Motion System Applications 2022 by WTWH Media LLC

NOVEMBER 2022

DESIGNWORLDONLINE.COM MOTIONCONTROLTIPS.COM

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WORLD-CLASS LINEAR

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MANUFACTURING Quality Linear Motion Solutions from THK THK is committed to meeting the worldwide demand for linear motion products. At THK Manufacturing of America, Inc (TMA), we manufacture, assemble, and ship all over North America from our location in Hebron, Ohio. We’ve also ramped up our automating processes at existing facilities including our U.S. manufacturing plant where over 70% of THK Robotics Components are manufactured. Automated processes at this state-of-the-art facility enable increased production while maintaining the high standard of precision associated with our products.

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Servo Systems at Stepper Prices These L7C systems offer popular features at a fantastic price

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Starting at $610.00 (100W system with cables and I/O breakout) LS Electric servo systems provide the most requested features-setup wizards, auto tuning, built-in indexers and more - in an extremely cost-eﬀective package: • 5 standard servo systems from 100W to 1kW • 200-230VAC single-phase input power on all systems • Control via high-speed pulse train, analog speed or torque signal, or internal indexing • Use with AutomationDirect CLICK, Do-more BRX, or Productivity Series PLCs; or any other host controller • Auto-Tuning and FREE setup software (with built-in o-scope function) • Fully digital with up to 1kHz velocity loop response • 30-day money-back guarantee

Need more torque? LS Electric® MSS Series Inline Planetary Gearboxes Starting at $264.00 (96200004)

Pre-matched LS Electric gearboxes oﬀer easy mounting to the servo motor. Use these gearboxes to increase the available torque or to solve inertia mismatch problems. • 5:1, 10:1 and 20:1 gearbox models perfectly matched to each motor size • Increase the available output torque by 5x, 10x or 20x • Full motor output torque allowed for all pairings • Reﬂected inertia of the load is reduced by the square of the reduction ratio! • Mounting hardware included

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Online L7C System Selector Tool Use our L7C Servo Selector Tool to size your system, and to specify all the required and optional accessories for YOUR application. Get all the parts you need on the ﬁrst order! www.automationdirect.com/selectors/ls-servo

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Motion System Applications

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Motion system applications take center stage As

the calendar year comes to a close, it’s time again for Design World’s annual Motion System Applications special issue. The fourth and ﬁnal installment of our motion

control-focused series, this edition houses a collection of case histories and in-depth looks at myriad real-world application challenges for motion systems.

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Here, the Design World editorial staff has curated some of 2022’s top stories. This issue showcases the immense versatility of motion control components — from near-boundless applications in the medical and agricultural space, to packaging, robotics, and more. Of course, we couldn’t leave out the continuing focus on automation solutions. As all industries are feeling the squeeze with labor and logistics, engineering teams and end-users alike are looking to automation to relieve some of the pressure on their respective operations. For example, automation is helping usher in a new era of modernization in agriculture by updating antiquated systems. Here’s just one example from AutomationDirect: “Existing systems typically use limited or outdated automation, such as hardwired relays, specialized electronics, or sometimes older PLCs or smart relays. These can become problematic to service, and lack the ability to provide modern conveniences, especially remote connectivity… These needs have provided great demand for SIs able to apply new technologies to specialized equipment.” Furthermore, it’s hard to talk about automation, in agriculture or elsewhere, without another hot topic this year — predictive maintenance and IoT. Included in this issue is a section focusing on how network connection reliability is critical to automation efficacy. This example comes from Moxa: “One way to achieve intelligence at the edge of industrial networks is by deploying computers that can collect, process, and analyze data in uncrewed or remote sites. The consequences are dire when these computers have a performance issue or run out of memory, therefore preventing them from performing their role efficiently, if at all.” The Design World editorial staff and I hope you find this year’s Motion System Applications issue useful. What challenges have your engineering team overcome? Would you like our readers to hear your story? Please reach out to me at msantora@wtwhmedia.com or on Twitter at @DW_MikeSantora. Please visit our motion-specific sites, motioncontroltips.com and linearmotiontips.com, along with bearingtips.com and couplingtips.com for the latest news on motion control and the industry at large.

E SANTORA • MA

11 • 2022

Contents VOLUME 8 NUMBER 4

EDITORIAL

STAFF

BRAKES & CLUTCHES

LINEAR COMPONENTS

BELTS & PULLEYS

NETWORKING

ACTUATION • MOTION CONTROLS

CONVEYORS

COUPLINGS

ENCODERS

PROGRAMMABLE AUTOMATION CONTROLLERS (PLCs)

MOTORS & DRIVES — AC

MOTORS & DRIVES — SERVO

MOTORS & DRIVES — BRUSH DC

SHOCKS & DAMPING

SPRINGS & RINGS

AD INDEX

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11 • 2022

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DESIGN WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. DESIGN WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care. DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2022 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher. Subscription Rates: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only. Subscriber Services: To order a subscription or change your address, please email: designworld@omeda.com, or visit our web site at www.designworldonline.com POSTMASTER: Send address changes to: Design World, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114

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Brakes & Clutches

Railway relies on advanced backstopping clutch technology THE MOUNT WASHINGTON COG RAILWAY IN NEW HAMPSHIRE HAS BEEN TRANSPORTING VISITORS TO THE SUMMIT, 6,288 FT. ABOVE SEA LEVEL, SINCE 1869. THE SIX-MILE THREE-HOUR ROUND TRIP FEATURES AN AVERAGE GRADE OF 25% … SOME SECTIONS APPROACH NEARLY 38%. COURTESY OF MT. WASHINGTON COG RAILWAY

The

famous Mount Washington Cog Railway in New Hampshire has been transporting visitors to the highest peak in the Northeastern US since

1869. At the summit, 6,288 ft above sea level, the mountain experiences some of the most extreme weather conditions in the world with wind chill temperatures down to -102° F. A directly measured surface wind speed of 231 mph is a Northern and Western Hemisphere record. The six-mile three-hour round trip features an average grade of 25% ... and some sections approach nearly 38%.

FSO 800 CLUTCHES HAVE A TORQUE CAPACITY OF 13,000 LB.FT (17,680 NM). UNITS ARE GREASE LUBRICATED WITH STEEL LABYRINTH SEALS AND FEATURE PCE SPRAGS WITH FORMCHROME AND FORMSPRAG FREE-ACTION RETAINERS.

motioncontroltips.com | designworldonline.com

The railway ﬂeet currently consists of a pair of steam locomotives, seven biodiesel locomotives, and seven passenger coaches. The railway’s ﬁrst diesel-powered locomotive was designed primarily by Al Laprade, now a consulting mechanical engineer. The locomotive was built entirely onsite by the Cog’s shop crew. In 2001, LaPrade also designed the unique sprag clutch system installed on the passenger coaches that replaced the original ratchet-pawl system in use since the late 1800s. The bothersome dinging noise created by the older ratchet system during the entire trip up the mountain was a major passenger complaint. In addition, the ratchet could not be trusted as an emergency stop mechanism because if it were suddenly applied with any speed, it would either bend the pawl or break a crossmember, bearing, or even an axle shaft. Formsprag FSO clutches were selected to meet the challenging backstopping 11 • 2022

DESIGN WORLD — MOTION

Motion System Applications

THERE ARE 12 HYDRAULIC CALIPER BRAKES THAT HOLD THE CLUTCH ROTOR STATIONARY WHEN APPLIED. TO ENGAGE THE CLUTCH, THE BRAKEMAN FLIPS A VALVE WHICH APPLIES HYDRAULIC PRESSURE TO THE BRAKE CALIPERS, PREVENTING THE SPRAG ROTOR FROM ROTATING. COURTESY OF MT. WASHINGTON COG RAILWAY

application requirements and are currently installed on every coach in the fleet. According to Caleb Gross, mechanical engineer at the railway, the Formsprag clutches were chosen for several reasons: “Formsprag had the most engineering information available. Compared to competitors, the clutches also appeared to be thoroughly tested and engineered to give us confidence in using them. Product documentation and honesty were key.” During the early phases of the sprag clutch system development, LaPrade visited Bretton Woods — a ski area located nearby and formerly owned by the owners of the Cog Railway — to view a Formsprag clutch that was installed on a chairlift carousel. Based on the successful ski-lift application, no other clutch manufacturers were considered. The ski lift clutch turned out to be a similar model to the FSO unit specified for the railway coach retrofits. The specific Formsprag Model FSO 800 clutches (featuring PCE sprags with Formchrome and Formsprag Free-action retainers) were chosen based on superior 13,000 lb-ft. torque capacity and the general ruggedness of their construction. The compact 10 in. diameter FSO units also fit within the existing hardware and the small space available on the older coaches. The supplied FSO units are greaselubricated with lip seals. Grease lubrication was specified because of the concern of lubricating oil leaking onto the adjacent caliper brake

DESIGN WORLD — MOTION

rotor which could allow the brake calipers to slip. Also, grease will seep out slower and presumably more visibly than oil allowing more time to identify a leak. “The specified FSO clutch has a lip seal mainly for the slow application shaft speeds of about 50 rpm and the maximum design forward/reverse speed is just shy of 5 mph — and this is a direct-acting clutch,” said Gross. “The simplicity of the lip seal allows for easy, inexpensive service if replacement is ever needed.” A critically important FSO backstopping

sprag clutch is installed on the down-mountain axle of each coach. The sprag clutch is engaged by the brakeperson for the upmountain portion of the trip, preventing any roll-back of the passenger coach. There are 12 hydraulic calipers that hold the clutch rotor stationary when applied. To engage the clutch, the brakeperson flips a valve which applies hydraulic pressure to the brake calipers, preventing the sprag rotor from rotating. The settings are left in this configuration (only forward motion allowed) until right before the train leaves the summit. For the down-mountain leg of the trip, the clutch is disengaged to allow downward movement. When the engineer is in the cab and ready to go, he or she gives the brakeperson a signal to flip the valve back and release hydraulic pressure on the clutch rotor brake calipers. The brakeperson stands ready at the brake wheel on the down-mountain end of the coach for the entire trip from the summit. The coach clutches are field-tested often. Every time a train comes to a switch, the locomotive must stop until the brakeperson signals an all clear to proceed. Every time this happens, the coach remains in position and doesn’t follow the locomotive backwards downhill. The railway is pleased with the long-lasting performance of the clutches. “The first clutch was installed on one of the coaches for the 2001 summer season. That coach has been in service since, and the clutch has yet to give us a reason to consider replacement,” said Gross.

THE COMPACT 10-IN. DIAMETER FSO UNITS ALSO FIT WITHIN THE EXISTING HARDWARE AND THE SMALL SPACE AVAILABLE. THE SPRAG CLUTCH IS ENGAGED FOR THE UP-MOUNTAIN PORTION OF THE TRIP, PREVENTING ANY ROLL-BACK OF THE PASSENGER COACH. FOR THE DOWN-MOUNTAIN LEG OF THE TRIP, THE CLUTCH IS DISENGAGED TO ALLOW DOWNWARD MOVEMENT. COURTESY OF MT. WASHINGTON COG RAILWAY

11 • 2022

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Motion System Applications

Linear systems excel in battery cell production Linear

actuators come in many different types including

screw drives, belts and pulleys, as well as electric actuators and those driven by fluid power such as hydraulic or pneumatic actuators. However, electric actuators can deliver repeatability that’s indispensable for moving loads to a given position. Often, they’re also more controllable than fluidpower actuators and they’re also programmable and can adapt to changing conditions. New manufacturing and production applications call for integrated automated control systems that can handle a range of functions to meet unique manufacturing needs. Linear motion components such as actuators play a central part in such systems.

A CANTILEVER HANDLING SYSTEM BASED ON SPINDLE AXES ELGT ENSURES DYNAMIC AND SAFE LOADING AND UNLOADING OF THE PROCESS CHAMBER.

DESIGN WORLD — MOTION

11 • 2022

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Motion System Applications

THE CORE OF THE DEGASSING APPLICATION IS THE PROCESS CHAMBER. PNEUMATIC AND ELECTRIC ACTUATORS MANIPULATE HOLLOW LANCES AND PIERCE THE BATTERY CELLS.

DESIGN WORLD — MOTION

11 • 2022

Take battery production, for example. Recently, Festo demonstrated a degassing cell in battery production with both pneumatic and electric actuation, as well as decentralized I/O. The pneumatic and electric actuators from Festo handle and pierce battery cells in a critical part of the battery production process. In battery production applications, high speeds and throughput are required, as are reliability and repeatability. In the production of lithium-ion batteries, the production environment plays a decisive role. Low humidity and the lowest possible contamination by interfering particles during the production process have a major inﬂuence on the quality and safety of the manufactured battery cell. Gas forms in the battery cell during production and must be extracted from the welded battery cells without losing electrolytes. To do this, pneumatic cylinders move the hollow lances that pierce the battery cells in the degassing chamber and evacuate the gas

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Linear Components

THE FINRAY GRIPPER FROM FESTO FEATURES TWO FLEXIBLE BANDS WHICH MEET AT THE TOP LIKE A TRIANGLE TO FORM THE BASIS OF THE GRIPPER. THE BANDS ARE CONNECTED BY RIBS, SPACED AT REGULAR INTERVALS USING FLEX HINGES, ALLOWING THE GRIPPER FINGERS TO ADAPT TO THE CONTOURS OF A WORKPIECE.

until the first electrolyte is also sucked in. The system then switches and blows the electrolyte back into the battery cell. The remaining gas is then removed. After the suction process, the cells are sealed again, typically done by thermal or ultrasonic welding. At the center of a degassing demonstration is the process chamber. A cantilever handling system based on Festo’s spindle axes ELGT ensures dynamic and safe loading and unloading of the process chambers. The compact and cost-effective spindle axes, with an integrated double guide, are suitable for creating 2D and 3D cantilever systems. As a 3D delivery system, for example, it packs up to 20 kg at speeds of up to 0.5 m/ sec. With a copper and zinc content of less motioncontroltips.com | designworldonline.com

than one percent, the axis is perfect for use in assembly systems in battery production or in small parts handling. During the degassing process, the process chamber is evacuated using VZQA process valves. The VZQA’s open architecture makes these valves durable, energy-efficient, easy to maintain, and flexible. They’re a suitable alternative to conventional valves such as diaphragm valves or ball valves. The pressure switch SPAN-B from Festo monitors the pressure in the process chamber. The remote IO system CPX-AP-I integrates all I/O and IO-Link devices such as sensors and valve terminals into the communication network of the plant, creating seamless communication from the workpiece to the 11 • 2022

cloud. Another feature of the handling systems for battery cells is based on bionics: the FinRay gripper from Festo offers gripper fingers that adapt to the workpiece. The FinRay allows safe and tactile gripping of workpieces with plastic malleability such as pouch cells. It’s important for automation components in secondary battery production to have the correct properties. Depending on the electrolyte and electrode material, copper, zinc, and nickel can be interfering particles in the production of lithium-ion secondary batteries. So Festo has restricted copper, zinc, and nickel for its products. All Festo products for battery cell production have clean room certificates and are suitable for use in dry rooms.

DESIGN WORLD — MOTION

Motion System Applications

THE DRYLIN ZLW TOOTHED BELT AXIS FROM IGUS IS BASED ON HYGIENIC DESIGN PRINCIPLES AND USES FDA-COMPLIANT MATERIALS AND FEATURES MAXIMUM STROKE LENGTH OF UP TO 3,000 MM.

Belt drives power motion in food manufacturing In the

most general sense, industrial belt drives

include rubber belts that wrap around drive pulleys, in turn driven by electric motors. In a typical setup the belt also wraps around one or more idler pulleys that keep the belt taut and on track. Engineers pick belt drives largely because modern varieties require little to no maintenance, they’re less expensive than chain drives, and they’re quiet and efficient, up to 95% or more. Belt and pulley systems are generally suitable for use in many different environments. For instance, dusty environments don’t generally

DESIGN WORLD — MOTION

present problems if the particles are fine and dry. However, particulate matter can act as an abrasive and accelerate belt and pulley wear, so debris should be prevented from falling into belt drives as much as possible. As for water, light and occasional contact with water, such as in washdown conditions, has little serious effect on belt drives. However, prolonged contact with constant spray or submersion can reduce tensile strength in certain belts (such as fiberglass) and cause aramid belts to break down and stretch out. Application-specific belts are designed to operate in specific environments, such as food manufacturing. Belts for use in the food industry are available for tasks such as conveying raw food products and 11 • 2022

packaging, all while satisfying FDA and USDA sanitation standards. Belt axes can be incorporated into complete drive systems for use in food manufacturing. An example of such a system comes from igus. Recently the company introduced a maintenance-free toothed belt axis specifically designed to improve sanitation in food manufacturing systems. The company’s drylin ZLW toothed belt axis is based on hygienic design principles and uses FDA-compliant materials. It features a maximum stroke length of up to 3,000 mm and can optionally be equipped with a suitable stepper motor. Cleaning complex machines and systems in food production leads to longer and motioncontroltips.com

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Motion System Applications

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therefore expensive downtime. For instance, industrial bakeries are faced with the challenge of regularly cleaning huge vats and mixers, including the moving parts – the linear axes and linear slides on which the mixers are lowered into the containers. If traditional linear axes are used here, there is a high risk that flour and dough residues will be deposited in hard-to-reach places, make cleaning much more difficult and, in the worst case, introduce contamination risks. “In order to reduce the cleaning of systems in the food industry or even in the pharmaceutical and cosmetics industries, we have now expanded our portfolio of ZLW toothed belt axes,” says Michael Hornung, igus Product Manager for drylin linear and drive technology. “The new model can be cleaned particularly quickly and thoroughly – whether with high-pressure steam jets, chemicals or simply running water. This also increases product safety.” Designed using the guidelines of hygienic design during development, the new linear axis is easy to clean. Undercuts in the entire system are minimized where food remnants could accumulate. Likewise, there are no gaps that can occur, for example, if screw heads disappeared into a recess in order to be flush with the surface. Equally important; rounded corners, which ensure that water can flow better during high-pressure cleaning and carry dirt particles along more easily. Water cannot collect and the formation of germs is reduced. Wherever a dead end was unavoidable, boreholes ensure that liquid drains away completely. igus used only FDA-compliant materials for the new toothed belt axis. Both the shaft end supports and linear carriages are made of corrosion-resistant stainless steel. The plain bearings, on which the carriage moves over the rail, are made of the food-grade triboplastic iglide A160, which enables low-friction dry operation without external lubricants, which could become a contamination hazard and pollute the environment. RoHS-compliant iglide plastic plain bearings offer a technical and economic advantage over metal plain bearings. iglide bearings are self-lubricating, maintenance-free, chemical resistant, universally applicable and reduce costs by up to 40 percent. They can withstand extreme temperatures and are suitable for special machine construction, underwater applications, and the food industry.

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SDP/SI offers a comprehensive selection of reliable Motors, Gearheads, and Motion Control Products for Industrial Automation and Robotics Applications. STOCK AND CUSTOM | ONE SINGLE SOURCE No one type of product can provide the universal solution to all motion control problems: therefore, many designs are available, each possessing construction features to accommodate one or more types of application requirements. Get the complete drive solution for your product 1. Low voltage DC Brushless Servo Motors 2. Low voltage DC Brushless Frameless Motors 3. Low voltage DC Brushed & Brushless Single and Multiple Channel Controller 4. Spur & Planetary Gearheads from 3:1 to 100:1 ratio for all sizes DC Brushless Servo Motors 5. AGV & Mobility Motors Assemblies & Kits 6. Integrated Motor Drive Controllers 7. Gearmotor Modular & Custom Assemblies We can help you achieve your design goals. Let’s talk! Motion-control products are critical components and early selection ensures you get the best solution to meet your specific needs. Expertise in creating the best combination of motor, mechanical transmission, and controller to meet your most stringent performance and reliability requirements. Our engineers are available to assist with part selection and customized design. Applications • Industrial Automation: conveyors, autonomous vehicles, packaging equipment • Medical and Healthcare: motorized wheelchairs, stair lifts patient assisting personal robots, patient transport systems • Recreational: golf carts, electric scooters, electric bikes • Robotics: agricultural, pick & place With over 70 years of engineering development and precision manufacturing experience, SDP/SI is a proven partner to the most recognized names in medical, aerospace, defense, automation, and robotics industries. Stock components available for immediate delivery!

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Motion System Applications

Networks key to predictive maintenance in IIoT systems Predictive maintenance and IoT and IIoT go hand in hand. Predictive maintenance ensures higher machine and equipment reliability and maintains system uptime. And a key part of ensuring that IIoT systems are functioning as they should is both the network connection and the computer systems. More emphasis on automation in manufacturing and throughout industry in general means that a good and reliable network connection is critical to attaining

and maintaining the advantages of automation across a range of applications. For smart manufacturing to be successful, networking is a key part of making systems more intelligent. One way to achieve intelligence at the edge of industrial networks is by deploying computers that can collect, process, and analyze data in unmanned or remote sites. The consequences are dire when these computers have a performance issue or run out of memory, therefore preventing them from performing their role efficiently, if at all. If an industrial process malfunctions because of a failure to detect and fix computer issues on time, it could also lead to accidents that result in employee injuries. For these reasons,

computers used in IIoT-enabled systems must be treated as critical equipment that require a higher level of maintenance strategy than noncritical devices. Traditionally, manufacturers have maintained their assets using manual processes that are time-consuming and resource-intensive. The IIoT brings with it a paradigm shift with respect to the operation and maintenance of industrial equipment. Now, instead of waiting for equipment to fail before fixing it, or scheduling timebased maintenance that sometimes leads to unnecessary maintenance of equipment and downtime, companies are adopting predictive

SINGLE-PAIR ETHERNET (SPE) TECHNOLOGY IS POISED TO TRANSFORM THE IIoT. THESE CONNECTORS, SUCH AS THOSE PICTURED HERE FROM WEIDMULLER, ENABLE POWER AND DATA TO FLOW IN BOTH DIRECTIONS THROUGH ONE SINGLE TWISTED PAIR OF WIRES, AND OFFER A PATH TO SIMPLIFIED, FASTER, AND MORE POWERFUL INDUSTRIAL ARCHITECTURES. SPE CAN TRANSMIT UP TO 1 GBIT/SEC AND 60 W OF POWER IN A FORM FACTOR THAT IS 50% SMALLER THAN AN RJ45 CONNECTOR.

DESIGN WORLD — MOTION

11 • 2022

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DEVELOPMENT TIME Performance, reliability, low-cost, and faster time to market. For over 20 years Performance Motion Devices (PMD) has been helping engineers and managers like Mike integrate high-performance motion control into their machines. PMD gives OEM’s the ﬂexibility to choose powerful motion control ICs, modules, or boards—whatever they need to get their automation products to market faster, and stay there. au

MOTION CONTROL FOR YOUR DESIGN

Motion System Applications

IN RAIL SYSTEMS, RUGGED INDUSTRIAL COMPUTERS TYPICALLY FEATURE BUILT-IN PROACTIVE MONITORING SOLUTIONS THAT HELP REDUCE THE COSTS OF REMOTE SYSTEM MAINTENANCE AND MAXIMIZE SYSTEM UPTIME. COURTESY OF MOXA

Onboard Computer

maintenance strategies to stay ahead of the game. These same practices can be applied to industrial computers. Predictive maintenance tools for a computer can keep track of any variance from expected behavior for key parts, such as CPU usage, CPU temperature, memory usage, and disk usage. Predictive analytics empowers users to explore potential root causes and apply appropriate remedies. By identifying issues early on and allowing repairs to be scheduled in an orderly fashion, predictive maintenance provides lead time to purchase parts for the necessary repairs and reduces the need for maintaining an inventory of key parts. Hard drives, processors and other damaged parts are replaced before failures occur, and since maintenance work is only performed when needed, production capacity is likely to increase as well. The goal of any predictive maintenance program is to enable proactive access to data for each piece of critical equipment, enabling the monitoring of its real-time health status, analyzing historical trends, and planning maintenance downtime based on the data. Predictive maintenance tools for industrial computers monitor its health in order to make

DESIGN WORLD — MOTION

repairs well in advance to maximize system uptime. The tools will feature a well-designed dashboard that helps operators keep an eye on key indicators such as CPU loading and memory usage, plus an alarm function to trigger audio or visual alarms when parameters go over predetermined thresholds. For example, in a metro transit system, computers are widely deployed in onboard control and video recording systems. Because space is limited on refurbished train cars, computing systems are often installed in places that are hard to reach and even more difficult to maintain such as cabinets, compartments under passenger’s seats, or on the ceiling. Having ready access to a computer’s current condition so that you can implement a preventive maintenance routine is an important aspect of ensuring a smooth transit system. Rugged industrial computers typically feature built-in proactive monitoring solutions that help reduce the costs of remote system maintenance and maximize system uptime.

11 • 2022

INFORMATION FOR THIS ARTICLE WAS PROVIDED BY JOHNNY FANG, PRODUCT MANAGER, MOXA

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Motion System Applications

Artificial intelligence and machine learning solutions for sit to stand robotic chairs

People

around the world, especially

those with injuries or limited mobility, experience sit to stand (STS) difficulties in their everyday lives. Detailing just some of these challenges is an August 12, 2022 New York Times article, Embarrassing, Uncomfortable and Risky: What Flying is Like for Passengers Who Use Wheelchairs. The author described the discomfort, danger, and embarrassment that wheelchair users experience on airlines. Travelers with limited mobility often need two attendants to support them while sitting and standing in the wheelchair and moving in and out of the airline seat. But travelers aren’t alone. The World Health Organization (WHO) estimates that more than one billion people live with disabilities, and 75 million require wheelchairs. Mobility challenges often create uncomfortable, dangerous, and embarrassing experiences for individuals at hospitals, nursing homes, assisted living communities, physical-therapy facilities, and even private homes. Limited mobility also prevents individuals from exercising to support their physical health. Powered STS solutions are evolving to improve the global community’s comfort, motion support, quality of life, and longevity. The next generation of robotic chairs includes a new artificial intelligence/machine learning

DESIGN WORLD — MOTION

(AI/ML) approach, dynamic programming, single-axis exoskeleton, sensors, and reinforcement learning (RL) motion control. The goal is to use AI/ML to reach optimal cost/ performance solutions for nonlinear, random STS environments and create building blocks for higher-level AI/ML exoskeletons.

State-of-the-art powered STS solutions Powered STS systems help people with limited mobility and those who assist them in moving safely, comfortably, effectively, and independently. Their designs include kinematic linkages and actuators powered by motion controllers that automate the chairs to reduce or eliminate user muscle and joint torques required for motion. And their price points generally align with their mobile assistance abilities. The Karman Standing Wheelchair is a state-of-the-art solution with advanced

11 • 2022

POSTURE TEST RESULTS AGREED WITH THE RL SIMULATION THAT KEEPING THE TORSO VERTICAL AND BUTTOCKS ON THE BACK SEAT TIP IS THE SAFEST AND MOST COMFORTABLE POSITION WHILE USING SAAR’S ROBOTIC CHAIR. COURTESY OF SAAR.

functionality and adjustability features for comfort and safety. It weighs 180 lb, costs about $15,000, and provides a standing angle nearly perpendicular to the floor; the latter requires minimal knee and hip moments to reach a fully erect position. Lift chairs are commonly used as powered comfort chairs. They cost a few hundred dollars and are available in various reclining options. The reclining angle of the lift chair seat is limited to a partial stand position, which requires some user knee and hip moments to reach a complete standing posture. Powered seats, made by Carex, are portable lifting seats for use on sofas and motioncontroltips.com

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Actuation • Motion Controls Empowering Automation

THE PRICE OF POWERED STS CHAIRS INCREASES RAPIDLY AS PRODUCT MOBILITY INCREASES. COURTESY OF SAAR.

armchairs. They cost less than $200 depending on their features. A typical seat has a limited lift angle that provides up to 70% assist lifting, according to Carex. RoboChair, made by SAAR, is a next-generation powered STS system prototype (currently not for sale). It monitors user posture for comfort and safety and includes AI/ML options for various applications, such as work, dining, resting, physical therapy, and routine exercises. This chair costs a few thousand dollars and is intended to support people in stationary or wheelchair versions. It’s designed for comfort as well as minimal knee and hip moments — and has wheels for easy maneuverability.

Robotic chairs with AI/ML SAAR’s robotic chair has an aluminum base frame that supports a linear actuator, feet plate, seat, and back support. The seat comprises two parts: a front seat for thigh support and a back seat tip for buttocks support. The back seat tip remains parallel to the floor for safety and comfort during STS motion. The ballscrew actuator is fixed to the frame at the stationary bottom end and hinged to the front seat at the moving upper end. NEXT-GENERATION STS CHAIRS The robotic chair includes AND EXOSKELETONS WILL USE AI/ wheels for easy transfer and ML TECHNOLOGY TO MONITOR AND motorized folding for compact CONTROL MOTION FOR BETTER storage and efficient transport. STABILITY AND COMFORT.

A gripper inspired by the motion of a human finger ADAPTIVE DESIGN Finger modules flex multiple joints to conform and adapt to various workpieces, offering an unmatched level of versatility and application potential.

CONFIGURABLE SYSTEM Modules can be assembled in radial or parallel hub arrays with one to five fingers in each position.

WIDE RANGE OF USE Suitable for both industrial and collaborative robots.

DESIGN WORLD — MOTION

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Motion System Applications

Precision Motion Control

SAAR’S ROBOCHAIR PROTOTYPE ACTUATES THE SEAT SO THAT THE SEAT TIP REMAINS PARALLEL TO THE GROUND FOR COMFORT AND SAFETY. COURTESY OF SAAR.

for Your Toughest Automation Challenges

For improved performance, the chair also includes AI/ML and sensors that send signals such as force, position, and velocity to the controller in real time during STS motion. These signals give the controller information on the STS system’s stability, safety, and comfort and can result in actions such as actuator motor torque and sending the user warning signals. The controller can also compare information to performance data sets for people with similar weight, height, age, and medical limitations and output exercise rating feedback. Next-generation robotic chairs should combine design simplicity with AI/ML readiness at various complexity levels. Their simplest version

FOR PASSENGERS WHO USE WHEELCHAIRS, AIR TRAVEL CAN BE AN EMBARRASSING, UNCOMFORTABLE, AND PERILOUS PROSPECT. COURTESY OF THE NEW YORK TIMES.

FIND YOUR

SOLUTION 30

DESIGN WORLD — MOTION

Actuation • Motion Controls

Karman Healthcare’s motorized wheelchair provides powered lifting to a near-standing position.

can be shaped like a chair with a single motorized axis and an adjustable link to yield up and down motion with a click of a switch. This solution can help people who experience discomfort and pain and rely on hand support, a forward posture lean, or assistive human support while sitting and standing. Getting to and from the chair may not be the problem, so simple assistive STS motion support may increase independence and reduce pain. In its higher-level version, a robotic chair can be an assistive physical therapist. The chair can support people during repetitive STS activities at various start and stop angles while activating other limbs as part of their prescribed or recommended daily exercises. A robotic chair can advance further and become the next-generation solution for people who cannot execute STS motion without human support. In this version, AI/ ML technology monitors the user’s posture, controls the chair motion, and provides feedback signals to change the user’s posture for better stability and comfort during STS motion. This robotic chair can be an exoskeleton with one degree of freedom at the knee joint. Its most advanced version can be part of a complex exoskeleton system that provides STS motion and assistive robotic solutions for short travel gaits, extended travel wheelchair riding, climbing stairs, and resting.

Reinforcement learning motion control

Esright’s power lift chair includes a reclined position (left) and partial standing position (right).

Carex’s powered seat is portable with an estimated 70% assisted lifting capability.

SAAR’s RoboChair prototype is a next-generation powered STS system with AI/ML features. POWERED STS MOTION SYSTEMS INCLUDING THOSE FROM ESRIGHT AND CAREX PROVIDE ASSISTED LIFTING CAPABILITIES FOR INDIVIDUALS WITH LIMITED MOBILITY.

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The motion of complex automated systems, such as exoskeletons and robotic chairs, can be controlled in different ways. Bang-bang (on/off) is considered the most efficient, while PID is the most common. There are also Kalman filters for random environments and fuzzy logic for nonlinear processes. Reinforcement learning (RL) motion control — part of AI/ML technology — is a relatively new approach that could be used for highly complex, nonlinear, random environments, which are expected in human-robot interactions. RL Agents learn to optimize hundreds of neural network (NN) parameters using linear programming in a simulated environment. The program includes a custom Reward function for desired performance, which is determined by system modeling and validation. RL Agents perform the tuning process and employ Critic and Actor estimators of the total expected Reward for the process. Dynamic programming and the Bellman equation are used to optimize performance by minimizing the difference between the Critic and Actor total Reward estimates, which are functions of system States and Actions. States can be measured by force, position, or velocity sensors. Actions may include controller commands, such as motor torque or alarm signal. Unlike PID, which implies proportional, integral, and derivatives of the error between actual and desired motion, the resulting NN control parameters may not be intuitively meaningful. Control engineers commonly use tools like Tensor Flow, Python, and MATLAB to optimize the NN parameters, then deploy the resulting NN Policy, which converts system States to Actions, to the real system’s motion controller. Since the simulation model may not be an exact representation of the real environment, engineers use trial-and-error with different RL Agents, Reward functions, and programming tools. The final resulting performance, which may have been difficult or impossible to visualize before the simulation, may make engineering sense.

Simulation testing In an STS chair simulation, an Actor was responsible for the Action of driving the chair actuator. The Actor received State variables and position error input and used the NN control parameters to output an Action, a control signal to the actuator. The actuator acted on the chair along with nonlinear (shock) and random (unexpected reaction) disturbances from the user’s behavior. As a result, the chair seat accelerated and yielded a new system motion State, including force, position, 11 • 2022

DESIGN WORLD — MOTION

Motion System Applications POC system testing

DURING THE AI/ML DEVELOPMENT PROCESS, THE DESIRED PERFORMANCE IS DETERMINED (1. PLANNING), A SIMULATION OPTIMIZES THE NEURAL NETWORK PARAMETERS (2. RL SIMULATION), AND THE RESULTING POLICY IS DEPLOYED TO THE REAL SYSTEM (3. OPERATION) COURTESY OF SAAR.

and velocity. The new State, which also implied a new user posture, entered a Reward function and together with the Action yielded a Reward. A high Reward was given for a safer user posture, a lower Reward was given in a warning zone, and a high penalty was given for unsafe slip conditions. The calculated Reward was then fed to a Critic, which estimated the total expected Reward of the entire STS process for its NN calculations. The RL Agent took the estimated total

rewards as a result of the Actor action, compared it to the total reward estimate from the Critic, and applied dynamic programming with a Bellman equation to change the actor NN control parameters and minimize the difference between the Critic and Actor’s total reward estimates. After a few hundred episode iterations in MATLAB, the Actor’s total Reward estimate converged to the Critic’s total Reward estimate. It implied an optimal posture, shown as an animated stick figure, where the user’s torso was vertical, and the user’s buttocks were positioned as back as possible on the seat tip.

DESIGN WORLD — MOTION

RL AGENTS LEARN TO OPTIMIZE HUNDREDS OF NEURAL NETWORK PARAMETERS USING LINEAR PROGRAMMING IN A SIMULATED ENVIRONMENT. COURTESY OF SAAR.

11 • 2022

Proof of concept (POC) testing is an integral part of RL product development that starts with safety and stability testing and results in conceptual design changes. For example, the initial robotic chair model was unstable at certain seat positions, so the development team added a stabilizing feet plate to eliminate chair rocking. Additional testing helped determine an optimal posture for stable STS motion, as the user tended to slip at about 45°. Adding fabric with a high

coefficient of friction increased the slip angle but was not enough to prevent slipping. More testing proved that keeping the torso vertical to the ground and the buttocks as back as possible on the seat tip yielded STS stability. However, the user felt discomfort while sitting on the very narrow back corner of the seat. Therefore, the development team oriented the seat tip to provide comfortable buttocks support throughout the STS process. POC tests also validated the optimal sitting posture and compared it to the simulated RL test results. A person with limited mobility tested the optimal STS posture on a regular chair and showed the opposite — buttocks toward the chair front, torso bent forward, hands on the chair seat

for support. The POC tests of the robotic chair resulted in the same conclusions as the RL process simulation. The safest and most comfortable posture for STS motion in the robotic chair was keeping the torso vertical with the buttocks positioned as close to the back seat tip as possible. This example shows how AI/ML features may provide a competitive edge in product cost/performance and manage conflicting performance objectives such as maximum safety at the highest speed. However, the

DURING AN RL SIMULATION, MATLAB SHOWED THE CONVERGENCE OF THE ESTIMATED TOTAL REWARD (YELLOW LINE) AND RESULTING USER POSITION (ANIMATED STICK FIGURE). COURTESY OF SAAR.

requirements for including AI/ ML capabilities in product development may imply higher level engineering analysis, simulations, validations, and deployment, compared with traditional processes.

THIS ARTICLE WAS CONTRIBUTED BY BOAZ EIDELBERG, PH.D., AT SAAR.

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Motion System Applications

Conveyors see uses in range of applications The grow th

in automated material handling applications as well as assembly and distribution operations has

put conveyor systems at the forefront of automation.

INTERROLL’S LIGHT CONVEYOR PLATFORM, OR LCP, TRANSPORTS SMALL CONVEYED GOODS, AS WELL AS BOXES OR POLYBAGS WEIGHING UP TO 50 KG. THE CONVEYORS CAN ALSO HANDLE INCLINES OR DECLINES AND ARE DRIVEN BY ENERGY-EFFICIENT DRUM MOTORS THAT HAVE AN EFFICIENCY OF OVER 85%, KEEPING ENERGY CONSUMPTION AND ENERGY COSTS LOW.

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11 • 2022

Conveyor platform for automated production environments One example of new conveyor systems for use in automated production comes from Interroll. The company’s Light Conveyor Platform (LCP) is a plug-and-play modular system that lets system integrators implement scalable belt conveyor sections easily in order to quickly meet customerspecific automation requirements for material flow. Efficient material feed and discharge play a crucial role in meeting the productivity potential of manufacturing cells, assembly and packaging stations. At the same time, rapidly changing process environments in many other industries require flexible conveyor solutions that can easily adapt to new requirements. Corresponding LCP-based belt conveyors can be easily assembled from factory-preassembled and predefined modules without any engineering effort. They can be put into operation quickly and safely via an autonomous machine control system, optionally without an additional programmable logic controller (PLC) though connection to an external PLC with user-specific programming is also possible depending on user requirements and the application. The LCP is designed to transport smaller conveyed goods, as well as boxes or polybags weighing up to 50 kg. The conveyors, which can also

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Conveyors

Conveyor verticaltransfer basics Pallet conveyors move products on individual carriers for significant flexibility in assembly, automation, and inspection processes —transporting them asynchronously in virtually any configuration imaginable ... even through curves, turns, and elevation changes.

IN THIS EXAMPLE OF A VERTICAL INSTALLATION USED BY AEROFARMS, PLANTS GROW UPWARD FROM TRAYS THAT ARE MOVED VERTICALLY BY A MATERIAL HANDLING SYSTEM THAT MIGHT INCLUDE ROLLER CONVEYORS, BELT CONVEYORS, VERTICAL ELEVATORS, AND FLOW RAIL SYSTEMS. COURTESY OF ULTIMATION

handle inclines or declines, are driven by drum motors that have an efficiency of over 85% — keeping energy consumption and energy costs low. The fully modular system can be planned and assembled easily and conveniently on the PC monitor using Interroll’s Layouter tool. This reduces project lead times and the necessary effort for system integrators. The new platform was developed with workplace safety and a pleasant working environment in mind. Testing included extreme endurance and load tests, and the platform was developed in accordance with Design for Manufacture and Assembly (DMFA) standards. It also features an integrated emergency shutdown at the push of a button, complies with all relevant safety regulations and has a quiet noise level during operation.

Vertical farming gets a lift from conveyor system Besides more traditional uses for conveyors such as in packaging and distribution, manufacturers are seeing new applications as well. Take vertical farming, for instance. Indoor farming is all about maximizing food production per acre, but growers who want to further increase yields are taking up vertical farming with the help of motioncontroltips.com | designworldonline.com

conveyor technologies that make use of the available vertical space within a facility. Indoor vertical farming is poised to increase over the next few years, especially due to higher yields when compared to conventional farming, its capacity for year-round crop production and advances in lighting and other technologies. “Conveyors are one of the simplest and quickest productivity improvements a fast-growing business can implement and are especially suited to the vertical farming industry,” said Richard Canny, president of Ultimation Industries, a conveyor manufacturer for the food processing, vertical farming, warehousing, delivery and other industries. “Simple roller conveyors or overhead I-beam trolleys can have a payback of days or weeks, while larger custom-built systems often have payback periods of only 3-6 months,” adds Canny. Ultimation is currently building the material handling system for what is believed to be the world’s largest indoor vertical farming facility. Conveyor systems help increase indoor farming productivity by taking advantage of unused vertical space above a work area. Overhead conveyors can lift growing trays when they’re not being actively managed and bring them back to operator level for tending and 11 • 2022

Beyond these basic movements, special modules for pallet conveyors can transfer products horizontally or vertically to another conveyor or offline process ... or re-orient the pallet (and therefore the product) on the conveyor without changing the direction of transport. Why pallet conveyors? Pallet conveyors are often used because the product being transferred needs to be precisely located on the conveyor — typically for precision assembly or inspection operations. If during the transfer some operations need to take place on different sides of the product, a lift and rotate module can facilitate this. These specialty conveyor modules lift the pallet slightly above the conveying media and rotate the pallet so that its orientation is changed ... but the original direction of transfer is maintained. How are pallets vertically moved? Pallet conveyors were traditionally used to transport products in two horizontal dimensions. But a type of conveyor module called a vertical transfer unit or VTU allows pallets to be transferred vertically to a different elevation — above or below the primary conveyor. Elevation changes allow so-called over-under conveyor designs, where a second conveyor segment runs above (or below) the main conveyor. They also allow automatic transfer of pallets to workstations located at a higher or lower elevation than the conveyor. Vertical transfer units can also be used for static operations that take place in the midst of product transport such as temporary storage or buffering while a longer process (such as glue or adhesive curing) takes place. VTUs can be operated by pneumatic or electric lifts, with electric lifts allowing multiple programmable stop positions and tight control over velocity.

DESIGN WORLD — MOTION

Motion System Applications

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harvesting, allowing more produce to be grown within the same footprint. Conveyors can also help reduce the manual labor of carrying items by hand, quickly and safely transporting plants from point A to point B. Ultimation uses materials made of galvanized steel, zinc-plated materials and powder-coated frames which are approved for food-grade applications and are easily cleaned, which offers productivity savings for indoor farmers. Different types of conveyor systems are typically used for different parts of the growing process, according to Canny. For example, the sections of the farms where plants are sitting still can use simple, standardized material handling systems. Vertical format conveyors such as hanging towers or horizontal formats such as growing trays can be customized to match the grower’s needs. Once plants are grown, more sophisticated technologies like automated motorized conveyors and automatic storage and retrieval systems are needed to safely move produce to the harvesting area. The most commonly used industrial automation equipment for indoor farming are gravity roller, belt, and skate wheel or flow rail conveyors. These systems use the force of gravity to move the load, allowing the product to roll along the upper surface. More recently, the technology used in larger vertical farming systems is including motorized and overhead conveyors that take advantage of the generally unused vertical space above the working area. Using curved sections or even lifters, they bring produce down to operator level and back up to higher elevations as needed.

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DESIGN WORLD — MOTION

Couplings

Dynamical torsional stiffness: some couplings need finer tuning The

coupling is normally the softest element in the drive

line — literally — but by no means is it the weakest link in the chain. Its configuration plays a decisive role in the functionality of the driving and driven machine and the reliability and lifetime of the entire drive system. The optimum coupling adjustment to the connected machine units is critical in all cases where failures and breakdowns are a concern. motioncontroltips.com | designworldonline.com

The dynamical characteristics of a coupling influence the natural frequencies of a machine unit and whether resonances are likely to occur in the operating speed range. The critical resonance state is reached when the system is excited at one of its natural frequencies (depicted in Fig. 1). The entire system swings up, leading to an increase in the amplitude. This puts additional loads on the components and leads to system or material failures. High costs for replacement parts and frequent maintenance operations are the consequences. 11 • 2022

For drives using combustion engines, it is common to use a coupling designed to allow the plant to be continuously operated even in non-optimal speed and torque ranges. This is achieved by an optimal stiffness adjustment so that the natural frequency is shifted into less critical speed ranges. Every drive system operates optimally and is not subjected to damage or failure if stiffness and damping are tuned individually. Only with this new generation of highly flexible couplings is this flexibility possible. It is because of one DESIGN WORLD — MOTION

Motion System Applications

FREQUENCY RESPONSE ANALYSIS

FIG. 1: FREQUENCY ANALYSIS WITH PRESENTATION OF THE 1ST AND 2ND NATURAL FREQUENCY ALONG WITH THE CORRESPONDING AMPLITUDE RATIOS.

distinctive feature: the spatial separation by arranging the elastomer buffers in series. This allows engineers to tailor stiffness to the requirements of the application by selecting the available elastomers for the inner and outer buffer rows.

Three example applications to show why it is beneficial to use these couplings Example 1: The combined heat and power plant A combined heat and power generation plant may be equipped with different drives. A CPH manufacturer offering 15 different combined heat and power units, configured by three engines and five different generators, also

needs up to 15 suitable couplings to adjust the torsional vibration behavior of each unit. For storage reasons, and to keep the maintenance operations to a minimum, this is seldom the case in practice. In fact, compromises for vibration behavior are made. With an individually adjustable coupling equipped with replaceable elastomer buffers, the manufacturer only needs one single coupling and uses different sets of elastomer buffers to satisfy specific requirements. Hence, the attached parts remain the same, and only the buffers must be changed. In addition to saving inventory costs, the manufacturer can supply its customers with an optimally tailored drive with an individually adjustable coupling. This results in long equipment lifetime and low maintenance costs.

CRITICAL OPERATION POINT WITH AND AMPLITUDE INCREASES

Example 2: The emergency power unit High reliability demands, safety, and long service life are made on emergency power units in hospitals or offshore platforms. Yet, large power generators are especially difficult to adjust concerning their resonance vulnerability. The required stiffness is generally determined by calculation. If deviations are observed during real operation conditions compared to the simulated model, there is only one way to solve the issue in case a conventional disc coupling is installed — the operator must replace the entire coupling. The individually adjustable coupling with replaceable elastomer buffers offers a second option to the operator — the step-bystep optimization of the design by replacing individual buffers. This will save time and costs.

Example 3: High-power drive systems This again refers to large systems, that is, engines with a power above 1000 kW. If the coupling is not correctly designed in terms of stiffness and damping, uneven operation and vibrations can result. Contrary to standby power generators for which no risks are generally taken, production facilities and other applications attempt to counter-act resonance phenomena by using a torsionally stiff coupling design. The operator thereby accepts the risks of higher costs and maintenance efforts for replacing the coupling and more frequent and longer equipment breakdowns. If the operator uses an individually adjustable coupling with replaceable elastomer buffers, the step-by-step optimization of the entire system will be possible.

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FIG. 2: SUB- AND SUPER-CRITICAL OPERATION POINT WITH CORRESPONDING AMPLITUDE RATIO.

DESIGN WORLD — MOTION

11 • 2022

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• Slit couplings are available in short and long styles giving designers a variety of body sizes to choose from to fit application envelope and performance requirements. • Controlflex is a highly flexible encoder coupling designed for applications with high speed, low torque, and wide differences in shaft sizes (up to a 4:1 small to large ratio). • Slit couplings are available in bore sizes from 1.5mm to 12mm (1/8” to 1/2”) and controlflex couplings are available in sizes from 6mm to 40mm (1/4” to 1-1/2”).

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Controlflex Coupling

MOUNTABLE SHAFT COLLARS • Available with OD flats and holes for direct mounting of the collar to other components. • Proprietary manufacturing processes ensure superior fit, finish, and holding power.

MODULAR MOUNTING SYSTEMS • Assortment of components that allow users to build small assemblies for mounting sensors, conveyor rails, machine guards, and more. • Optional pre-designed kits make it easier to select the right system for your application.

• Manufactured in a variety of sizes, styles, and materials.

QUICK CLAMPING COLLARS

UNIVERSAL JOINTS

• Hand operated: no tools required to install, remove, & adjust.

• Widest selection in the industry: over 3000 standard single and double universal joints to start your next design with. • Available from Ruland in 2 weeks or less for the shortest lead times in the industry. • Yokes, pins, and blocks are precision machined, ground, and selectively heat treated for smooth operation at high operating angles.

www.ruland.com | sales@ruland.com

• Best suited for systems that require frequent adjustments.application.

Motion System Applications

Absolute rotary encoders make omnidirectional motion a VR reality Encoders

THE USER CAN WALK IN ANY DIRECTION ON A DECK ATOP A STATIONARY PLATFORM.

are critical motion

control components that provide feedback on a system’s position and speed. They are used in almost every industry — such as aerospace, robotics, packaging, and textiles — and are building traction in virtual reality (VR) treadmills. VR treadmills let users physically move in real-life space while navigating virtual environments. But unlike exercise treadmills that move in one direction and dictate the user’s speed, VR treadmills must respond to the user’s varying speed and position. In virtual environments, the user is in control, and the treadmill needs to adjust without knowing the user’s next move, which could be in any direction. The world’s ﬁrst and only commercially viable omnidirectional VR treadmill debuted in 2018 when Inﬁnadeck provided Warner Brothers Studios with a prototype for the Stephen Spielberg movie “Ready Player One.” The omnidirectional treadmill is located on a deck atop a stationary platform and allows the user to walk in any direction. The design includes one continuous 400-ft belt that serpentines throughout the system and mechanical components such as bearings, molded plastics, and aluminum extrusions. Among more than 5,000 parts

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Encoders

TWO HEIDENHAIN ECI 1118 ABSOLUTE ROTARY ENCODERS SEND FEEDBACK ON THE USER’S POSITION AND SPEED AND HELP CONTROL THE SYSTEM’S X AND Y MOVEMENTS.

that make up the Infinadeck system, two absolute rotary encoders provide critical feedback for motion control. In the fully closed-loop system, motion control is based on an X-Y coordinate system. The X-axis consists of various bridges, and the Y-axis uses a continuous belt. SANYO DENKI amplifiers and motors drive the system, and the two HEIDENHAIN ECI 1118 absolute rotary encoders on the motors and walking surface tell the system exactly how the surface is moving. “These are important because they help control the system’s X and Y movements, as the encoders provide the system position feedback on each axis,” said Infinadeck COO Benjamin Freeman, emphasizing the critical sub-millimeter accuracy of the encoder. Absolute rotary encoders have the advantage of nonvolatile memory — meaning they can report position even after power fails and returns. So even if something moves the machine shaft when power is off, an absolute encoder keeps track of the rotary-position change when the machine powers on again. Absolute rotary encoders can operate point-to-point as well. They are useful in situations in which safety is a concern because they position whenever machines power on. Immunity to electoral noise is another benefit. The HEIDENHAIN ECI encoders feature high ruggedness and reliability in a compact, small-diameter design, making them a good fit

Your Your Responsive Responsive Experts Experts II N N M MO OT T II O ON N C CO ON NT TR RO OL L

EPC encoders provide reliable motor feedback in compact housings EPC encoders provide motor in compact designed for long dutyreliable cycles in harshfeedback conditions, and are housings designed for long duty cycles in harsh conditions, and are manufactured in Idaho, USA. manufactured in Idaho, USA.

Contact EPC Contact EPC TO L E A R N M O R E TO L E A R N M O R E

motioncontroltips.com ·| encoder.com designworldonline.com 1-800-366-5412 1-800-366-5412 · encoder.com

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Motion System Applications

for Inﬁnadeck’s tight space constraints. The encoders’ blind hollow shaft directly couples to the system’s mating shaft for optimal rigidity. Their inductive scanning principle is particularly tolerant of contamination and vibrational loads of up to 400 m/sec² on the stator and 600 m/sec² on the rotor. Rotary encoders from this HEIDENHAIN series provide positioning accuracy of ±120 arcsec and 524,288 positions per revolution, or up to 65,536 revolutions with the multiturn version. Single-turn absolute encoders can verify position within a single turn of the encoder shaft. This makes them useful for short travel situations. In contrast, multiturn absolute encoders are better for more complex or longer positioning situations. Measuring tasks over more than one actuator or axis revolution necessitate multiturn encoders.

Multiturn encoders can track the absolute position because the digital position value is not repeated until the maximum number of rotations is reached. Such functionality is important in applications involving linear motion — particularly on electromechanical actuators relying on rotary electric actuators that may spin many times for some small advancement of the axis’ carriage or other output. The ECI absolute rotary encoder series also offers functional safety and a safe mechanical connection. Once integrated into an application with up to safety integrity level (SIL) 3, they minimize malfunctions and facilitate the safe operation of machines and systems. Information from the rotary encoders and a virtual-position tracker located on the user’s back is delivered to Inﬁnadeck’s control loop software,

THE INFINADECK USES AN HTC VIVE TRACKER ON THE BACK OF THE USER TO DETERMINE WHERE THE USER IS IN 3D SPACE.

Your partner for innovative manufacturing

Superior encoders for position and motion control With a comprehensive line up of encoder solutions, Renishaw brings the expertise needed to address your manufacturing challenges. Whether your application calls for optical, magnetic or laser technology, our encoders achieve the highest levels of accuracy, durability and reliability. Powerfully positioned for innovative motion control.

www.renishaw.com/encoders Renishaw Inc., West Dundee, IL 60118

usa@renishaw.com

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Encoders INFINADECK’S OMNIDIRECTIONAL TREADMILL REVOLUTIONIZES THE VR EXPERIENCE BY GIVING USERS TRUE 360° MOTION.

YOUR EXPERT SOURCE FOR ENCODERS Ten Fundamental Reasons Why We Should Be Your First Choice

which manages the calculations for user position and speed to keep the user balanced and walking naturally in any direction. The omnidirectional VR treadmill has already ventured into healthcare applications, such as Khymeia’s “Moonwalker” for neurological rehabilitation, and suggests applications for VR in defense and government, training, research and education, fitness, and — of course — gaming. “Infinadeck’s platform is ground-breaking for the VR landscape, and we’re proud to be a part of this exciting motion control endeavor,” said Jonathan Dougherty, HEIDENHAIN’s Business Development Manager of the Automation Division.

• 5 YEAR WARRANTY • Hollow shaft ranges from 1/4” to 4.5” • Unbreakable code discs made in house • Customized designs and niche solutions • ATEX certified Explosion proof encoders • Exceeding industry durability standards • Flexible production/rapid delivery • Worldwide sales & support • Manufacturing in Canada and Germany • Continuous product development

1.888.277.6205 www.globalencoder.ca info@globalencoder.ca

HEIDENHAIN HEIDENHAIN.US

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FAULHABER applications

Drive for the next evolution in the operating room With FAULHABER drive systems, medical robots are opening a new era in modern medical technology. www.faulhaber.com/surgical-robotics/en

WE CREATE MOTION

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Programmable automation controllers (PLCs)

Retrofitting automation in agriculture AUTOMATING THE AGRICULTURAL INDUSTRY PRESENTS MANY CHALLENGES DUE TO THE WIDE-RANGING LOCATIONS AND THE NEED FOR SOLUTIONS TO BE COST-EFFECTIVE AND MAINTAINABLE. WE’VE SUCCESSFULLY UPGRADED EXISTING SYSTEMS USING PLC, HMI, NETWORKING, AND AUTOMATION PRODUCTS. BY VINNY ENDRES • BITMASKED AUTOMATION

family farm or dairy can be an interesting place for a kid to grow up. In this environment, I learned to work on

mechanical aspects of vehicles and equipment. More interesting was tackling electrical and controls projects; eventually I mastered the use of industrial programmable logic controllers or PLCs. By the time I left the family farming operation to attend college, I took a systems integration role by founding Bitmasked Automation. Agriculture in recent decades has increasingly relied on automation to improve safety, production, and quality. Regardless of the final product, there are countless growers, processors, and transporters that directly use automated equipment … or indirectly rely on support and utility systems. My on-the-job education provided background into what such end users need and how evolving technologies can help develop and support automated systems.

Manageable modernization of agriculture Agricultural end users operate a lot of different equipment spread over multiple sites and remote locations. This includes tractors and harvesters as well as packaging and processing equipment along with other support and utility systems. While these users typically can’t afford to have full-time engineering or technical personnel on staff, they would like to take advantage of automation advancements. New equipment sometimes comes with modernized controls, but most

BITMASKED SPECIALIZES IN PERFORMING AUTOMATION TECHNOLOGY REVAMPS ON SYSTEMS SUCH AS THIS HYDRAULICALLY OPERATED EQUIPMENT TO CLOSE CLAMSHELL DOORS AROUND BROCCOLI TOTES. THEN THE MACHINE FILLS THE TOTE WITH SLUSH ICE TO REMOVE “FIELD HEAT” AND COOL THE PRODUCE — THEREBY PRESERVING THE HARVEST FOR TRANSPORT. NEW AUTOMATION SYSTEMS ON SUCH EQUIPMENT GREATLY INCREASE ITS RELIABILITY AND PERFORMANCE — GIVING FARMERS NEW WAYS TO OPTIMIZE AND MAINTAIN OPERATIONS. COURTESY OF BITMASKED AUTOMATION

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Motion System Applications

equipment is existing, and often it makes sense to perform an automation system retrofit. Existing systems typically use limited or outdated automation, such as hardwired relays, specialized electronics, or sometimes older PLCs or smart relays. These can become problematic to service, and lack the ability to provide modern conveniences, especially remote connectivity. Agricultural end users are eager to upgrade these systems and leverage: • Efficient automation functionality. • Local touchscreen visualization. • Remote access for monitoring and adjustments. • Proactive notification of trouble (email notifications and text messages). • High reliability so production avoids bottlenecks, especially during the critical peak processing times of seasonal products. • Ready access to easily replaced spare components.

BITMASKED HAS STANDARDIZED ON AUTOMATIONDIRECT PRODUCTIVITY SERIES PLCS AND C-MORE HMIS AS WELL AS BRX PLCS AND STRIDELINX NETWORKING/VPN/ SOFTWARE SOLUTIONS — ALONG WITH MANY CONTROL-PANEL ACCESSORIES. COURTESY OF BITMASKED AUTOMATION

These needs have provided great demand for SIs able to apply new technologies to specialized equipment.

Automation options abound for pragmatic controls When I started out with repairing and automating equipment on the family farm, one supplier in particular was my go-to resource. Their barrier to entry is very low, from both a technical and a financial standpoint. Products are easily selected online, and much of the software is free or low-cost. Almost everything conceivable needed to create a control panel is available and quickly shipped. The documentation is comprehensive, and it’s supported by countless online videos, along with web-based or phone support options, all at no additional cost. The hardware is robust enough to withstand challenging field conditions, and basic functionality is more than adequate. In addition, advanced features boost development efficiency efficient and functionality. User defined structures (UDS) are flexible data formats that make it easy to organize and replicate the associated PLC logic and HMI graphics. MQTT has become the industry standard for transmitting IIoT data from the field to supervisory computing resources, either onsite or in the cloud. The product family also includes StrideLinx cloud VPN and IIoT platforms, which I use to implement simple, yet powerful, cybersecure remote connectivity.

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C o n g r a t u l a t e s

maxon is a developer and manufacturer of brushed and brushless DC motors. as well as gearheads, encoders, controllers, and entire mechatronic systems. maxon drives are used wherever the requirements are particularly high: in NASA’s Mars rovers, in surgical power tools, in humanoid robots and in precision industrial applications, for example. To maintain its leadership in this demanding market, the company invests a considerable share of its annual revenue in research and development. Worldwide, maxon has more than 3000 employees at nine production sites and is represented by sales companies in more than 30 countries.

www.maxongroup.us • 508.677.0520

Programmable automation controllers (PLCs)

Standardizing on this portfolio of products has helped us reliably and rapidly create control panels. We have a high degree of confidence that we'll get parts in a timely manner —and create designs with a compact footprint usable for new and retrofit projects.

Automating produce-icing equipment A given automation specialty for Bitmasked has been the upgrading of existing icemaking equipment. Modern farming relies on the ability to cool product to temperatures around 40° F for preservation as it’s transported to processing and market. There are many ways to preserve food depending on the environment and the product, and certain applications need large quantities of ice to perform the task. The principles of mechanized ice production were established in the 1800s. While there have been countless mechanical and automation improvements over the years, a significant quantity of older equipment remains in service. Unfortunately, these legacy systems often need considerable attention to operate and maintain, and they may lack adjustability to optimize operation in relation to outdoor temperature, water supply temperature, and other conditions. In some cases, manufacturer support becomes hard to obtain, or impossible when suppliers go out of business. Bitmasked has re-automated many of these icemaking machines — preserving existing functionality and adding to it wherever possible. Examples of improvements are incorporating user adjustability for freeze time and temperature settings, and even providing automatic or dynamic adjustment in some cases. Automating single machines is straightforward, but the greatest efficiencies are achieved with multiple interconnected machines which must be precisely synchronized to ensure efficient refrigeration system performance. In both cases, strategies such as PLC-enabled lookup tables improve operation, and we give users the flexibility to tune properly to create the fastest cycles with the most yield. For example, adding adjustments for how much to unload the compressor(s) and when to do so before pressure demand it can help gain extra seconds that add up to significant production efficiencies. A typical system uses a Productivity 1000 motioncontroltips.com | designworldonline.com

PLC, 10-in. C-more HMI, and a StrideLinx VPN router. The control-panel designs use various AutomationDirect parts available online so we can adapt to project needs while maintaining high performance standards and consistency. The PLC offers powerful arrays and nested UDS to support control strategies, along with comprehensive data handling and remote data publishing via MQTT. The HMI is easily configured, provides clear visualization for operators, and is remotely accessible if desired. The StrideLinx IIoT cloud service (connected over the internet or a cellular connection) enables ongoing operational support from

Bitmasked, offered as a subscription service. Considering that the 40 tons of ice some machines produce per day can retail for $5,000, performance-improving retrofits quickly yield full ROI. That’s especially true where cooling-room alarming features are added.

BITMASKED USED AN AUTOMATIONDIRECT PLC, HMI, AND NETWORKING COMPONENTS TO AUTOMATE THIS ICE PRODUCTION EQUIPMENT. THE RETROFIT BOOSTED PERFORMANCE AND IMPARTED MODERN COMMUNICATIONS INCLUDING WEB-DATA DASHBOARDS SUPPORTED BY MQTT. COURTESY OF BITMASKED AUTOMATION

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YOUR CUSTOM SOLUTIONS ARE

CGI STANDARD PRODUCTS

Advanced Products for Robotics and Automation CGI Motion standard products are designed with customization in mind. Our team of experts will work with you on selecting the optimal base product and craft a unique solution to help differentiate your product or application. So when you think customization, think standard CGI assemblies. Connect with us today to explore what CGI Motion can do for you.

800.568.GEAR (4327) • www.cgimotion.com

Motors & Drives — AC

Pertinent operating conditions for ac gearmotors and motors AC MOTORS. COURTESY OF BODINE ELECTRIC CO.

Nameplate

values stipulate the limits at which a motor or gearmotor can safely operate. To operate the motor

either over or under the nameplate rated limit can degrade motor performance and safety. Let’s now review some of these restrictions and the consequences of ignoring them.

MOTOR AND RUN CAPACITORS RELY ON PROPER MOTOR INPUTS, ENVIRONMENTAL CONDITIONS, AND LOADING FOR PROPER OPERATION.

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Operating voltage: Don’t operate AC induction motors at voltages beyond ±10% of nameplate rating. Higher voltages produce detrimental motor temperature, noise and vibration, and operation of current-sensitive relays. Operating beyond rated voltages can also shorten motor life and capacitor life and could create nuisance operation of thermal overload protectors. On the other hand, voltages more than 10% below the nameplate rating can damage current-sensitive starting relays and cause delayed tripping of thermal overload protectors having internal heating coils — leaving windings exposed to temperatures exceeding maximum allowable limits. Operating frequency: Don’t operate AC induction motors from a nominal power source frequency other than that specified on the nameplate. AC motor speed directly varies with the power source frequency. While it’s understandable that some OEM machines are designed to operate at more than one line frequency (including U.S. equipment exported to Europe) any decrease in speed arising from frequency reduction may cause detrimental temperatures and improper operation of centrifugal cutout switches (in split-phase motors) and relays. Increased frequencies reduce torque capability … and starting relays may fail to engage the auxiliary winding. AC motor laminations (and the windings installed in them) are specifically designed for operation at nameplate frequencies. For example, the laminations for 60-Hz motors are considerably different than those used for 400-Hz motors. In addition, manufacturers of AC motors usually don’t performance-test their fixed-speed AC motors at frequencies other than the nameplate frequency rating. Because the amount and type of noise and vibration emanating from a motor will change directly with frequency, undesirable hum and other resonance effects are quite likely with deviations from nameplate frequencies. Dual frequency (50/60 Hz) AC motors can be provided by most gearmotor manufacturers, usually at output ratings lower than the standard 60-Hz rating for a given frame size. 11 • 2022

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MAKE NOTE OF NAMEPLATE VALUES, AND DON’T SUBJECT THE AC MOTOR OR GEARMOTOR TO CONDITIONS FOR WHICH IT WAS NOT DESIGNED.

Nameplate torque ratings: Don’t operate any AC gearmotor or motor at torques in excess of nameplate rating. The rated torque can be calculated from the desired operating speed, torque, and motor power (in Watts or Horsepower). Overload limitations also apply to gearmotors where maximum gearhead torque is shown. Technical assistance should be requested from the manufacturer if overloads are anticipated. Operation at higher torque

loads can result in lower speeds, higher winding temperatures, reduced life of windings, gears and bearings, and nuisance operation of thermal overload protectors. In many cases, overloads can create hazards to personnel. Noise and vibration also increase with excessive loading. PSC gearmotors or motors at light loads: Use caution when operating permanent split capacitor (PSC) gearmotors or motors at light loads. An inherent characteristic of PSC AC induction motors is they generally operate at elevated temperatures when lightly loaded. While some motor manufacturers may take this condition into account as part of their design methodology, others may assume that the motor will always be operated at the nameplate load point. To prevent PSC motors from running too hot, they should be load matched to the application. Ambient temperature rating: Don’t exceed a geared motor’s nameplate ambient temperature rating. Lack of air intake, ventilation obstructions, and other deviations from nameplate parameters will spur excessive motor temperatures. Operating at such elevated temperatures will shorten motor life and typically reduce available motor torque and speed. High temperatures may also spur nuisance operation of thermal overload protectors, and motor start failures where currentsensitive relays are employed. These hazards can be avoided by ensuring that the setting provides the motor with adequate ventilation. AC gearmotor/motor run and start capacitors: Don’t deviate from the speciﬁed capacitance of an AC gearmotor run capacitor

IN SPLIT-PHASE AC MOTORS AND GEARMOTORS WITH A CENTRIFUGAL START SWITCH (AS SHOWN HERE) MOTOR-START CAPACITORS ARE TYPICALLY SPECIFIED TO REACH MAXIMUM STARTING TORQUE — AND MINIMUM LOCKED-ROTOR CURRENT DEVIATIONS SHOULDN’T BE MADE BY THE USER.

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Meeting Customer Needs with Diverse Product Categories and Customized Products

Linear Piezo Motor

DC Brushless Servo Motor

Canon Precision proprietary technology and internal production systems provide our partners with micro-motor design flexibility, quality control and rapid delivery. Canon Precision motors can also be equipped with optional gear units and encoders and can be optimized to meet your size, speed, gear ratio and reliability requirements. CANON U.S.A., INC. Motion Control Products 3300 North 1st Street • San Jose, CA 95134 TEL: 1-408-468-2320 • Email: motors@cusa.canon.com www.usa.canon.com/ Canon is registered trademark of Canon Inc. in the United States, and may also be registered trademarks or trademarks in other countries. All other referenced product names and marks are trademarks of their respective owners. Specifications and availability subject to change. Not responsible for typographical errors. ©2021 Canon U.S.A., Inc. All rights reserved.

Motion System Applications

CONTINUOUS DUTY OPERATION

SHORT TIME DUTY

TC P

INTERMITTENT DUTY OPERATION

DON’T SUBJECT THE AC MOTOR OR GEARMOTOR TO DUTY CYCLES FOR WHICH IT WAS NOT DESIGNED.

for permanent split capacitor motors. In split-phase AC motors and gearmotors (with centrifugal start switch) motor-start capacitors are typically speciﬁed to reach maximum starting torque — and minimum locked rotor current deviations shouldn’t be made by the user. Changing to a higher value of capacitance will increase the starting torque and, in some cases, speed. It can also introduce hazards such as higher winding temperatures, shortened motor life, nuisance operation of thermal overload protectors, and increased noise and vibration. The voltage rating of the employed capacitor mustn’t be less than the value indicated on the AC motor nameplate. Third-Party safety testing for OEM

equipment by safety test laboratories (including UL, CSA, and Intertek) might fail thermal testing if the applied capacitor differs from the value specified on the motor nameplate. Always obtain assistance from the motor manufacturer when evaluating the proposed deviation and explore the possibility of changing the nameplate rating or developing a more satisfactory AC motor design. Duty Cycle – Continuous versus Intermittent: Don’t subject the AC motor or gearmotor to duty cycles for which it was not designed. Continuous (CONT) or intermittent duty (S2 or S3 for example) as indicated on the gearmotor nameplate, identifies the designed mode of operation for the motor and is generally based on the motor’s insulation system class and the power (watts) that the motor must dissipate as heat when energized. Adverse effects can develop from operating a continuous-duty motor in an application needing frequent starts and stops … or from continuously operating an intermittent-duty motor. In general, deviating from the duty rating will spur higher winding temperatures with a shortened motor life and the possibility of nuisance operation of thermal overload protectors. Increased frequency of starts could spur failure of electrolytic motor start capacitors and a reduction in the life of motor starting switches or relays. Note: Once the load magnitude is determined, the end user must identify or define the duty cycle as either continuous or intermittent. A gearmotor or motor that continues to operate after reaching normal operating temperature is considered to be operating under continuous-duty conditions. If a gearmotor or motor never reaches a steady temperature and is permitted to cool between operating cycles, then it’s operating under intermittent-duty conditions. Gearmotors or motors that are operated intermittently will be given a time rating that’s listed on the nameplate. This article was edited by Tim Oliver, V.P. of Engineering at Bodine Electric Co.

SHOWN HERE ARE THE BRAKE-TEST RESULTS FOR A PERMANENT SPLIT CAPACITOR (PSC) GEARMOTOR.

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Better Performance. Smarter Motion. Designing advanced semiconductor, electronics, or display manufacturing equipment? Meet the Intelligent Drive Module (IDM) Series drives designed to maximize high-precision motion stage performance in high-tech manufacturing equipment. • Advanced servo control algorithms and performance optimization tools • High-frequency position-based I/O for device triggering and data capture • Single- and multi-axis models for single- and multi-axis stages

Challenge us with your high-performance OEM motion control application! www.acsmotioncontrol.com

Motion System Applications

FACTORY AUTOMATION SOLUTIONS SIMPLIFY ENGINEERING AND INTEGRATION, IMPROVE TIME TO MARKET, AND PROVIDE MORE FLEXIBILITY TO MODIFY AND UPGRADE SYSTEMS WHEN A FACILITY’S OPERATIONS CHANGE.

Best practices for designing automated production lines The

newest generation of factory automation technologies is transforming production lines in every major industry

— from consumer-packaged goods and electronics manufacturing to electric vehicles and battery production. As automation technology becomes increasingly sophisticated and connected, manufacturers are exploring new ways to add flexibility, achieve higher productivity, and capture real-time insight across operations. But not all solutions are created equal. Turning possibilities into reality requires a smarter, more streamlined approach to automation.

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Until recently, it could take up to two years for new automation systems to go from initial design to full operation. Proprietary protocols and closed architectures have hampered engineering freedom to create or modify production lines and processes rapidly. As a result, companies found it difficult and time-consuming to stay competitive and see returns on automation investments. Now, new hardware and software solutions are simplifying the engineering and integration of automated installations that are more flexible and scalable than systems of the past. For example, open automation platforms are removing interoperability hurdles that closed and propriety systems typically create. These open platforms make it easier to program robots for a range of applications. Additionally, motioncontroltips.com

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Motors & drives — servo

mechatronic systems increase speed to market, and online selection tools make it easier for design engineers to ﬁnd and purchase the mechatronic components they need. When designing or deploying new factory automation equipment (whether a single pickand-place linear handling robot or end-to-end production line upgrade) consider the following best practices to get the most value from the latest technologies.

From Concept

Make use of open automation platforms Automation platforms built around closed proprietary hardware, software, and connectivity architectures can seriously complicate implementation. With closed systems, integrating new solutions or programming basic machine functions requires esoteric coding languages and specialized engineering resources that are increasingly hard to come by and costly to procure. These proprietary systems also create interoperability challenges that complicate engineering, integration, and data exchange. But with the latest advances in controls and automation platforms, production lines today have access to open systems that offer far more ﬂexibility, scalability, and engineering freedom. With these systems, manufacturers and OEMs can use a simpliﬁed, app-based approach — much like using a smartphone — to engineer sophisticated automation solutions. They can choose apps from the automation platform provider or third-party suppliers or create apps for functions tailored to their application. Programmers can use coding languages they already know, such as Python, Blockly, C++, or even IEC 61131, to develop new automation functionality.

Factory automation solutions are complex — with crosstechnology platforms incorporating multiple controls, drives, electric motors, material transport, linear motion, and other systems. Choosing technology partners with complete automation portfolios and comprehensive solutions can optimize and future-proof machine builds.

An open approach to automation also unlocks a new world of possibilities for process transparency, product tracking, and predictive maintenance. With an open ecosystem, operations can more easily integrate machines and other technology into a complete system that provides DESIGN WORLD — MOTION

To Creation

Bison Gear & Engineering is an industry leader in designing and manufacturing custom gearmotors for the fractional horsepower market. Our engineering team will work with you to find the perfect solution for your power transmission needs. Challenge us today with your custom project

www.bisongear.com

The right gearmotor for your application. With over 1,400 standard products to choose from you can count on the engineers at Bodine to help you find a gearmotor with the right torque, power and speed for your application. We’ll get your design moving. OEM SOLUTIONS

bodine-electric.com

visit us at bodine-electric.com | info@bodine-electric.com | 773.478.3515 (USA)

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Motors & drives — servo

connectivity and real-time, machine-level data for advanced production and operational analytics. That means almost any equipment can also operate as an edge device, collecting data on processes and production flows to optimize efficiency.

Leverage hardware with mechatronics capabilities

PLATFORMS SUCH AS BOSCH REXROTH’S CTRLX AUTOMATION PROVIDE ACCESS TO OPEN SYSTEMS THAT OFFER FLEXIBILITY, SCALABILITY, AND ENGINEERING FREEDOM USING AN APP-BASED APPROACH TO ENGINEER SOPHISTICATED AUTOMATION SOLUTIONS.

Mechatronic systems such as linear robots for pick-and-place applications offer significant opportunities for reducing engineering time and improving speed to market. However, automation engineers and OEMs need still faster ways to select, order, and deploy components for manufacturing applications such

as joining, dispensing, pressing, and handling. Here, engineers can benefit from the use of smart mechatronic components. With special online selection tools, OEMs and system integrators can quickly size and select smart mechatronic linear modules, motion control, drives, motors, cabling, and more to create and order complete solutions and have them delivered as a single product with a CAD model as a digital twin. Consider how some motor drives (so essential to the function of automated equipment) come with commissioning software to give machine controls and other systems the ability to automatically recognize the drive. Some software ecosystems supporting such hardware feature preloaded drag-and-drop motion sequences preconfigured for a range of functions common to handling, pressing, or joining applications. All this eliminates the need for special programming knowledge and saves time during installation. The systems also have connected features that track performance and let operators modify sequences or add new ones as needed.

BOSCH REXROTH’S SMART MECHATRONIC SYSTEMS USE A PLUG-AND-PRODUCE CONCEPT TO SIMPLIFY THE DEVELOPMENT PROCESS AND ELIMINATE THE NEED FOR COMPLEX AND TIMECONSUMING AUTOMATION PROGRAMMING.

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Include advanced conveyance and transport where possible Designing conveyor flow and choosing materialhandling technology early in the process can help maximize an operation’s flexibility and connectivity. Today’s transport technology is more sophisticated and modular than ever, making it one of the easiest ways to enhance manufacturing agility and lean productivity. For example, conveyor and pallet features need to be compatible with all the equipment through which they’ll run. Therefore, various material transport technologies provide a broad range of speed and load capabilities for OEMs and end-user engineers to create customized conveyor solutions with specific production requirements. Technologies like modular plastic chain conveyor systems offer new levels of flexibility with components that can easily be configured and reconfigured to meet any manufacturing footprint or change in production flow. What’s more, production lines that contend with high volumes or demanding environments can rely on the high speed and high positioning accuracy of linear motordriven transfer systems. These systems can also offer builtin connectivity with visual displays that monitor power consumption, lubrication, and temperature. They can even enable virtual simulations that help determine optimal throughput. By factoring connectivity into a transfer solution from the beginning, companies can ensure their production lines are tooled for the future.

Consider inclusion of AMRs and cobots Open control platforms make it progressively easier to program robots like autonomous mobile robots (AMRs) or collaborative robots (cobots). AMRs can handle a range of payloads and come with 360° obstacle detection, allowing them to navigate different spaces or adapt to changing production floors. Cobots are also well equipped to improve flexibility in task assembly, box forming, case packing, and palletizing operations. New technology like seven-axis cobot systems improve reach and maneuverability, providing more options to position robots to help with ergonomics and optimize floor space without needing extra safety guarding or fencing.

DESIGN WORLD — MOTION

Advances in AMRs and cobots make them practical solutions for a range of use cases, and they can even be used in combination for mobile pick-and-place functionality. With an open technology ecosystem and app-based approach to programming, engineers can easily change robot functions with simple dragand-drop configuration apps.

Compare suppliers’ support services Full lifecycle support is an essential requirement for any truly complete automation solution, and it should be a major consideration from the beginning of any automation project. Factory automation solutions are complex with cross-technology platforms that incorporate multiple controls, drives, electric motors, material transport, linear motion, and other systems. Therefore, finding the right technology and honing factory production processes are only part of the automation puzzle. Manufacturers and OEMs should choose suppliers (preferably global suppliers with robust service infrastructures) offering full lifecycle support as well as components featuring sensors and other machine-life monitoring accessories to gain real-world insights into production-line performance. Together, support and monitoring functions can impart predictive-maintenance capabilities to equipment. Plus, OEMs and end users can leverage such providers’ expertise to get training and (in some cases) apply new IoT approaches to stay ahead of performance issues — to get the most from their technology. Ultimately, automated production-line innovation and evolution take a team of industry experts who can assess production holistically and objectively, identify and solve roadblocks and complications, and select an optimal set of components and systems for best performance.

THIS ARTICLE WAS CONTRIBUTED BY MARK ZIENCINA, BATTERY AND EV BUSINESS DEVELOPMENT MANAGER AT BOSCH REXROTH.

11 • 2022

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Motion Components

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Motion System Applications

Servo drives meet challenges in high-precision motion stage control For

demanding motion control applications like semiconductor

wafer metrology, where nanoseconds and nanometers are critical, servo drives specially developed for controlling highprecision motion stages can offer the best of both worlds – higher accuracy and better throughput. Such applications include wafer inspection and metrology systems, display screen manufacturing and inspection systems, and electronics assembly systems. Designers of serial production high-tech manufacturing equipment employing highprecision motion systems face a number of motion control engineering challenges. In direct

connection to Moore’s Law, every generation of machines producing semiconductors and microelectronic devices has increasingly demanding throughput and accuracy requirements. To illustrate, think of moving loads weighing tens of kilograms over distances of tens of millimeters, in tens of milliseconds, to an accuracy of tens of nanometers. To meet these requirements, equipment design engineers employ novel direct-drive linear motor stages, direct-drive rotary motor stages, voice-coil motor stages and other types of high-precision motion stages. There are a number of challenges associated with controlling high-precision motion stages when attempting to simultaneously achieve high levels of

accuracy and throughput, or stability and bandwidth. Among the most critical are resonance. All mechanical systems have resonant frequencies which can be excited by environmental disturbances and injected kinetic energy, or motion. The more aggressive the motion, the more difﬁcult it is to minimize excitation of resonance. Another issue is that motion stages used in industrial production equipment can suffer from complex non-repeatable environmental disturbances. Mechanically coupled stages such as gantry systems and Z/Tip/Tilt platforms can disturb one another when controlled independently. Dealing with non-linearity is another challenge. Real-world systems are typically modeled with linearized approximations but behave increasingly non-linear as resolution increases to the nanometer scale.

A PHYSIK INSTRUMENTE STAGE CONTROLLED BY AN ACS DRIVE.

DESIGN WORLD — MOTION

11 • 2022

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Motion System Applications

Any Master Controller

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A DIAGRAM SHOWING HOW IDM SERVO DRIVES WORK WITH OTHER ETHERCAT-BASED CONTROLLERS OR DRIVES TO CONTROL COMPLEX MOTION SYSTEMS.

DESIGN WORLD — MOTION

EtherCAT drives optimized for high-precision motion stage control Ever since the SEMI organization approved EtherCAT as an industry standard in 2007, EtherCAT has been the control system ﬁeldbus of choice for an increasing number of semiconductor and other high-tech equipment manufacturers. As the number of EtherCAT-based control system installations and high-precision motion stage installations continues to increase within the semiconductor equipment market and related markets, the demand for EtherCAT drives optimized for highprecision motion stages is also expected to increase. One example of how EtherCAT-based drives are meeting this demand comes from ACS Motion Control and their IDM (Intelligent Drive Module) Series of EtherCAT drives. The drives employ a multiprocessor architecture that enables unique control algorithms and performance optimization tools. For instance, comprehensive auto-tuning and frequency response function (FRF) measurement and design tools optimize servo bandwidth and stability margins, and identify and log manufacturing variations in motion stages. Additionally, special algorithms help handle some of the challenges that come with controlling high-precision motion. Adaptive control algorithms help to identify and attenuate disturbances during motion while non-linear control algorithms address non-linear mechanical phenomena. Plus, multi-input multi-output (MIMO) control algorithms help eliminate disturbances between mechanically coupled stages, while dynamic error compensation helps to increase the accuracy of motion stages. The IDM’s standard DS402 CANOpen over EtherCAT (CoE) interface lets machine designers install the advanced servo drive under any EtherCAT master controller without impacting the control system architecture. Here’s an example of how such a drive can fulﬁll challenging design needs. A large-format display OEM was recently faced with the challenge of designing a machine control system. It needed to control many motion axes, including several high-precision high throughput motion axes requiring micron level accuracy or better. It also needed to precisely synchronize process control with high-precision motion axes and manage machine safety as well as process large volumes of data for process control quality assurance. The OEM’s control engineering team selected a leading EtherCATbased automation platform supplier for the machine control system. Servo drives from a combination of suppliers were selected to control various standard servo motion axes. And for the high-precision motion axes, including a linear motor gantry pair, the OEM selected an IDM servo drive from ACS Motion Control.

Up to 4 Axis Motion System

On the manufacturing side, tolerances come into play. Serial production of motion stages can be prone to unit-to-unit or batchto-batch manufacturing variations in mechanical resonances and the transmission of disturbances. Lastly, there may be electrical noise to contend with. Encoder/ sensor signal ﬁdelity can be diminished in the presence of EMI. As ampliﬁer bandwidth and power increases, which is necessary to achieve higher speeds and accelerations, noise increases.

11 • 2022

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Motion System Applications

NEGATIVE-STIFFNESS VIBRATION ISOLATORS ISOLATE THE GEO600 DETECTION BENCH FROM GROUND MOTION. COURTESY OF H. LÜCK ALBERT EINSTEIN INSTITUTE HANNOVER

Vibration isolators aid detection and measurement of gravitational waves Detecting

and measuring gravitational waves requires extremely

sensitive instrumentation. In the 1970s, American physicist Rainer Weiss pioneered the concept of using lasers for interferometric gravitational wave detection. Extensive research over the past several decades has produced extremely advanced interferometric techniques, providing a means to observe phenomena in the universe that previously could not be studied otherwise. “With laser interferometry we can retrieve information from spaces in the universe that are otherwise not accessible, and we can look back in time much further,” said Dr. Harald Lück, Research Group Leader for the Laser Interferometry and Gravitational Wave Astronomy division of the Max Planck Institute in Gravitational Physics (alternately known as the Albert Einstein Institute) in Hannover, Germany. Together with its UK colleagues, and Leibniz Universität Hannover, the Laser Interferometry and Gravitational Wave Astronomy division of the Albert Einstein Institute operates the gravitational-wave detector,

DESIGN WORLD — MOTION

11 • 2022

GEO600. Funded by the Max Planck Society, and the Science and Technology Facilities Council, GEO600 is a ground-based interferometric gravitational wave detector located near Hannover, Germany. The GEO600 project aims at the direct detection of gravitational waves by means of a laser interferometer. Scientists at GEO600 have pushed research into interferometryrelated technologies to their limits, encompassing laser stabilization, absorption-free optics, control engineering, vibration damping, and data acquisition and processing. “GEO600 is also the first gravitational wave detector that uses squeezed laser light to improve sensitivity,” continued Dr. Lück. “Squeezed states are of high interest since they show a squeezed uncertainty which can be used to improve the sensitivity of measurement devices beyond the usual quantum noise limits. The quantum nature of light has an influence at all frequencies, but at about 1,000 to 4,000 Hz – where signals from supernovae and the birth of neutron stars are expected – quantum noise dominates at these higher frequencies. Hence, it is at high frequencies where we currently benefit from squeezing the most.” “Individual photons will hit the detector at an uneven rate,” explained Lück. “Because of quantum fluctuations, these photons will

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Shocks & Damping

NEGATIVE-STIFFNESS VIBRATION ISOLATORS SUPPORT THE GEO600 DETECTION BREADBOARD. COURTESY OF H. LÜCK ALBERT EINSTEIN INSTITUTE HANNOVER

show up as a fluctuating background signal that could completely obscure the expected short gravitational wave signal from the event itself. GEO scientists have managed to tame unwanted signal noise by manipulating the fluctuations, so as to produce this squeezed light. Both LIGO and Virgo now use squeezed light. Virgo uses a squeezed light source built and operated by GEO, while LIGO uses a squeezed light of its own design.” The increased sensitivity of the LIGO detectors is based on many technologies developed and tested at GEO600.

INDUSTRIAL GAS SPRINGS ARE THE SMART WAY TO LIFT AND LOWER

Shielding optics from terrestrial vibrations A significant challenge in gravitational wave interferometry is to get rid of disturbances like air pressure and temperature fluctuations, as well as seismic vibrations of all sorts that would conceal a signal. “The central elements in all gravitational wave detectors are mirrors,” said Dr. Lück. “The GEO600 mirrors, which are used to direct the laser beams, weigh about 6 kg. These mirrors are suspended as triple pendulums, so that they’re isolated from various disturbances. Thin threads made of quartz glass – fused silica fibers – are bonded directly onto the mirrors and a second pendulum mass, which means there is no friction at the point of contact. This increases the overall sensitivity of GEO600 through reduced mechanical loss.” The detection bench, carrying mode matching optics, a Faraday isolator, an output mode

• Enhance operator and machine control through the entire range of motion without excess strength • Perfect support of muscle

CLOSE UP OF MINUS K TECHNOLOGY NEGATIVE-STIFFNESS ISOLATOR CUSTOM-BUILT FOR THE GEO600 PROJECT. COURTESY OF H. LÜCK ALBERT EINSTEIN INSTITUTE HANNOVER

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11 • 2022

DESIGN WORLD — MOTION

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Motion System Applications

cleaner, and the photo diode are situated on a breadboard, which is sitting upon three Negative-Stiffness vibration isolators to isolate from ground motion. This entire assembly is enclosed within a vacuum chamber. Speciﬁc attention was given to the selection of vibration isolators supporting the breadboard within the vacuum chamber. Seismic disturbances are particularly noticeable when making measurements in the low-frequency range below 100 Hz. “We selected Negative-Stiffness vibration isolators because they are very simple to use, compact, and operate without the need for compressed air or electronic cabling,” explained Dr. Lück. “In a vacuum we try to minimize connecting cable components. These isolators are not only more vacuum compatible, they are more reliable than air tables or active systems. They isolate very well from the outside world.”

Negative-Stiffness vibration isolation Negative-Stiffness vibration isolation was developed by Minus K Technology. These vibration isolators are compact, and do not require electricity or compressed air which enables sensitive instruments to be located wherever a production facility or laboratory needs to be located. There are no motors, pumps or chambers, and no maintenance because there is nothing to wear out. They operate purely in a passive mechanical mode. One big advantage of Negative-Stiffness isolators is that they achieve a high level of isolation in multiple directions. These isolators have the ﬂexibility of custom tailoring resonant frequencies to 0.5 Hz vertically and horizontally (with some versions at 1.5 Hz horizontally). Note that for an isolation system with a 0.5 Hz natural frequency, isolation begins at 0.7 Hz and improves with increase in

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the vibration frequency. The natural frequency is more commonly used to describe the system performance. “Vertical-motion isolation is provided by a stiff spring that supports a weight load, combined with a Negative-Stiffness mechanism,” said Dr. David Platus, inventor of Negative-Stiffness isolators, and President and Founder of Minus K Technology. “The net vertical stiffness is made low without affecting the static load-supporting capability of the spring. Beam-columns connected in series with the vertical-motion isolator provide horizontal-motion isolation. A beamcolumn behaves as a spring combined with a negative-stiffness mechanism. The result is a compact passive isolator capable of low vertical and horizontal natural frequencies and high internal structural frequencies.” Negative-Stiffness isolators deliver high performance, as measured by a transmissibility curve. Vibration transmissibility is a measure of the vibrations that are transmitted through the isolator relative to the input vibrations. Negative-Stiffness isolators, when adjusted to 0.5 Hz, achieve approximately 93% isolation efﬁciency at 2 Hz; 99% at 5 Hz; and 99.7% at 10 Hz. “One issue with our systems that we use is the suppression of the resonance,” added Dr. Lück. “And here, the Negative-Stiffness isolators turn what is usually considered a disadvantage into an advantage. If you build a low-frequency suspension system then you typically ﬁnd that the mechanical Q values go down and the dissipation goes up. I think that is what the Minus K isolators use for keeping the resonance peak low enough, and that is a neat use of turning this seeming disadvantage into an advantage.”

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DESIGN WORLD — MOTION

Springs & Rings

Springs and retaining rings Springs

and retaining rings are

mechanical components found in countless assemblies in many sectors. Springs introduce load to an assembly through tension, compression, or torsion. Retaining rings fasten components in a housing when engaging a groove or on a shaft. Springs used in motion system designs come in three main types: compression, extension, and torsion. Springs and retaining rings are two types of hardware that are essential to all sorts of industrial, consumer, and medicalgrade assemblies. All springs are either for applying load in tension, compression, or torsion. Tension springs work for assemblies where applications rely on a stretched spring to pull the kinematic system back to some setting. Compression motioncontroltips.com | designworldonline.com

springs work for assemblies where applications rely on a shortened spring to re-expand. Torsion springs work for assemblies needing application of torque. Compression-type wave springs are by far most common. Single-turn wave springs can have overlapping ends to save axial space; nested wave springs deliver higher axial forces; multiple-turn wave springs are up to 50% shorter than a coil spring of otherwise comparable performance. What’s more, multiple-turn wave springs prevent torsional moves during compression — which is an issue with coil springs. Wave springs are critical to countless gear, actuator, clutch, and consumer-grade motion assemblies. They are load bearing — included in designs to address play or compensate for dimensional variations. Wave springs apply load in axially — so are speciﬁed by working height (and other parameters). Material science looms large for wave11 • 2022

spring design. Some manufacturers tout the high strength and reliable performance of their springs. Many of these characteristics are quantified in terms of tensile strength, shear strength, modulus of elasticity, and more. The material from which the spring is made as well as the mode of wave-spring manufacture influence many of these values. Case in point: Some edge-wound springs made of flat wire can outperform springs stamped out of sheet metal, as their metal crystallites having long axes tending towards an orientation parallel to the spring’s curvature.

Retaining rings Retaining rings are fasteners that hold components together on a shaft or in a housing when engaging a groove. Three main types of retaining rings include tapered section, constant section, and spiral. Tapered-section rings typically have decreasing thickness from the center of the DESIGN WORLD — MOTION

Motion System Applications

Radial retaining ring

Bowed preloading ring

Internally mounted axial ring

Spiral ring 360° contact Constant-section ring points of contact Tapered-section ring uniform contact

Standard housing ring

Standard shaft ring

Axially assembled inverted housing ring

Axially assembled reinforced shaft ring

Axially assembled shaft teeth ring Housing teeth ring Inverted shaft ring

DESIGN WORLD — MOTION

11 • 2022

ring out to the ends. They mount either axially or radially. The taper is there to ensure full contact with the groove when installed. 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 are installed into the housing or onto the shaft, making full contact with the groove and component. Their grooves are relatively shallow, so their load bearing capability is reduced. Spiral rings are often selected when full contact with the retained component or a lower axial profile is required. Spiral rings have no protruding ears to interfere with mating components in an assembly. The ring has a uniform cross-section and no gap or lugs for a functional and aesthetically pleasing ring. Unlike traditional fasteners, retaining rings eliminate machining and threading, reducing costs and weight. Spiral retaining rings do not require special tools for removal and are supplied standard with removal notches for easy extraction from a groove. When selecting a retaining ring for an application, several factors dictate which is most suitable. The first question to ask: What kind of assembly does the application require? Is it a housing assembly or shaft assembly? Next, determine the main critical dimensions. These include the housing or shaft diameter, groove diameter and the groove width. Also, what is the rotational speed (usually in rpm) of the assembly? Next, determine the maximum thrust applied to the ring. Generally speaking, designers define this thrust as either a light, medium, or heavy-duty load. It’s important that the design engineer define the maximum thrust because its value also helps determine if groove deformation or ring shear could be a problem. Basically, groove deformation occurs because the groove material is soft, which in turn limits maximum capacity. Ring shear, on the other hand, occurs when the groove material is hardened but the load exceeds the ring’s maximum capacity. Other factors, such as the temperature and the presence of any corrosive media, also dictate the most suitable choice for ring material.

The basics of extension springs Extension springs, also known as tension springs, are springs that can be stretched to increase their length. When extended, these springs are under tension. Typically, each end of the extension spring is attached to a different component, when the components are pulled apart the spring tried to pull them back together. Most extension springs are coiled springs manufactured from sprung steel spring wire. Extension springs can be stretched to increase their length, causing tension force within the spring. Generally, extension springs have a hook or an eye at each end to facilitate fastening. Variations on the ends include open hooks, extended hooks, side hooks, and double full loops. Extension springs are often used to create a restoring force in mechanisms such as latches and counterbalances. Because extension springs are under tension, they require no support along their length. This often leads to a simpler mechanism than if a compression spring were used.

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Ad Index VOLUME 8 NUMBER 4

Ace Controls.......................................................................... 67 ACS Motion Control, Inc. ...................................................... 55 Aerotech ................................................................................ 30 AllMotion................................................................................. 6 AutomationDirect .................................................................... 5 Beckhoff Automation ............................................................ 11 Bison Gear ............................................................................. 57 Bodine ................................................................................... 58 Canon U.S.A. ......................................................................... 53 CGI Inc. ................................................................................. 50 Chieftek Precision ................................................................. 18 CMT ................................................................................. 12, 21 Del-tron ................................................................................. 17 Diequa ................................................................................... 61 Digi-Key Electronics ................................................................ 3 Encoder Products Company ................................................. 41 Faulhaber .............................................................................. 44 FESTO ................................................................................... 33 Industrial Encoder Corp ........................................................ 43

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Intech................................................................................. 8, 52 KHK USA Inc. ........................................................................... 7 maxon .............................................................................. 47, 63 Mitsubishi Electric Automation ............................................ BC mk North America, Inc. ......................................................... 36 Oriental Motor USA Corp ....................................................... 4

Parvalux ................................................................................. 48 PBC Linear ........................................................................... IBC Phd ........................................................................................ 29

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PMD ...................................................................................... 25 POSITAL FRABA .................................................................... 10 Pyramid Inc ............................................................................ 22 Renishaw ............................................................................... 42 Rotor Clip .............................................................................. 71 Ruland Manufacturing ........................................................... 39 SEW-Eurodrive ........................................................................ 1 Siemens Industry, Inc.w ........................................................... 9 Sorbothane ............................................................................ 68 Stock Drive Products/Sterling Instrument ............................. 23 THK America Inc...................................................................IFC US Tsubaki ............................................................................. 15 WAGO Corporation .............................................................. 27 Yaskawa Electric America ...................................................... 65 Zero-Max, Inc. ......................................................................... 2 72

DESIGN WORLD — MOTION

11 • 2022

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