Motion System Applications 2017 by WTWH Media LLC

NOVEMBER 2017

D E S I G N W O R L DO N L I N E . CO M

M OT I O N CO N T R O L T I P S . CO M

motion

system

applications

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M O T I O N S Y S T E M A P P L I C AT I O N S

4 AXIS SERVO

motion components help speed system design

from

improved

2.25”

The

third annual Motion System Applications special issue from Design World is here. Each year we highlight some of the most intriguing applications using motion control technology. As design requirements continue to evolve, manufacturers of motion components and systems, from mechanical elements like couplings and gears to electromechanical components such as motors and encoders on to newer intelligent integrated packages (think robotic systems), are responding to changing demands by offering innovative new designs that address current challenges as well as anticipate future needs. In fact, it may be easier now more than ever to design a motion system. There are many reasons this is so. For starters, the commodification of components means that they are more readily available as off-the-shelf standards, which makes putting together a complete system a lot easier. Of course, there is still the need for custom components, but here too the process has gotten easier with online design and configuration leading to faster turn-around times. Motion systems are also becoming more compact as component integration continues apace. So there is more functionality in, say, a stepper motor with an integrated encoder, drive, and controller, eliminating the need to source individual components and spend time connecting them all together. Take robotics, for instance. These days, you can hardly visit a news site or scroll very far in your twitter feed without seeing a story about robots. Robot surgeons. Robot farmers. Robotic vehicles. Robots, it appears, have gone mainstream. At their heart, robots are highly sophisticated motion control systems. So it’s no surprise that this year’s Motion System Applications issue features a section on a range of robotics applications. Senior Editor Lisa Eitel shows how robots are fast becoming the go-to technology in a host of new medical and design applications, while also improving and evolving systems in traditional applications such as packaging and material handling. We hope you enjoy this special issue and that it offers you insight into your own design challenges. Drop us a line and let us know what you think.

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Linear Mount Products PMK Parallel mounting kit

EPL-H Inline gearbox, with hollow output design for easy mounting to linear actuators

WDS

DL-DC

Bellows style distance coupling

Right angle Dyna Lite gearbox with hollow output design for easy mounting to linear actuators. Includes output adapter tailored to the actuator

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APPLICATIONS

MOTION SYSTEM

‘industrial network’ is another way of saying ‘hack me’

article in Wired Magazine raised eyebrows awhile back when it explained a way hackers could destroy motors powered by variablespeed drives. It described work by a researcher at IT security firm Digital Bond Labs who pointed out that several VSDs have no way of authenticating commands sent to them over the network to which they are attached. Those commands can include setting motor speed. Worse, someone with nefarious intent could query the VSDs about the highest safe operating speed of connected motors. It was then possible, the researcher pointed out, to reset the maximum-speed setting over the network and tell the VSD to exceed it. The tone of the Wired article was such that readers could come away with the impression of VSD makers as a bunch of bumblers who were clueless about hacking. But those knowledgeable in industrial controls probably realized the article fingered the wrong culprit. The real problem is the industrial network to which VSDs and other industrial devices connect. Many of these networks use a Modbus serial protocol originally developed in 1979 for programmable logic controllers. Back then, of course, nobody worried about hacks. So in the interest of speedy network communications, Modbus includes no security measures; devices on the network just assume commands on the bus are valid and originate from something that is supposed to be there. That assumption applies for any device on a Modbus, not just VSDs. Nor is Modbus the sole network with this vulnerability. In terms of security, all common industrial networks are similarly configured. This makes all industrial networks prime targets for determined mischief makers.

The ramifications of poor industrial-network security got highlighted in an episode of the TV series Mr. Robot in which hackers penetrated a misconfigured HVAC network. Like Modbus, widely used HVAC network protocols lack security. In the show, administrators had put the HVAC server on a network connected to the internet, which left it visible to anyone trying to break in. Industrial device makers are well aware of such problems, despite what the Wired article may have implied. Security measures have begun to emerge. One widely used way of fortifying open protocol networks such as Modbus is at the gateways connecting them to other networks. Many gateway devices for Modbus now include firewalls and other features to thwart malicious applications and defuse them before they ever get access to Modbus connections. But those sorts of security measures don’t help if an attacker has physical access to the Modbus network. Most worrisome is a Trojan Horse-style approach in which miscreants add villainous software to legitimate Modbus devices. With that scenario in mind, vendors have begun fielding security techniques that let IT personnel use software to inspect individual Modbus packets for trouble. Unfortunately, none of these countermeasures are foolproof. So industrial networks hacks are likely to be a thorn in our sides for a long time to come.

L E E T E S C H L E R | E X E C U T I V E E D I TO R

DESIGN WORLD — MOTION

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Flexible Solutions for Motion Control. • Prevent bearing failure • Zero backlash • Eliminate vibration failures • Integrated attachments • Precision spring rates • One piece solutions

H eli-C a l.c o m

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EDITORIAL

VIDEO SERVICES

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

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Graphic Designer Allison Washko awashko@wtwhmedia.com

Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_LeeTeschler Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_Motion

@wtwh_designer

Traffic Manager Mary Heideloff mheideloff@wtwhmedia.com Production Associate Tracy Powers tpowers@wtwhmedia.com Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

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DIGITAL MEDIA/MARKETING

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DESIGN WORLD — MOTION

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INSIDE

THE MOTION SYSTEM CASEBOOK VOLUME 3 NUMBER 4

Improved motion components help speed system design

‘Industrial network’ is another way of saying ‘hack me’

Actuators Electrical .............................................................8 Pneumatic ......................................................... 12 Ballscrews ................................................................. 14 Bearings..................................................................... 17 Belts & Pulleys . . ........................................................ 21 Brakes & Clutches ................................................... 22 Cables & Management . . .......................................... 26 Chain . . ....................................................................... 29 Controllers ............................................................... 32 Conveyors ................................................................ 37 Couplings ................................................................. 38 Drives .. ...................................................................... 43 Encoders .................................................................. 46 Gearing ..................................................................... 50 Gearmotors .............................................................. 56 HMIs .......................................................................... 58 Leadscrews .............................................................. 69 Linear Guide Rail Slides & Ways .. ........................... 61 Motors AC ..................................................................... 68 DC ..................................................................... 70 Servo ................................................................ 73 Stepper ............................................................ 75 Networking .............................................................. 76 Retaining Rings . . ...................................................... 78 Robotics ................................................................... 80 Shocks & Vibration Damping ................................. 82 Positioning Stages, Gantries & Tables .. ................ 86

22 14

COVER IMAGE COURTESY iSTOCK

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DESIGN WORLD —Network MOTION DESIGN WORLD — EE

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APPLICATIONS

MOTION SYSTEM

applications for

electric actuators Electric

actuators are integrated motion components that usually include an electric motor and rotary-to-linear device to output repeatable linear strokes for moving loads to a given positions. Because electric actuators are more controllable than fluid-power actuators, engineers often choose them as an option to shape the speed and force of the strokes of machine axes. In fact, most electric actuators even deliver multiple outputs with programmable controls that adapt to changing conditions. Applications with similar dynamics often make use of the same actuator types — those that pair motors with ballscrews or leadscrews; incorporate brushless dc motors and belt-and-pulley setups; take a rod-style morphology; use motors with planetary roller screws; or integrate built-in guides. Electric actuators running closed-loop or with a micro-stepping motor can match force and speed output commands best with feedback to overcome most of the mechanical limitations of rotary-to-linear devices. When picking an electric actuator for a given application, determine the power draw and whether the axis is expected to draw power continuously or intermittently or both ... because that parameter largely determines actuator size and type. Bigger isn’t always better: Besides being inefficient, overly large electric actuators are often less responsive than suitably sized actuators.

That said, appropriate safety factors ensure that electric actuators run coolly. Plus, lighter loads on the mechanical components can extend life. Halving load on a leadscrew can extend its life eightfold, for example. Also account for where the actuator will operate. Will it need to withstand exposure to dirt, chemicals and liquids? If so, its O-rings and seals must be made of materials to withstand application contaminants. Another tip: Analyze the final installation point to ensure that the electric actuator can handle side, radial and axial loads. Application example: Electric actuators eliminate shocks at end of stroke Consider a horizontal loading and unloading module for a press machine that produces lids for cans. A raditional version of the module processes 10,000 workpieces a day; it takes discs from a feeder to a press and

The PBC Linear SIMO Series Linear Motion Platform is flexible and affordable. It offers versatility to mix and match features within the same design so engineers can test multiple configurations — and get actuator speed, accuracy, environmental rating, and life with a linear-motion system that is on budget and on time.

DESIGN WORLD — MOTION

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ELECTRIC ACTUATORS

BraunAbility uses Warner Linear K2x electric actuators for the kneeling option on its side-entry Chrysler Town and Country, Toyota Sienna, and Honda Odyssey conversion vans.

(once the plate is stamped) unloads the finished lid, carries it to a finished-lid chute, and releases it. Previous designs used air cylinders for the loading and unloading module, even though they induced shocks at stroke ends — sometimes even making the grippers drop the plates and lids. The compromise was to slow the air cylinder, though this degraded overall production volume. More specifically, the cycle time was 4.6 sec with a defect rate of 0.1% — translating to about defective lids a day that had to be scrapped. Now a new version of the loading and unloading module for the press machine uses a ROBO Cylinder from IAI America for the horizontal stroke actuation instead. The ROBO Cylinder is an electric actuator with an integrated ballscrew, linear guide, and servo motor. Because the press-machine builder was able to set the cylinder’s speed, acceleration, and deceleration, the highspeed operation now runs without inducing shock loads at stroke ends. Cycle time was reduced 1.7 sec (to 2.9 sec total) and line operating hours went from 12.8 to 8.1 hours a day; the defect rate (due to dropped discs and lids) also went to zero. The end user estimates that switching to the ROBO Cylinder results in an annual operating savings of more than $21,000. Another actuator case study: New angle on wheelchair vehicle accessibility Kneeling systems have become widespread on custom wheelchair-accessible vehicles from BraunAbility and other accessiblevehicle converters. Here linear actuators motioncontroltips.com | designworldonline.com

Electric Acuators — Motion Casebook 11-17.V3.LE.indd 9

lower vehicles’ rear suspension to reduce In fact, the incline angle of wheelchair ramps BraunAbility also sells an for easier access. Because the actuators MXV wheelchair accessible SUV typically mount under the vehicle chassis, built on the Ford Explorer platform for those they must be rugged. who prefer SUVs over minivans. “Our vehicles typically kneel 2.5 to 3 in. Converting a standard factory model We add a mount near the shock absorber van or SUV into a fully functional wheelchair or lower outboard A-Arm pivot and attach accessible vehicle is a challenging a chain that typically runs up into the body endeavor. The process typically includes reand attaches to an actuator,” said Mike engineering the factory vehicle by lowering Laird, BraunAbility Senior Engineer and the floor, moving fluid lines, installing new Commercial SE Vehicle Manager. seats, and integrating retractable ramps One inch of kneel reduces the ramp with their electric or hydraulic systems. angle by roughly one degree, so kneeling As BraunAbility began incorporating yields 2.5 to 3° — a seemingly small angle the kneeling feature on their vehicles, they that significantly reduces the effort a tried some hydraulic units, but there were wheelchair user needs to exert to get up not many compact actuators available when the ramp — and that’s a critical feature for some of its vehicle model lines someone with limited mobility and strength began production. or using a manual wheelchair. The Americans with Disabilities Act (ADA) spurred the need for more personal transportation setups, which contributed to the overall growth of the accessible-vehicle industry. So BraunAbility and other vehicle converters have expanded their product offerings and continue to add more userShown here is a horizontal loading and unloading module for a press friendly features to their machine that produces lids for cans. Now a new version of the loading vehicles. In North America, and unloading module for the press machine uses a ROBO Cylinder sales of wheelchair-accessible from IAI America for the horizontal stroke actuation. Cycle time was vehicles could reach $1.9 reduced 1.7 sec (to 2.9 sec total) and line operating hours went from Billion by 2024, with full-size 12.8 to 8.1 hours a day; the defect rate (due to dropped discs and lids) vans and SUVs accounting for also went to zero. 73% of the market. 11 • 2017

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APPLICATIONS

MOTION SYSTEM

Based on previous successful collaborations, BraunAbility worked closely with Warner Linear to provide an electric actuator setup for the kneeling function. According to Laird, “During development of a new vehicle platform, there’s very little space to mount an actuator inside the cabin. Thus, needing us to position the actuator under the chassis, below the third row of seats or on the top of the vehicle’s rear suspension subframe. These tight envelope spaces minimize space for limit switch mounting brackets. In most cases, limited available space led to external switches being added directly to the actuator.” To meet the challenging space requirements, Warner Linear engineers developed a modified B-Track K2x model actuator that incorporated adjustable limit switches mounted in a low-profile channel on the cover tube. Adjustable channel caps allow the flexibility of setting the stroke length at any position within the actuator’s full stroke range. “Having the limit switches integrated into the actuator meant we didn’t have to assemble,

PA programmable actuators from Nook Industries deliver continuous-duty performance. They incorporate a direct or toothed-belt drive for high mechanical efficiency and quieter operation. Ballscrew-driven programmable actuators are made with high-strength materials and come in parallel and in-line models (with either a servomotor or stepper motor). The screw shaft is of medium-carbon induction-hardened alloy steel ... and the ball nuts are high-grade bearing steel. Both ballscrew and nut are heat treated to 58 to 60 HRC surface hardness. Acme screw-driven actuators are made from 4140 alloy steel with a black-oxide finish and 2C thread form.

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ELECTRIC ACTUATORS

mount, and service a switch bracket tucked away in a small cavity under the vehicle,” said Laird. K2x electric actuators have a rated load capacity to 2,800 lb (12,455 N) and travel speeds up to 2.1 in. (53.35 mm) per sec. Units are available with stroke lengths 2 to 24 in. (50 to 600 mm). All models incorporate a patented in-line load transfer design which provides high load capability for rugged-duty use, an integral holding brake, and a ball detent overload clutch. Models feature a compact package size and an efficient ball nut screw system yielding high-impact capability and long screw life. Double ball-bearing motors with thermal overload, heat-treated gears, heavy wall construction, O-ring seals, and rugged extension rod bearing support provide bestin-class capabilities. Actuator sound during kneeling was also a concern. Silent operation is ideal,

but realistically a modest amount of linear-motor sound is acceptable. As load increases, so does the sound pressure level with no strong peaks. But free impact sounds from engaging and disengaging transmission components can cause user anxiety because it sounds as though malfunction may be eminent. Warner Linear K2x models operate smoothly, but during development on one van model, the actuator seemed to shudder on extension. “After a vehicle arrived at the lab, we determined that its natural rebound rate and actuator’s extend rate matched closely for some spring and shock packages,” said Jared Zammuto, new product development team manager of engineering at Warner Linear. “This caused the actuator’s controlling brake to intermittently engage and release — the source of normal sound that was nevertheless a concern for customers. So we made a simple no-cost modification to the load control brake that eliminated the issue,” said Zammuto. The actuators usually install in a steel housing under the chassis to get some protection from the elements. But on some vehicles, the actuator is fully exposed to water, snow, salt, and debris. Here, the corrosion resistance of Warner Linear K2x models is key to withstanding harsh under-chassis environments. BraunAbility is satisfied with the Warner K2x actuators’ field performance and uses the actuators for kneeling options on its side-entry Toyota Sienna, Chrysler Town and Country, Dodge Caravan, and Honda Odyssey conversion vans.

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APPLICATIONS

MOTION SYSTEM

new

pneumatic actuator applications

Fast pneumatics from Aventics shorten the cycle time on diffusionwelding systems. Two machines now do the work of three.

Pneumatic

actuators come in an array of permutations for automation. Rod and rodless actuators are the two most common ... though rodless are far more common in the U.S. Rodless actuators include bearings to address moment loads in X. Y, and Z. Note that most pneumatic-actuator applications are linear-stroke setups needing two or more position stops. Minimizing stop times in many pneumatic actuators are air cushions. Damping seals are another option. Choosing pneumatic actuators over electrical options is common in applications that need motion axes to work without electricity — where sparking poses a problem (as in applications that involve flammable materials for example).

DESIGN WORLD — MOTION

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Limitations include lack of total controllability and air consumption, but few actuators outperform pneumatic actuators in applications that need clean operation, low upfront cost, and high force-speed ratios. Even so, pneumatic actuators deliver moderate to high load at 120 in./sec or better. Plus advanced pneumatic actuators have wireless valve controls and sensors for IoT and predictivemaintenance functionality. Cylinders, electro-pneumatic pressure regulators, and other precision pneumatics cut one plant’s cycle times Bosch is the world’s largest automobile supplier, and it makes many of its starters at a plant in Hildesheim, Germany. The production

lines at the plant include 25 machines surrounding a diffusion welding system. This welding unit was designed and built by the GAteK association for automation technology and design. A premounted armature is transported on workpiece pallets, aligned for position detection, and brought into position for welding by grippers. After welding, additional grippers return the armatures to workpiece pallets and transport them to the next production step. Supply, swiveling, and welding are performed at rapid speeds in parallel to maintain the line cycle times. The first GAteK machines had three separate control processes for contact movement during welding.

motioncontroltips.com | designworldonline.com

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PNEUMATIC ACTUATORS

ED series valves combine control electronics, pressure sensor, and direct drive (in the form of a proportional solenoid) in a single closed unit.

This meant waiting during switching times. But now with proportional valves, the plant operators can take the three movements and simulate the smooth sequence of a robot — to cut the time for the operation by half. GAteK uses ED series electro-pneumatic pressure regulators. The regulators detect possible drops or increases in pressure; based on a target-actual value comparison, they immediately generate the necessary pressure change to ensure process stability.

“Compared with legacy machines, these deliver faster and more stable processes and optimized weld quality. This extends the machine service life and reduces cycle times by 50%,” said Hoffmeister. “So we can reduce the number of machines in a system from three to two.” The electro-pneumatic concept also includes the AV03 series valve system — combining with the pressure regulators to maximize precision ... and all seven production lines are planned for gradual conversion. “We’ve also solved all stroke and travel motions with Aventics,” said Hoffmeister regarding the plant’s use of the supplier’s cylinders. To query the exact position and needed travel time, some cylinders include SM6 distance-measuring sensors. These sensors allow operators to check guide wear, enabling preventive maintenance while ensuring the quality of the welding process (for IIoT functionality).

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MOTION SYSTEM

APPLICATIONS

I nt e gr ated

ballscrew

assemblies offer synchronization One

of the most enduring actuation methods for linear motion is a ballscrew. Perhaps the biggest reason is that ballscrews feature high efficiency, which can be well over 90%. Combined with providing smooth and precise positioning, they are often the perfect choice in applications from machine tools to assembly devices requiring precise x-y motion. The most important ballscrew parameters include lead accuracy, axial play, preload and life-to-load relationship. Lead accuracy is the degree to which the shaft’s rotational movements are translated into linear movement. With lead accuracy and axial play determined by the manufacturing method of The Electrak HD from Thomson Industries is a ballscrew-driven the ballscrew shaft and electric linear actuator with onthe assembly of the nut, board electronics that eliminate high lead accuracy and the need for external controls. zero axial play is generally Higher power ratings combined associated with relatively with an IP69K rating make it higher-cost, precision suitable for some hydraulic ground ballscrews, while applications.

DESIGN WORLD — MOTION

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lower lead accuracy and some axial play is associated with lower-cost, rolled ballscrews. Fabricated by rolling or other means, these ballscrew shafts yield a less precise, but mechanically efficient and less expensive ballscrew. A number of recent developments in manufacturing and materials have improved ballscrew performance. Some improvements include the fact that the latest generation of ballscrews has more load density than ever, giving designers higher capacity from a smaller package. Other improvements have made ballscrews even faster, and this applies to both rolled and ground screw manufacturing methods. Also, more integration is now commonplace. Ballscrew-based linear actuators are readily available as allin-one packages. Such integrated packages significantly reduce design time as well as time required for assembling a system and programming the actuator itself.

Case in point; new linear actuators from Thomson Industries that put ballscrews to work in a unique way. The company’s line of Electrak HD heavy duty electromechanical linear actuators feature new synchronization capabilities. This means that designers of equipment in which large or awkward loads must be moved repeatedly and evenly, such as large solar panels or heavy hoods on construction equipment, can now simultaneously distribute that load using up to four actuators. Synchronizing multiple actuators using traditional methods can be inflexible. For instance, gas spring technology is limited in application, while hydraulic cylinders can be prone to leakage and costly to maintain.

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M O T I O N S Y S T E M A P P L I C AT I O N S

 precision ball screws • Manufactured from your existing part, a print, or based off your specific application

Electrak HD linear actuators can be synchronized by embedding all load-

• Diameters up to 6” and long lengths (longest to date: 54 feet)

handling technology into a single electromechanical actuator, which is then wired in sequence with up to three other similarly equipped actuators. On-board electronics can detect speed changes that indicate load imbalances, eliminating bouncing and other effects of imbalance.

Non-integrated electronic systems have more flexibility and are cleaner but require external devices such as encoders and potentiometers to track position and send feedback to an external PLC. “The ability to synchronize movement of large and potentially awkward loads is something our customers have been requesting as they seek to automate larger applications or improve ergonomics,” said Chad Carlberg, Product Line Manager for Industrial Actuators at Thomson. Synchronization enables motion integration of up to four Electrak HD actuators. Installing multiple units with the synchronization option lets designers take advantage of a more stable and potentially quicker lift, with no additional guides, and improved handling of uneven loads. What makes this synchronization possible is embedding all loadhandling technology into a single electromechanical actuator, which is then wired in sequence with up to three other similarly equipped actuators. Designers install these wherever linear movement is needed without the need for external assemblies. Once the actuators are installed,

made-to-order in 4-5 weeks (most sizes)

ContaCt Us today: Dynatect Lead Screws Intl. 2101 Precision Drive Traverse City, MI 49686 Sales@Dynatect.com Phone: (231) 947-4124 www.Dynatect.com Ballscrews — Motion Casebook 11-17 V2.indd 16

DESIGN WORLD — MOTION

customers synchronize them instantly by wiring them together and operating a single unit with a simple switch. During operation, system electronics detect speed changes that indicate load imbalances, thereby eliminating bouncing or other effects of imbalance. Using multiple synchronized actuators increases system movement speed more efficiently. A larger load that might normally use a single, heavy load actuator, for example, could be moved faster by combining multiple, lower load actuators. Synchronization also retains all Electrak HD mechanical capabilities, including the handling of bidirectional loads of up to 10 kN (2,250 lb-ft) with stroke lengths up to 1,000 mm (39 in.) and accuracy of 1% of stroke from 100 to 1,000 mm. High-quality ballscrew assemblies provide efficient current draw and support speed options up to 43.5 mm/sec (1.7 in./sec), using the 1.7 kN (382 lb-ft) version. The benefits of synchronization apply in many cases. So in addition to solar panels and off-highway agricultural equipment, potential applications include industrial logistics trains for automatic correction of imbalances as well as ergonomic patient-handling equipment such as lift tables. 11 • 2017

11/15/17 8:41 AM

BEARINGS

bearings applications and new approaches to integrate them into machines Bearing

variations abound to satisfy an array of loads, environments, speeds, expected design life, and more. Consider the bearings and slewing rings in wind turbines. These can reach 2 m in diameter and must sometimes bear hundreds of tons. In contract are miniature bearings for medical applications. These often go into tiny handheld devices and other compact equipment necessitating bearings of just a couple millimeters in diameter (with rollers that are even smaller). Some going into equipment subject to washdown have treated steel subcomponents; others for disposable or quiet designs are made of plastic. Industrial machines that endure hot, fast, or lubrication-starved conditions pose their own bearing-design challenges. Some of these benefit from the use of hybrid bearings — those with steel raceways and rollers or balls made from ceramic. No matter the design, each bearing type satisfies specific parameters. Ball bearings use balls to provide low-friction motion between bearing races. When selected properly, they require little maintenance. This feature and their limited heat generation make them indispensable. They are found in everything from skateboard wheels to turbine engines — in aerospace applications, medical equipment, and home appliances. Roller bearings have cylindrical rollers instead of balls to transmit loads and reduce friction. Thanks to this shape, roller bearings have greater surface contact than ball bearings, so handle larger loads without deforming. Their shape also allows for a moderate amount of thrust load because weight is distributed across cylinder line contacts instead of point contacts. These bearings are common in conveyor belt rollers, turbine engines, transmissions and gearboxes, as well as the mining, food and beverage, pulp and paper, waste-water and marine industries. Needle roller bearings have rollers with lengths at least four times their diameter. The large surface area accommodates high radial loads even in compact designs. Needle bearings often go in compressors, rocker-arm pivots, pumps, transmissions, and other automotive designs. Needle bearings are also common in construction and agricultural equipment, two-cycle engines, outboard engines, and paper-moving equipment.

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Bearings — Motion Casebook 11-17.V3.LE.indd 17

The Airframe human exoskeleton supports movement during assembly work — which reduces stress on the back, neck, and shoulders. Manufacturer Levitate Technologies uses a wide variety of igus iglide plastic bearings to minimize the design’s weight and maintain smooth rotation while under high axial loads.

11 • 2017

DESIGN WORLD — MOTION

11/14/17 8:55 AM

APPLICATIONS

MOTION SYSTEM

Thrust ball bearings go in applications with mostly axial loads and can handle shaft misalignment. These bearings excel in high-speed aerospace, automotive, and oil and gas applications. Thrust ball bearings also work in machine tools, fluid-control valves, and spindles. Thrust roller bearings transmit load from one raceway to the other to accommodate radial loads. Bearings like these also have a self-aligning capability that makes them immune to shaft deflection and alignment errors. Typical applications include: crane hooks, pulverizers, cone crushers and other heavy-load, medium-speed applications. Tapered roller bearings have tapered inner and outer ring raceways with tapered rollers between them. The rollers are angled so their surfaces converge at the bearing’s axis. These bearings can handle axial and radial loads. Common applications include helicopter transmissions, fuel pumps, and agricultural equipment. Plain bearings don’t have rolling elements. They’re compact and lower-cost bearings for many applications, but automotive and construction are some of the most common. Plain bearings go in steering cylinders, hydraulic excavators, and more. Heavy-duty bearings in tunnel-boring machines The city of Akron is currently seeing the creation of the Ohio Canal Interceptor Tunnel or OCIT. This tunnel cuts through 6,240 ft to connect the Little Cuyahoga River (on the Ohio & Erie Canal Towpath) and Lock 1 of the canal at West Exchange Street in downtown

Akron. To connect the two locations, a tunnel boring machine (TBM) is clearing shale, soft rock, hard rock, and boulders. The builder of the TBM on this job — Robbins — used bearing from nearby bearings maker Timken in the machine. The project is already started on soft ground with fairly low cover over the tunnel; the machine here was run in closed mode — essentially like a submarine. Pressure at the excavation face and the bulk head of the machine was the barrier. “Inside the machine is an atmospheric pressure, and at the cutting face it's pressurized to a level needed to counteract ground pressure, hydrostatic pressure, or ground water — to a maximum of 3 bar,” said Robbins’ chief engineer Dennis Ofiara. But once the machine gets into shale and the cover over the tunnel increases, the sturdier rock lets it operate in open mode. Then the machine’s bulkhead acts as a gate that (when opened) lets engineers move material as fast as they can cut it. Overall, the project is a balance between the machine operating in open and closed mode ... and allowing both without making the machine too complicated. Usually in open mode, the excavated material is removed with a belt conveyor. In

The 1963 Eero Aarnio Ball Chair and other heavy moving furniture uses mediumgrade tapered bearings.

DESIGN WORLD — MOTION

Bearings — Motion Casebook 11-17.V3.LE.indd 18

11 • 2017

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APPLICATIONS

MOTION SYSTEM

The geometry Timken uses for the heavy-duty bearings on the Robbins TBM have evolved to be optimal for general tunnel boring The wall section on the bearing is thick and can carry a high load and also has a high power density. The geometry of the interfaces of the rollers on the races, and the roller end on the large rib of the inner race, is optimized to minimize degeneration.

closed mode, it's removed with a screw conveyor. The real catch is that it’s a big job to interchange belts on a screw conveyor. So for the OCIT project, the plan is to change modes a couple times along the line of the tunnel where depth of the cover varies. The bearings needed to handle this are fairly standard in the industry. They have been refined for years to handle the specifics of TBM applications like this. “For this application, we’re using heavy sectioned bearings,” said Timken Principal Application Engineer Tim Murphy. They're called HH bearings, which stands for very heavy duty. There are two different types — a 19-in. cutter bearing and a 17-in. cutter bearing — and these are ubiquitous in the industry. The geometry on them has evolved so it’s now optimal for general tunnel boring. The wall section on the bearing is thick and can carry a high load … and has suitable power density. Plus the roller end on the large rib of the inner race minimizes degeneration ... even while providing support to accommodate overturning moments encountered in tunnelboring environments. Cutter technicians change the cutter ring regularly, as the ring on the outside of the bearing actually does the cutting into the tunnel face. It’s common to see four to five rings changed

before a bearing is changed out. Ultimately, changing the rings is entirely dependent on the geology. The ground involved in the OCIT project is rather forgiving by industry standards — mostly soft. “But we'll have some mixed space with soft ground and perhaps some boulders. That's tough because large boulders can induce high impact forces and bearing problems,” said Ofiara. The other challenge is keeping the bearing sealed. In closed mode, there's pressure at the excavation face, and even the cutters are under pressure. Here, metal-based seals keep contaminates out, but sometimes the seals are breached and that can spur a bearing failure. Complicating things is that in soft ground the cutters don’t have much traction. Consider cutters pressed against a rock base: There’s enough of a resistant force to cause them to turn as they should. In soft ground, that force may not be present, so there’s a risk of skidding. Plus soft ground with a lot of sand is abrasive and wears the cutter — even through the hub of the cutter and into the bearing. But 6,200 feet into the ground, the aim is to not change the bearings, underscored Ofiara.

56 iglide plastic bearings from igus replaced this car’s standard parts before a 60,000-mile world tour. One X6 bushing in the throttle valve (taking the place of a carburetor on newer vehicles) withstands high temperatures ... including those inside throttle valves. More specifically, the X6 material is resistant to temperatures to 482o F and short-term exposure to temperatures reaching 599o are acceptable.

DESIGN WORLD — MOTION

Bearings — Motion Casebook 11-17.V3.LE.indd 20

11 • 2017

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11/14/17 8:57 AM

BELTS & PULLEYS

belt drives and pulleys are mainstays in motion

Many

motion applications make use of belts and sprockets — often taking the form of urethane, double-sided, mini-pitch, and made-to-order (MTO) belts and sprockets. Double-sided belts have covered teeth to transfer up to 100% of the maximum rated load from one or both belt sides. These come in trapezoidal timing-belt configurations and HTD curvilinear tooth profiles. Urethane belts maximize motion transfer, especially when incorporating polyester or aramid tensile members. Their tooth profile is a miniature version of belt with standard 40° angle teeth. Speed ratios reach 8:1 and torque output is to a couple lb-in. These belts excel on positioning axes, thanks to their low torque and minimal backlash — especially in printers and copiers that need clean operation. Made-to-order (MTO) belts take myriad forms, but most are trapezoidal and HTD. Those that go into applications involving the assembly or transport of electronics or explosive substances include a body and tooth-facing fabric made of conductive material such as carbon to prevent static discharge. In contrast, belts for power tools and appliances are often made of non-conductive materials that insulate internal components. Belts that run in harsh environments incorporate oil-resistant and temperature-resistant compounds. Elsewhere, tensile members made of aramid withstand shock loads, and steel members help belts maintain positioning accuracy. Engineers can even customize the twist of members to alternate or go left or right to

satisfy tracking requirements. Another option is thick or backed belts to convey or grip objects in tandem with mating belt drives. Backings can also extend belt life and address vibration. For industrial applications, most belt sprockets are made of either cast or ductile iron. That said, steel excels in designs that run at speeds exceeding those safe for iron pulleys — to 20,000 fpm. Likewise, aluminum pulleys run at high speed and have low inertia to boot. Another lightweight option is non-metallic pulleys — common in lawn equipment and power tools that transmit little torque and have relatively short design life. Other synchronoussprocket options include specialty tooth profiles for better positioning accuracy or custom hub mounts and flanges.

Electric skateboards from Boosted Boards use two battery-powered electric motors to drive front and rear wheel axles through belt drives. The belt drive triples motor output torque to impart faster acceleration, braking, and hill climbing than electric skateboards with hub motors.

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11 • 2017

DESIGN WORLD — MOTION

11/14/17 8:59 AM

APPLICATIONS

MOTION SYSTEM

example of

torque-limiter

integration for overload protection Ideally

engineers would anticipate the need for overload protection in a drivetrain and include it in the original design. But overload problems often only appear after equipment is in use. Such designs require torquelimiter retrofits, even if existing assembly geometry is tight. Making the issue more challenging is that end users often want a solution right away. In one such aircraft-wing assembly application, an arm to position components had problems with overload shortly after going into use. Arm articulation is through a timing-belt pulley at a pivot point, which in turn is driven by a belt engaging the motor output shaft. Extra load on the wing assembly transferred backward through the arm to the motor. Adding a torque limiter was the clear solution, but there was only one inch of axial space available between the frame and pulley. No torque limiters thin enough to fit could deliver the needed 530 lb-in. of required torque. It appeared that the only option was to redesign and rebuild the arm — a costly and time-consuming proposition.

Instead, the aircraft-assembly operation found an option for an emergency retrofit — so in 12 business days from initial inquiry to delivery, got a new component for the kinematic system combining the drive pulley and torque limiter. That addressed the space constriction while still delivering 760 lbin. of torque. Engineers from Mach III Clutch Inc. designed the specialty component to combine the timing-belt pulley and torque limiter into one component that uses less than one inch of available axial space. Nothing in the rest of the design had to be moved; even the belt position was maintained. Mach III also expedited production of the custom component to keep the maker of the assembly arm out of trouble with the end user. Other brake and clutch uses Brakes, clutches and torque limiters work in medical equipment, packaging machinery, industrial hoists, and installations. Brakes stop and hold loads. Clutches and torque limiters disengage and engage power-transmission outputs to transfer torque from an input. Torque limiters modulate power transmission to protect mechanical equipment from overload.

TIMING BELT PULLEY INTEGRATES TORQUE LIMITER Engineers from Mach III Clutch Inc. designed a specialty component to combine a

DRIVE PULLEY DRIVE BELT

timing-belt pulley and torque limiter into one component. This addressed a serious overload problem in a piece of aircraftassembly equipment identified after

TORQUE LIMITER

operations had begun. In fact, 12 days after getting details of the application and problem, Mach III had designed, manufactured, and delivered five complete torque-limiter/pulley assemblies.

DESIGN WORLD — MOTION

Brakes & Clutches — Motion Casebook 11-17.V2.LE.indd 22

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Power Transmission and Motion Control Solutions for Industrial Applications

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Altra -- Motion System Casebook 11.17.indd 23

11/14/17 12:01 PM

Highest Torque in the Smallest Space

To maximize mounting flexibility, XS brakes come with a custom-designed mounting plate tailored to end-user application needs. The actuating coil runs off a 24-Vdc pow-

... or the largest.

er supply as standard with other voltage options available to suit other applications. Warner Electric XS Series brakes are available in six sizes with overall diameters of 22

Maxitorq® clutches and brakes deliver power, reliability and are customized to meet your exact needs. Land, sea and air – CJM is everywhere.

mm, 29 mm, and 33 mm. The most powerful XS-Series brake delivers holding torque to 0.5 Nm from a 100-g design.

When selecting clutches, brakes, and torque limiters for an application, options include mechanical, electric, fluidic or self-actuation. Electric brakes are easy to control and cycle, even to a couple thousand cycles per minute. In contrast, common air-actuated brakes and clutches run coolly and maintain hold with minimal power. Friction brakes with disc, drum and cone morphologies work well as emergency brakes because of their failsafe holding—essential on conveyors, escalators, airport-baggage handlers, elevators and other safety-critical designs. The size and type of brake most suitable for a given design depend on whether the machine needs emergency stops or softer stops that sacrifice brakes to protect loads from shock. Then, other application criteria (including the machine envelope, thermal capacity, cycle rates, and inspection and repair schedules) dictate the final selection. In other machines, it’s more important that brakes prevent shifting loads and misalignment. In most cases, it’s best to size brakes and clutches to the motor torque of the machine axis. But especially for axes where the brake must stop a vertical load, engineers should account for the fact that motors can temporarily draw added current to output more than their rated torque. Helpful resources include published performance curves from brake and clutch manufacturers. These list dynamic torque ratings for various operating speeds to help engineers match brakes and clutches to peak motor-output When evaluating which clutch or brake to torque. select, it is important to consider installation Beyond these general and performance criteria as well as unit guidelines, fast, hot and other capabilities. Both the clutch and brake extreme applications require extra models of the Carlyle Johnson MAXITORQ evaluation. Some tips: Spring-set EMA800 adapt to high-speed applications brakes benefit motion designs that with three balancing holes in the body for slow loads with the motor before dynamical balancing. the brake engages; they’re also suitable as holding mechanisms.

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Brakes & Clutches — Motion Casebook 11-17.V2.LE.indd 24

DESIGN WORLD — MOTION

11 • 2017

11/14/17 2:58 PM

Bluegrass Bourbon &

BRAKES & CLUTCHES

Brakes

Warner Electric’s engineering team worked with an aerospace OEM during development of airplane seats to supply an XS brake that meets (or exceeds) all application requirements for compactness, quiet operation, and power. Source: iStock / servet yigit

Machinery that runs beyond a few hundred cycles per minute may require brakes and clutches that are larger than performance curves indicate. Industrial designs that operate in hot environments may benefit from friction brakes with specialty friction-surface geometries and materials (such as phenolic resin or ceramic). Motion applications that don’t get a lot of maintenance also benefit from the longer life these friction materials get. Brakes that use permanent magnets for operation automatically adjust for wear. Brakes for quiet and powerful braking in lightweight airline seats Some spring-actuated electrically released brakes work with actuators that are usually stationary. Such actuators move a load to the target position and then hold it there while a product or machine performs its job. Typical applications include positionadjustment systems in medical equipment and first and business-class airline seats. Here, it’s critical that actuators maintain fixed positions regardless of changes in the applied load or powersupply interruptions. That means mechanical brakes are a leading choice. But because these applications are limited by stringent weight, space, and cost constraints, the brakes must be highly specialized designs. Consider XS-Series spring-actuated electrically released brakes from Warner Electric — part of the Altra Industrial Motion Corp. — specifically designed 11 • 2017

Brakes & Clutches — Motion Casebook 11-17.V2.LE.indd 25

to meet stringent compactness requirements in weight-sensitive applications. They boost reliable braking performance in packages weighing as little as 27 g. The XS brakes are also statically engaged holding, so can stop moving loads in exceptional situations. The most powerful XS-Series brake delivers holding torque to 0.5 Nm from a package weighing only 100 g. The actuating coil runs off a 24-Vdc power supply as standard with other voltage options available to suit other applications. Operation of the brakes takes only 3 W of power for the smallest units (and only 7 W for the largest). XS Series brakes are available in six sizes with overall diameters of 22 mm, 29 mm, and 33 mm. One of the first customer applications for the new XS Series brakes is on actuators in first and business-class seats for a major global aerospace OEM. There were extremely stringent space and weight requirements, and the customer needed exceptionally quiet operation. Seat specifications called for a brake having characteristics exactly matching that of the model XSB29 brake. Working closely with the aerospace OEM during seat development and testing, Warner Electric’s engineering team supplied an XS brake that met or exceeded all application requirements. Plus the design is more cost-effective than competing permanent-magnet brake variations. DESIGN WORLD — MOTION

Yes, Brakes

For 45 years, Mach III has produced made-to-order friction brakes, clutches and torque limiters that meet the exact requirements of our client’s applications. • 2,000+ models • Torque to 60,000 in-lbs. • Quick & reliable lead times • Expert engineering assistance

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859-291-0849 machiii.com 11/14/17 9:10 AM

APPLICATIONS

MOTION SYSTEM

cables satisfy specific applications

This is a retail-ready case-packer machine called the 424 T2 (D). Designed and integrated by SOMIC America, it forms and loads soft and flexible products into condensed packages. Notice the arcs of its cable carriers rising above the machine enclosure.

Cables

come in versions to customized to application requirements. Usually, a cable’s conductors and strands are an exact match to the design motor’s need for power and the design sensors’ and controller’s need for feedback and signals. In fact, cables in motion-control applications must often handle tight bending radii, abrasion, flexing and possibly even torsional movements. Some must also isolate the effects of strands conducting power. In VFD cables, for instance, a symmetrical ground design with three grounds and three power conductors offers a small outer

DESIGN WORLD — MOTION

Cables & Management — Motion Casebook 11-17.V2.LE.indd 26

11 • 2017

diameter and less EMI. However, a four-conductor design with three power conductors and one ground is better for continuous flex applications. The latter are common in machine tools, assembly lines and industrial-production applications. Jacket material must also be compatible with the application. The cable jacket protects conductors and insulation and may also provide a level of shielding. For example, cables used in harsh environments, such as on mobile machinery and machine tools, require special jacketing to withstand chemicals such as cutting fluids and oils and abrasion. Cables used in these tough environments or in welding applications may also require a flame-retardant jacket or low-smoke, zero-Halogen design. Cables used in flexing and rotating applications, such as those on robots, must have high tensile strength and abrasion and flammability resistance. These are most often manufactured of polyvinyl chloride (PVC), chlorinated polyethylene (CPE), polyurethane (PUR) and thermoplastic elastomer (TPE). motioncontroltips.com | designworldonline.com

11/14/17 3:00 PM

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11/14/17 12/21/15 12:02 9:58 PM AM

APPLICATIONS

MOTION SYSTEM

On the other hand, cables used in medical applications must be biocompatible. The most common material used in cables for medical equipment is silicone, as it is durable and can be easily sterilized, disinfected and cleaned without disintegrating. Other medical-grade materials include thermoplastic elastomers, thermoplastic polyurethanes and PVC. Still other cables are manufactured with antimicrobial jacket materials to prevent bacterial growth. As mentioned, shielding protects cables from outside electromagnetic interference, but also protects users and machines from voltage spikes and other internal interferences. For cables that will be inside cabinets or machines, or those with light to medium loads, unshielded designs may be used, as they usually are smaller and offer a tighter bend radius. But cables installed on machines that are in motion require shielding, especially when they connect to a motor or drive enclosure.

Cicoil's flat cable assembly withstands constant exposure while supplying power and data to the (constantly moving) outdoor sign.

Application example: Flexible cable powers Coca Cola's sign at Times Square Cicoil recently helped Coca Cola revolutionize its Times Square sign with a new 3-D Robotic Video Display. The sophisticated 68 x 42 ft robotic billboard includes 1,760 high-resolution LED cubes in continuous motion, exposed to all kinds of weather, and operating 24-7. Because this is a very high-profile location, Coca Cola needed one reliable cable to withstand the outdoor exposure. That’s because if one cube doesn’t function, the entire sign won’t work. The company turned to Cicoil, which supplied a long-term cable solution that was flexible and extremely durable. Cicoil tested various cables for almost four years beforehand to ensure maximum durability and flexibility. Besides physical requirements, the cables has to reliably provide power and signal transmission to each of the large sign’s actuators and display panels. Unlike the other cables considered, Cicoil’s flat cable was the only one to survive the rigorous testing. Cicoil’s lightweight flat cable was chosen for its flexibility and also because it provides excellent heat dissipation, tolerates cold (-65° C) and hot temperatures (to 165°C) and withstands extended exposure to vibration, sunlight, wind, acid rain, ice, fungus, humidity and chemicals.

Coca Cola's 68 x 42-ft robotic billboard includes 1,760 high-resolution LED cubes in continuous motion and exposed to all kinds of weather. Flat cable from Cicoil ensures they reliably run 24/7.

DESIGN WORLD — MOTION

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CHAIN

chain drives

and chain-actuated applications

Chains

excel where designs require reliable transmission of power or conveyance of products in machinery. Roller chains are mainly used with drives, but also work in harsh environments that subject chain to weather, water or chemicals, where other options would fail. Most drive applications use an ASME/ANSI roller chain wrapped around a driver sprocket connected directly to the motor or reducer. Conveyor chains go in applications that require moving product horizontally, vertically or around curved radii. Most common conveyor chains are ASME-style (ANSI-style) attachment chains. Types

include single-pitch attachment chain, doublepitch attachment chain, hollow-pin chain, curvedattachment chain and plastic-sleeve chain. The attachments accommodate special fixtures or blocks for specific conveyor functions. Accumulating conveyors use one conveyor-chain subtype that works in applications needing more control over product flow — in packaging or assembly, for example. Rigid chain is a special type of chain that pairs with electric motors to push and pull loads. Locking links form rigid series or coil upon retraction. Small consumer-grade applications for rigid chain include

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DW half page rv.indd 1 Chain — Motion Casebook 11-17.V2.LE.indd 29

4/12/2016 2:17:33 PM 11/14/17 9:27 AM

This tray-packer chain uses Tsubaki Lambda chain

APPLICATIONS

with sintered oil-impregnated bushings. The lubricant is NSF-H1 food-grade lubricant. Pushers on the transport chain include attachments mounted with an engineered extension pin that allows flexible spacing to accommodate myriad packing configurations. Realworld use of the chain in demanding 24/7 production

MOTION SYSTEM

processes shows minimal chain elongation.

powered skylight mechanisms for opening and closing. Larger industrial applications include those for jacks and platforms, material handling, and actuation of vertical axes. Some applications need guides to maintain stability and not buckle under angled loads. Otherwise, engineers can design the application to run the rigid chain with links shoulders down. Standard rigid chain is carbon steel to withstand heat to 200°C, but some machinery benefits from stainless, high-temperature, and coated chain. In a similar way, self-lubricating power-transmission chains excel in harsh environments or where regular maintenance is difficult. They are useful in applications in food and beverage, paper product or wood-processing industries where traditional lubrication presents too much of a contamination or clogging risk. Case in point: Chain specific to the packaging industry Traypackers are machines in the food and beverage industry that load cardboard trays and boxes with cans, boxes, or pouches of food or drink. Contamination is unacceptable, and the machine can’t tolerate lubricated chain that might attract dust or paper particles. The challenge is that insufficiently lubricated chain can become stiff and elongate over time due to wear. To satisfy application parameters, a chain offering specific to the task of traypackers from Tsubaki now includes sintered oil-impregnated bushings that makes for an internal lubrication arrangement that can’t contaminate products

Shown here is a consumergrade rigid-chain application in a skylight application. Image courtesy Velux

DESIGN WORLD — MOTION

Chain — Motion Casebook 11-17.V2.LE.indd 30

11 • 2017

or the traypacker’s surroundings. It also eliminates the need to schedule reapplication of expensive food-grade lubricant. The Traypacker Chain is also narrower than standard offerings to fit typical tray-packing geometries. Specialty coatings and more Chains with specialty coatings are often required in rugged environments. Stainless steel is a good choice in applications exposed to corrosion, but because this material cannot be hardened in the same manner as carbon steel, it doesn’t have the same load carrying capacity. Nickel-plated chains are another alternative, providing some protection for mildly corrosive environments. If a chain application needs long life without contamination, pick chain with self-lubricating subcomponents. If the roller-chain application requires high precision, pick chain with precision roller bearings at each link connection.

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11/14/17 1:55 PM

AN UNBEATABLE PACKAGE:

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Total Package USTSUBAKI.COM

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APPLICATIONS

MOTION SYSTEM

r a n g e o f a p p l i c at i o n s f o r

motion controllers Motion

controllers — those precision command centers of motion designs — are central to today’s motion-system innovation. They range from single-axis smarts to programmable automation controllers (PACs) that synchronize hundreds of axes and plant data communications. As usual, the latest motion-controller application examples showcase the best innovation in motion design.

control loaders mimic the feel of the flight stick, and they can simulate nose wheel steering, throttle controls and automotive steering wheels.” But motion-control systems require a variety of I/O interfaces — and not just any interfaces but high-performance ones. Plus it’s often useful to have more than just basic I/O functions. The 826 solved a couple design problems. Motion-platform maker Previously, Servos & Simulation needed two standardizes on I/O for measurement and control analog boards for every motion system and now Servos & Simulation Inc. is a manufacturer of motion platforms the builder needs only need one. In this way, and control loaders. Recently the systems builder picked a Sensoray solved an expense problem from the Model 826 analog and digital I/O system on a PCI Express board start. “Additionally, we needed a digital-to-analog from Oregon-based Sensoray for the primary measurement and converter that would handle at least six axes for control interface of their full product line. the motion bases and up to eight for the control Servos & Simulation provides motion platforms and control loaders,” said Baker. “We needed an analog-toloaders to commercial, military, and simulation applications. digital converter to handle up to 16 inputs — 12 These applications include aviation simulation, full flight for the six-axis motion platforms and up to 16 for simulators, flight controls, autopilots, and more. Servos & the eight-axis control loaders.” Simulation’s motion platforms are fully electric and high precision. The most important aspect of the D/A and “We make two types of control loaders — Model 300-x is A/D was 16-bit resolution and real-time speed. for FAA level 1-6 applications and Model 400-x is for all levels By using Sensoray’s 826 board as a single central of FAA requirements up to and including Level solution, Servos & Simulation streamlined all D,” explained Rachel Baker, owner aspects of what it builds and produces — from and engineer at Servos & documentation to the drawing sets to actual build. Simulation. “The “We also have safety factors that needed to be addressed. The watchdog circuit on the 826 board accomplishes this with little engineering or hardwiring on our part, as it’s part of the card. With a slight change in the source code, we now have a robust system for the safeties across our entire product line,” added Baker. In fact, realtime This is a Model 826 board from sampling recalls an Sensoray. Functions include a often-overlooked three-stage watchdog timer and issue. It's not failsafe outputs. System builders enough to just (including Servos & Simulation) are using the board’s high-speed counter digitize quickly, as FIFOs in new ways. there must be a way to efficiently move

DESIGN WORLD — MOTION

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APPLICATIONS

MOTION SYSTEM

sample data off the board and into the context of the application program. Many board vendors employ callbacks for this purpose, which makes life easy for the vendor but quite complicated for the software engineer. The problem with callbacks is that they lack context, so it's left to programmers to marshal samples into the appropriate context. A common workaround is to have the callback send samples through a pipe, but this increases latency and clutters the source code. Model 826 eliminates these problems by providing blocking API functions. The program simply calls a function to wait for a sample, which arrives in-context with minimal latency. So sampling is very fast and it's easy-to-write and clean and maintainable source code. Baker said that her company used the board's failsafe system on the motion bases for a hard emergency stop and a software stop. The hard stop is triggered by hardware in the drive amplifier chassis and is sensed by the 826 card (via a digital I/O line) so that it shuts down the software and control outputs. “The software stop is a little different; the user pushes a button to stop the software, and the button is sensed by the 826 card ... which then stops the system playback, sets the motion base back to egress, and shuts down the system,” she added. Get more on the Servos & Simulation application and the Sensoray 826, integrated failsafe systems, addressing legacy designs using PCI slots, and how Servos & Simulation and Sensoray collaborated on software at motioncontroltips.com.

Controller-drivers steer sample-transfer machine Gatan Inc. makes specimen-preparation equipment and recently built an alpha prototype of a new machine. The iPrep prototype mounts to a scanning electron microscope (SEM) and shuttles samples back and forth between a processing chamber and SEM receiving dock. Within the chamber, two broad-beam ion guns polish samples. The iPrep’s automated transfer mechanism allows use of SEM-related imaging techniques for 3D reconstructions of sample areas with exact control over slice thickness. The iPrep machine employs an AllMotion controller to command a transfer arm’s end effector to accurately open and close … and move a sample carrier to the polishing chamber and SEM. Another AllMotion EZHR23EN48V controller is part of a kinematic mounting system on the

DESIGN WORLD — MOTION

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Servos & Simulation Inc. picked a Model 826 analog and digital I/O system on a PCI Express board from Oregonbased Sensoray for the primary measurement and control interface on their full product line.

receiving dock inside the SEM. Stepper motors drive the end effector and receiving dock. The EZHR23EN48Vs are controller-drivers measuring 2.25 by 2.25-in. and bolt to the backs of the stepper motors they control. The controllers use a single four-wire bus with two power wires and two for communication. Simple commands are made via any serial terminal program or from the EZStepper Windows application. Because every operation the iPrep performs occurs in a vacuum chamber, it’s impossible to hear or see when things go wrong. So Gatan relies entirely on sensor data (leveraging EZHR23EN48V wiring for OptoSwitch inputs) to identify problems in the chamber.

Get more on the iPrep machine employing an AllMotion controller at motioncontroltips.com.

Filament extrusion machine builder gets industrialgrade performance with PWM drive Filabot, a manufacturer of plastic-extrusion machines for the 3D printing market, has just released its new and improved EX6 filament extrusion machine. The Filabot EX6 improves overall extrusion process control and consistency compared to previous models — mostly by adding features that are standard on industrialscale extruders. The EX6 has a higher output compared to other systems of this size, but is efficient enough to run motioncontroltips.com | designworldonline.com

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StepSERVO

Integrated Motors

Fully programmable motion control Ideal for position, velocity, or torque control On-board industrial Ethernet and ﬁeldbus Largest range of frame sizes available IP65 ratings for splash zone

The Evolution Continues StepSERVOTM technology from Applied Motion Products combines the high torque capabilities of step motors with the closed loop dynamic control of servo systems. The result is a motor + drive solution that operates more quietly and eﬃciently, while providing greater torque and higher acceleration rates than traditional step motor systems.

In 2017, Applied Motion Products evolved the broad line of StepSERVO™ Integrated Motors, ranging in frame size from the miniature NEMA 11 to the largest NEMA 34, to include improved EtherNet/IP and CANopen communications. These already successful products now feature greater industrial networking power, enabling them for even more advanced automation projects, and further empowering you to Make it Move.

800-525-1609 www.Applied-Motion.com Email: sales@applied-motion.com

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APPLICATIONS

MOTION SYSTEM

This Filabot filament extruder is called the EX6. It has the power and features of larger industrial-grade extruders, but in a small format.

off a 15-A 120-V outlet. Filabot also focused on versatility for the new EX6, which can extrude filaments in an array of different polymer grades and types. The EX6 has multiple-zone heating and cooling for the barrel and feed throat and an industry-standard 24:1 length-to-diameter screw ratio. A motor upgrade allowed Filabot to use a screw that’s longer than those on legacy systems. Therefore, boosting material output. So, why is that important? In single-screw polymer extrusion, a longer screw improves output pressure and material consistency. It also allows for more room in the machine to accommodate multiple screw geometries that Filabot offers to improve the output performance of specific polymers. In fact, the main design improvement that differentiates the EX6 from other offerings is its longer screw — a screw that necessitates a compact but powerful and consistent drive system. For this portion of the design, Filabot turned to Klauber Machine & Gear, a fractional horsepower gearmotor manufacturer based in Missouri. Klauber engineers assisted the team at Filabot by executing performance tests on prototype drive motors and then helped Filabot choose a gearmotor with suitable output power. “The array of gearbox and motor

configurations from Klauber made the motor we chose easy to integrate and decreased the complexity of the overall system design,” said Filabot CEO Tyler McNaney. Klauber is part of Trident Motion, a new group in the motion-engineering industry. Another company of Trident, American Control Electronics (ACE) also supplies motion components to Filabot for the EX6. “PWM drive options from ACE also Get more on the made it easy to choose Filabot story at a small, simple to motioncontroltips.com. integrate drive with the options we needed … including potentiometer speed control and IR compensation,” added McNaney. The high-quality output of the ACE drive runs the motor cooler and more efficiently than other drives Filabot tested, which Filabot engineers say will improve the durability and expected life of the EX6.

A PWM drive from American Control Electronics completes the Filabot EX6.

DESIGN WORLD — MOTION

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CONVEYORS

conveyor innovationS

Conveyor

functions are as varied as the applications they complete. Consider one in which conveyors now help a medical-product manufacturer package (and temporarily store) product. CooperSurgical is a maker of diagnostic and therapeutic medical devices to women’s healthcare providers. Recently the manufacturer turned to QC Industries to setup a new production line that maintains the cleanliness required for packaging medical products, but with high throughput in a tight plant footprint. Ultimately the engineers designed an installation that uses several QC Industries conveyors. Then CooperSurgical took the lead to design and build an automation system to make optimal use of the equipment. “QC Industries helped CooperSurgical put together a new overhead conveyor system that moves parts from our molding to the packaging cell — and it also acts as our stock room, using more than 80 feet of straight conveyors,” explained Kevin Hicks, senior manufacturing engineer at CooperSurgical.

This is the QC Industries conveyor installation. Read more at motioncontroltips.com.

This is a Bosch Rexroth TS 5 roller-conveyor system connects with i4.0 tools to let operators visualize production processes in realtime. An MTpro planning tool makes it easy to implement layouts with three-way diverters, rotate units, frontend drives, and compact stop gates.

better products. better solutions.

Pallet-conveyor systems from mk North America work in an array of industries. The pallets carry loads weighing a pound or less to several hundred pounds. The modular conveyor systems are also configurable into systems that move items long distances, change elevations, and go around corners. For more on palletconveyor systems (including technical data contained in a white paper and the full version of this infographic from mk North America) scan the QR code here.

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DESIGN WORLD — MOTION

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Conveyor solutions for all of your material handling needs. www.mknorthamerica.com 11/14/17 1:53 PM

APPLICATIONS

MOTION SYSTEM

couplings for servo applications

Couplings

for servo applications usually connect precision drives to sensitive loads, so they cannot induce error. That’s why servocouplings should be zero backlash — to prevent issues with timing and predictability (not to mention failures due to hammering on reversing axes). Couplings for servo applications must also have high torsional stiffness while imparting slight forgiveness of misalignment (within specifications) of rotating shafts … even while holding transmitted rpm steady to motor output rpm. But these are just a couple servocoupling considerations. Consider a typical application for servocouplings — to connect a servomotor to a ballscrew. Here, couplings with low inertia let the axis deliver faster acceleration and deceleration without degrading overall system efficiency. In fact, couplings for servo designs must often compensate for subtle power-transmission issues to minimize errors down to 1 arc-min. or lower. That’s especially true where servo systems operate exacting positioning axes. Here’s a more complete list of parameters to consider for proper coupling operation in such designs: 1. Coupling type: Couplings shouldn’t be the last motion component specified because proper servo-machine function relies on having a suitable coupling in place. Torsionally rigid options (ideal for motion designs) include specialty bellows couplings, rubber-jaw couplings, and disc coupling.

Curved-jaw couplings have good damping characteristics to optimize performance of axes with quick acceleration and deceleration. But both disc-type couplings and certain bellows couplings excel on high-speed axes. Other offerings abound to serve other design objectives. One caveat on coupling type though: Never use rigid couplings to replace flexible servocouplings on axes where the latter seem to fail frequently. Here, this issue is most likely insufficient alignment between the motor-output shaft and next component in the powertrain. There’s sometimes a misconception that rigid couplings are exceptionally strong, so can address issues in such situations. The fact is that rigid couplings only work when shafts are perfectly aligned, because these couplings transmit to connected motion components (potentially extreme) forces that arise from misalignment. 2. Sizing for torque (and speed): After specifying the coupling type, the design engineer must select a coupling size. This is dependent on axis speed (rpm); the levels of torque the axis must transmit; and the service factor the application requires. Axes that transmit steady torque are simpler to specify; in contrast, axes that transmit

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

DESIGN WORLD — MOTION

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PRECISE. ROBUST. AVAILABLE. These new generation CD® Couplings feature zero backlash precision and high torsional stiffness. They answer today’s demanding needs in servo motor applications with high reverse loads and positioning requirements. New clamp style hubs handle increased torque on shafts without using keyways. Manufactured of RoHS compliant materials. Now size, select and see the right CD® Coupling solution for your coupling application with Zero-Max 3D CAD files. Check our FAST deliveries.

www.zero-max.com 800.533.1731

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APPLICATIONS

MOTION SYSTEM

variable torque need additional consideration. Here, define the application’s average operating torque and the peak torque. (Also consider the parameters listed in Ability to handle reversals below.) One tip to avoid servocoupling oversizing: Quantify actual system requirements and base coupling selection on those values — and avoid defining a whole axis by the connected gearmotor’s peak torque output. 3. Stiffness: Along with exacting control of position, force, or output velocity, it’s often essential to maintain high efficiency. Couplings that exhibit windup or backlash degrade this efficiency because they must overcome load inertia every

Heavy-duty couplings customized to oil and gas application Consider a coupling application that contrasts with the servocoupling setups we’ve profiled. Recently an oil-and-gas OEM needed a new design of torque-dense disconnect coupling for its hydraulicfracturing pumps. The truck-mounted pumps run off electric motors instead of traditional diesel engines. The couplings install between a 5,000-hp motor (running at 1,800 rpm) and the pump. They also allow for quick disconnections from the drive motor to prevent drivetrain damage during vehicle transport. The OEM chose Ameridrives couplings FDC flexible gear couplings with a torque rating to 551,000 in.-lb. The OEM worked with Ameridrives engineers to get flanged-sleeve double-engagement disconnect couplings with shifting collars designed to meet quick connection or disconnection application requirements. The flexible gear couplings include a synthetic rubber lip seal that allows for disengagement. The 16-in. diameter. couplings have a 6-in. diameter keyed bore on the motor hub and a 5-in. diameter keyed bore on the pump hub. Fully crowned gear teeth provide operational benefits including maximum load-carrying capacity with minimum size and long life. Separation of gear meshes permits high parallel offset capacity.

Bellows couplings must be installed at the proper length (and not under tension or compression). Ruland Mfg. Co. makes such bellows couplings suitable for high-torque applications requiring minimal position error. These have low inertia to maintain system responsiveness and are balanced to excel in applications even to 10,000 rpm. One caveat is that these bellows couplings are intolerant to misalignment or impact loads.

move cycle. This can be a significant drawback in some setups ... which is why (especially on axes employing rigid couplings) couplings should be prevented from inadvertently functioning as flywheels. Note that if a coupling’s torsional stiffness is insufficient, other system functions must compensate. One standard solution is to adjust PID controls and reduce servo gain, though that degrades system response and performance. In contrast, excessive torsional stiffness compromises the ability of an axis to withstand quickly reversing loads. That’s because servocouplings with excessive stiffness can be brittle and prone to failure on demanding axes that must make frequent and sudden directional reversals. Servo-application tip: Balance coupling characteristics for stiffness. Excessive torsional stiffness may induce premature failure. On the other hand, axes that must hold timing (as for positioning commands) benefit from incorporation of torsionally stiff couplings. 4. Inertia: As mentioned, this is an important parameter for a few reasons. Applications with particularly aggressive motion profiles rely on low servocoupling inertia most of all. 5. Damping capabilities: Disc couplings, certain bellows couplings, and high-gain rubber-type couplings are all options for coupling-based damping in servo applications. In fact, the most demanding servo applications have in recent years spurred improved response frequencies ... but vibration (and hunting) arise with high gain settings on assemblies using torsionally stiff couplings. Visit couplingtips.com and search on “damping” for more on this issue and some solutions. 6. Shaft connections: Most servocouplings connect shafts with clamping or locking mechanisms (and not keyways). TOP: This flanged-sleeve, double-engagement disconnect coupling has

The Amerigear couplings compensate for all three types of misalignment. They also feature machined medium-carbon-steel hubs and sleeves. Positive-type O-ring seals keep lubricant in and contaminants out.

a 551,000 in.-lb torque rating and can run to 2,000 rpm. Fully crowned gear teeth maximize load-carrying capacity and power density. BOTTOM: This is a truck-mounted pump at a hydraulic fracturing site. Source: iStock - sasacvetkovic33

DESIGN WORLD — MOTION

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Metal Bellows Transfer Pressure or Temperature into Linear Movement ISO 9001:2008 Certified RoHS Compliant ITAR Certified

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Features: • Highest stroke length (90%) • Highest cycle life • Customization • Repeatability • Media compatibility • High temperature • SS, Titanium, alloys, etc.

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This is a Zero-Max composite-disc (CD) coupling for high-speed and high-torque servomotor and motion-control applications. CD couplings have high dynamic load capacity and excel in precise positioning — even on axes that make quick reversals. Though comparable couplings of other designs may have high torsional stiffness, some are too brittle to withstand such reversing.

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Though keyways are often offered as an option to prevent shaft slippage, the truth is that they can be a liability — adding concentrations of stresses in shaft connections, unnecessary cost, risk of imbalance, and other potential drawbacks. 7. Ability to handle reversals: Servo applications that must make quick directional changes require special consideration. Here, consider torque associated with system inertia starting and stopping. Service factors can often quantify the effect this value will have on assembly dynamics. Another aspect of reversing loads to consider is couplingmaterial fatigue. Keep in mind that some servocouplings that excel in regular applications can fail within weeks (or sooner) when forced to transmit power under reversing conditions. 8. Function to protect more expensive subcomponents: Though system failures are best avoided, couplings can be designed to protect the axis actuator or motor and gearbox by breaking if there is a machine crash or catastrophic overload. That’s especially useful in high-speed servo applications where drive-based current limits aren’t fast enough to address existing kinetic energy associated with the drivetrain and load upon a jam or sudden impact. 9. A realistic understanding of allowable misalignment: Flexible couplings for servo applications do accommodate misalignment. However, OEMs must be realistic about the level of permissible misalignment for a given axis — and specify assembly techniques and mounting that ensure levels never exceed the rating of the coupling. Otherwise, coupling or other component failure may occur.

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DRIVES

AutomationDirect DURApulse GS4 series of AC sensorless vector drives include dynamic braking, PID, and a removable keypad. The keypad has an embedded Quick Start menu and can

drives

be remotely mounted with a simple bezel kit and standard Ethernet patch cable. The drives are available to 300 hp in 460-V models and to 100 hp in 230-V models.

play key role in modernizing, updating control systems

Drives

— both ac and dc (including variable frequency drives or VFDs) — are essential elements in a variety of applications. Some common applications include conveyor systems, lift and hoist machinery, grinding, fan, pump and compressor operations, and large machinery installations. Common servo systems use feedback and an array of dc drives to control motor-driven axes, but the most common ac drives control induction and ac synchronous motors. A typical ac drive runs applications that need speed control, which is anything from basic functions to VFDs paired with induction motors or synchronous permanentmagnet types. Such ac drives first convert ac to dc and then use switching techniques to vary voltage and frequency to the motor. Constant-voltage VFDs (which

motioncontroltips.com | designworldonline.com

Drives — Motion Casebook 11-17 V4.indd 43

use pulse width modulation or PWM) are most common. These feed a train of dc pulses with different widths into the motor windings with a shaped current waveform. Machine builders often use VFDs to boost energy efficiency. Controlling current drawn by the motor can reduce energy bills because it prevents the motor from constantly running at full load. But VFDs help boost efficiency in other ways, too. With three-phase motors, they outperform single-phase induction motors — common in industrial washers and similar applications. In a similar way, VFD setups also outperform pairings of triac control with universal motors. Applications involving vertical arrangements and those with frequent stopping and starting can benefit from regenerative braking possible with VFDs. Here, the 11 • 2017

DESIGN WORLD — MOTION

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APPLICATIONS

MOTION SYSTEM

drive’s solid-state components channel energy back into the ac mains or a braking resistor. That boosts design efficiency and lets machine axes slow down faster than they would if left to coast down. What’s more, many common applications benefit from ac drives that deliver safety features (brake controls and stops, for example) and acceleration or speed monitoring and limiting. Environmental factors may also be a consideration. For instance, in some cases ac drives must withstand exposure to dust, extreme temperature and humidity. Here, drives with rated enclosures (NEMA 1 or NEMA 12 ventilated, for example) may need to be selected. A recent example illustrates the advantages of retrofitting an existing biopharmaceutical application with updated drives and controls. A biopharmaceutical company needed to address obsolescence in two of its purification skids, and saw it as an opportunity to make some additional operational improvements in the process. The company has multiple tangential flow filtration (TFF) skids for different batch sizes, but it was the two midsize TFF skids that were nearing the end of their service lives. The first skid was put into use in 1998, and the second skid was brought in shortly thereafter. Both skids had PLC, VFD, and HMI components that were either going to be discontinued soon or had already been discontinued. “The company knew these systems were getting near the end of their lives and needed to be replaced or upgraded,” said Tom Brown, project engineer with Banks Integration. “Based on the overall health of the skid system, it made sense to upgrade the control systems.” The company worked with Banks Integration Group, a Rockwell Automation PartnerNetwork program Solution Partner, to design, engineer and validate the controlsystem upgrade process based on the PlantPAx modern DCS platform. This involved upgrading the legacy skids’ PLCs and VFDs to Allen-Bradley ControlLogix 5570 controllers and Allen-Bradley PowerFlex 525 VFDs.

DESIGN WORLD — MOTION

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A single fault tolerant EtherNet/ IP network replaced the company’s existing Data Highway Plus network for better device-level communications and real-time performance monitoring. Additionally, the control systems were integrated into a redundant, clientserver SCADA architecture to enable a greater level of access, including remote access. The new skid systems use the PlantPAx process objects for life sciences – a library of controller code, display elements and faceplates that are customized for the life sciences industry. These predefined elements can help company operators more quickly configure applications to speed up production deployments and shorten cycle times. The new systems also use FactoryTalk Batch software with equipment editor and recipe editor capabilities that let operators create models and build individual recipes. The FactoryTalk Batch with PhaseManager capability simplifies phase logic programming and configuration by making it possible to create equipment Together with PowerFlex VFDs, Alphases without phase logic len-Bradley ControlLogix 5570 coninterface (PLI) code. trollers helped a biopharmaceutical When any issues arise, company integrate their control systems the new systems give the into a redundant, client-server SCADA producer’s team greater architecture to enable remote access. visibility into the skids for faster resolutions. For example, the VFDs on the old systems were not being monitored. As a result, operators would re-start a machine rather than sorting through several dozen fault codes to pinpoint the issue. Now, fault codes from the new VFDs are reported back to the PLC and collected in a data historian. “With the new system and the device-level ring, it can tell you exactly where a failure is occurring,” Brown said. “It probably saved the company a day’s worth of troubleshooting in just the first week of implementation.”

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Proven Worldwide

23 million inverters, 15 million servo axes and 360,000 robots in the field are proof positive that Yaskawa has the engineering expertise, innovative technology and unsurpassed quality to inspire complete customer confidence.

F 50.00

ALM

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FOUT

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RESET

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RUN

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V1000 Freq Reference: FWD/REV Sel : Output Freq : Output Current: Selected Monitor: Monitor : Verify : SetUpGuide : Program : Auto-Tuning :

! WARNING

F6000 (Hz) For 6000 (Hz) 00R(A) 00u (v) Mon urFY SrUP PrG ARUN

Risk of electric shock.

• Read manual before installing. • Wait 1 minute for capacitor discharge after disconnecting power supply. • To conform to CE requirements, make sure to ground the supply neutral for 400V class.

Great things come in small packages with Yaskawa’s V1000 AC Microdrive. Achieve optimum balance of energy input, product output, maintenance risk, and long life with models ranging from 1/8 HP up to 25 HP. No matter how you add it up, nobody equals Yaskawa. Call us today.

For more info: http://go.yaskawa-america.com/1099 Yaskawa America, Inc.

Drives & Motion Division

Yaskawa -- Motion System Casebook 11.17.indd 45

1-800-YASKAWA

yaskawa.com

11/14/17 12:07 PM

The AC58 absolute encoder series from Hengstler feature optical scanning and are available as solid-shaft or hollow-shaft models and can meet requirements for a wide array

APPLICATIONS

of demanding industrial applications. Pictured here is the clamping flange version with IP64

MOTION SYSTEM

protection class rating.

encoders:

motion feedback stalwarts

Encoders

provide position information in motion control systems. They are classified in a number of ways including by the method of sensing (optical, magnetic, capacitive, for instance), whether output is absolute or incremental, or if they are rotary or linear. Rotary encoders are the most common type. They’re used in industrial applications that range from speed monitoring on conveyor systems to position control on automated machine axes as well as robotic systems.

DESIGN WORLD — MOTION

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Encoders also see action in plenty of extreme and demanding environments. Especially in heavy industrial equipment such as in metal stamping, wind turbines, printing, and steel processing, it’s common to see machinery that necessitates high-speed rotary encoders— those that can run and reliably track speed and position to 40,000 rpm. Such applications may also demand rugged and rated encoders with oversized bearings, specialty seals, metal and not glass or plastic read disks, and reinforced housings. Common

motioncontroltips.com | designworldonline.com

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Kuebler’s Safety-Lock bearing design, a mechanical design feature that protects bearings from wear or damage due to shock, vibration or misalignment.

MOTION SYSTEM

APPLICATIONS

The four models in the F58 Series use

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Custom-designed encoders, disks, and linear strips From light touch customization to fully-tailored designs Best-in-industry lead times with same-day fulfillment on in-stock products

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industrial-rated encoder uses can include interior elevators, automated process machinery, and robot joints. Other applications benefit from reflective encoders with built-in interpolation for highresolution measurement on small motors (in many cases, closed-loop steppers) that drive axes on consumer products such as printers. One German manufacturer of agricultural equipment used absolute encoders to improve harvesting technology. More than 80 years ago, Grimme developed the first potato harvesting machine. Besides the actual harvesting, efficient storage technology is equally important to ensure that potatoes remain available in top quality to meet demand. For this type of requirement, Grimme offers the SL80 store loader that uses the AC58 Hengstler absolute encoder. Using suitably adapted sensors, the store loader detects the current filling level. Using these values and the positioning data, the encoder controls the travel and angle of the conveyor mechanism using an intelligent control system. The storage of fresh potatoes is the littleknown link between automated harvesting and on-time processing or marketing. 48

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The onl can

• • •

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ENCODERS

In a different kind of application, encoders are helping packaging machines operate faster. In this case, the Sendix F58 encoder from Kuebler combines certified EtherNet/IP support with patented mechanical and electro-optic technologies for accuracy and reliability. These optical absolute single- and multi-turn EtherNet/IP encoders have a diameter of 58 mm. The encoders have a RPI time as low as 1 msec, which allows them to transmit position data about 5 times faster than many conventional encoders. This speed advantage makes the encoders well suited to packaging, textile and printing applications—or any other application with fast machines that could be even faster with a position sensing upgrade. EtherNet/IP also makes the encoders easy to commission because they start up instantly as soon as they receive power and look for their IP address settings and configure them through software. Due to EtherNet/IP’s Device Level Ring feature, the F58 encoders will not lose communication in the event of a single cable break or signal interruption.

NEW

Programmable thru-bore encoder

Program your CPR, waveform, and output type The new Model 58TP Programmable Accu-CoderPro™ encoder is so configurable, it may be the only compact, incremental thru-bore encoder you need. With the simple-to-use interface, you can program these specs: CPR – any resolution from 1 to 65,536 Waveform – choose from 32 options Output Type – 6 different outputs

Mechanically configurable to almost any application: • Available in Thru or Hollow Bore • Flexible Mounting Options • Standard and Metric Bore Sizes up to 5/8” and 15 mm

• Variety of Connector Types • Operating Temperature Range of -40º to 100º C • Sealing up to IP67

Call EPC today to learn how the Model 58TP can be your encoder solution.

1-800-366-5412 • www.encoder.com

WATCH ONLINE!

Product demos and more at youtube.com/user/EncoderProducts

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APPLICATIONS

MOTION SYSTEM

Interroll synchronous drum motors (for conveyor applications) have only 9% power loss. Their steel planetary gearboxes are 92 to 95% efficient in transmitting power to the conveyor. That makes these drum motors suitable for applications needing high torque and dynamic driving over a wide speed range — or subjecting equipment to high duty cycles.

gears in motion: Gearboxes drive automated parking garage PARKPLUS

is a designer and builder of both mechanical and fully automated high-density parking setups for North America. The manufacturer recently developed an advanced parking system based on free-roaming battery-operated AGVs with omnidirectional maneuverability. Drivers drive their cars into a vehicle-receiving area and onto a large waiting platform called a tray; then an AGV goes underneath the tray to lift it from below, and transport it and the vehicle to storage garage. Traffic-

management software, lasers and machine vision, and markers give the AGVs self-guidance functionality for automated storage and retrieval of vehicles on trays. PARKPLUS system install in new or existing multi-level parking structures. The challenge here is that many such garages have low ceilings to maximize vertical space. So the AGVs that serve the PARKPLUS setup must be quite flat … but still powerful enough to transport a vehicle around a garage. These conflicting design objectives put severe limitations on the AGV design, especially for the drivetrain. In fact, the drivetrain consists of two motors and gearboxes that mount directly into the omnidirectional wheels. PARKPLUS partnered with GAM Enterprises — manufacturer of precision gear reducers, servo couplings, linear-mounting kits, and other automation ElectroCraft LRPX 22 and 32 products — to develop a compact gearbox setup to handle the gearmotors are optimized demanding performance requirements of transporting vehicles. to accommodate gear speed Given the predefined space limitations, GAM selected a 64-mm limitations. The LRPX22 delivers frame size EPL gearbox able to fit into the assembly properly and torque to 3.0 Nm. The LRPX32 accommodate the basic torque requirements. The standard EPL is a 32-mm motor with a peak series is extremely reliable with hardened and ground straight-cut torque of 8.0 Nm.

DESIGN WORLD — MOTION

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Servo Mount Gearheads Low Backlash For Life!

HPN Harmonic Planetary® value series provides a low cost solution without the need to compromise on quality or performance. This new value series of planetary gears carry the reputation for quality and reliability for which Harmonic Drive® products are known throughout the world. • • • •

Helical Gearing Available in 5 frame sizes Peak Torque: 9Nm to 752Nm Ratios: 3:1 to 31:1, new two-stage ratios available soon • Quick Connect® mounting system

• High Efﬁciency • Backlash: <5 arc-min (single stage), <7 arc-min (two stage) • Fast Delivery • Shaft output available with key and centertapped hole or with center-tapped hole

Harmonic Drive LLC | 247 Lynnﬁeld Street | Peabody, MA 01960 | 800.921.3332 | www.HarmonicDrive.net Harmonic Drive®, Harmonic Planetary® and Quick Connect® are registered trademarks of Harmonic Drive LLC.

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M O T I O N S Y S T E M A P P L I C AT I O N S

It’s largely because of GAM gearboxes that automated-garage AGVs for a PARKPLUS design are as space efficient as they are.

gears and heavy-duty angular contact bearings for a 30,000-hour life rating. To absorb the shock and reversing loads the AGV encounters when moving through the parking structures, GAM engineers designed a modified gearbox solution with an output housing and shaft that’s more robust than other offerings. Plus they added tie rods for additional reinforcement. The EPL gearbox setup also satisfies a 12x safety factor specified by PARKPLUS. “We worked with GAM because of the flexibility their engineering team offered given the stringent requirements placed on them as well as the willingness to provide the exact gearbox to suit the AGVs,” said Andreas Wastel, V.P. and Chief Engineer of PARKPLUS. It’s largely because of the GAM gearboxes that the AGVs are as space efficient as they are, he added. The PARKPLUS AGV system has been in operation for more than two years in several locations and has been performing to specification. Gears in motion: Other application examples Gears complement electric motors in industrial and consumer designs. Consider some examples: Amusement rides to consumer-grade beard trimmers make use of spur gears. These roll through meshing for up to 98% or higher efficiency per reduction. The only

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caveat is that they exhibit tooth sliding and noise due to initial tooth-to-tooth contact and audible shock loads. Helical gear reducers are costlier upfront than spur sets, but work in designs needing high horsepower and efficiency. Textile machinery, conveyor drives, rolling mills, and elevators all use helical gear teeth to engage gradually over the tooth faces for smooth operation and high load capacity. The only caveat is that the machine setup must include framing or supports to resolve thrust loads originating from the gears. Non-parallel and right-angle gears go into motion applications for material handling, aerospace and defense, packaging equipment and foodprocessing machinery. Input and output shafts protrude in different directions; gear teeth are worm, hypoid, bevel (straight, spiral or zerol), skew or crossed-axis helical. Common bevel gearsets often go into materialhandling and packaging equipment. Hypoid gears (useful for high-toque applications) are like spiral-bevel gearsets, but output and input shaft axes don’t intersect — and that simplifies integration of supports. Common in aerospace, zerol gearsets have curved teeth that align with the shaft to minimize thrust loads. Gear reducers or speed reducers work with an array of motors. These are 11 • 2017

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PLQE

Call us: Charlotte, NC 980-299-9800 Neugart 1-17.indd 53

www.neugart.com

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APPLICATIONS

MOTION SYSTEM

How the Jetsons undermined gear understanding By Brian Dengel | General Manager KHK USA Inc.

For those of us of a certain age, the thoughts of flying cars and home robots originated with watching popular 1960s cartoon The Jetsons. The Jetsons’ world was that of a simple family living a typical 1960s life, but in a futuristic setting. Mr. George Jetson’s employer was Mr. Cosmo Spacely, the proud owner of Spacely Sprockets. In most episodes, Mr. Spacely engages his chief rival, Spenser Cogswell, the owner of Cogswell Cogs, in a manner that backfired for both companies — and Jetson inevitably was the fall guy.

AGVs that serve PARKPLUS automated garage systems must be quite flat, but still powerful enough to transport vehicles on trays around garages. A gearbox solution from GAM Enterprises helps satisfy these conflicting design objectives.

Never mentioned in the show was, what a sprocket or what a cog was. The show implied that these two distinct widgets were interchangeable, as Cogswell Cogs and Spacely Sprockets were competitors. But Hanna & Barbera did a great disservice here. A cog is a tooth on the rim of a wheel or gear, but it can also be defined as a toothed wheel as well. In contrast, a sprocket is a toothed wheel whose teeth engage the links of a chain. So a sprocket is a cog that engages with a chain. But the inverse isn’t true, as there are several types of toothed wheels that aren’t sprockets. One example is a timing pulley — a toothed wheel that only engages a toothed belt. Another example of a cog is a spur gear. However, a gear only meshes with another gear. Thus, a gear is a cog ... but not all cogs are gears. With the understanding that all sprockets are cogs, but all cogs are not sprockets, George clearly worked for a company that specialized in one product type ... and Mr. Cogswell’s company produced many types of similar products. As we await the time when flying cars or capsules are common, engineers must know the proper application for components they chose when creating a design and what the limitations of those products are. Even simple components can have vastly different performance specifications, and interchangeability isn’t always possible.

DESIGN WORLD — MOTION

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gears or sets that alter the torque of a motor—usually as an increase proportional to rpm reduction. Common in material-handling setups, shaft-mounted gear reducers come in shaft-mounted designs that use special couplings to address reactionary torque. Other shaft-mounted reducers actually mount to the machine housing (especially in machine setups with surrounding enclosures) so the input shaft doesn’t support the reducer. The American Gear Manufacturers Association (AGMA) defines the term speed reducer as units with pitch-line velocities not exceeding 5,000 fpm or pinion speeds not exceeding 3,600 rpm. Consider worm-gear reducers. These typically go into low to moderate-horsepower motion applications because they have high ratios and high output torque, but are cost effective and compact. Most worm gears are cylindrical with teeth of consistent size; some wormbased reducers have double-enveloping tooth geometry (in which pitch diameter is deep and short and then deep again) to boost tooth engagement. Metal cutting and forming machinery, construction equipment, and packaging machinery all benefit from the low backlash of this gearing type. To illustrate, printing-press rolls hold tight print registration at high speeds thanks to the ability of double-enveloping worm gearing to resist shock and withstand extreme acceleration. The low inertia of this gearing also lets presses start and stop more quickly than those with multi-stage gearing. Gearheads, much like gear reducers, are useful where applications call for high torque at low speed. They reduce a load’s reflected mass inertia, so ease the acceleration of big loads ... which in some cases, even lets machines run off smaller motors. Gearheads range from basic spur gearheads to complex planetary gearheads and harmonic gearheads, all excelling in select applications. The latter (also called strain-wave gearing) is for special speed-reduction applications. More specifically, this gearing is indispensable in robot-arm articulation, medical equipment and offshore drilling. (Strain-wave gearing sets are motioncontroltips.com | designworldonline.com

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GEARING

called Harmonic Drives, a registered trademark term of Harmonic Drive Systems.) Strain-wave gearing helps designs with zero backlash and high-torque operation from a small package. Much machinery integrates servogears into application-specific electromechanical arrangements, and several of these arrangements are common enough to have their own labels. Gearmotors (most useful in machines that move heavy loads) include a gear reducer integrated with an ac or dc electric motor. Gearboxes are contained gear trains; planetary gears are a common form. Planetary gears are particularly common in servo systems. Usually, the planet gears mount on a movable arm that rotates relative to a sun gear. In most applications, an outer annulus meshes with the planet gears. In fact, planetary gearsets offer applications several advantages over other gearsets — multiple kinematic combinations, power density, big reductions from volume compact setup and pure torsional reactions. Planetary gearboxes also boost overall design efficiency. Losses never exceed 3% per stage, so transmit most energy for productive motion output. Planetary gearboxes distribute load efficiently as well. In applications driven by servo systems, gearboxes also reduce settling time, which can be a problem when load inertia is high compared to motor inertia.

The POWER KNEE is the world’s first motorpowered artificially intelligent prosthesis for above-knee amputees. It uses a special gear component set from Harmonic Drive.

DieQua offers more gearboxes Are You Selecting The Right Technology?

For Power Transmission

Whether your application is for precise motion control or for general power transmission, there are several gear technologies that can do the job. But which one does it best? Only DieQua offers the widest range of gearmotors, speed reducers and servo gearheads along with the experience and expertise to help you select the optimal solution to satisfy your needs.

Worm Reducers

Helical Gearmotors

Spiral Bevel Gearboxes

For Motion Control

If you are using gearboxes, you should be talking to DieQua!

Planetary Gearheads

www.diequa.com half page horizontal ad 2017.indd 1

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Servo Worm Gearheads

Precision Cycloidals

630-980-1133 10/17/17 9:29 AM

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APPLICATIONS

MOTION SYSTEM

gearmotor

applications benefit from improved gearing Gearmotors

typically outperform other motor-gear combinations. They also simplify design implementation because they save engineers from having to integrate motors with gears, which in turn reduces engineering costs. If the application requirements are known, engineers can order the right gearmotor directly from a supplier. When gearmotors are sized properly, the right combination of motor and gearing can prolong design life and boost overall design efficiency. Gearmotors can also eliminate the need for couplings and potential alignment problems that come with those components. Such problems are common when a design includes the connection of a separate motor and gear reducer, which increases the potential for misalignment and bearing failure.

Applications for gearmotors keep expanding, which is changing end-user expectations from manufacturers. For instance, end users have an increased expectation for more integrated designs, so much so that such designs are becoming the new standard. Other companies are finding that the design requests they’re receiving are becoming more complex, requiring more custom designs. To take just one recent example, packaging equipment is one area where there has been steady technological innovation, including on the motors and drives side, and gearmotors in particular. Gearmotor packages are typically used for specific heavier duty conveyor applications. However, using advanced helical bevel technology allows for the use of lower horsepower motors. This in turn means smoother starts, high torque control, better operating efficiency and less energy consumption, all important considerations when specifying gearmotors. As a way of simplifying the selection process, most manufacturers provide downloadable CAD files for easier design integration by the builder and end user communities, facilitating both in-plant and engineering system documentation. In addition, all mechanical data are usually available online for gearmotor mounting, a real plus for installers.

SIMOGEAR gearmotors from Siemens offer performance from 1/8 to 75 hp (0.09 to 55 kW), achieving a gear unit torque up to 8 Nm. Featuring helical, parallel shaft, helical bevel and worm geared units, the units are compatible with most gearmotor configurations for new or retrofit applications.

DESIGN WORLD — MOTION

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presence

The gift of global presents.

Thinking global, but acting local. With 15 manufacturing facilities and locations in 52 countries, SEW-EURODRIVE is truly a global company. But, itâ&#x20AC;&#x2122;s the 17,000 employees providing the best in service that makes us a real local partner. Whether you need inverter drives, motors, large industrial gear units, or smaller gear units, you can get the whole package from one source.

seweurodrive.com

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MOTION SYSTEM

APPLICATIONS

hmis

on medical-device manufacturing equipment Most

hospitalized patients receive an IV soon after admission … and sometimes insertion of the needle is painful. But once placed, discomfort subsides — as the plastic tubing that connects the IV bag to the arm is shaped to smoothly glide into veins and remain comfortable during use. Equipment made by Silverstone Automation — the manufacturer’s SilverCATH 1100 and 2200 series machines — forms plastic tubing that functions as these catheter tips. When Silverstone designed the SilverCATH machines, they needed a display to deliver a high-resolution touchscreen with built-in recipe functionality; a USB port for saving recipe data; user-friendly programming; and password-protected screens. So Silverstone ultimately integrated Maple Systems HMI5100L human-machine interfaces (HMIs) into their machines. The HMI5100L is slim and affordable. Its 1.57-in. depth allowed for easy mounting, and its easy-to-read 10-in. color touchscreen lets operators quickly set parameters. The touchscreens (which display separate screens for operators and technicians) simplify controls and prevent unintended entries. Preprogrammed recipes also freed operators from entering lots of data before each changeover. In fact, Silverstone also includes Maple Systems HMIs into an array of custom machine designs. Maple Systems tailors them to Silverstone requirements with offerings from 4.3 to 15 in.

Silverstone Automation makes an array of medical-device manufacturing equipment. The machine builder’s SilverCATH 1100 and 2200 machines accurately form introducer and catheter tips. These incorporate Maple Systems HMIs for cost-effective and user-

HMIs are core to systemintegrated solutions and IoT functionality in HMIs on the rise in all automation. Image courtesy automated machinery Beckhoff Automation HMIs include software and hardware to give machine operators a way to interact with and manage machine functions through a graphical user interface (GUI). Communication is to supervisory and machine-level functions. Development of this software can be expensive upfront but ultimately lower long-term costs and redundancies. Applications for HMIs dictate which software features are relevant. Some machines demand data collection and logging; others require that the HMI software is programmed to show operators various system parameters. Other pieces of HMI software to go on equipment with lots of changeovers are setup to let programmers or even plant personnel switch run modes on the fly. Choosing the right HMI software for an application starts with analysis of machine specifications — including system architecture, performance requirements, integration and cost of procurement and operations. Other HMIs works with portable platforms. This trims cost, as the operating systems are distributed on machinelevel embedded HMIs, solid-state open HMI machines, distributed HMI servers, and portable HMI devices. Also, some applications in pharmaceutical and medical machinery use advanced HMI features to differentiate themselves from competitive offerings.

friendly operation.

DESIGN WORLD — MOTION

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APPLICATIONS

MOTION SYSTEM

lead screws

give vertical stages a lift Recent

innovations in materials and helix geometry address old issues associated with lead screw friction, bringing it down to better than 0.10 in some cases. This makes them a good fit for fast and dynamic applications. In fact, there’s also been an uptick in lead screw use in machines for 3D printing, manufacturing and medical applications. Designers of both additive manufacturing (3D printing) and traditional subtractive processes (plasma cutter, laser and waterjet manufacturing) are driving new lead screw uses. The same holds true for factory automation. Engineers are also specifying more integrated or pre-engineered lead screw systems, which are helping to reduce engineering costs as well as design time.

Custom System Solutions from

HaydonKerk Pittman specializes in the design and manufacturing of customized motion control solutions utilizing our broad portfolio of linear and rotary products. You can trust in our 85 years of meeting our customer’s quality requirements and challenging application needs by utilizing our capabilities in: • Mechanical, electrical, software and application engineering • Certified lab testing • Global manufacturing • Rapid prototyping

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Leadscrews — Motion Casebook 11-17 V2.indd 60

At the heart of the AT20-100 Motorized Vertical Lift Stage from Optimal Engineering Systems, Inc. (OES) is a precision ground lead screw.

One example of this is a lift stage that uses high-precision lead screws. The AT20100 Motorized Vertical Lift Stage from Optimal Engineering Systems, Inc. (OES) is a stable, high precision, high-load vertical lift stage that can be integrated into almost any application. The drilled and tapped platform measures 120 mm x 180 mm (4.72 in. x 7.08 in.) and has a vertical travel of 100 mm (3.93 in.) As for high precision, it features 3.315 µm (non- Micro-Step) resolution, 5 µm repeatability, and 15 µm positional accuracy. The high precision is enabled by the use of a precision ground lead screw, precision linear bearings, and the rigid box construction of the moving component of the elevator stage. Together, they assure smooth, flat (parallel to mounting surface) vertical motion. The lead screw-powered vertical lift stage is used across a range of applications including testing, inspection, assembly, sampling, laser drilling and machining in a broad range of industrial, medical, semiconductor, and research facilities. The stage is constructed of black-anodized aluminum alloy and steel shafting, and weighs just 10.5 kg (23.15 lb.) The powerful 2-phase NEMA stepper and precision ground lead screw offers a high load capacity to 50 kg (110 lb.) without the concern for cantilevered effects (loss of parallelism.) Additionally, the moving platform has access from all four sides. Highlighting the user demand for more integration in motion designs, these lift stages come with optional integrated encoders, servo motors and also as a plug-and-play system with a motion controller.

DESIGN WORLD — MOTION

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LINEAR GUIDES, RAILS, SLIDES & WAYS

pest-control drone uses

Ballscrews & Rollerscrews

LIGHTWIEGHT SLIDES Industrial Robots

The

TSA Center in Spain recently developed the FitoStinger drone to accurately spray for pest control. The drone is a durable design that flies into insect-infested areas and then extends an arm into spaces to accurately dispense pesticides. For the telescoping arm, the lightweight drone uses a linear guide from igus — an extremely light carbon rail on which a solid plastic carriage travels. The lightness of the linear-rail material means the drone needs less drive force to maneuver while airborne. Other advantages of replacing metal motion components better drone dynamics, durability outdoors, and self-lubricating reliability. The drone also uses miniature cable carriers (E2 micro energy chain) from igus to prevent tangles during tilting, turning and rotational movements.

Linear Motors

Linear Actuators

Linear components in other motion designs Linear guide systems include guide rails, slides and ways. Industry categorizes them into a few basic types — including profile rails, drawer slides, linear bearings, guide wheels and plain bearings. A typical arrangement includes a rail or shaft and carriages and runner blocks. Linear guide systems are also distinguished by method of contact — either sliding or rolling. A major function of rolling guides is to reduce friction in machines. They’re used in applications ranging from advanced

Linear Guideways

Linear Encoders / Positioning Measurement Systems

AC Servo Motors

Installations where slides aren’t horizontal require special consideration. Crossed-roller linear rails are often an option here — especially those that feature anti-creep features. Shown here is

Hiwin D1 and D2 Servo Drives

a customized vertical design from Del-Tron Precision.

For more information visit

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DESIGN WORLD — MOTION

www.hiwin.com

11/14/17 10:00 AM

Linear Line

DESIGN FAST

Don’t let misalignment slow you down. Compact Rail self-aligns in three axes. • QUICK DELIVERY TIMES • WEB-BASED DESIGN TOOLS • LIVE TECHNICAL SUPPORT

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For data sheets, application guides and white papers, visit www.rollon.com

Contact one of our applications engineers for help selecting a profile and slider type. Call 1.877.976.5566

Come see us at ATX West at Booth #3450 Rollon Corporation | 101 Bilby Road. Suite B, Hackettstown, NJ, 07840 (+1) 973 300 5492 | info@rolloncorp.com

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LINEAR GUIDES, RAILS, SLIDES & WAYS

WE Series Linear Guideway Wide Series Ball Type.

This is an optical linear encoder guideway with a laser-etched optical scale from SCHNEEBERGER

PG Series Linear Guideway Integrated Magnetic Encoder.

Inc. The integrated linear encoder offers the benefit of no extra assembly needed. If the rail is correctly aligned, so is the encoder. Such linear encoders are suitable on more linear axes and actuators than ever using electric motors paired with ballscrews. Some even allow use loweraccuracy screws by compensating for positioning errors with controls to reduce costs. One application is on laboratory equipment running off stepper-based designs but needing position feedback to prevent damage to the machine and the test samples.

semiconductor manufacturing devices to large machine tools and construction equipment. Semiconductor manufacturing equipment or inspection apparatus that requires high precision positioning is a good application for linear guides. In the case of a machine tool for cutting, linear guides are used instead of sliding-contact linear-motion bearings to cope with temperature rise and durability issues associated with everincreasing feed speeds. The classic application for profile rails is in the machine tool industry where load capacity, stiffness and accuracy are paramount. In medical equipment such as CAT scan, MRI and x-ray machines, square rails are more common. On the other hand, round rails can offer several advantages, one of which is the ability to run smoothly when mounted to less than

11 • 2017

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Long linear strokes of certain linear-guide installations benefit from IKO Intl. rails.

DESIGN WORLD — MOTION

MGN / MGW Series Linear Guideway Stainless Steel Miniature Linear Guideway Size 5 Now Available.

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

11/14/17 10:01 AM

LET’S SET THE RECORD STRAIGHT

When it comes to components and systems, you get what you pay for. If “good enough” is what you’re looking for, we don’t carry it. With SCHNEEBERGER, you get über accurate linear motion systems and components, backed by über service, support and know-how. All at a competitive price. That’s straight up value. Get all the straight talk at schneeberger.com or (800) 854-6333.

schneeberger.com

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LINEAR GUIDES, RAILS, SLIDES & WAYS

This FitoStinger drone includes a light (yet tough) carbon linear guide from igus (bottom left). Image courtesy igus GmbH

LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

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

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

This FitoStinger drone was among 541 submissions to a recent igus-sponsored manus competition to showcase innovative plain-bearing applications. The FitoStinger combats pests from the air by precisely applying pesticide. Image courtesy igus GmBH

perfect surfaces—defined as having a flatness error of over 150 μm/m. For cleanroom and food-processing applications that can’t tolerate contamination, certain linear guides that use rolling elements (as well as plain bearing systems) are unsuitable because of their need for lubrication. In contrast, applications demanding extremely high precision and accuracy use fluid-floated bearings. These are hydrostatic or aerostatic bearings using a high-pressure fluid between the rail and carriage. They’re more expensive and harder to manufacture than other linear options, but get top precision and accuracy. Considerations for choosing a linear-motion rolling guide include the loading (both static as well as applied), stroke and speed, as well as the desired precision and accuracy and the required life. Preloading is sometimes needed as well depending on application requirements. Lubrication is another important consideration, as is any method to minimize contamination of the linear guide system from environmental factors such as dust and other contaminants using bellows or special seals. 11 • 2017

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DESIGN WORLD — MOTION

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

AC Servo Motors.

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

11/14/17 10:02 AM

APPLICATIONS

MOTION SYSTEM

Some telescoping rails (as those from Rollon shown here) have optimal running properties due to inductively hardened raceways … so are suitable on the picking arms of automatedwarehouse shuttles.

Automated storage and retrieval systems (AS/RS) make copious use of linear systems AS/RS installations contrast with traditional warehouses that use forklifts with limited height, as they make far more efficient use of vertical space. The only caveat is that the expansive volumes preclude regular access by personnel for operations or maintenance — so necessitate particularly reliable linear guides, slides, and actuators for automation. In some cases, these linear systems take the form of aluminum components (in areas where the motion design must handle moderate loads) or steel components where payloads exceed 100 kg or so. Consider an automatedwarehousing shuttle arm that uses inductively hardened raceways (paired with carriages) and telescopic rails from Rollon Corp. to prevent deflection under load, even when extended. One such installation serves the medical industry by moving test-tube samples around a refrigerated warehouse for tests. In this application, a robot moves along rails to reach shelves running along warehouse corridors. Quick directional changes and rail irregularities are two main challenges, because the robot must go from track to 66

DESIGN WORLD — MOTION

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perpendicular track with speed and precision. Ultimately, the solution was to use compact rail to let the robot reach and collect shelved test tubes. Myriad rail profiles with hardened raceways (and sliders that mate with theses profiles) help these linear systems compensate for any framing surface misalignments. Robot transfers from the X to the Y axis is via a pair of carriage sliders. Two rail sections perpendicular to the primary sections let the carriage reach a target position and then unhook from the main X axis. Then the two other sliders enter the perpendicular rails to guide the robot along the Y. Passage of sliders from carriage rail sections to perpendicular rail tracks is easier thanks to the compactness of the mating rail bearings.

motioncontroltips.com | designworldonline.com

11/14/17 10:02 AM

ISO 9001:2015 CERTIFIED

I’ll carry that for you! with precise straight line accuracy

CU S SL TO AV ID M AI ES LA BL E

Del-Tron’s Ball & Crossed Roller Linear Slides

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

Other

Precision Linear Motion Products

Non-Magnetic Ball Slides

Precision Linear Motion Required. Del-Tron Preferred. • Accuracy ranging from 0.0005”/” to 0.0000040”/” of travel. • Low friction straight-line design reduces the coefficient of friction to 0.003. • Factory preload adjustment prevents side-play and backlash.

DL Linear Actuators Lead Screw/Ball Screw Driven

• Lightweight aluminum carriage and base with high load capacity. • Built-in holes simplify installation and component mounting. • Available with ball slide or crossed roller slide technology, varying precision grades and corrosion resistant materials.

Order Today! 800.245.5013 Solid Models Available for all Del-Tron Model Numbers

Del-Tron Precision, Inc. -- Motion Systems Handbook 8.17.indd 67

Micrometer Positioning Stages Micrometer Driven Ball & Crossed Roller Stages

Designed & built in the U.S.A.

www. b u yd e l t ro n .co m

11/14/17 12:23 PM

APPLICATIONS

MOTION SYSTEM

Medical, electric vehicle applications make use of

ac motors Long

a standard in core industrial settings, ac motors continue to power applications here. However, motor designs also continue to respond to new application demands. A key feature that is beneficial for all uses is that their speed can be varied and controlled fairly easily and they are more reliable and require less maintenance compared with brush dc motors, for instance. In addition to well-established industrial applications, medical equipment is driving new demand for ac motors that are smaller, lighter, more powerful and efficient and generate less noise. Regardless of application, however, designs incorporating ac motors are seeing requirements for smaller footprints to continue to decrease sizes of machines and systems as well as better efficiencies that can improve manufacturing production rates. Combined with improved drives and motion controllers, complete integrated systems with drives, controllers, motors and HMIs can simplify designs and improve production throughput on manufacturing or packaging lines as well as simplify overall operation. A few of the more interesting applications demonstrate the range of uses for today’s ac motor designs. One application involves a treadmill that uses two three-phase motors. The MOBIUS treadmill from AMTI comes in two models, one fixed-tilt and one inclinable, capable of a 25% gradient. Both models have two independent, 8,800-N capacity force platforms, and a newly designed frame engineered to achieve the highest possible natural frequency. The treadmills are specially suited for biomechanical studies including running, as they are capable of highly accurate gait data. Both models come fully equipped with removable handrails and plug-and-play, USBenabled signal conditioners that integrate with all major motion capture and electromyography (EMG) software. Another application area where ac motors have found a natural home is in electric vehicles. A good example is the variety of available custom traction and steering motors and drives for electric vehicles. For instance, consider the traction drive systems for electric vehicles from ABM. They’re available in a number of different configurations

MOBIUS treadmills from AMTI feature two three-phase motors, one in front and one in the rear.

DESIGN WORLD — MOTION

AC Motors — Motion Casebook 11-17 V2.indd 68

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AC MOTORS

Custom traction and steering motors from ABM are designed especially for use in electric vehicle applications.

including bevel gearboxes, helical gearboxes and hub wheel drives. The drives feature high efficiencies and low noise and high static wheel loads are possible with compact design gearboxes. Typical applications include forklifts, pallet trucks and sweeper/ scrubbers, which require sophisticated drive technology with high output at low energy consumption. ABM traction motors are available in outputs up to 16 kW (duty cycle S2-60 min) and ABM induction and SINOCHRON motors provide high-power density. The compact, modular bevel gearbox designs also provide maximum flexibility for easy adaptation to the requirement of the vehicle. Electrically steered modular units

AC Motors â&#x20AC;&#x201D; Motion Casebook 11-17 V2.indd 69

incorporate induction motors, manufactured for specific vehicle battery voltage and integrated holding brake with minimal torsional backlash. Modular designs make it possible to manufacture OEM drive units even in small and medium volumes. It also provides the possibility to offer different drive options to end-users. For example, fixed motors can be used for traction as well as steer functions requiring minimal space allowing for compact vehicle designs. Motors are available with sensor bearings or coils and even customer-supplied sensors can be integrated into the motors. The complete motor-brake-gearbox units are manufactured completely in-house. For vehicle OEM's purchasing complete traction and steer units with matched components this reduces engineering, interface work as well as significantly reducing assembly time.

11/14/17 4:42 PM

APPLICATIONS

MOTION SYSTEM

dc motors

rise to the occasion

Whether

brushed or brushless, a host of uses exist for dc motors. From traditional industrial applications to new uses in medical devices and robotics, the tried-and-true dc motor is still out there powering all sorts of applications. One traditional use is in elevators. Electric motors have been powering elevators since at least the 1880s, so the application is not new. What is new is the style of the motor and the way it powers the elevator and ancillary operations, as a recent example from a globally recognized elevator manufacturer shows. A lot of technology is out of sight — in the elevator shaft, in the motor chamber, in the control box, and in the cab itself. A motor installed in the cab works to open and close not only the door of the cabin, but also the door to the respective floor. The demands on this motor are high: It must be small yet powerful, energy efficient, reliable, and most importantly, intelligent. In some versions, a direct drive saves space. Together with the Swiss elevator manufacturer Schindler, maxon motor has developed a drive system that moves the doors and meets the listed requirements. The maxon Door Drive is available in two power levels. The more powerful version uses a belt drive and is able to move doors of up to 400 kg. The smaller and newer version is a direct drive that saves space and is suitable for doors up to 120 kg.

DESIGN WORLD — MOTION

DC Motors — Motion Casebook 11-17 V2.indd 70

11 • 2017

The complete drive setup from maxon motor for Schindler elevator doors consists of a brushless flat motor that’s just 90 mm diameter, an integrated MILE encoder, and a customer-specific positioning controller based on the EPOS2 series. (Copyright Schindler AG)

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11/14/17 4:45 PM

maxon control electronics for strong DC brushed and brushless motors.

maxon motor control

Power under control.

When good control properties and fast startups are needed, maxon motorâ&#x20AC;&#x2122;s servo controllers are the ideal choice. The 4-Q PWM servo controllers have fast digital current and speed controllers with a large range. They offer highly efficient control of permanent magnet-activated DC motors.

228.6x276.225.indd 13 Casebook 11.17.indd 71 maxon -- Motion System

maxon precision motors 101 Waldron Road, Fall River, MA 02720, USA Phone 508-677-0520 info@maxonmotorusa.com, www.maxonmotorusa.com

04.08.2016 13:40:12 11/14/17 12:24 PM

SOLVE YOUR MACHINING PROBLEMS NIPPON PULSE’S HIGH-PRECISION LINEAR SERVOMOTORS Our Linear Shaft Motor’s patented magnetic design is extremely efficient, so it operates cooler than similar linear servos.

It does not require an external heatsink, so its moving mass is smaller.

Select the motor that fits your application, instead of making your application fit the motor.

Nippon Pulse Your Partner in Motion Control nipponpulse.com | info@nipponpulse.com

On some Schindler elevators, maxon motor drives now make cabs more efficient. (Copyright maxon motor)

This system setup consists of a brushless dc motor with a 90-mm diameter integrated with a MILE encoder. It’s combined with a customer-specific positioning controller based on the company’s EPOS2 series. Encased in a housing, the Door Drive can be mounted directly to the lift cab, where its real work starts. Integrating motors together with other drive and control components into single units is an ongoing trend for motion systems. Such integrated units are compact, taking up less space, and making them viable options in designs where space is limited, such as in some elevator applications. There are many different types of elevators, with differently sized cabs, different materials and, depending on the country, different safety standards. After a calibration procedure, the Door Drive controller detects the size and weight of the doors, autonomously calculates the optimal parameters, and corrects them if necessary. This greatly simplifies the elevator technician’s work. In just a few steps, the Door Drive configuration is complete, and the drive is ready for use. The advantage of the flat motor’s narrow design is that the cab can be made bigger. The drive also saves energy and delivers sufficient torque to smoothly move the doors. The integrated controller is intelligent and (with continuous operation) it collects valuable data that the technicians can access at any time. 72

DC Motors — Motion Casebook 11-17 V2.indd 72

DESIGN WORLD — MOTION

11 • 2017

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SERVOMOTORS

tiny

servomotors pack a big punch

The 2264…BP4 DC micromotor from FAULHABER features a 32-mm diameter and 74-mm length with 165 mNm of torque. Weighing only 320 g, it’s less than half as heavy compared to traditional drives with similar performance.

Servomotors

power applications in a wide range of industries. Traditionally they have found use in controlling the movement of machines in packaging, semiconductor manufacturing, as well as medical equipment and food and beverage production. Other common applications include robotics and positioning and tracking systems for solar panels. Here and elsewhere, servomotors help boost accuracy and output. One of the industries challenging and changing servomotor design is medical technology. As medical devices in general continue to get smaller and more compact, the design challenge is to make the motors themselves as well as other components smaller. This follows existing industry trends, most notably the

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Servo Motors — Motion Casebook 11-17 V3.indd 73

move towards miniaturization and more compact designs. There are many examples of how individual performance demands in different industries are leading to innovative new product designs. Take servomotors, for instance. Power demands as well as space restrictions in small, handheld products such as those in medical and power tools demand greater size to power ratios. That’s what a new motor from FAULHABER delivers. The 2264…BP4 brushless dc servomotor sports an impressive ratio of torque to size and weight and offers integrated sensors and a wide speed range. The new drive achieves a torque of 59 mNm with a weight of just 140 g and a diameter of 22 mm. It can also reach speeds up to 34,000 rev/min.

This level of performance is enabled by an innovative segment winding of the coil. Anne Schilling, product manager at Faulhauber, explains: "We developed not only the winding, but the corresponding production technology ourselves. Thanks to the overlapping, nested, individually wound segments, an especially large amount of copper can be accommodated in the coil. The desirable effect is a high winding symmetry with minimal losses and a correspondingly high efficiency.” With the patent-pending winding the performance of the motor increases with the copper content. With the compact coil, a resilient shaft with 4-mm diameter and suitable bearing can also be installed. As a result, the small motor can also readily serve as a direct drive, e.g., in handpieces of motorized tools.

11 • 2017

DESIGN WORLD — MOTION

11/14/17 4:54 PM

With overlapping, nested, individually wound segments, a

MOTION SYSTEM

APPLICATIONS

large amount of copper can be accommodated in the coil. A desirable side effect is high winding symmetry, minimal losses and a correspondingly high efficiency.

Furthermore, the four-pole motor has a low inertia and is therefore well suited for dynamic start/stop operation. The motor also features compact and economical sensors. Optional analog Hall sensors precisely determine the position of the output shaft. The sensors are integrated in the motor, so they do not require additional installation space. In most cases, they can replace an encoder, thereby making compact and light solutions possible. If even more precision is required, e.g., with optical systems, in measurement systems or in semiconductor production, compatible optical and magnetic encoders are available. They can easily be attached to the rear multifunction flange of the motor. The 2264…BP4 is overload-resistant. It operates without wear-prone mechanical commutation and, as a result, has a service longer than standard dc micromotors. Another benefit is the large temperature range in which the motor can be used, spanning from -40 to +125°C.

It’s a suitable drive solution for nearly all applications of this size class – whenever space is tight or weight plays a decisive role yet a high torque is required. Schilling adds that she considers the two most important areas of application to be in handpieces of electrical tools and in industrial automation. "With electric loppers, electric screwdrivers or motorized instruments for surgery, users often work with their devices for many hours. Thus, every gram that needs to be held and moved counts. At the same time, the tools should be fast, robust and effective. They need to operate at maximum performance so that every work step can be completed on the first pass." Similar requirements, at least with respect to the size-torque ratio, apply in many areas of factory automation, e.g., with grippers or robots, with mobile robots such as sewer robots, in aerospace with cabin equipment or with active prosthetics that can perform an ever larger range of functions for missing limbs.

Motors · Gearboxes · Controllers

Our MODULAR SYSTEM Flexibility, delivery performance & complete motion solutions.

DESIGN WORLD — MOTION

Servo Motors — Motion Casebook 11-17 V3.indd 74

1500 Bishop Ct - Mt Prospect, IL Call: 773-289-5555 www.dunkermotoren.com 11 • 2017 info@dunkermotoren.com

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11/15/17 10:57 AM

STEPPER MOTORS

stepper motors help boost production

Applications

using stepper motors take advantage of their superior positioning capabilities. One case in particular shows how compact stepper motors and controllers were used to add extra precision to laboratory equipment. Tomtec, a designer and manufacturer of automated liquid handling equipment, recently upgraded their Quadra4 liquid handling workstation for life science workflows. The workstation is designed using a fixed-head, air displacement syringe design, which services a six-station shuttle. Each of the six stations can support a range of accessories for automating complex workloads such as solid phase extraction (SPE) and an optional plate-stacker can be used to queue up to 50 assays. The latest upgrade of the Quadra4 uses stepper drivers and linear actuators for precision or high-speed movements depending on the specifications for the given stage. Where the Quadra4 used to have an embedded PC board with older-technology drivers, the company has upgraded considerably through the use of AllMotion motor controls and drivers. By switching to stepper motors, Tomtec was able to increase the overall precision of the workstation. The AllMotion controls allowed the company to use NEMA 11 to NEMA 34 motors without having to switch to a different control system. The Quadra4 is a liquid handling workstation with a built in XY shuttle, an XYZ stage that brings the microplate into position for the dispensing, and a pipetting head with linear actuator that vertically moves 96 pistons on the 96-tip head. The standard unit incorporates 96 dispensing tips used with the standard 96 well microplate, but can also operate with up to 384 standard well microplates through a unique design strategy where the 96 footprint is indexed through

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Stepper Motors — Motion Casebook 11-17 V2.indd 75

four quadrants. The workstation can also operate with an optional 384 pistons created for a small volume tip head. The indexing portion of the workstation uses three axes, while the shuttle system uses two, and the pipette pistons use only one. This means there are six AllMotion controller drivers used in each Quadra4. Two models of stepper motor controls are used in each workstation. There are four EZHR23 controllers used, three in the XYZ staging system and one in the pipette pistons. Then there are two EZHR23ENHC controllers used in the robotic shuttle operation. Both controllers were specifically designed for user-friendly implementation of stepper motor setups, especially for automation, and have found their way into medical, aerospace, electronics production, consumer products, and other applications. The EZHR23 controller measures 2-in in diameter and is a fully intelligent controller that can be bolted onto the back of the stepper motor it controls. The EZHR23 uses a single 4-wire bus, which contains two power wires and two communications wires, and can link up to 16 controllers in a daisy chain. Commands are issued from any serial terminal program. The EZHR23ENHC controllers used for the shuttles are 2.25 x 2.25 in. and offer the same fully intelligent design that the EZHR23 provides. The controllers are capable of stand-alone operation with no connection to a PC. The controllers can also be set to execute a preset string of commands upon power up. Commands include nested loops and execution halt pending a switch closure, which is useful in stand-alone applications. A key operation for the Quadra4 is the system’s ability to run air through the piston of each dispensing tip. The compa11 • 2017

ny calls this operation time dispense/air dispense. Since liquid is hydrophilic when using plastic materials, it leaves a residual amount of up to 3 micro-liters of liquid behind in the syringe. The time dispense/air dispense system uses air to push that residue into the wells, which improves the overall accuracy of the station. Through simple straightforward programming, following the customer’s manual methods, the system can be programmed to add plates to the shuttle or put them back into the stackers. The customer can automatically move reservoirs of reagents from the stacker to the shuttle and back. With some creative ingenuity customers can easily program complete walk away automation for some very complex protocols.

The Tomtec Quadra4 automated liquid handling system incorporates six AllMotion stepper controllers.

DESIGN WORLD — MOTION

11/14/17 4:56 PM

For engineers bringing manufacturing intelligence to legacy production sites, B&R Automation introduced its new Orange Box at the 2017 Hannover Fair. It lets machine operators collect and analyze data from previously isolated machines and production lines and upgrade them

APPLICATIONS

for IIoT (Industry 4.0) operations with

MOTION SYSTEM

minimal effort.

Motion designs push envelope for

industrial networking Applications

for conveying, pick and place, assembly, machining, and more all rely on traditional industrial networking and new iterations to accommodate Internet of Things (IoT) functionality. Data collection is core to the latter, especially in machine designs dominated by motion tasks. Networking to support automated warehouse for e-commerce The Internet has changed human life around the world, and one major way has been in the form of e-commerce. Annual U.S. retail e-commerce sales now exceed $320 billion, according to the U.S. Department of Commerce. It’s even sustained 15% year-overyear growth, and retail e-commerce sales now account for more than 10% of total sales.

DESIGN WORLD — MOTION

Networks — Motion Casebook 11-17 V2.LE.indd 76

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No wonder then that more businesses than ever are eschewing brick-and-mortar stores for online-only selling. Consider iHerb, founded in 1996 to sell quality herbal and nutritional supplements. Today, the company has expanded to sell bath and beauty products, specialty grocery items, and other items for pet care, aromatherapy, and fitness. In fact, iHerb sells more than 35,000 different products from more than 1,000 brands to customers in more than 150 countries. Core to operations is a new distribution center in Hebron, Ky. This facility includes an automated goods-to-person picking system to quicken order fulfillment and maximize product storage. iHerb’s inventory and shipping originally went through one warehouse in Moreno Valley, Calif., but the company needed to expand operations with an East Coast facility. The 390,000-square-foot Moreno Valley warehouse opened in 2010 as the company’s first automated facility. It’s a climate-controlled facility with Good Manufacturing Practices certification and almost 100% accuracy for orders shipped globally. But iHerb wanted to get orders out faster from the Hebron facility — and wanted to implement something more efficient than batch picking. This approach bunches orders into motioncontroltips.com | designworldonline.com

11/14/17 10:13 AM

NETWORKING

batches instead of individually processing each one — which ultimately takes more time than modern pick-to-order approaches. The system also relies on manual processes ripe for automation. Today, a warehouse management system (WMS) processes orders in batches to help workers find the products and needed quantities. Items are then hand-placed in totes sent downstream on conveyors to workcells, where other personnel uses radiofrequency (RF) scanners to log each product. A light corresponding to each product scan identifies the shipping container into which each product should go … and a stoplight indicates when an order container is complete. Then the container goes onward to sealing, weighing, and shipping. iHerb teamed with Rockwell Automation OEM Partner Bastian Solutions to design the Hebron facility. It implemented the pick-to-order system because it wanted to let products get picked in real-time to each customer sale. It also harmonized the warehouse’s machine and human activities. That way, the correct products for each order get pulled from inventory and go to packing operators in tandem with an appropriate shipping container. Complementary systems run these tandem operations: A pick-to-order system contains 10 inventory aisles with robots to locate and pick products. Products are in totes and go to operators at workcells on 10 corresponding conveyor lines. In addition, a put-to light system guides workers to place products in the right shipping containers.

A material-handling system (including carton-erecting machines, sorters, 48 RF scanners, labeling and weighing machines, and packing-material dispensers) calls one of nine box sizes for each new order. A carton erector shapes each box which then rides on a conveyor to an operator (who concurrently receives products from the pickto-order system). All the binned products get transferred to the shipping container (with light-directed picking for iHerb’s popular products). Then a conveyor sends the completed container onward for packing, weighing, and shipping. Two panels with Allen-Bradley L72 ControlLogix controllers control the cartonerecting equipment and conveyors and interface with the pick-to-order setup. One remote panel with a third ControlLogix controller executes motor controls. Operators run material-handling operations while monitoring the conveyor and key metrics — including RF scanner read rates — using Rockwell FactoryTalk View HMI software. 13 field boxes with Allen-Bradley POINT I/O racks sit at areas with high I/O concentrations. The racks allow local wiring of I/O devices (to avoid the problem of having to bring wiring back to one of the two master control panels). That simplifies installation because it eliminates field wiring. In fact, machine control, I/O, and HMI data all execute on an Ethernet network with hostsystem communications. Today, iHerb processes orders (from induction to shipping) in as little as 15 minutes. Workers can fulfill up to 20,000

orders (containing as many as 100,000 individual products) every shift with an accuracy of 99% or so. The system boosts labor efficiency by about 300% compared to that for batch processing, as aisle operators pick up to 800 items every hour. “Order-fulfillment speed, order accuracy, and improved efficiencies have made the Hebron facility a success,” said iHerb Hebron director of operations Kurt Cheek. “This facility positions us for continued order-volume growth.” The facility currently operates one outbound shift, but could easily expand. If ever needed, the control architecture could also support more lines (for up to 30% more capacity) without more programming or hardware. The control architecture also made installation and commissioning easier to helping the facility go operational in four months. Case in point: One workstation program was written in Rockwell Software Studio 5000 Logix Designer software and then replicated for 20 workstations using identical tasks ... so there was no need to program each station from scratch. iHerb is now expanding and upgrading the Moreno Valley operations to employ the same approaches instituted at the Hebron facility.

Courtesy Bastian Solutions

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DESIGN WORLD — MOTION

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APPLICATIONS

MOTION SYSTEM

retaining rings keep assemblies together Motion

system designs make use of retaining rings in everything from electric motors and gear retainers to solenoids to aircraft to door handles and sports equipment. These fasteners hold together components on a shaft or in a housing when installed in a groove. In fact, the automotive industry may make the most use of retaining rings, especially for assemblies in air bags, timing-belt pulleys, radiator hoses, turbo chargers, door locks, carburetor assemblies, drive shafts, and brakes. Used in an array of oil-and-gas and other industries’ designs, tapered section rings have decreasing thickness from center to ends. They mount axially or radially, and the taper keeps full contact with the installation groove. Common in assemblies for lawn mowers, hand and power tools, agricultural machinery, nuclear equipment, and even computer equipment, constant section retaining rings have a constant width around the circumference of the ring. When installed, these rings do not maintain uniform contact with the entire component. They take on an elliptical shape and make contact with the groove at three points. Spiral retaining rings go into housings or on shafts with full contact with groove or component. Their grooves are shallow, so have less load bearing capability. So, spiral rings often go into applications that prioritize full contact with the retained component or lower axial profile. Spiral rings find use in torque converters, speed reducers, lamp assemblies, clutches, hinge pins, home appliances, robotic toys, pumps, couplings, valves, hydraulic equipment, and photography equipment. They don’t have protruding ears to interfere with mating components; they also eliminate the need for machining and threading. Spiral retaining rings don’t necessitate special tools for removal and come standard with removal notches for extraction. When selecting a retaining ring for an application, factors that dictate which retaining ring is most suitable include application environment (including temperature, speed, and thrust), critical dimensions (including the assembly’s housing or shaft diameter and the installation groove’s dimensions. In fact, maximum thrust is one of the most critical application parameters, as it dictates whether there’s risk of groove deformation or ring shear. Applications that run in corrosive environments also may also need retaining rings made of specialty materials.

MAXITORQ AHA25 clutches and brakes from Carlyle Johnson are rated from 15 lb-ft dynamic to 60 lb-ft of static torque ... and torque can be regulated by adjusting system pressures. They have a stationary cylinder assembly mounted on deepgroove ball bearings to accommodate thrust loads. Notice the retaining ring on the face of the unit shown here.

DESIGN WORLD — MOTION

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Rotor Clip -- Motion System Casebook 11.17.indd 79

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expand motion in automation

MOTION SYSTEM

APPLICATIONS

robotics

All-new

robot technologies for emerging medical and consumer uses are now spurring entirely new industries. Meanwhile, traditional robot setups serve an everexpanding array of industrial, military, and commercial applications — so that proven formats (including Cartesian, delta, and sixaxis selective-compliance-articulated robot arms or SCARAs) are seeing ever-expanding use in palletizing, machine tending, welding, machining, packaging, and assembly. In fact, the robotics market is currently a $30 billion industry and could grow into a $70 billion industry over the next 10 years. But robot morphology must match the task at hand: Consider how for pick-and-place applications in packaging and small parts assembly, delta robots are particularly suitable. These often integrate vision, I/O, and an HMI panel with one controller and network. Variations include extended-reach delta robots (for

DESIGN WORLD — MOTION

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11 • 2017

Robolink D modular kits from igus make for cost-effective robotic systems. Now more offerings in the line let designers combine motors and joints in several sizes (with standard controls) to make lightweight sixaxis robots of plastic and aluminum. Robolink strain-wave gearing is an option for axes at the radial connection between arm and gripper — a lightweight plastic component in two sizes as a standalone component or with a NEMA 17 or 23 stepper motor.

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ROBOTICS OptoForce HEX-E and HEX-H sensors (part of the manufacturer’s six-axis F/T sensor family) have a 5x overload capacity. Integrated sensor-mounting plates boost compatibility with ABB robotics. Original and enhanced sensor versions are fully compatible with Universal Robots and KUKA robots as well.

applications where the robot tends a wide conveyor, for example) and washdown delta robots for applications where the robot directly handles unwrapped food such as cookies, for example. One caveat: Delta robots are generally unsuitable for applications in which payload exceeds a few kilograms. Applications that require robots to operate around personnel are leveraging the increase of integrated safety in robots of all morphologies ... including everything from compact cobots to larger industrial robots traditionally associated with automotive applications. Here, integrated safety monitors robot position, speed, and torque … as well of the robots’ external barriers where applicable. Applications driving much of this move are consumer-electronics and warehousemanagement industries, as their processes demand more flexible safety than other industries that use robots. In contrast, packaging, wireless technology, and pharmaceutical applications have spurred robot manufacturers to make smaller and faster robots. Helpful here is that advances in controls and software have made integrating robotics easier ... even for advanced functions such as verifying product packaging, for example. Industries that currently lead the use of robotics are food and beverage and packaging. Though many manufacturers in these industries still use manual operations, there’s a steady move to automate processes and leverage its productivity.

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11 • 2017

Genesis Robotics (spinoff of Genesis Advanced Technology) recently announced an actuator that’s particularly suitable for powering the joints in SCARA robot arms and other kinematic setups. Called the LiveDrive, the actuator delivers three times more torque than conventional direct-drive motors. Innovations include amplified magnetics (with a design that doubles the effective force of already-strong neodymium permanent magnets), a structure to resist internal collapse from the tremendous magnetic forces, and good thermodynamic design for heat dissipation. Applications — taking to form of SCARAs, exoskeletons, cobots, and AGVs — abound. Read more by visiting therobotreport.com and searching on Mike Hilton (CEO of the company).

DESIGN WORLD — MOTION

11/14/17 10:29 AM

Engineered damping and isolation technologies from ITT Enidine — including pylon isolation systems, multi-modulus

APPLICATIONS

journal and spherical bearings, and cabin-interior vibration isolators — boost

MOTION SYSTEM

rotorcraft flight safety.

shock & vibration damping applications

Shocks

and vibration dampers help optimize an array of designs. Adding mass with heavy bases or mounting machines into steel or concrete flooring is one approach avoid natural frequencies during operation. But in applications where this is not possible or sufficient, isolating components and other passive dampers can absorb or attenuate vibrations. These often bear the whole machine weight to shift excitation off the natural frequency. In fact, shock and vibration-damping components range from heavy-duty machine tools to delicate designs that assemble semiconductor components. Addressing oscillations lets machines run faster for more throughput and accurate moves.

DESIGN WORLD — MOTION

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Isolators usually shift a design’s natural frequency so it’s no more than one-third of the excitation frequency. One caveat is that overly compliant isolators can actually increase the magnitude of motion. If this is a problem, hydraulic and magnetorheological setups can damp at system natural frequency but isolate like undamped designs. In contrast, active vibration controls use actuators and sensors to counteract vibrations with motion having an out-of-phase frequency. One such design is a negative-stiffness mechanism from Minus K that adjusts horizontal and vertical resonant frequencies separately. Such technology is particularly useful in aerospace and semiconductor applications with nanometer-level and better accuracy demands.

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11/14/17 4:20 PM

Find a solution fast.

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Get assistance selecting the right product for your needs.

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Free VibroChecker app (iOS) CAD downloads YouTube tutorials ACE website

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· Online sizing tool & calculator · One-on-one support from an application expert

800-521-3320 | www.acecontrols.com ACE Controls -- Motion Systems Handbook 8.17.indd 83 DesignWorld_ACEControls_find_a_solution_fast_FullPage_040417.indd 1

11/14/17 12:27 PM 7/26/2017 10:13:19 AM

FRT-G2 rotary dampers from ACE Controls are small and lightweight plastic components that rely on involute gearing for operation. They’re capable of continuous rotation and deliver

MOTION SYSTEM

APPLICATIONS

bidirectional damping torque. In the application shown here, FRT-G2-101-G1 rotary dampers integrate into a ShuffleMaster to ensure quiet shuffling of playing cards. These programmable machines are used in casinos all over the world. The FRTG2-101-G1 dampers can run to 50 rpm and output damping torque to 0.088 in.-lb … and though service life may be longer or shorter depending on the application, the dampers usually output more than 80% of their original damping moment even beyond 50,000 cycles.

Case in point: Vibration isolation and energy absorption in rotorcraft Rotorcraft designs are rotary-wing aircraft that include various forms of helicopters and autogiros. Consider some vibration-mitigation products specific for this application that ITT Enidine showed at the recent Helitech International show in London. These engineered setups extend the longevity of flight-critical rotorcraft components while making cabin interiors quieter and improving the safety and comfort of crew and passengers. Specific products to eliminate vibration and noise from flight (even under harsh operational

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environments) include multi-modulus journal and spherical bearings; spherical pivot bearings and pylon isolation systems; cabin-interior vibration isolators main engine (and APU) isolators; and elastomeric rod ends. Other options for mitigation of vibration No matter the subtype, shocks and vibrationdamping components have a reputation for being a commodity component. In fact, these devices are highly engineered and customized to very specific loads, impacts, and machine geometries. Mechanical subcomponents in the form of wave springs and compliant couplings are options to isolate vibrations in everything from precision electric-motor-driven machinery to those that run off internal-combustion setups. Another product to damp vibrations is magnetorheologic fluid from Lord Corp. This is a blend of magnetic powder in oil, water, or glycol that reversibly changes from free-flowing to semisolid when subject to an electromagnetic field. Particularly useful in automotive applications that must accommodate changing road and driving conditions, magnetorheologic components can replace traditional hydraulic fluid in shock absorbers. Yes another option is gas springs — sometimes called gas dampers, tension springs, gas-pressure springs depending on the setup and application. These compressed-air or oil cylinders install in motion designs to damp forces and return kinematic linkages and more complicated assemblies to default positions. Gas springs work through a piston on the end of a rod that protrudes from a steel cylinder body; usually compressed gas (often nitrogen) within the cylinder exerts force on this piston to reassume and maintain set positions. Nitrogen is common here because it’s inert and nonflammable. In such designs, oil or grease between the piston and other contacting parts minimize friction.

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APPLICATIONS

MOTION SYSTEM

How do

xy table USES differ from those for Cartesian and gantrY DESIGNS? There

are many ways to build linear systems for motion in the X, Y, and Z directions — also known as Cartesian coordinates. Industry terms for these systems depend on how the axes are assembled, where the load is positioned, and (to some extent) the application for which the systems are designed. In many industrial applications, Cartesian and gantry-style robots are prevalent ... but in precision applications, XY tables are often the better choice because they have a compact and rigid structure — and very high travel and positioning accuracies as well. Cartesian systems and robots Cartesian systems consist of two or three axes for X-Y, X-Z, or X-Y-Z setups. They often incorporate an end effector with a rotational component for orienting the load or workpiece … and always provide linear motion in at least two of the three Cartesian coordinates. Where Cartesian systems are used, the load is usually cantilevered from the outermost axis — Y or Z. For example, in an X-Y setup the load is mounted to the Y axis — either to the end of the axis or at a distance from the axis to create a moment arm on the Y axis. This can limit load capacity, particularly when the outermost axis has a very long stroke (and create a large moment on the lower supporting axes).

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Cartesian systems are suitable for myriad applications with maximum strokes on each axis typically one meter or less. The most common of these applications include pick-and-place, dispensing, and assembly. Gantry systems and robots To address the issue of outer axes causing a moment load on the inner axes, gantry systems use two X axes or (in some cases) two Y and two Z axes. Gantries almost always have three axes … X, Y and Z. The load on a gantry system is located within the gantry’s footprint and the gantry is mounted over the working area. But for parts that cannot be handled from above, gantries can be configured to work from below. Gantry systems are suitable in applications with long strokes (greater than one meter) and can transport very heavy payloads that are unsuitable for a cantilevered design. One of the most common uses for gantry systems is overhead transport, such as moving large automotive components from one station to another in an assembly operation. XY tables: Industry classifications XY tables are similar to XY Cartesian systems in that they have two axes (X and Y as their name implies) mounted on top of each other — and typically have strokes of one meter or less. But the key

difference between XY Cartesian systems and XY tables lies in how the load is positioned. Instead of being cantilevered, as in a Cartesian system, the load on an XY table is almost always centered on the Y axis, with no significant moment created on the Y axis by the load. This is where the principle of how the system is used helps distinguish between the various types of multi-axis systems. XY tables generally work only within their own footprint, meaning the load does not extend beyond the Y axis. This makes them best suited for applications where a load needs to be positioned in the horizontal plane (X-Y). A typical example is a semiconductor wafer being positioned for inspection or a part being positioned for a machining operation to take place. So-called open-frame or open-aperture designs have a clear opening through the center of the table. This allows them to be used in applications where light or objects need to pass through, such as backlit inspection applications and insertion processes. Because XY tables are primarily used for very high precision applications, the guideway of choice is that based on crossed-roller slides, as these provide extremely smooth and flat travel. Drive mechanisms are typically ball screw or linear motor, although very fine pitch lead screws are also common. motioncontroltips.com | designworldonline.com

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AD INDEX M O T I O N S Y S T E M A P P L I C AT I O N S

ACE Controls Inc. ............................................................ 83 Aerotech . . ......................................................................... 87 All Motion ........................................................................... 2 Altra Industrial Motion Corp. ......................................... 23 Applied Motion Products ............................................... 35 AutomationDirect .. ......................................................... IFC Beckhoff Automation ..................................................... 33 Bison Gear & Engineering Corp. ..................................IBC Carlyle Johnson Machine Company . . ........................... 24 Cicoil . . ................................................................................ 27 Del-tron Precision, Inc. ................................................... 67 Delta Products Corp. ......................................................BC DIEQUA Corporation ...................................................... 55 Dunkermotoren ............................................................... 74 Dynatect Manufacturing, Inc. . . ....................................... 16 Encoder Products Company ......................................... 49 GAM Gear ........................................................................... 3 Harmonic Drive ................................................................. 51 HaydonKerk/Pittman ......................................................60 HEIDENHAIN Corporation . . ............................................ 47 Helical Products Company .............................................. 5 Hiwin Corporation ................................................61 63, 65 igus, inc. . . ........................................................................... 19 Intech ................................................................................ 52

ITT Enidine .. ...................................................................... 85 Mach III Clutch Inc. .......................................................... 25 Maple Systems ................................................................ 59 maxon precision motors ................................................. 71 MICROMO ......................................................................... 69 mk North America, Inc. .................................................. 37 MW Industries Aerospace Solutions . . ........................... 41 Neugart . . ........................................................................... 53 Nippon Pulse America Inc. .. ........................................... 72 NSK Americas ................................................................... 15 PBC Linear .................................................................... 10, 11 R+W America ................................................................... 42 Rollon Corporation . . ........................................................ 62 Rotor Clip Company, Inc. .. .............................................. 79 Schneeberger .................................................................. 64 Serapid Inc. ...................................................................... 29 SEW Eurodrive .. ............................................................... 57 Sorbothane ...................................................................... 84 THK America, Inc. . . ............................................................. 1 Tolomatic, Inc. .................................................................. 13 US Digital . . ........................................................................ 48 US Tsubaki ........................................................................ 31 Yawkawa America, Inc. .................................................. 45 Zero-Max, Inc. .................................................................. 39

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Automation for a Changing World

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