength, forming a tight, leak-proof grip as the Swellex quickly evaporates. The process produces no residue affecting the qualification of the manufacturing process under FDA guidelines, according to Ferguson. Because the swelling fluid’s active ingredient is a methyl siloxane — a member of the silicone family — it doesn’t affect the integrity of the tubing, he said. The Swellex swelling capabilities are similar to those of hexane, but there is less weight gain due to swelling absorption, which enables the polysilicone tubing to return to its original state faster, according to MicroCare. The company also touts Swellex as VOC exempt, making an excellent replacement for hexane or tolulene. Much of the use for Swellex involves tubing made of silicone rubber, a go-to material for medical tubing. The swelling fluid, however, is compatible with other tubing materials, including polyethylene and polyimide, but prior in-use testing is important, Ferguson said. MicroCare also has a second swelling agent called Swellex P, a proprietary formulation that works on polyurethanes.

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Since you don't want to introduce heat, glue or anything else that can affect the integrity of the tubing or has to be qualified with the FDA, tubing is typically assembled by hand.

Swellex reduces the amount of force needed to insert a tube onto a barb or other type of connector. Image courtesy of MicroCare Medical

Ferguson acknowledged that there are a few challenges manufacturers should address before using Swellex:

• The fluid does pull some oils out of the skin. The recommendation is that workers wear gloves when assembling tubing.

• Out-gassing can take up to 24 hours. Ferguson has found this often isn’t a problem for tubing manufacturers. “In most applications, this is an inter mediate step. You’re doing more to the component than just assembling the tubing, so it will de-gas while you’re performing other tasks.” • Swellex is flammable, but medical tubing manufacturers generally only use about a liter at a time. “It’s no more of a challenge than having a little bit of IPA,” Ferguson said.

Overall, Swellex has been a best-seller for MicroCare. “After qualifying Swellex and seeing how it can speed assembly and throughput, many companies recommend it for their other divisions, Ferguson said. “Swellex is rapidly expanding throughout the medical manufacturing industry.” M

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Metal injection molding vs. machining: When MIM is best

Metal injection molding (MIM) works well for high-volume production of small, complex medical device parts of consistent quality. Steve Santoro Micro

Demand for small, lightweight, high-strength, complexly shaped components is growing across industries today, from automotive, consumer electronics, aerospace and defense to orthodontics and medical devices. Traditional machining and injection molding each has its pros and cons in producing components for medical devices, especially where parts may be smaller and require more maneuverability. Metal injection molding (MIM) is a hybrid technology that integrates the shaping capability of plastic injection molding and the materials flexibility of conventional powder metallurgy. Material selection, part size, volume and tolerance are all instrumental factors in the decision-making process.

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Materials MIM is a process like plastic injection molding but with metal feedstock. Powdered metal feedstock is processed at high temperature and pressure to effectively and efficiently produce small, precision, highperforming parts in large quantities. This proven technology yields highquality mechanical properties and excellent strength, ductility and magnetic response. It’s ideal for creating components with more sophisticated shapes and small, highly precise parts with unique geometries for surgical instruments, artificial joints and pacemakers. Process overview When using injection molding, it’s important to remember not all feedstocks and processes are equivalent. For optimal mechanical properties, high density and small dimensional variation, it’s critical to obtain consistent shrinkage and diffusion of organic binders and surfactants from the metal matrix. Poor diffusion increases the voids in the metal matrix by trapping gas; the lower density will dramatically reduce the strength of the part. Due to the flexibility of MIM technology, it’s possible to customize material compositions according to the specific attributes required by customers. Some of the compositions are stainless steels, low alloy steels, carbon steels, Ni-alloys, tool steels and tungsten alloys. Part size MIM is preferred for mass manufacturing of small, intricate geometric components of a variety of materials, as it can achieve 95% to 98% of its theoretical density at a much lower cost than comparable machined components.

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Typical MIM parts used in disposable surgical instruments and assembled in a clean room. Image courtesy of Micro

Volume MIM is well-suited to automation in producing large quantities with consistent quality. Machining typically requires longer cycle times and is thus better suited for lower production volumes requiring complex shapes with tighter tolerances. Finishing operations with MIM are quite minimal by comparison so long as the application has less critical tolerances. Although there’s an initial capital investment in creating the MIM mold, this cost can quickly be recovered when amortized over high-volume runs. Tolerance Expected tolerances range from +/2% to less than 0.4%, depending on feature size. The larger the feature, the larger the tolerance due to the propagation of error in shrinkage. Shrinkage generally ranges from 15% www.designworldonline.com

to 18% during sintering. Therefore, the larger the feature, the larger the propagation of error. One other phenomenon that affects expected outcomes is nonisotropic. There will be more shrinkage in the vertical direction because of gravity. The least shrinkage will occur in the longest lengthwise direction due to drag forces between the workpiece and the furnace furniture. MIM is ideal for producing intricately shaped parts for complex components as well as parts that require assembly. The same is true for high-production of small precision parts with complicated design geometry. The process lends itself to automation in which high volumes and consistent quality are required. MIM technology is also the best viable process for producing miniature parts economically. Companies that specialize in MIM technology and machining should work alongside engineers to address development early on. Engineers with expertise in both processes can suggest design modifications and provide input to get the best performance out of a product no matter what technique is ultimately used. While you can certainly switch operations midstream, factoring in design considerations upfront can save time and costs. M September 2019

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Medical device industry

supplier innovations you need to know Medical device innovation doesn’t just come from startups or big corporate R&D departments. Contract manufacturers and suppliers are increasingly playing a role, too.

LONG GONE ARE THE DAYS when medical device industry suppliers simply Nancy Crotti | Senior Editor

produced or manufactured according to specifications. Companies are increasingly coming up with their own answers to potential design and manufacturing challenges — enabling medtech innovation in the process. From two-component injection molding to greatly improved tube extrusion monitoring, here are eight medical device industry supplier innovations that caught the attention of Medical Design & Outsourcing’s editors this year.

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TRELLEBORG:

Two-component injection molding Swedish company Trelleborg developed an advanced two-component injection technology to produce complex, highprecision parts for medical devices. The fully automated, 2K molding process allows the injection of two dissimilar silicones or a silicone-thermoplastics combination in two shots into a single tool. It offers medtech companies broader design latitude and eliminates the need for secondary handling and assembly operations, according to Trelleborg. The process may be used for multiplecomponent devices or complete ones, according to Ursula Nollenberger, product line director of Trelleborg Sealing Solutions’ Global Elastomers Operations. “It’s a growing trend that we’re seeing, where it’s a matter of combining multiple materials, multiple components, multiple functions,” Nollenberger told Medical Design & Outsourcing.

“Device makers are looking to combine into one composite, solid, fully-bonded device versus the alternative, which a lot of times you have several components and you put them together in an assembly,” Nollenberger said. The process is especially wellsuited to devices that must be small enough to fit inside wearables or longterm implants such as pacemaker micropumps, she added. “We’re helping designers to be able to come up with solutions to near-impossible problems in terms of intricacy of shape, size of shape, especially with this trend of devices becoming smaller and smaller,” Nollenberger said. “For patients, I think it’s more freedom. It’s about the reliability of the devices that they’re in contact with.”

Trelleborg invented a new molding process for precision medical device parts. Image from Trelleborg

3M:

A medical adhesive that allows a variety of backings 3M added an extended-wear medical transfer adhesive that allows medtech design engineers to use a variety of backings. Company studies show that medical transfer adhesive 4075 offers up to 14day wear time, depending on the backing material used. It meets requirements for use on intact skin and has been tested to ISO:10993-5 and ISO:10993-10, which assess in-vitro cytotoxicity and a product’s potential to produce irritation and skin sensitization, respectively, according to 3M. The new adhesive is also compatible with ethylene oxide sterilization. “It’s unique that it allows the design engineers to use the backing of their choice to meet their specific design needs,” 3M Medical Solutions division VP Marcello Napol said of the new adhesive. “We encourage people to connect with

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us and work with us specifically in what they’re trying to accomplish and what their desired outcomes are.” Medical transfer adhesive 4075 is the latest in a series of specialty medical adhesives in 3M’s extended-wear portfolio. The company introduced medical tapes 4077 last year and 4076 in 2017 specifically for use with wearable devices such as continuous glucose monitors. “With this third arm of the family, we were trying to anticipate the unknowns,” Napol said. “We don’t understand the enduse cases because literally, we can’t be at the table with everyone. … We could come up with multiple backings to fit different applications but this allows the end partner to choose their backing. This is a way for us to capture a broader audience with a more flexible design.” www.designworldonline.com

3M's new 4075 medical tape can be used with different backings. Image from 3M

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NIKOMED USA:

Recyclable wires for patient monitors and ECG electrodes Nikomed USA launched a non-metal, disposable and universal lead wire system for patient-monitoring equipment and ECG electrodes. Many health providers find metal lead disposal challenging because they can’t recycle the material, according to Nikomed USA (Hatboro, Pa.). The company designed BioWire to be recyclable; it’s made of polyethylene terephthalate (PET) and silver ink. PET is light, flexible and strong, and silver ink is conductive and bonds well with PET, Nikomed USA president Steve Epstein told MDO. The company adds chloride to the silver to match the AAMI standard for ECG electrodes and lead wires because chloride prevents polarization of contacts after defibrillation. BioWire can easily adapt to most monitoring equipment and all ECG electrodes. Its ribbon-like design makes it possible to write on or apply a label to the wiring itself, according to the company. Healthcare customers’ desire for disposable wires has led to an issue with waste, Epstein added. “There’s miles and miles of metal wire being discarded every day,” he said. “I said, ‘There’s got to be a better solution.’” BioWire may also reduce the likelihood that disposable wires are reused from patient to patient, preventing cross-contamination and improving the bottom line for customers, Epstein told us. Nikomed sells exclusively through medical supply distributors.

Nikomed USA developed recyclable wires and reusable connectors for electrodes. Image from Nikomed USA

FREUDENBERG MEDICAL:

Freudenberg Medical multi-lumen silicone tubes. Image from Freudenberg Medical

Taking tube extrusion monitoring to a new level Freudenberg Medical developed technology that the company says can help ensure uniform geometries of its silicone tubing. The Vigeo platform uses tomographic sensors to deliver a cross-section view of the product, including the tube’s inner geometry, which was not possible using traditional laser sensor-based inline measurement systems. The industry standard for laser sensor inline systems requires inline measurement of the outer geometry, but this does not provide any information on the inner geometry of the tube (ID or multi-lumen). Quality checks for the inner geometries have traditionally been made in an off-line process by manual cuts at discrete cross sections of a tube.

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Vigeo’s sensors obtain measurement values that are displayed, documented and calculated by an algorithm, stitching together the pictures each sensor provide into one cross-section view. That view provides an accurate and continuous read of inner and outer geometries and tubing wall thickness during a complete production run, according to Freudenberg. Critical medical devices such as pacemaker leads and silicone tubing for pumps may benefit the most from this level of control and documentation of every dimension throughout the entire production run and not only on a sample basis, the company said. Having full documentation of measurement data may reduce

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customers’ incoming inspection routines, as well as their validation efforts, speeding time to market, Freudenberg said. The company has begun using Vigeo in its Kaiserslautern, Germany, facility, with plans to introduce it into one of its U.S. plants. “The company started using it two to three months ago, said Kai Opdenwinkel, general manager of the Kaiserslautern plant, told MDO. “We’re quite satisfied with what we see right now.” There’s no reliable data yet on how much waste the technology allows Freudenberg to save. “For now I think the bigger benefit is to tell the customer, ‘Ok, we monitor every single inch we extrude of your tube,’” Opdenwinkel said.

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COVESTRO:

A raw material for wound dressings and wearables Covestro recently featured its Baymedix FD103 waterbased polyurethane dispersion material at MD&M East as a raw material for wound dressings and long-term wearable medical devices such as continuous glucose monitors and heart monitors. Baymedix FD103 may be used to make roll stock for medical foams, adhesives and films. Covestro suspends polyurethane particles in water until the mixture reaches a consistent form, according to Bentley Mah, senior technical sales specialist. “Part of our proprietary technology is keeping it in that suspension so it doesn’t settle out,” Mah said. “That helps with the manufacturability.” Foam made from Baymedix FD103 is thermoformable, allowing for design flexibility for wearables and dressings. Medtech manufacturers may also embed sensors or other electronics within the foam, which provides temperature and damage insulation. The waterborne suspension also allows thinness, flexibility and moisture management in the finished product. “They are very, very breathable materials,” Mah said. “For wound care, having that fine balance of having a moist wound bed and having that breathability, it allows it to heal. This is well researched. With our materials, you can customize the breathability.” Medical foams made from Baymedix FD103 pull exudate away from wounds and absorb the fluids to aid healing, Mah added. Manufacturers can easily add antimicrobials and other healing agents, he said. Covestro makes raw materials for several industries and adjusted its processes to meet tough medtech industry standards in formulating Baymedix FD103. “We understood the design and quality and changemanagement systems for the medical design industry,” Mah said. “It was kind of adapting off our own internal quality systems, at least for the medical side, to fit what the medical OEMs or the medical device manufacturers needed so they can simply plug in and say that this product can be used for medical applications.”

Medtech manufacturers may embed sensors or other electronics within foam made from Covestro's Baymedix FD103. Image from Covestro

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TELEFLEX MEDICAL OEM:

A braiding process that enables complex suture designs

Teleflex Medical OEM developed an innovative manufacturing process for braid sutures that met customer expectations for strength and the ability to customize multiple configurations. Image from Teleflex Medical OEM

Integer Holdings developed and qualified programmable and automated dry filter electrostatic spray booths. Image courtesy of Integer Holdings

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Teleflex Medical OEM recently announced an advanced braiding technology that can divide a suture into multiple end branches or integrate several “loops” within the strand. The process can produce variations of complex, divided segments at the end of a suture, or between singular round or flat-tape segments. It eliminates the need for expensive and time-intensive manual sewing, according to the Gurnee, Ill.–based company. It also allows for a range of configurations that the company expects will to be used in orthopedic applications that currently require two sutures for fixation. Teleflex Medical OEM can use the furcated braiding process to customize its high-strength Force Fiber OrthoTape braid, a flat tape, as well as its Force Fiber Fusion suture, which transitions from round suture to a flat center and back to round suture in one strand. “There is potential to use the furcated product with anchor devices where the singular segment would be used

INTEGER HOLDINGS:

PTFE spray booths for discrete components Contract manufacturing giant Integer Holdings can now do high-volume, discrete component polytetrafluoroethylene (PTFE) spray coating, thanks to new spray booths it has developed. The Plano, Texas–based company developed and qualified the programmable and automated dry filter electrostatic spray booths with reciprocating spray heads. The spray booths can accommodate discrete medical components, subassemblies and devices.

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with the anchor and the split, or with a fixation button where the suture could be threaded through the furcation segment to create a loop,” said Jim McCormack, Teleflex Medical OEM’s global marketing manager, in an email to MDO. The company’s challenge was to develop an innovative manufacturing process for braids that met customer expectations for strength and the ability to customize multiple configurations. The bi/tri/quad furcated braids give OEM customers the ability to customize advanced configurations for applications in which a single suture segment might not have worked in the past. “Furcated-braid suture has potential to be used for orthopedic applications, specifically knee, foot and ankle, shoulder, and elbow,” McCormack said. “An additional potential application could be as a component in manufacturing devices, such as artificial heart valves. The loop within the braid makes it convenient to create a knotless loop.”

The spray booths have computer controls for critical processes, including spray pattern, spray duration and curing time. Each product is loaded into a fixture and attached to a speed-controlled conveyor system. The highly repeatable process yields optimal adhesion and durability, and allows for flexible coating processes, depending on the application, according to Integer. Integer’s customers were seeking a reliable, high quality, vertically integrated PTFE spray coating supplier that could

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produce efficiently and in high volumes, according to Andrew Senn, Integer’s VP of marketing. Devices that could benefit from this capability include guidewires, core wires, coated hypotubes, stylets, pull wires, delivery systems and catheter mandrels. The coating technology enables consistent, high-quality, highperformance, and efficient products and components, according to Integer. “High-quality devices contribute to patient safety, and consistent coatings lead to predictable, reliable device performance for physicians and patients,” Senn said.

HERRMANN ULTRASONICS: Improving ultrasonic assembly Herrmann Ultrasonics’ HiQ Dialog medical device manufacturing system is designed to increase manufacturing efficiency through optimized cycle time, changeover and downtime — three factors that affect manufacturing efficiency. HiQ Dialog has programmable stroke selection and a “SoftTouch” mode that reduces damage to sensitive joints. Its quick-change system and hinged tool-change cover can quickly mount an ultrasonic stack in less than a minute, according to the company. The amount of force applied to a part during the weld cycle is a critical process parameter, according to Michael Lindsay,

Herrmann Ultrasonics’ HiQ Dialog medtech manufacturing system Image courtesy of Herrmann Ultrasonics

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parameters to a level that’s closer to the middle of the potential process window. This reduces the risk of a bad weld, creates a higher yield and may improve efficiency by reducing machine cycle time. The HiQ Dialog also has position control, allowing a manufacturer to set an intermediate start position so the cylinder does not have to travel all the way back to the fully retracted home position after each weld. “Combine that feature with the ability to maximize the ‘free air’ travel speed to and from the part before and after the weld, and now you have the capability to significantly reduce your overall machine cycle time,” Lindsay

a Herrmann Ultrasonics applications engineer. The ability to vary the forces throughout the cycle allows for more precise control of the collapse rate while compressing both halves of the welded assembly together. An optimized rate of collapse can affect the final outcome of the welded assembly, especially in weld strength and appearance, Lindsay told MDO. “With traditional pneumatically driven systems, there are limitations to varying the forces throughout the stroke of an air cylinder,” he said. “Our goal was to engineer a solution that has the capability of force-profiling throughout the weld, allowing you to refine the process for an optimized result.” The HiQ Dialog’s force profiling capability allows a medtech manufacturer to refine its weld

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Engineering September 2019

A supplement of Design World

Fastening technology covering nuts, bolts, rivets, screws, u-clips, eye bolts, washers and more.

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EDITORIAL •• •• •

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The birth of a new brand In my almost-nine years of being here at WTWH Media, I’ve had the pleasure to be involved in numerous new publication launches. When the company began in 2006, Design World was the sole print publication and its website was the only one under the corporate umbrella.

But as the years ticked by, our corporate management realized that certain

markets were hot — readers were constantly drawn to the editorial, and advertisers kept jumping on board whenever that subject matter was covered. Eventually, Design World birthed other publications: Windpower Engineering & Development, and then Solar Power World, followed by Fluid Power World. Later came EE World and Medical Design & Outsourcing. At the same time, we were growing our websites — both vertically and horizontally oriented ones — at an even faster clip. We’ve come to joke in the office that Design World is the mothership, the initiator of so many new brands and offshoots.

So, it’s exciting for me to be able to announce our latest new publication, Fastener

Engineering, and its website, fastenerengineering.com. Fastening technology covers a wide swath of items: nuts, bolts, rivets, screws, u-clips, eye bolts, rod ends, washers, and springs. Not to mention adhesives, welding, tools, and more.

As you might guess from the above history, fastening technology isn’t something

new to our coverage or our editors. We’ve been writing about these very necessary (and ubiquitous) components from the start. But we now have a new way to bring you even more coverage of this industry, from technical descriptions of the products’ function to the latest industry news, and from what’s happening with distribution to personnel changes and even best practices on how to run your business.

I hope you enjoy this first edition of Fastener Engineering, and please drop me an

email at pheney@wtwhmedia.com and let me know what you’d like to see in future issues. Hope to see you in Las Vegas.

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

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•• •• •

guest column

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Why understanding fasteners is more important today than ever John Wachman • Managing Director • Fastener Training Institute Unfortunately, most of the details of how components are assembled is an afterthought. This can be a mistake and add to the complexity and cost of finished products. Design for manufacture is not a new concept, but reliable current information about fasteners is not only important but required. That’s why we are pleased to be invited to join in the inaugural edition of Fastener Engineering. The objective of FTI is to manufacturing team downstream Fasteners are produced and used elevate the level of technical — so they should have appropriate worldwide. Fastener manufacturing understanding and expertise input in selection up front. Our is a mature industry with many of individuals in the fastener industry is also very innovative primary producers supplying high industry by providing a variety of and without current knowledge volume parts with single digit PPM training programs presented by or training, a much better fastener defective. The bottom line is we are recognized industry experts. FTI solution may be missed. very good at what we do. The vast provides beginning and advanced Fasteners can also be very majority of fastener related problems training on fastener products, complicated components. Exotic arise from improper selection, standards and specifications. We materials, complex shapes, specification, misuse or installation. offer live classes throughout the secondary processes with very new These problems are real, can have country. Some are full-day classes eco-friendly coating and plating. significant consequences and but can also be weeklong classes Their installation regimes are evolving subsequently have to be addressed with visits to fastener producers. to ensure the design engineer gets by both the suppliers and end users. FTI offers live monthly webinars the desired results. The end users Regardless of the cause, a fastener or and an extensive On-Line often require real time verification joint failure can cost lives at worst or Training Library. Please visit www. of installation parameters. Newer simply be a costly inconvenience. FastenerTrainingInstitute.org for composite and high-strength, thin Fasteners can be simple complete class information. sheet materials offer challenges to components. Their complexity is The Fastener Training engineers responsible for assemblies. due to the vast options the design Institute’s core purpose is to Most university engineering engineer has when choosing them. enhance fastener use, reliability curricula do not offer much Consider a basic externally threaded and safety by providing fastener fastener, the bread and butter of most education about fastening and product and technical training at joining. Engineering grads are left assemblies. How many are needed all levels. Through this, FTI can to make their way mostly through to keep the components together for achieve its goal of strengthening on-the-job training. The Fastener the expected product life? Will the the industry and its personnel in Training Institute (FTI), a registered assembly need to be serviced and all segments. 501(c)(6) non-profit, was launched how often? Among the many options by experienced fastener industry are size (diameter and length), head professionals to provide fastener style, drive, material, coatings, plus product training and continuing any quality requirements. These education. design decisions will affect the

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•• •• •

•• ••

FAQ - Pin joints

Pin joints, also known as a revolute joints, allow only rotational motion about a single axis Dr. Jody Muelaner • Contributing Editor

A pin joint is a connection between two objects that allows only relative rotation about a single axis. All translations as well as rotations about any other axis are prevented — the joint therefore has one degree of freedom (1-DOF). A pin joint is formally called a revolute joint in kinematics and may also be referred to as a pivot point when analyzing motion in two dimensions, or as a hinge. A pin joint is a type of kinematic pair, an idealized description of the motion constraints within a machine, which allows motion analysis. There are many ways that pin joints are constructed, for example hinges and roller bearings. Three surface contacts are typically involved in constraining motion to create a pin joint. A cylindrical surface contact constrains four degrees of freedom (translation in the two radial directions and rotations not about the allowed axis). Two planar surface contacts are typically required to constrain the single degree of freedom of axial translation, with each surface contact resisting surface penetration but not separation. Kinematic pairs are classified as either a higher pair or a lower pair. Higher pairs involve point or line contact, for example a ball or a cylinder rolling over a surface. Lower pairs are normally considered as surface contact. Machines may have many higher pairs such as all the ball bearing contacts within roller bearings. However, analyzing a complete machine at the level of all of these kinematic pairs would be extremely difficult. Therefore, these higher pairs are normally only considered when designing and analyzing the individual machine elements such as bearings and gears. When considering the machine as a whole, these elements are modelled as lower pairs, for example a roller bearing would be treated as a pin joint. The types of lower pair are: • Prismatic joint (1-DOF): A joint that only allows linear motion along a single axis • Revolute joint (1-DOF): A joint that only allows rotational motion about a single axis (a pin joint)

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• Cylindrical joint (2-DOF): A combination of a prismatic and a revolute joint. This joint allows only linear motion along an axis and rotation about that axis. • Spherical joint (3-DOF): A joint that ensures two bodies remain connected at a common point, preventing any linear translation, but rotation about any axis is allowed. A ball and socket joint is a physical realization of this. • Planar joint (3-DOF): A joint that allows only translation over a plane and rotation about an axis normal to this plane. This type of joint is produced by a stable object resting on a flat surface. • Screw pair (1-DOF): A joint that constrains motion to a helical path, such as a nut on a bolt. Although both translation and rotation occur, they are coupled so that there is only on degree of freedom — position along the helix. Both prismatic and revolute joints may be considered special cases of the screw pair. The prismatic joint has a helix angle of 90° and the revolute joint has a helix angle of zero. September 2019

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Featuring a combination of thermal conductivity and electrical insulation properties, Master Bond Supreme 3CCM-85 is a new single component epoxy initially designed for glob top and chip coating applications.

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F a s t e n i n g

J o i n i n g

Working with

Die Attach Adhesives Die a tta c h m a ter i a ls ser ve a c r i ti ca l ro le i n sem i co n duc to r a s se m b ly and p ro d u c t p er fo r m a n ce. Ep oxy d i e a tta c h a d h es i ve s o f fe r a b roa d

array o f c h a ra c ter i s ti c s th a t s u p p o r t effi c i en t m a n u fa c t uri n g a s we ll as lo n g- ter m p ro d u c t reli a b i li ty.

When attaching layers and substrates in semiconductor assembly, a tight bond between the die and the substrates is critical to reduce the effects of mechanical and thermal stress. Among available die attach materials, epoxy adhesives not only meet these critical needs, they also offer a range of characteristics for even the most specialized application. As with many industries, a trend in the semiconductor industry is packing more function into smaller die. These tiny die are then assembled into integrated circuit (IC) packages, die-on-board systems, or complex stacked die-on-die assemblies. As the size of these die shrink, efficient assembly becomes more of a challenge. In the field, these packages, systems and assemblies must resist mechanical and thermal conditions that can degrade performance and lead to product failure. Adhesives have become the preferred solution to meet these demands. Adhesives support broadly diverse requirements for assembly, manufacturing, and product life. Along with their ability to tightly bind die to different materials, adhesives handle the needs for electrical and thermal conductivity as well as other physical characteristics including viscosity and thermal stability. Epoxies enhance product reliability because they offer high-strength bonds and reduce the effects of thermal cycling and mechanical stress. These polymeric materials react with one-part heat or two-part heat curing epoxies, forming a mechanically robust and thermally stable bond. Epoxies are among the strongest and most durable of adhesives, offering mechanical strength, dimensional stability and excellent adhesion. Specialized epoxy adhesives address the unique demands of individual applications for thermal and electrical conductivity, temperature range, outgassing, and other requirements.

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Tips 1 Proper assembly with epoxies Successful semiconductor assembly depends on the nature of the die attach adhesive. The adhesive must form a tight, uniform bond between die and substrate. After semiconductor wafer fabrication, the individual die are separated from the wafer. Then, highspeed die bonders lift each die and place it on a layer of die attach material spread onto the substrate by material dispensers. These dispensers precisely control the volume of material placed on the substrate, typically using vision to ensure placement. As the die bonder places the die on the adhesive, it adds a slight and carefully controlled amount of pressure to mate the die to the adhesive-treated substrate. The right amount of adhesive is critical. Too much, and the resulting fillet can flow up the sides of the die and contaminate the circuits etched on the die. Too little and the die could lift from the substrate or crack. Some

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Die

Fastening + Joining manufacturing processes heat the substrate during adhesive placement to partial cure the die attach material. Lastly, the die/substrate assemblies are often subjected to a final cure using heat or UV treatment. For heat-sensitive circuits, UV-cured epoxies offer rapid volatile-free curing to reduce the chance of substrate warping or shrinkage. The UV curing systems require access to UV light without shadows for curing. An adhesive’s cohesive strength is only one of many necessary characteristics. Other characteristics include appropriate viscosity (resistance to flow) and thixotropic index (ability to hold its shape) to ensure proper formation of bonds. Adhesives must flow smoothly over irregularities in die and substrate surfaces. Despite the precision of the semiconductor fabrication process, die can nonetheless exhibit micrometer-size peaks and valleys. Incomplete filling of valleys or flow around peaks can lead to voids that weaken the bond, resulting in delamination and eventual separation of the die from the substrate. 2 How epoxies enhance product life The adhesive’s ability to make a uniform but thin bond becomes important throughout the product life. Minimum thickness means fewer chances of air voids that can lead to eventual bond failure. Minimum thickness also ensures

Master Bond EP3HTSDA-1 is a single part, no mix epoxy adhesive designed primarily for die attach applications. It exhibits a die shear strength of 20-22 kg-f and has a high thermal conductivity of over 4045 BTU•in/ft2•hr•°F [5.7-6.5 W/(m•K)].

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Bond line Die Pad Dispensers precisely control the volume of material placed on a substrate. As the die bonder places the die on the adhesive, it adds a slight and carefully controlled amount of pressure to mate the die to the adhesive-treated substrate.

maximum heat transfer from the die. Die attach material often serves as a path for die heat dissipation. The efficiency of that heat-transfer path depends on the thickness of the die attach layer, the thermal conductivity of the die attach material, and the thermal resistance between the die attach material and the two surfaces it bonds. The thermal characteristics of the die attach material directly impact long-term reliability. 3 Meeting unique requirements Die attach adhesives offer advantages for meeting specialized requirements found in every application. Different epoxy die attach adhesives can provide electrically insulated bonds or electrically conductive bonds such as those required for exposed pad devices, for example. For applications targeted for outer space, high vacuum or optical applications, manufacturers can find epoxies with low outgassing characteristics. Most applications must deal with more mundane environmental factors such as high temperature and humidity, which can erode IC reliability. Specialized epoxies for humid environments resist moisture absorption that can lead to fractures in the bond or weakening at the bonded interfaces and eventual delamination and failure. Temperature stability is important for any die attach application but particularly so for devices targeted for high temperature applications. Adhesives are available across a wide temperature range, supporting requirements from cyrogenic applications to those operating at hundreds of degrees. During assembly, the ability to minimize curing temperature can be vital

September 2019 www.fastenerengineering.com

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fillet

for achieving acceptable manufacturing yield. Similarly, the ability to meet specific requirements for bond strength, thermal conductivity, and avoiding CTE mismatches can spell the difference between early failure and extended lifetime of semiconductor products. 5 Diverse solutions Today’s two-part epoxies go beyond traditional epoxy systems with resin and hardener combinations for specific handling times as well as different curing times and temperatures. One-part systems such as Master Bond Supreme 3HTND-2DA further simplify the assembly process. Delivered as a nonpremixed and frozen system, these onepart systems help eliminate potential problems such as air entrapment during preparation or concerns about limited potting time. Formulated specifically for die attach applications, MasterBond Supreme 3HTND-2DA is delivered in syringes to simplify handling and cures in only 5-10 minutes at 150°C. Epoxies offer another advantage,they can be combined with specialized filler materials to meet specific requirements. For example, epoxy vendors can add glass microbeads to enhance uniformity of bond thickness; silver fillers to dramatically enhance electrical conductivity; special thermally conductive fillers to enhance thermal conductivity; and other filler materials to optimize individual characteristics. MasterBond | www.masterbond.com Material for this article came from a MasterBond white paper: “Die Attach Adhesives Impact Product Quality Well Beyond Manufacturing” DESIGN WORLD

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U l t r a s o n i c

W e l d i n g

How ultrasonic

welding

can meet packaging sustainability goals

Leading global companies have set ambitious sustainability goals to reduce waste by making plastic packaging more reusable, recyclable, or biodegradable. As they implement the design, material, technology, and process changes needed to deliver sustainable plastic packaging, their successes will raise the bar for everyone.

Bill Reed â&#x20AC;˘ Business Development Manager, Packaging â&#x20AC;˘ Emerson Automation

Todayâ&#x20AC;&#x2122;s headlines are filled with the news of the latest ban, regulation, or law aimed at controlling or eliminating plastic waste. The challenge is huge: Plastic packages protect and deliver an array of products. The variations of plastic packaging are almost endless. Virtually all of these package designs, and the materials and processes used to make them, must evolve and become more sustainable. But how will packaging meet sustainability goals such as improving reusability, reducing overall material content, improving compostability, expanding recycling, incorporating the use of greater post-consumer recycled material content, and reducing carbon footprint? What happens when traditional packaging methods, specifically the sealing/ fastening of plastic packaging, converge with the challenges associated with sustainability? And, what will be the implications for designers and builders of the next generation of packaging and packaging equipment?

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Branson ultrasonic components for Vertical Form Fill and Sealing (VFFS) systems by Emerson can seal directly through package contents, eliminating contaminants, reducing waste and weld failures for a wide variety of product packages.

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Photo 3—

Company Profile

Leading global companies

have set ambitious sustain-

ability goals to reduce waste by making plastic packaging

more reusable, recyclable, or biodegradable.

We don’t know all of the answers, though a few answers are certain: • Major consumer goods companies won’t compromise on the traditional mission of their consumer packaging. Next-generation packaging will have to perform, combining all of the safety, attractiveness, and convenience of current generation packages. And now, they’ll have to be reusable, recyclable, biodegradable, or otherwise sustainable, too. • Plastic packaging materials will be changing. We already see tremendous demand for material and sealing solutions involving biodegradable polymers, especially in single-use packages. The percentage of postconsumer material used in new packages will continue to grow, as will the pressure to use less, lighter, or thinner materials. • Package sealing technology will have to evolve, not only to provide the greater degree of control needed to repeatably seal new materials, such as biopolymers, but the data collection and analysis capabilities to meet increasing demand for product quality assurance, traceability, regulatory, or usage data. • Consumer-packaged goods manufacturers who are serious about

Figure 1: Comparing package sealing process controls Heated tool sealing controls • Temperature setting • Pressure setting • Time setting

Ultrasonic welding digital control • Operating Frequency • Tool Amplitude • Weld Modes: • Time • Energy • Collapse • Velocity • Trigger Force • Seal Force • Hold Time • Programmable reject limits • Data acquisition for QA, traceability, and regulatory requirements

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sustainability are also concerned about reducing the carbon footprint of their operations. So, they will be looking for package manufacturing and sealing technology that reduces material and energy consumption. As an alternative to traditional ‘heated tool’ sealing, ultrasonic welding offers numerous sustainability advantages: 1 Compatibility with new bio-based materials. Central to any sustainability program is the commitment to develop and expand the use of biodegradable, single-use packages that rely on biobased materials like polylactic acid (PLA). But adapting packaging designs and traditional thermal sealing equipment to bond these materials with commercialgrade quality and reliability poses challenges, since biopolymers contain significantly less polymer content. Compared to the simple time, temperature, and force settings of a heated tooling sealer, the precise, programmable controls of ultrasonic welding technology provide the user far more capability to manage the narrower processing ‘windows’ of biobased resins (see Figure 1). Ultrasonic sealing methods include weld-byenergy; peak power; and weld-by-time. Programmable amplitude provides finetune control of the heating potential from the resonating tooling. Because the process is digitally controlled, ultrasonic welding also offers a range of quality assurance, validation, and product traceability data for every weld. Weld cycle data validates energy set point achieved, time required to reach the set point, and total power expended. Users may set high/low limits on selected parameters, triggering alarms that flag weld cycles and parts that fall outside of process limits. These alarm signals are latchable, enabling automated bad-part processing and automatic data logging.

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2 Eliminates seal failures due to contamination. Certain products can leave residue on the sealing surfaces that can become encapsulated within conventional, heated tooling seal surfaces, resulting in contamination, leaks, or failures. These include many food and beverage products, leafy produce and powders, as well as feeds, viscous liquids, and oils and greases. The high-frequency vibratory motion (typically 20 or 30 kHz) of ultrasonic welding not only heats the sealing surfaces, but first vibrates potential contaminants out of the seal area. For example, with heated tooling seals particles of the product can get caught within the seal surfaces, potentially compromising the seal. With ultrasonics, the vibratory action cuts through any large pieces of a product (e.g., produce leaves) and also disperses smaller fragments and moisture out of the area of the seal. The result is less waste through rejects, improved seal quality, repeatability, and reliability. 3 Reduces packaging material consumption. A snack food packager producing small snack bags (6-inch size) consumes about 1.0 inches of total package length to produce two conventional heat seals (0.500 inch each on top and bottom) per bag. Two comparable ultrasonic welds require just 0.25 inches of total package length (0.125 in. each on top and bottom) resulting in a savings of 0.75 inches (0.375 in. x 2) in material for a bag with the same net product volume. 4 Eliminates adhesives and consumables. Ultrasonic welding requires no adhesives or consumables to produce high-quality, consistent package seals. There is no contamination within the seal surface. The plastic-to-plastic bond it creates not only simplifies package design, but also material recycling and/or compostability.

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The Bosch VIS flavor protection valve allows degassing of aromatic coffee packages while preventing the influx of damaging oxygen. Ultrasonic welding bonds this vital component to film that is formed into a packaging using Vertical Form Fill and Sealing (VFFS) technology.

Package 1: Heated tooling seals 6.0” 0.50” (1.00”) 5.0” 24 million -----

Overall package height Width per seal (x 2) Internal package height Production rate Material savings/pkg. Net material savings

Heat seal 100

Seal rate/min Consumption W/hr.

4 x 500 W cartridge heaters = 2,000 W/hr.

Total consumption (W x 16 hr.)

32,000 W/day

Savings 5 Reduces energy consumption and cost. Because conduction heat-sealing systems must be continually powered and maintained at a specific operating temperature, they consume relatively high amounts of energy compared to ultrasonic welding systems of identical production capacity. Compare the energy requirements needed to produce 100 welds/min over two eight-hour shifts per day: A typical conduction sealing process would require four, 500watt cartridge heaters (2,000 watts/hour or 32,000 watts/day) to continuously maintain seal-tooling temperatures. An ultrasonic welder of the same capacity

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Package 2: Ultrasonic seals 5.25” 0.125” (0.25”) 5.0” 24 million 0.75 in. 24 million x 0.75 in. / 36 ~ 500,000 yards/year

Ultrasonic seal 100 1,500 W power supply = 1,500 W/ hr max. with continuous operation; = 500 W/hr max in non-continuous operation. 24,000 W/day – continuous operation 500 W/day – non continuous operation 25 to 75% depending on the application

would be equipped with a power supply rated at 1,500 watts, but would consume power only in short bursts (e.g., ~200 ms/ weld) totaling about 20 seconds/min of power consumption. Meeting the ambitious sustainability goals announced by leading global companies to reduce waste by making plastic packaging more reusable, recyclable, or biodegradable is going to take an industry-wide, worldwide effort. And, as these leaders begin to implement the design, material, and technology and process changes needed to deliver truly sustainable plastic packaging, their successes will raise the bar for everyone.

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C o m p a n y

P r o f i l e

Looking out for the industry — and toward the new generation

Paul J. Heney • VP,, Editorial Director

Chat with Frank Devito of Solution Industries for even a few minutes, and you’re a believer in the fastener industry. His energy and enthusiasm — not to mention his knowledge — are sure to draw you in.

Middleburg Heights, Ohio-based Solutions Industries has been around for 15 years under its current name. Devito explained that the founder was a machinist; he sold his car for $586 to start the company in his garage. Solutions Industries was then known for doing hard-to-find parts … the owner would gladly machine five or six pieces for a customer. Then they started electroplating sockets — which was taboo at the time, Devito said. Today, the services that the company provides is procuring the plain part or the base part material. It is in more of an importer role than domestically purchasing or procuring parts, but they have the capability to do both in the U.S. or overseas. “Then we work with all the applicators, whether they’re electroplate or mechanical plate or dip spin,” Devito said. “We’ll put a coating on, and it can be as simple as a commercial zinc to an OEM spec by John Deere or GM or Ford or Bobcat or Harley Davidson.” Solutions Industries only sells through distribution, not direct to the end user, he noted. “Then we’d apply some type of thread lock as well, or they might need a pellet or just a nylon patch or adhesive. If that were the case, we would private label it,” Devito said. “The industry often says, ‘Here’s our carton, here’s our product. You’ve got to buy this many.’ We don’t do that. Our fit is whatever the customer wants, we do. If you want

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a million pieces packed one per with a bar code on it and your insignia, that’s what we do.” Devito said that is where they have found their success, by creating a niche for themselves. “A lot of these larger global companies have found it more cost effective for us to do this because there’s a lot of handling they don’t specialize in. The drive is for lean manufacturing. Everything’s lean. Well, we’re

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the opposite model of that, and we’re actually succeeding in this, so we’ve drawn some attention that way,” he said. Solutions Industries focuses more on the non-standard side of things. Devito said they can design a CAD drawing for a customer; a lot of the labs they use to test products are certified as 17025, so they can achieve all of the accreditations that would be

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needed. If there are certain PPAPs, or if there are certain requirements that a customer wants specifically for their PPAP, the company will do those things. “I always tell people, ‘I’m going to fit in your box. I’m not trying to fit you in my box, so you tell us how it needs to be.’ We look at every customer individually — and every item specifically for that particular customer,” he said.

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Las V Company Profile The future “We’ll continue to evolve, and we look to grow,” he explained. “We’re creating websites to be a little bit more friendly for the younger generation. Everybody says millennials in a bad way, but this new generation is not a bad thing. They’re already the largest living population and they’re going to change the industry — all industries — because they do things a little bit differently. We still need to cater to that. Then we have the old industry. It spans two centuries, so we have to gap the older generation.” Devito is concerned about manufacturing losing its work force as people are retiring. Workers aged 45-54 represent the largest manufacturing age group, in the range of 3 million people. “From 20-24, it’s like 1.15 million people, so how do you gap that?” he asked. “That’s one-third the number. Where is the manufacturer going to go at that point? It’s going to go overseas.” The other issue is that some educators and parents think manufacturing is dirty and they push kids away from it as a career path. But Devito sees positivity in the end. “Somebody has to do these trades. As the cycle goes, as those jobs become rarer and rarer, there will be more money coming to those jobs, so I hope it will start to cycle back,” he said. “In America, 80% of the GDP is service-oriented. As of 2017, only 12% was manufacturing. I know the current administration’s trying to change that, but we’re not going to be creating millions and millions of new manufacturing jobs. In my opinion, that ship has sailed. That’s just the bottom line.” So how is the industry going to adjust? Instead of pushing away the younger generation, Devito thinks we need to embrace them. With youth comes more energy, he said. And future technology will change everything, he believes. “They have better tools and technology’s there, the digital presence is always there. And 5G is coming. They’re saying in two or three years, that’s going to change the world,” Devito said. “Who’s to go against technology? It continues to prove itself.”

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I F E

C o n f e r e n c e

International Fastener Expo returns to Las Vegas this September

IFE 2019 will run September 17-19 at Mandalay Bay, Las Vegas, Bayside D-E. Early preview Source Global & Machinery from 8:00–10:00 AM Wed. The show officially opens at 10:00 AM–4:00 PM Wednesday and Thursday.

Edited by: Mike Santora • Associate Editor

The International Fastener Expo is the largest B2B of industrial fasteners and tooling & machinery in North America. Since its inception in 1981, the event continues to connect the manufacturers and master distributors of fasteners, precision formed parts, fastener machinery & tooling, and other related products and services with distributors and sales agents in the distribution chain. Held annually in Las Vegas, the event consists of an all-day conference program presented by endorsing fastener associations and a show floor with more than 850 exhibiting companies from around the world.

Attendees

Each year, more than 5,000 attendees from more than 30 countries travel to North America’s trade show hub, Las Vegas, Nevada to network and do businesses with suppliers, showcasing every type of fastener for the industrial, construction, aerospace, and automotive industry including electronic fasteners, specialty tooling products, special application fasteners, tooling and machinery, hand tools, power tools, service solutions, and more. From industrial to construction, electronic to automotive and aerospace, this is a trade show where all

types of distributors come to network and see customers, build new relationships, and find new products. The IFE show has been endorsed by more than 30 publications and long-standing fastener associations. The show’s comprehensive conference program helps grow and strengthen attendees’ businesses and provides opportunities to build new relationships, network with peers, industry leaders, and business partners. Also, attendees can meet with current suppliers, prospective suppliers, and can find new products and learn the latest technologies being used in the fastener industry.

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SourceGlobal at Fastener Expo Looking to go overseas and sources directly from factories? Cut traveling cost by sourcing first at SourceGlobal at the International Fastener Expo. SourceGlobal is the destination for importers, distributors, and sourcing professionals to connect and source directly with manufacturers from around the world in one location. As part of the largest fastener, mill supply, tooling and machinery trade show — The International Fastener Expo, SourceGlobal is a sourcing area where U.S. distributors, importers, and sourcing professionals can meet face-to-face with hundreds of international factories without leaving the states. There is no better place to source for new suppliers and products and make the best buying decisions for your business.

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Product categories include: • Fasteners • Production Machinery, Tool & Die, and Supplies • Inspection/Testing/Packaging Equipment • Specialty Fasteners and Tooling • Plant Maintenance & Safety Supplies • Fastener Technology and Services

Exhibitors According to the IFE, 89% of exhibitors say the event is the “must exhibit” event. This event is know as the #1 show in North America where customers and prospects come to see the supplier. At the International Fastener Expo, suppliers will find more than 2,500 qualified eager buyers looking for new sources and solutions to myriad manufacturing and fastening applications all in one place. All within three days of the expo.

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IFE Conference This event is an obvious opportunity for manufacturers of industrial products, fasteners, and fastener related products. But manufacturers/suppliers of mill supply products including, plant maintenance, safety, installation tools, and services will also find high value in exhibiting. Additionally, exhibitors in software, logistics, inspection testing, and packaging machinery are represented each year. Exhibitors by the numbers • 82% of IFE attendees have purchasing authority. • 72% said IFE is the most important fastener event they attend. • 89% consider IFE a must-attend event. • 63% of attendees are buyers, sourcing procurement, owners, and executive management.

Conference Schedule Controllers, Accounting, Credit & Accounts Receivable Managers Meeting • Room: South Pacific Ballroom A • Session Number: FC1 • Tuesday, September 17, 2019: 8:00 AM - 5:00 PM Fastener company financial managers are encouraged to attend. This education session discusses maximizing cash flow, the financial implications of sales agreements, providing effective customer financial services, proper determination of credit limits, and prudent risk management. Discuss effective open account credit evaluation techniques, when to seek third party help in recovering receivables, bad debts, and what alternatives are available when customers file bankruptcy, dissolve or go out of business. These issues continue to challenge companies as they seek to expand market share. Round table discussions on these and a variety of other important industry and critical business topics leads to the exchange of information, ideas, industry best practices, risk analysis procedures,

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timely handling of bankruptcy law procedures, fighting preference demands, and comparing payment habits of those purchasing from fastener industry suppliers. Avoiding unnecessary risk, effectively managing cash, and knowing what your options are in dire situations, is critical to your company’s health, stability, and profitability. Fastener Platings & Coatings – including new innovations and processes • Room: South Pacific Ballroom B • Session Number: FC2 • Tuesday, September 17, 2019: 8:30 AM - 4:30 PM Platings and Coatings are one of the most critical post-production processes that fasteners receive. They enhance the performance and appearance of fasteners and are one of the most important value-added services that fastener suppliers provide. There have been some recent and significant changes to the specifications used use for plating and coating fasteners. These are not minor changes – it is information you need to know to properly process your plated/coated product and to manage the associated risk. Owners, managers, quality assurance, sales, and purchasing personnel need this training program. This is essential content even if your company does not

www.fastenerengineering.com

engage directly in post-processing of your fastener product. Fastener Coatings and Platings is intended for all levels of experience. If you are new to fasteners you will come away with a wealth of knowledge and a solid understanding of the coatings used in the fastener industry. This is a hands-on, interactive training program. Attendees will conduct fastener testing, search through standards for answers to important fastener coating questions, process decisions for the selection of fastener finishes, and test their knowledge about fastener platings and coatings. To register for the International Fastener Expo visit https://www.fastenershows. com/attendees/register-to-attend/ International Fastener Expo www.fastenershows.com

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FASTENER FASTENER

Selecting the Optimal Washer Flat: Generally used for load disbursement Tab/Lock: Designed to effectively lock an assembly into place Finishing: Often found on consumer products Wave: For obtaining loads when the load is static or the working range is small Belleville: Delivers the highest load capacity of all the spring washers Fender: Distributes a load evenly across a large surface area Shim Stacks: Ideal for simple AND complex applications

Boker’s Inc. 3104 Snelling Avenue Minneapolis, MN 55406-1937 Phone: 612-729-9365 TOLL-FREE: 800-927-4377 (in the US & Canada)

bokers.com

Keystone Electronics Corp. A world class manufacturer of precision electronic components & hardware for over 75 years. Manufacture precision stampings, in metallic or non-metallic materials for all industries. Specialists in progressive dies, fourslides, wire forming, in-die tapping and high-speed blanking. Screw machine products on automatic machinery and support equipment produce competitively priced precision turnings from .020” to 1.00” diameters, in metallic or nonmetallic materials. Cost effective assembly procedures in eyeleting, riveting, staking, swaging, inserting, crimping, soldering or screw insertion, with automatic & semiautomatic operations to assemble metallic or non-metallic components into finished products.

DESIGN WORLD

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Keystone Electronics 55 S. Denton Ave. New Hyde Park, NY 11040

www.keyelco.com

www.fastenerengineering.com

Tel: 1.800.221.5510 www.keyelco.com

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FASTENER FASTENER

Fastener Specialty, Inc. “Close-Order” Connector Mounting System Another Innovation From The Connector Mounting Specialists The Fastener Specialty, Inc. “Close-Order” (FSCO-Series) Connector Mounting System can LOWER THE WEIGHT and COST of your airborne equipment by using less material in the manufacturing of your box or panel. The custom designed bracket is a timesaver at installation and makes connector change-out during field service easier. FOD risk is eliminated. Contact us for our Design Form, submit your preferred connector layout and we will design the configuration for your consideration at NO COST. Rapid prototype for “PROOF OF CONCEPT/DESIGN” available.

“Our Success Is Mounting”

Fastener Specialty, Inc. 2435 109th Street Grand Prairie, TX 75050 www.fastenerspecialty.com info@fastenerspecialty.com P: 972.988.0064 F: 972.660.3153

Retaining Ring Solutions to Reduce Noise, Vibration and Harshness for Applications with High RPMs and Balancing Needs Retaining rings are often used in high RPM applications to fix bearings on shafts or in bores. One frequent problem that contributes to NVH during high rotational speeds is axial endplay as a result of accumulated tolerances. Rotor Clip offers beveled retaining rings that are designed for rigid endplay take up. Beveled retaining rings feature a 15º bevel that allows them to act like a wedge between the retained part and the ring groove wall, rigidly taking up endplay space. This permits manufacturers to work with larger tolerances in the parts being assembled and still achieve required performance characteristics.

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Rotor Clip Company, Inc. 187 Davidson Avenue Somerset, NJ 08873 www.rotorclip.com sales@rotorclip.com Tel: 1.732.469.7333

DESIGN WORLD

9/3/19 1:05 PM

Aggressive Work Ethic Developing Leading Products

Product World Four-port serial communication module Opto 22 opto22.com The groov serial I/O module GRV-CSERI-4 plugs into a groov EPIC chassis alongside Opto 22’s new groov Edge Programmable Industrial Controller (EPIC) and discrete and analog I/O modules, to provide the mix of analog, discrete, and serial signals you need at any location.

Many industrial automation applications require communication between the controller

and multiple serial devices. This new module provides four independent and isolated serial ports for this purpose, communicating with RS-232 or RS-485 serial devices. Up to 4 modules can be installed in one groov EPIC chassis, providing a total of 16 serial ports to support

BallscrewsState-of-the-art machining technology, providing in-stock solutions, solutions exact groove profiles by grinding or precision rolling, with protective coating options.

these communication requirements. Each port is selectable for RS-232 or RS-485 mode, with programmable termination and bias as well as half- or full-duplex options in RS-485 mode. Baud rates of up to 1 Mbps are supported.

Linear dc resistance spot welding power supplies Amada Miyachi America amadamiyachi.com

Linear GuidewaysEffective linear motion utilizing precision rolling elements perfecting up/down and side-to-side loads.

The DC1013-T and DC613-T Series of linear dc resistance spot welding power supplies manufactured by MacGregor are typically used in aerospace, medical, and electronic assembly applications. DC1013-T and DC613-T units are suitable

for

butt welding fuses, welding components to leadframes, gold

For More Information: info@hiwin.com

ribbon bonding, and welding fine wire to pads. High-speed automation and communication ports offer users full remote-control capability.

The DC1013-T and DC613-T Series incorporate statistical process control (SPC) data

collection and reporting capability via Ethernet. The high performance 1000 ampere (A) precision linear DC spot welding power supplies combine touch panel integrated database process control and monitoring with a high accuracy. Also, a zero ripple linear transistor output stage delivers 10 micron per second (µs) dynamic process response rates, with

Linear Guideways

Rotary Tables

Ballscrews Ball Splines

AC Servos & Drives Articulated Robots

Harmonic Gearing System Linear Motors Single Axis Robots

Crossed Roller Bearings Positioning

Torque Motors

Measurement Systems HIWIN Grease

absolute closed loop 1 A incremental accuracy and repeatability. Offering high-speed, ultra-low ripple closed-loop output control, the DC1013-T and DC613-T Series provide

Huntley, IL USA

consistent welding process definition and control.

847.827.2270

www.hiwin.com

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Non-Invasive

Flow, Bubble, Level Sensors Self-adjusting sensor for consistent sensitivity Clamp-on level switch for use on metal pipes

Product World Precision limit switches AutomationDirect automationdirect.com

Flow sensors for use on any non-metallic tubing

Metrol limit switches provide precision,

Level switches for Piston Accumulators

actuator of new sliding/angled offset

Bubble size output

repeatability, and long service life. The limit switches detects objects traveling straight on or sliding into the actuator from an angle with 5-micron repeat accuracy. Metrol low contact-force limit switches are available with 5 or 10-micron repeat accuracy and an ultra-sensitive contact force of only 0.1 Newtons and are suitable for applications requiring extra sensitivity. Highvacuum resistance style limit switches with 3-micron repeat accuracy and an ultra-small design are an excellent choice for installations inside a vacuum, such as environmentally controlled manufacturing processes.

High-temperature stopper limit switches are rated up to 200 deg. C and incorporate a

mechanical stop along with the limit switch function, eliminating the need for a separate stop in many applications.

NEMA 24 frame integrated motors with dual-port communications Applied Motion Products applied-motion.com By incorporating two M12 Ethernet connectors instead of just one on each axis, the SWM24IP-3DE Integrated Stepper Motor and TXM24IP-IDG StepSERVO Integrated Motor support more efficient network topologies such as line

Software for easy parameterization

networks and daisy-chain connections.

Flow down to 1ml/min

used industrial protocol for manufacturing automation

Accuracy down to 1% Built-in electronics, no external electronic board

EtherNet/IP network communications are the widely

applications. With EtherNet/IP, users can control, configure, and query a drive using an open, standards-based, industrial Ethernet connection at speeds up to 100 Mbits/sec. All drive and motor features are accessible over the EtherNet/IP network, including more than 100 commands and 130 registers for controlling motion, I/O, configuration, polling, math, register manipulation, and Q programming. The additional Ethernet communications port on the motors allows for cost savings and design simplification by reducing cables, eliminating bulky cable trays, and downsizing network switches.

sales@sonotecusa.com www.sonotecusa.com (631) 415-4758

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

Innovation of Motion Control Components

Inductive factor 1 sensors detect ferrous and non-ferrous metals

HIWIN® Ball Spline

Balluff balluff.com

Rolling Guide Motion Component FS, FSR, FBR Type

This new generation of high-precision inductive factor 1 sensors accurately detect ferrous (iron-based) metals like steel and non-ferrous metals like aluminum and brass at the same rated switching distance. Typical inductive sensors have a reduced range for non-ferrous metal, requiring a correcting factor to calculate their switching distance. Not so with Factor 1 sensors; they detect both types of metal with no correction factor needed.

These inductive factor 1 sensors keep operating in harsh environments. They are

magnetic-field resistant, so their function is not disturbed by strong electromagnetic fields, which are often found in welding applications. A PTFE coating on the housing helps keep weld spatter from sticking to the sensor. This new generation of sensors has been engineered with an IP68 rating and extended the working ambient temperature range to –40 to +85 °C. Add their improved housing and they are a clear improvement over the previous IP67-rated generation of devices.

Digital sensorless motor drive

Effective Transmission of Torque

Koford koford.com

Precision with a Compact Design

High Speed Acceleration Advanced Lubrication Path

This new series of 60-A 24-V digital

For More Information: info@hiwin.com

sensorless drives features 99% efficiency, compact size, and high performance. They run motors to 80,000 rpm and can run twopole motors. The design can run at 100% duty cycle compared to many other drives that are limited to 95% duty cycle. This gets top output from the motor.

The drives also ensure reliable startup even for loads with higher inertia.

Operation at high altitude or in a vacuum is possible. The drive offers a brake function, and braking modules are available for applications where the power

Linear Guideways

Rotary Tables

Ballscrews Ball Splines

AC Servos & Drives Articulated Robots

Harmonic Gearing System Linear Motors Single Axis Robots

Crossed Roller Bearings Positioning

Torque Motors

Measurement Systems HIWIN Grease

source cannot accept regenerated power from the load. Huntley, IL USA 847.827.2270

www.hiwin.com DESIGN WORLD

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Product World High torque flanged gearboxes Zero-Max zero-max.com Flanged gearboxes are well suited for these CD Couplings. They provide high torsional stiffness in precision applications with fluctuating torque loads caused by aggressive acceleration/deceleration and reversing rotation. A flanged hub on the CD Coupling attaches directly to the gearbox output flange. This direct connection and use of the torsionally stiff CD Coupling construction provides optimal system torsional stiffness and performance.

The CD Coupling’s high torsional stiffness is due to the coupling’s composite disc design. The precision composite material and

disc pack design provide a high degree of torsional stiffness while also handling inevitable shaft misalignment in the system.

CD Couplings are designed to withstand the punishment and stress of flanged gearbox applications. Also important, the

coupling’s composite disc withstands all types of environmental elements, including temperature extremes from -70 to +250°F, as well as moisture and a wide range of chemicals. The robust disc and overall coupling design help increase the longevity and reliability of the motion system in which the coupling is used.

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

Providing Value Through Technological Advancements

PLCs integrate I/O for speed and flexibility

Introducing the HIWIN® Harmonic

Rexroth boschrexroth-us.com

Gearing System, Datorker®

IndraControl XM21/22 programmable logic controllers (PLC) combine the speed of the Sercos automation bus with the IndraControl S20 input/output (I/O) series for one functionally complete and scalable control system. The controllers are available with either an Intel 600 or 1,300 MHz ATOM processor (XM21/22), along with an onboard Sercos master featuring a cycle time as low as 250 µs.

Rexroth’s IndraControl XM42 expands the XM range to provide scaled modularity and a fully

functional control system for more demanding factory automation applications. The XM42 is a modern control platform with a powerful Intel Core i Dual Core processor and onboard Sercos master for clocked fieldbus connections.

Single-acting and centric clamping vises SCHUNK schunk.com

Compact and Light Weight High Torque

The manually actuated SCHUNK KONTEC KSC

Variety of Reduction Ratios

clamping vises are efficient all-rounders for

High Precision Motion Control

raw and finished part machining. They combine high clamping forces, convenient operation, and short set-up times. Particularly for use in

For More Information: info@hiwin.com

automated machine loading, this component is an expansion of a standard program with the affordable KONTEC KSC-F single-acting clamping vises with a fixed jaw. It has quick

Linear Guideways

Rotary Tables

adjustment of the clamping range, flat design, and low weight.

Ballscrews Ball Splines

AC Servos & Drives Articulated Robots

Harmonic Gearing System Linear Motors Single Axis Robots

Crossed Roller Bearings Positioning

The three sizes KSC-F 80, KSC-F 125, KSC-F 160 are designed for the common pallet

sizes 320 x 320 mm, 400 x 400 mm, and 500 x 500 mm. Due to the 160° quick clamping, workpieces are clamped with a torque wrench in a second, and the vise is safely locked. Due to clamping by tension, the bending load at the base body is minimized.

Torque Motors

Measurement Systems HIWIN Grease

Huntley, IL USA 847.827.2270

www.hiwin.com

DESIGN WORLD

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POWER TRANSMISSION-PART CONVEYING

Product World

PYRATHANE® BELTS Lifetime Warranty Against Manufacturing Defects

New components for conveyors ELESA elesa.com These conveyor components allow the creation of support structures for production lines in diverse industrial markets such as bottling, packaging, and material handling.

LINE SHAFT CONVEYOR BELTS

Original Equipment and Connectable

CUSTOM MADE IN INCH, METRIC & O-RING SIZES • Round, Flat and Connectable Polyurethane Belts • Very Clean Operation • Eliminates Tensioning Devices • Exceptional Abrasion Resistancexxxxxxxxxxxxxx

Elesa now offers new roller sides and central guides, linear

guide rails, also with a shaped profile and a series of accessories.

The new side and central guides together with the

articulated side guides are constructed from polyethylene-based (PE) technopolymer with grey color rollers.

AN ISO 9001 CERTIFIED COMPANY

641.792.2405 sales@pyramidbelts.com

Side guides (GLA series) and central guides (GCA series) are

available with an anodized aluminum body, acetal resin-based (POM) technopolymer supports, and AISI 304 stainless steel pins.

pyramidbelts.com

The articulated side guides (GLB-1 and GLB-2 series) are

modular self-supporting structures for the side guide of products 19Pyramid_4x475_PC.indd 1

MECHANICAL COMPONENTS

12/4/2018 4:56:13 PM

are constructed of acetal resin based (POM) technopolymer

ENGINEERING

and the pins in AISI 304 stainless steel. These guides are also suitable for use in environments in the presence of liquids subject to frequent washing or filling areas. The joint in the roller

Precision Gears Timing Belts & Pulleys Bearings Couplings and More

CUSTOM ENGINEERING & MANUFACTURING Est. 1950 AS9100 Registered RoHS & REACH l ITAR

www.sdp-si.com 250 Duffy Avenue, Hicksville, NY 11801 800-819-8900

with limited vertical dimensions on conveyor belts. Guide bodies

side guides allows an external curvature radius of 500 mm and an internal curvature radius of 350 mm.

MANUFACTURING ASSEMBLY

DOWNLOAD: - Product Specifications - 3D CAD Models REQUEST A CATALOG 152

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September 2019

DESIGN WORLD

8/30/19 8:26 AM

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

3D sonar sensor Toposens toposens.com The TS3 is a 3D ultrasonic sensor suitable for systems market that require a strong need

Pneu-Connect® is a pneumatic end-effector system that provides seamless integration for Universal Robots and other collaborative robots at a third of the price of its electrical equivalents.

for reliable object detection and situational awareness.

Seamless Integration of PHD Grippers to Universal Robots

a range of applications in the autonomous

In comparison to conventional ultrasonic

sensors, which usually measure the distance only to the closest reflecting surface, these new 3D sensors achieve a wide field of view of up to 160° and provide simultaneous 3D measurements for multiple objects within the scanning area. The operation thus mimics the echolocation techniques used by bats and dolphins for navigation and orientation in the wild.

NOW WIT

AnNaSOlRo!g SE

With Series GRH Gripper Only

The new TS3 sensor combines carefully

selected hardware components with proprietary signal processing algorithms. It is suited for indoor robotic navigation and object avoidance. Systems benefit from its real-time processing capabilities while keeping data transmission

New!

bandwidth and power consumption low, which is crucial for battery-powered robots. More Gripper Choices!

Series ESU Electric Belt-Driven Linear Actuators • Robust, enclosed design • High capacity rail bearing system • Exceptional moment and load capability

See our working displays in Booth

LS-6184

• Long life and high quality solutions • Pneumatic, hydraulic, electromechanical, built-to-need components, and price alternative components • Online sizing and CAD Configurator with myPHD

1-800-624-8511 for more information, visit: DESIGN WORLD

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phdinc.com/pneuconad

P.O. Box 9070 • Fort Wayne, IN 46899 USA

8/30/19 8:27 AM

Product World Epoxy polysulfide hybrid for advanced chemical resistance Master Bond masterbond.com EP21TP-2NV is a two-part epoxy polysulfide formulated for use as an adhesive, sealant, and

the addition of heat. For example, when cured

potting system. It withstands prolonged exposure to many harsh chemicals including fuels, oils,

at 200°F for 2-3 hours its hardness decreases

hydrocarbons, and hydraulic fluids. It is also fully RoHS compliant, meeting RoHS3 Directive (EU)

to 15-20 Shore D.

2015/863.

substrates such as metals, glass, ceramics,

EP21TP-2NV offers an elongation between 40-80% at room temperature and superior

EP21TP-2NV bonds well to a variety of

toughness with a tensile strength of 3,000-4,000 psi. It resists aggressive thermal cycling over

and many rubber and plastic materials.

the service temperature range of -80°F to +250°F [-62°C to +121°C]. With a dielectric constant

This compound is available in standard size

of 3.7 at 60 Hz, the system provides robust electrical insulation properties.

containers from ½ pint, pint, quart, and gallon

kits as well as specialty packaging including

EP21TP-2NV cures at room temperature in 48-72 hours to form a rigid material with a Shore

D hardness measuring 60-65. A unique feature of EP21TP-2NV is its ability to cure softer with

double barrel syringes and gun dispensers.

For Absolute Feedback, we’ve got your solution EPC’s Absolute Encoders offer: • 16 bits resolution for single turn, and 43 bits resolution for multi-turn • SSI, CANopen, or EtherCAT communication protocols • Electronic cam switches on CANopen and EtherCAT models • Maintenance-free and environmentally-friendly magnetic design • Energy harvesting magnetic multi-turn technology • No gears or batteries

Call us today.

We’ll help you find the motion feedback solution you need.

1-800-366-5412 • encoder.com

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8/29/19 11:01 AM

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

Food-grade roller chain Timken timken.com Drives Element roller chain is a maintenancefree, sintered bushing chain designed specifically for applications where regular lubrication is not possible or practical. With more than 2.5 times the wear performance of the current industry-

COMPACT CNC MILLS

WITH MORE BOOST

leading sintered bushing roller chain, Drives Element is a suitable choice for packaging, food and beverage, or general applications where traditional lubrication and lubrication systems are

More Speed. More Brains. All the Mores You’ve Been Asking For.

not an option.

The name “Element” reflects the

combination of three essential roller chain performance elements into a single patented

We took our popular 1100M and 770M CNC Mills, added servo motors, an encoder for rigid tapping, and a BT30 spindle.

bushing that maximizes the lubricant available to

Greater travel speeds to reduce program times, higher spindle speeds (10,000 RPM on both) and a beefier BT30 spindle chews through aluminum, titanium, hardened steels, and alloys.

the pin, thus eliminating the need for traditional

Customize your 1100MX or 770MX package at tormach.com.

design: • Integrated Lubrication – Drives Element uses an H1 food-grade lubricant with a proprietary

in-application lubrication and reducing the opportunity for product contamination. • Wear Performance – Extended Life CHP chrome-hardened pins offer a smooth, hard pin surface that works in concert with the lubricant and bushing to minimize wear, thereby reducing chain elongation and providing greater than 2.5 times the wear performance of the industryleading sintered bushing product. • Corrosion Resistance – Element chain also features Silver Shield CR coating on exposed surfaces, providing three times the corrosion protection of nickel-plated chain and making it suitable for high-humidity applications.

TORMACH.COM

DESIGN WORLD

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Product World Slewing ring bearing offers reduced weight, size igus igus.com This is a maintenance-free and wear-resistant slewing ring bearing for medium loads that also offers reduced weight and space. The new bearing is 50% smaller in installation height, 60% lighter, and can save users up to 20% in costs. The bearing will be particularly effective in automation, stage technology, and control panels.

High cycle rates and loads in welding systems, indexing tables or the packaging industry, are extremely demanding for

slewing rings. The iglide polymer slewing ring bearings (PRT) have sliding elements between the inner and outer bearing rings made of aluminum or stainless steel. The maintenance-free sliding elements made of high-performance iglide J plastic ensure that friction and wear are minimized without lubrication.

The new PRT-04 range allows users to use slewing ring bearings even in compact installation spaces with medium loads.

The bearing takes up to 50% less space and the moving mass is reduced. Compact applications can be implemented, for example, in automation technology, sorting systems, control panels, and stage and lighting technology. The sleeker bearing also reduces costs by up to 20%.

CARLOSensors GAVAZZI Proximity with IO-Link and IO-Link Smart Configurator Automation Components

CARLO GAVAZZI Automation Components Inductive Sensors with IO-Link

Rugged Ø4, M5, M8, M12, M18 and M30 housings, offering extended ranges up to 22 mm. Easily configured, providing advanced functionalities such as the detection counter (RPM) and the speed controller. Each sensor is fully programmable, providing the means for hundreds of configurations in a single device.

IO-Link Smart Configurator

Configure any IO-Link sensor or actuator via a wireless device that replaces the need to program via a USB IO-Link Master connected to a PC or via a network connected master device. The portable Smart Configurator can be used anywhere, as it’s battery powered and equipped with WiFi for IODD files, sync and cloud storage.

CARLO GAVAZZI

Capacitive Sensors with IO-Link

Popular M18 and M30 diameter sensors provide the ideal solution for applications where flexibility or sensing performance needs to be constantly and accurately monitored and logged. IO-Link mode provides added functions such as: QoR (Quality of Run), QoT (Quality of Teach) and Diagnostic Parameters.

Contact us today, and one of our field sales representatives will show you why we are one of the fastest growing automation companies Automation Components worldwide. We’ll even provide a free evaluation sample to qualified OEMs. USA Tel: 847.465.6100 Canada Tel: 888.575.2275 GavazziOnline.com Mexico Tel: 55.5373.7042 • 847.465.6100 • Info@CarloGavazzi.com

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Brazil Tel: 55.11.3052.0832 www.GavazziOnline.com • Info@CarloGavazzi.com September 2019 twitter.com/CarloGavazziNA www.designworldonline.com facebook.com/CarloGavazziNA

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Visit our website for downloadable data sheets, brochures and pricing: www.GavazziOnline.com

DESIGN WORLD

8/28/19 9:21 AM

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

Custom shaft collars and couplings Stafford Manufacturing staffordmfg.com These Clamp-type shaft collars, couplings, and mounting devices can be finished in custom colors to exactly match commercial OEM and military MIL product specifications.

These shaft collars and couplings

feature custom colors or finishes and are offered in anodized aluminum, painted steel, chrome, and other platings. Available in a broad range of styles and sizes, they are suited for matching commercial agricultural machinery and products and can include desert tan and olive green for military applications.

Providing a smooth bore to protect

expensive shafts, tubing, and pipes, these shaft collars and couplings are also available in a plated finish and are offered in sizes from 1/8 to 6-in. I.D. and various

The Gold Standard for Performance

one- and two-piece styles. They can also incorporate threaded bores and a wide range of special face and O.D. treatments such as flats, holes, and knurls.

Titan® chain offers the ultimate in extended wear-life. When it comes to critical applications, reliability is everything. But not just any chain can withstand the nonstop stress of high speeds and harsh conditions. That’s why Tsubaki designed its Titan chain to deliver superior durability in challenging environments. Specially coated pins, solid lube groove bushings* and a patented ring-coining process increase fatigue strength while minimizing wear. The result is a significantly longer wearlife, even in extreme environments. So go on, hold your chain to a higher standard — the Titan gold standard.

To learn more, call 800.323.7790 or visit ustsubaki.com

DESIGN WORLD

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congratulates

WAGO Corporation has been connecting North America since the opening of their North American headquarters in Wisconsin in 1979. As the innovators of CAGE CLAMP®, WAGO has been the world leader for over half a century in the design and manufacture of termination systems incorporating spring pressure connection technology. Today, WAGO offers a full range of products including rail mount and PCB terminal blocks, interface electronics and fieldbus independent I/O systems. As WAGO’s founder Wolfgang Hohorst famously said, “Whether it has to do with wires, people or thinking, it’s all about making a connection.”

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Product World Allen-Bradley FLEX 5000 safety I/O modules Rockwell Automation rockwellautomation.com These Allen-Bradley FLEX 5000 safety I/O modules can meet the needs of producers in process and heavy industries that require fixed field-wiring terminations or both vertical and horizontal I/O mounting in their distributed safety applications.

These three FLEX 5000 safety I/O modules provide distributed safety I/O for the Allen-

for use in fail-safe applications up to SIL 3

Bradley Compact GuardLogix 5380 and GuardLogix 5580 controllers. The safety modules

and PLe, Cat. 4. They can operate in extreme

can be combined with FLEX 5000 standard I/O modules to achieve integrated safety and

environments and be directly connected

control in one distributed I/O platform.

to copper and fiber networks. They’re also

available with conformal coating options

The modules offer safety reaction times as fast as 4.5 milliseconds to help designers

The safety I/O modules are TÜV certified

create smaller, simpler, and less expensive smart machines and equipment. They also offer

for added protection against environmental

extensive diagnostics to help users easily identify faults based on real-time data.

stresses.

VPX 6U carrier cards Acromag acromag.com The Model VPX4520 and VPX4521 6U carrier cards provide mezzanine slots for one XMC and four mini-PCIe or AcroPack I/O modules. The XMC module site can host a network communication, FPGA, GPU, SBC, or other I/O signal processor card. The four AcroPack slots provide a rugged PCIe mini card interface for a mix of analog, digital, serial, and other I/O

10-gigabit Ethernet NIC capabilities. To

functions. A PCIe Gen 3 x16 interface connects to the VPX bus either via the data plane or

meet requirements for higher reliability, mini

expansion plane. Convection and conduction-cooled versions are available with support for

PCIe-based AcroPack I/O modules securely

extended temperature ranges from -40 to 85°C. Air-cooled models offer front panel access

route I/O signals directly through the carrier

to the I/O while conduction models route all signals to the rear backplane connectors.

to eliminate any loose internal cabling.

AcroPacks can interface A/D, D/A, DIO,

Designed for critical computing applications, Acromag’s VPX carrier boards and I/O

modules are well-suited for use in military, aerospace, laboratory, and industrial applications.

232/485, 1553, CAN, and other signals.

Typical applications include data acquisition and control, test and measurement, simulation, and communication operations. For broader flexibility with 3rd-party modules, the XMC site is available with either VITA 42 or VITA 61 connectors.

Support for upstream and downstream PCIe links provides compatibility with

prXMC single board computers. There is a variety of XMC modules with FPGA and up to

DESIGN WORLD

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www.designworldonline.com

September 2019

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Ad Index ABB Motors & Mechanical ...........................9 Accumold .......................................................103 Aerotech .......................................................... 75 Allied Electronics ..........................Cover,3,108 AllMotion .............................................................4 Altech Corp. ............................................17,19,21 Altra Industrial Motion Corp. ....25,26,27,28 Anchor Fluid Power ....................................150 Applied Motion Products, Inc. . ............... 45 Aurora Bearing Company ......................... 52 Automation24, Inc. ..........................................7 AutomationDirect ................................ 1,Insert Beckhoff Automation ................................. 78 Bimba ..........................................................Cover binder USA .....................................................101 Bishop-Wisecarver ....................................... 67 Bison Gear and Engineering ....................66 BRECOflex CO., L.L.C. .................................102 Carlo Gavazzi ................................................156 Carlyle Johnson ............................................ 58 CGI Motion ...................................................... 59 Chieftek Precision ...........................................6 CIT Relay & Switch ....................................... 55 Del-tron ............................................................64 Diequa .............................................................IBC Digi-key ............................................................. 15 DMIC .................................................................105 Dura-Bar .......................................................... 70 ebm-papst Inc. .............................................. 37 Eisele Connectors .......................................107 Emerson .......................................................... 57 Emerson Automation Solutions .............. 71 Emerson’s Aventics ...................................... 41 Encoder Products Company ...................154 EXAIR Corporation ..........................................5 Fixtureworks .................................................... 12 Harwin .............................................................. 20 HIWIN ................................................. 147,149,151 icotek Corp ...................................................... 47 IFM Efector ...............................................Insert igus ..................................................................... 13 Interpower ........................................................ 51

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A Supplement to Design World - September 2019

J.W. Winco, Inc. .............................................. 47 Keller America ................................................99 Keystone Electronics Corp. ...............43,123 KNF USA ........................................................ 106 Lenze Americas ............................................ 76 Master Bond .................................................. 52 Memory Protection Devices ..................... 53 METCASE ........................................................89 Miki Pulley US ................................................. 16 Nason ............................................................ 100 Neugart ............................................................. 31 Novotechnik ..................................................104 Opto 22 ............................................................49 Oriental Motor ............................................... 95 Parker Hannifin Corp (Pneumatic Division) ..............................50 PAVE Technology ......................................... 83 PBC Linear ................................................ 22,23 PHD, Inc. .........................................................153 Phoenix Contact ...........................................88 PolySource .....................................................94 Pyramid Incorporated ................................152 R+W America .................................................. 79 ROLEC .............................................................. 39 Rotor Clip ......................................................... 30 SDP/SI-Stock Drive Product .....................152 SEW Eurodrive ..............................................BC Smalley Steel Ring ........................................ 10 Smart Products USA .................................... 61 SONOTEC US Inc ..................................87,148 Spartan Scientific ........................................104 Tadiran ............................................................. 93 THK America, Inc ..........................................IFC Tormach ..........................................................155 Trim Lok ............................................................ 42 US Tsubaki .....................................................157 Vlier ................................................................... 36 Wago USA ............................................... 69,158 Whittet-Higgins ............................................. 35 Xcentric Mold & Engineering ....................80 Yaskawa America, Inc. ................................ 82 Zero-Max, Inc. ...................................................2

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Mike Caruso

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Jim Dempsey

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Fastener Engineering Supplement

Fastening technology

Boker’s Inc. .............................................................142 Fastener Specialty, Inc. .....................................138 Keystone Electronics Corp. .............................. 131 MW Industries - Accurate Screw Machine .139 Rotor Clip ................................................................144

covering nuts, bolts, rivets, screws, u-clips, eye bolts, washers and more.

COVER_FASTENER ENGINEERING 9-19_Vs1.indd 124

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A supplement of Design World

Jim Powers

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Medical Tips Supplement

Engineering September 2019

Jami Brownlee

Bansbach Easylift ........................119 Bay Associates Wire Technologies, Inc. ....................120 Nitto Kohki USA ............................117

Medical device innovations industrysupplier you need to know Medical Tips cover 9-19_FINAL.indd 109

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