Motion System Applications 2016

designworldonline.com

motioncontroltips.com

November 2016

MOTION

System APPLICATIONS

Precision Gearboxes for Servomotors SureGear® Precision Servo Gearboxes

$674.00

SureGear high-precision servo gear reducers are an excellent choice for applications that require accuracy and reliability at an exceptional value.

(PGB070-05A1)

These planetary gearboxes, available in right-angle, inline, and now hub-style versions, have a thread-in mounting style, along with precision and torque capacity that is best in class.

• NEW hub-style models are perfect for applications requiring high-speed, high-precision indexing movement • Industry-standard mounting dimensions • Best-in-class backlash • Multiple gear ratios available (5, 10, 15, 25, 35, 50:1) • Uncaged needle roller bearings for high rigidity and torque • Maintenance free: no need to replace the grease for the life of the unit • At nominal speed, service life is 20,000 hours • Can be positioned in any orientation • 5-year warranty • Starting at: $398.00 (70mm Frame - PGA070-05A1)

Use SureGear with our practical SureServo systems start under $1,000**

** All components sold separately.

The SureServo family of brushless servo systems from AutomationDirect is fully digital and offers a rich set of features at dynamite prices.

Beginners to experienced users can take advantage of this easy-to-use family for as little as $986.00** (100W system).

• Eight standard systems from 100 W to 3 kW • Use with most AutomationDirect PLCs or any other host control • Drives feature on-board indexer and adaptive tuning modes • Free set-up software • 2 year warranty

Example models shown

$398.00

(PGA070-05A1)

$722.00

(PGD047-05A1) Mates easily to SureServo motors

Research, price, buy at: www.automationdirect.com/motion-control Gearbox Selector: www.go2adc.com/gearbox-selector Servo Systems

AutomationDirect Price/Part Number

Allen-Bradley Price/Part Number

Digital Servo Drive

$488.00

$1,370.00

100W Servo Motor with connectorized Leads

$325.00 SVL-201

$575.00 TLY-A130T-HK62AA

Breakout Board Kit for CN1 Control Interface

$94.00 ASD-BM-50A

$268.00 2090-U3BK-D4401

10’ Motor Feedback Cable

$49.50 SVC-EFL-010

$91.80 2090-CFBM6DF-CBAA03

10’ Motor Power Cable

$29.50 SVC-PFL-010

$103.00 2090-CPBM6DF-16AA03

Configuration Software

FREE SV-PRO*

$75.00 2098-UWCPRG

SVA-2040

2098-DSD-005

*SureServo Pro software is FREE when downloaded and is also available for $9.00 on a CD

Complete 1-axis 100W System

$986.00

$2,482.80

All prices are U.S. list prices, AutomationDirect prices as of 4/27/2016.

The Allen-Bradley 100W system consists of part numbers shown in table above with prices from www.wernerelectric.com, www.todaycomponents.com 4/18/2016.

Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2016 AutomationDirect, Cumming, GA USA. All rights reserved.

Automation Direct Motion Casebook 11-16.indd 1 1611-DesignWorldSupplement-Servos-MAG.indd 1

1-800-633-0405

the #1 value in automation

11/8/16 12:43 PM 10/6/2016 10:08:42 AM

FOR MOTION CONTROL INNOVATION, SOLUTION CITY NEVER SLEEPS.

Whatever keeps you up at night, we’ve got a solution—the largest selection of motors, pumps and air-moving devices available. Plus, one-of-a-kind solutions ready to be custom-engineered for your precision industrial, commercial, combustion or transportation application. If you can dream it, you’ll find it at Solution City.

100 East Erie Street Kent, OH 44240 ametekdfs.com

© 2015 by AMETEK Inc. All rights reserved.

AMETEKPMC 18611_City Never Sleeps Ad_9x10.875.indd 1 AMETEK PMC (Solutions City) 8-15 (NEW).indd 1

7/29/15 9:14 AM 11/8/16 12:44 PM

APPLICATIONS

Precision design: When it goes wrong and when it goes according to plan

Motion System

LIS A EIT EL SENIO R EDIT O R @DW _LISA EIT EL

2

WELCOME to the second annual Motion System Casebook from Design World magazine — an inspiring collection of application stories from 2016 detailing real-world use of motion components in successful designs. We hope you enjoy reading it as much as we enjoyed assembling it, as this is one of our splashiest motion issues yet.

Much can go wrong in the build of motion machinery. Some problems find their origins in design proposals or a statement of work; others originate from subsequent selection of inappropriate motion components. It’s also common for engineers to play it safe and oversize electric motors, actuators, or even entire machines at the cost of higher initial purchase price and power consumption when the machine is up and running. A related pitfall is to base a machine’s new iteration on past design selections without reanalysis.

Here, calculating required safety margin from scratch yields a design that’s smaller and more efficient than competitive offerings — though sometimes those analyses go undone or unheeded.

Read about designs that avoid such hazards from my colleague Miles Budimir (on Twitter at @DW_Motion) in his Casebook pieces on integrated motors and servomotors. One is a bottling machine that uses motors

DESIGN WORLD — MOTION

Lisa Editorial - MSCasebook 11-16 V2.LE.indd 2

11 • 2016

with integrated drives and fast control interpolation for smooth motion trajectories. Another is a packaging machine that uses a linear motor doing double-duty as a rotary direct drive for container filling and closing.

Other design problems relate to vibration — in the form of machinebuild compliance, unmitigated vibration, or a poor ratio of motor to load inertia that causes overshoot and ringing. Lower ratios drive resonant frequencies higher and vice versa, but sometimes the latter situations enter normal operating bandwidths and cause problems that no controls can tune out. Mary Gannon (@DW_MaryGannon) details systematic approaches to damping in her piece of shocks, and you’ll find additional examples of design features that address vibration in this year’s Casebook sections on controllers, encoders, and (from our own Mike Santora — @DW_MikeSantora) bearings as well.

We found that several of the most exotic applications from this year relate to the use of Cartesian and robot setups. Just consider how University of Wisconsin-Madison researchers are using an XYZ vertical gantry to take time-lapse movies of plant growth. The gantry moves cameras over a 1-m-by-1-m area with positioning resolution of 10 µm (and another linear axis to focus the cameras on the seedlings).

In my opinion, the most fascinating application stories are those in which engineers detail changes to fix critical design problems and prevent replays of failures — as in HMIs that reincorporate hard buttons for common functions as a way to avoid excessive touchscreen wear (see HMIs); actuators that replace mechanical linkages that forced users to muscle assemblies into position (see electric actuators); and the transition to PROFINET as a way to phase out defunct networking technology (see encoders). In the case of the packaging machine using linear motors capable of rotary actuation, previous versions were heavily mechanical and necessitated modifications to the motion sequence for each product changeover. Sometimes they also needed installation of different closure heads and cam discs. The new machine version doesn’t need all this changeover work, because the direct drive and electronic stroke curves deliver various outputs on the fly.

So check out the details on these applications and drop me a line about what inspiration you draw from them. We applaud the hard-won successes of these motion designs.

motioncontroltips.com | designworldonline.com

11/9/16 10:52 AM

840-15203 THK Value Ad_R1_pick_Layout 1 6/18/15 6:34 PM Page 1

We go out of our way to ensure complete customer satisfaction. We reach out and listen to customers around the globe and deliver the world-class products you've come to expect from THK. Our range of solutions are a part of the latest technological advances in the medical, automotive, aerospace, semiconductor, seismic and many other industries.

To learn more, call 1-800-763-5459 or visit www.thk.com.

LM GUIDES

THK 7-15.indd 3

|

BALL SCREWS

|

BALL SPLINES

|

A C T U AT O R S

|

CROSS ROLLER RINGS

11/8/16 12:47 PM

APPLICATIONS

When intuition fails – How big companies get out-innovated

Motion System

LEE T ES C HLER EXEC U T IVE EDIT O R @DW _LEET ESC HLER

4

“THAT’S NOT how we do things around here.”

As with many young engineers, I used to hear that phrase a lot when I was first starting out. Though often meant as well-intentioned advice, it was like fingernails on a chalk board for somebody who had what today is called an out-of-the-box idea.

Out-of-the-box ideas are a bit like the holy grail of product development. But would-be innovators often still find themselves having to deal with not-inventedhere-type put-downs, particularly if they work for big, established companies. Academics who study how innovative products gestate say the result is often a big waste of research dollars. And that’s particularly true for research in big companies that yields developments that could be termed disruptive.

As you might suspect, there has been a lot of navel gazing about why big companies get out-innovated by smaller competitors with fewer resources. Insights into the causes come from researchers Rebecca Henderson of M.I.T. Sloan School of Management and Sarah Kaplan of the University of Pennsylvania.

Surprisingly, they found that the explanation has little to do with technical issues. It more generally involves biases set by how managers are rewarded.

DESIGN WORLD — MOTION

Lee Editorial - MSCasebook 11-16 V2.indd 4

11 • 2016

Specifically, the two researchers found that senior managers often want to look at the economics of new technologies according to values they’ve internalized after years and years of working in industry. The trap is that senior managers generally have received a long string of promotions “on the basis of what should be done.”

Worse, they may reject as unimportant information alerting them to radical shifts in the environment. Thus to entrenched managers, going against these learned behaviors just seems intuitively wrong.

Of course, the economics and market tactics that make disruptive technologies successful are far different than that of the industries they disrupt. Sometimes savvy top managers recognize this and isolate the cutting-edge stuff in a skunk works. The most visible example is the IBM personal computer introduced back in the 1980s. It was initially run out of Boca Raton, Fla., far from IBM’s headquarters in Armonk, N.Y. The problem with those kinds of schemes, say the researchers, is that the skunk works managers tend to eventually get politically out-maneuvered and reabsorbed back into the business’s main stream. The reason is that as organizational frames of reference become more deeply embedded in the organization, they become harder to argue against.

Ditto for incentives. A sure way to undermine support for a new company division is to provide enticements perceived as unfair by employees close to HQ. A remotely located skunk works can mask the incentive structure, but it also isolates the operation from company assets that could make the venture a success.

Consequently, Henderson and Kaplan figure it may be harder for companies to learn how to evaluate and reward people working in new technologies than to do the technical work.

You’d be correct to say this all sounds discouraging from the standpoint of large companies. It often proves impossible for large companies to manage both a disruptive technology and an established business within the same organization, the researchers say.

That’s a discouraging thought for people with big ideas, but it’s also something to keep in mind when fuddy-duddy managers follow their instincts and shoot down your latest brain child.

motioncontroltips.com | designworldonline.com

11/7/16 3:23 PM

Helical Motion Casebook 11-16.indd 5

11/8/16 12:48 PM

MOTION SYSTEM

APPLICATIONS

MOTIONCONTROLTIPS.COM

p02

Precision design: When it goes wrong and when it goes according to plan

VOL 2 • NO 4

Actuators

HMI Hardware ..............................................69

Electrical ..................................................12

HMI Software ................................................71

Pneumatic ...............................................16

Leadscrews....................................................72

Ballscrews .....................................................18

Linear Guides Rails, Slides & Systems ..........74

Bearings ........................................................20

Motors

Belts & Pulleys ..............................................24

AC ...........................................................78

Brakes & Clutches .........................................28

DC ...........................................................80

Cabling .........................................................32

Integrated ...............................................84

Chain ............................................................34

Linear ......................................................86

Compression Springs ...................................38

Servo .......................................................90

Controllers ....................................................39

Stepper ...................................................93

Conveyors .....................................................44

Networks.......................................................96

Couplings .....................................................45

Retaining Rings .............................................98

Drives

Shock, Vibration Damping ......................... 100

AC ...........................................................49 DC ...........................................................52

12

Encoders .......................................................53 Gearing .........................................................57

Robotics ..................................................... 103 Stages & Tables ......................................... 104 Transducers ................................................ 108 Wave Springs ............................................. 110

Gearmotors ..................................................66 Grippers & Workholding Parts .....................67

57

66

Cover photography by Miles Budimir

6

DESIGN WORLD — MOTION

Contents Motion Casebook 11-16.indd 6

11 • 2016

motioncontroltips.com | designworldonline.com

11/8/16 4:20 PM

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

Your ball screw Your servomotor Our coupling

Together a winning combination for today’s servomotor applications.

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

3 New sizes now available.

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

Check our FAST deliveries.

www.zero-max.com 800.533.1731 © 2010 ZERO-MAX

Zero Max ad 8-15.indd 7

11/8/16 12:50 PM

Your Partner in Custom Plastic Components

MOTION SYSTEM A P P L I C A T I O N S

Precision Plastic Machining Complex Plastic Injection Molding Quick Turnaround Prototyping

EDITORIAL

DIGITAL MEDIA/MARKETING

VIDEO SERVICES

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

Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_WebDave

Videographer Manager John Hansel jhansel@wtwhmedia.com @wtwh_Jhansel

Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3Dprinting

Digital Media Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick

Videographer Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh

Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_LeeTeschler

Senior Web Developer Patrick Amigo pamigo@wtwhmedia.com @amigo_patrick

Videographer Derek Little dlittle@wtwhmedia.com

Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_Motion

Web Production Associate Skylar Aubuchon saubuchon@wtwhmedia.com @skylar_aubuchon

FINANCE

Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_MaryGannon

Web Production & Reporting Associate Jennifer Calhoon jcalhoon@wtwhmedia.com @wtwh_Jennifer

Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_LisaEitel

Custom Plastic Couplings, Adapters, Bearings, Fittings and More!

Associate Editor Mike Santora msantora@wtwhmedia.com @dw_MikeSantora

Plastic Injection Molding to +/-.001.

DESIGN & PRODUCTION SERVICES VP Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com

Controller Brian Korsberg bkorsberg@wtwhmedia.com Accounts Receivable Specialist Jamila Milton jmilton@wtwhmedia.com

Manager Webinars Stacy Combest scombest@wtwhmedia.com @wtwh_Stacy Marketing Manager, Social Media & Events Jen Kolasky jkolasky@wtwhmedia.com @wtwh_Jen

2014 Winner

Marketing Coordinator Lexi Korsok lkorsok@wtwhmedia.com @wtwh_Lexi Digital Marketing Specialist Josh Breuler jbreuler@wtwhmedia.com @wtwh_Joshb

@wtwh_designer Graphic Designer Allison Washko awashko@wtwhmedia.com

Marketing Associate Aly Ryan aryan@wtwhmedia.com @wtwh_Aly

Custom Plastic Connectors, Insulator, Caps, Poppets and More Traffic Manager Mary Heideloff mheideloff@wtwhmedia.com

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

2011 - 2016

Production Associate Tracy Powers tpowers@wtwhmedia.com

www.brogan-patrick.com Brogan & Patrick Manufacturing Wisconsin Office 515 E. Centralia St. Elkhorn, WI 53121 Phone: 262-723-6909

Illinois Office 505 Wegner Drive West Chicago, IL 60185 Phone: 630-639-5011

Contact: Shawn Healy • shawn@brogan-patrick.com • 630-639-5011

Staff - Motion Casebook 11-16 V1.indd 8

FOLLOW THE WHOLE TEAM ON TWITTER @DESIGNWORLD 8

motioncontroltips.com | designworldonline.com

11/8/16 4:36 PM

t material of SCM415. carburizing (case hardening), SCM415 is normally used. requirements for harder material, SNCM220 and/or SNCM420 y used. hardness is determined by production condition. pected hardness value is informed in a quotation of gears.

Gear precision grade table : entioned equivalent grades are for reference only. ades completely match each other.

Largest selection of

Stock Metric GEARS in North America

15/05/21

14:20:18

259 Elm Place, Mineola, NY 11501 Phone: 516.248.3850 | Fax: 516.248.4385 Email: info@khkgears.us

KHK_MSHandbook9-16.indd 9

11/8/16 12:51 PM

Advanced Products for Robotics and Automation.

Precision Gears

Precision Gearboxes

Precision Mechanical Components

Precision Bearings

CGI’s World Class Vertically Integrated Flow Processes • • • • • • • • •

Customer Driven Innovation

Design for Manufacturability - DFM Fixturing Design and Fabrication Prototyping Support 3-D Model Printing on-site Process controls designed and implemented Process development for Assembly and Testing of Motion Control Assemblies for Advanced Devices and Systems Complete Test Device, Design & Development Minitab Statistical Analysis Tools Computer Aided Machining (CAM) Six Sigma black belt expertise

Prototype to Product Launch

Design Engineering

From customer driven innovation to contract manufacturing, we help differentiate your product and applications. Connect with us today to explore what CGI Motion can do for you.

Download our full capabilities brochure at cgimotion.com copyright©2016 cgi inc. all rights reserved. 0425CCBS

CGI_MSHandbook9-16.indd 10

11/8/16 12:42 PM

CGI Enables Design Excellence.

Precision Mechanical Assemblies

Customized Components

Electro-mechanical Assemblies

CGI’s Quality Equipment: Highly Qualified Inspection Department • • • • • • • • • •

Zeiss Contura Coordinate Measuring Machine (CMM) Brown and Sharpe Coordinate Measuring Machine (CMM) PECo Next Dimension 300 Gear Analyzer Micro-Vu Vertex Vision System Starrett Optical Comparators with Digital Readout TESA Scanner PECo Dual Flank Test Roll Checker Micro Check Dual Flank Test Roll Checkers Vari-Roll Dual Flank Test Roll Checkers Inspection Xpert software for First Article Reports

Manufacturing Engineering Support

Testing & Validation

Worldwide Support

www.cgimotion.com 800.568.GEAR (4327)

CGI_MSHandbook9-16.indd 11

11/8/16 12:43 PM

APPLICATIONS

Motion System

Applications for electric actuators ELECTRIC ACTUATORS COME IN VERSIONS as small as syringes for medical applications to those big enough to drive industrial presses. These muscles of precision motion usually incorporate an electric motor and rotary-to-linear device for conversion of torque to linear force.

No matter the application, electric actuators deliver repeatability that’s indispensable for moving loads to a given positions. Often they’re also more controllable than fluidpower actuators, giving engineers a way to shape speed, force and acceleration of machine-axis moves.

Another benefit for applications that need multiple outputs over time is that most electric actuators are programmable so adapt to changing conditions.

Applications with similar dynamics often make use of the same actuator types — those that pair motors with ballscrews or leadscrews; incorporate brushless dc motors and belt-and-pulley setups; take a rod-style morphology; use motors with planetary roller screws; or integrate built-in guides.

Electric actuators running closed-loop or with a micro-stepping motor can match force and speed output commands best with feedback to overcome most of the mechanical limitations of rotary-to-linear devices.

Some application tips: Establish the design’s power draw and determine

Deutz-Fahr 9 Series tractors now incorporate electric actuators to operate electronic hood mechanisms. These make engine access less of a hassle for farmers.

Electric actuators from LINAK replace gas springs on tractor hoods. This eliminates loss of force and the need for auxiliary safety mechanisms.

12

DESIGN WORLD — MOTION

Electric Actuators - MSCasebook 11-16 V2.LE.indd 12

11 • 2016

motioncontroltips.com | designworldonline.com

11/7/16 3:28 PM

Want us to make you a hero?

Meet the Tolomatic high-force electric rod actuator family

Heavy-duty IMA, hydraulic-class RSX, high-force RSA, washdown-ready ERD (left to right)

• Wide range of forces: Up to 50,000 lbf • Replace pneumatics or hydraulics: Improve accuracy and repeatability • Screw choice: Ball or roller • Washdown ready: Stainless steel, IP69K, clean-in-place • Compact, high performance: Integrated linear servo actuator designs Visit www.tolomatic.com/ electric-rod

Powerful linear motion solutions that help you save the day (and simplify your machine design).

Build your next machine exactly as you envision it. With Tolomatic’s broad line of electric linear actuators and motion control systems, you can conquer virtually any application adversity with ease. You’ll find the speed, force and accuracy that precisely fit your machine goals, plus expert specification help through our online tools and customer support.

Face your linear motion challenges with Tolomatic at your side.

Contact us to find out how easy it is to get the job done.

Visit www.tolomatic.com or call 877-385-2234.

Be heroic! Sign up to receive Tolomatic’s blog and register to win a GoPro® HERO camera. www.tolomatic.com/Heroic

www.tolomatic.com

Tolomatic Motion Casebook 11-16.indd 13

11/8/16 12:52 PM

APPLICATIONS

Motion System

whether the machine will draw power continuously or intermittently or both, as that ultimately determines actuator size and type. Remember that overly large electric actuators are often less responsive than well-sized units.

That said, appropriate safety factors ensure that electric actuators run coolly. Plus, lighter loads on the mechanical components can extend life. Halving load on a leadscrew can extend its life eightfold, for example. Also account for where the actuator will operate. Will it need to withstand exposure to dirt, chemicals and liquids? If so, its O-rings and seals must be made of materials to withstand application contaminants.

Another tip: Analyze the final installation point to ensure that the electric actuator can handle side, radial and axial loads.

Getting under hood just got easier thanks to linear actuators Engineers at DEUTZFAHR no longer use simple tilt mechanisms and gas springs on their 150-kg vehicle hoods, because these designs are impractical.

Now they use kinematics driven with actuators from LINAK. These don’t tilt the hood, but raise and lower it parallel to the vehicle. More specifically, the kinematics run off a LINAK LA36 actuator that can move up to one ton over stroke lengths from 100 to 999 mm. The actuator also withstands the high heat associated with sitting right above the engine. That’s another reason why the OEM picked the LA36.

Farmers who have tried the technology on new tractors praise it. The actuator gives them electric hood adjustment so they can easily access all areas in the engine compartment.

One caveat: The solution is more complex than basic mechanical offerings, so is harder to service during maintenance. To prevent this from being a problem, the LA36 is solid and rugged to operate under tough and harsh conditions, with a die-cast aluminum housing and quality components. So the LA36 withstands cold, heat, and high temperature fluctuations of being so close to an engine in a vehicle that operates outside. It also withstands splashes and moisture from precipitation and chemicals. In the static state the LA36 is rated to IP69K and in operation to IP66.

Electrification in agricultural machinery makes this a growth industry for LINAK, according to Johannes Gruber, product manager at DEUTZFAHR. The sheer size of off-highway machines and demand for ergonomics and user-friendliness will only increase demand for electric adjustments in the future.

Automation in consumer-grade products is increasingly common. This TV-lift actuator is a Touchstone Whisper Lift II. It raises and lowers flat-panel screens to 100 lb with a 24-V electric actuator. The linear actuator has a steel casing for safe and reliable operation.

14

DESIGN WORLD — MOTION

Electric Actuators - MSCasebook 11-16 V2.LE.indd 14

11 • 2016

This is the LINAK LA36 that goes into the Deutz-Fahr hood lifts. The actuator comes with a 12, 24 or 36-Vdc permanent-magnet motor to output 500 to 10,000 N depending on gear ratio. Speed is to 160 mm/sec partly depending on load.

“Electrification with attachments and tractors will increase in coming years,” Gruber added.

Matching actuators to design demands Electric actuators for automation must deliver set levels of speed and force requirements.

Here, better feedback and controls can increase responsiveness to overcome any mechanical limitations while boosting output-motion accuracy. OEMs and end users can pick from myriad actuators to get needed accuracy for everything from lumber-processing machines to those medical applications that need accuracy to a few micrometers. Electric-motor actuators that use belts and acme screws for rotary-to-linear conversion of motion abound. That said, the majority of general motion applications (including positioning tables, workpiece-pivoting stations, robotic end effectors and machining axes) make use of actuators that integrate ballscrews. With precision of down to micrometers, these satisfy designs that need thrust to thousands of poundsforce or linear positioning speeds to several feet per second.

Elsewhere, on injection-molding applications, packaging machines, presses and other setups that need high thrust, actuators that pair electric motor with roller screw (sporting a nut loaded with roller bearings that work like planetary gears around the screw) are a newer and increasingly common option. Stroke is about 2 m with acceleration to a few gs.

motioncontroltips.com | designworldonline.com

11/7/16 3:28 PM

What’s 15 years to one of our blowers?

A warm-up.

Nothing moves air with more rock-solid reliability than AMETEK® Rotron regenerative blowers.

Fifteen years’ service life is not unusual. These low-pressure, high-volume blowers feature rugged, compact construction and quiet operation. Their proven design makes them ideal in applications from chemicals, wastewater and furnaces to vapor recovery and more. Plus, they’re backed by the industry’s most knowledgeable engineering experts. AMETEK can customize your blower for harsh environments, high voltage and specialized applications, too. So make your next air-moving challenge a breeze.

Call us at +1 330-673-3452 or visit our website to get started.

100 East Erie Street Kent, OH 44240 ametekdfs.com

© 2015 by AMETEK Inc. All rights reserved.

AMETEKDFS Regen Blower Ad_9x10.875.indd 1 AMETEK-DFS_MSHandbook9-16.indd 15

6/1/15 5:03 PM 11/8/16 12:53 PM

APPLICATIONS

Motion System

Pneumatic actuators excel in key applications PNEUMATIC ACTUATORS come in an array of permutations for automation. Rod and rodless actuators are the two most common, though rodless are far more common in the U.S. Rodless actuators include bearings to address moment loads in X. Y, and Z. Tip: Avoid undersized pneumatic actuators for applications by accurately calculating application force; subtracting piston-rod area; accounting for the energy to overcome friction; and accounting for unusual application kinematics.

Note that most pneumatic-actuator applications are linear-stroke setups needing two or more position stops. Minimizing stop times in many pneumatic actuators are air cushions. Damping seals are another option. Choosing pneumatic actuators over electrical options is common in applications that need motion axes to work without electricity — where sparking poses a problem (as in applications that involve flammable materials for example).

Limitations include lack of total controllability and air consumption, but few actuators outperform pneumatic actuators in applications that need clean operation, low upfront cost, and high force-speed ratios. Even so, pneumatic actuators deliver moderate to high load at 120 in./sec or better. Plus advanced pneumatic actuators have wireless valve controls and sensors for IoT and predictive-maintenance functionality.

Here a machine saws wooden planks into slats. Pneumatic actuators from Festo press rollers into the wood to help the saw adjust to different wood types (while moving at 3 m/sec).

Controls to adjust contact pressure include CPX terminal with a local CPX-FEC, Profibus interface, three CMAX modules, and an I/O module.

16

DESIGN WORLD — MOTION

Pneumatic Actuators - MSCasebook 11-16 V2.LE.indd 16

11 • 2016

motioncontroltips.com | designworldonline.com

11/7/16 3:30 PM

PNEUMATIC ACTUATORS

Another variation on pneumatic actuation: Bladders Bladder actuators are another form of pneumatic actuation for short strokes and constant-force motion. Where appropriate they outperform other systems. In part positioning, footed bladder actuators output consistent lifting force for plates and other wide and flat loads and workpieces. Another application is automatic door seals to work as flood barriers and chamber closures. These inflatable actuators also work in material-handling applications. Such actuators can’t deliver on precision positioning, so only work where designs are forgiving on that parameter. They’re also unsuitable for pointsource applications. That said, these actuators are capable of very accurate force control, and strokes can reach a couple inches.

This label picker must glue labels to packages of different sizes in onesecond cycles as they pass on a conveyor. An analog distance sensor determines distance to the package to get label ejection 15 mm above each package. Here, a Festo DNCI cylinder works with a CPX controller and I/O module to deliver 50 to 500-mm strokes for advancement and return in less than a second.

3-phase Power Analysis Static, Dynamic, Complete tlec-2015_power-poster-final-cmyk-HIRES.pdf

1

11/9/15

Get a Free Power Basics Poster

2:54 PM

Line Voltage, Current, and Power – The Basics LINE VOLTAGE Three-phase line voltage consists of three voltage vectors.

• By definition, the system is “balanced” • Vectors are separated by 120° • Vectors are of equal magnitude • Sum of all three voltages = 0 V at Neutral

Line

At any given moment in time, the voltage magnitude is V * sin(α) • V = magnitude of voltage vector • α = angle of rotation, in radians

ω (rad/s) or freq (Hz)

Line

Poster for free:

The resulting time-varying “rotating” voltage vector appears as a sinusoidal waveform with a fixed frequency • 50 Hz in Europe • 60 Hz in US • Either 50 or 60 Hz in Asia • Other frequencies are sometimes used in non-utility supplied power, e.g.

• 400 Hz • 25 Hz

Important to Know • Voltage is stated as “VAC”, but this is really VRMS • Rated Voltage is Line-Neutral • VPEAK = 2 * VAC (or 2 * VRMS ) • 169.7 V in the example below • VPK-PK = 2 * VPEAK • If rectified and filtered • VDC = 2 * VAC = VPEAK AC Single-Phase “Utility” Voltage

teledynelecroy.com/staticdynamic-complete

120 VAC Example

Volts (Peak), Line-Neutral

200

120VAC

150 100 50 0

-150 -200

“True” RMS

THREE-PHASE

Voltage value = VX*sin(α) • VX = magnitude of phase voltage vector • α = angle of rotation, in radians

Voltages can be measured two ways: • Line-Line (L-L) • Also referred to as Phase-Phase • e.g. from VA to VB, or VA-B • Line-Neutral (L-N) • Neutral must be present and accessible • e.g. from VA to Neutral, or VA-N • VL-L conversion to VL-N • Magnitude: VL-N * 3 = VL-L • Phase: VL-N - 30° = VL-L

VA-B

Neutral

120°

800

Important to Know • Voltage is stated as “VAC”, but this is really VRMS • Rated Three-phase voltage is always Line-Line (VL-L) • Line-Line is A-B (VA-B), B-C (VB-C), and C-A (VC-A) • Line-Line is sometimes referred to as Phase-Phase • VPEAK(L-L) = 2 * VL-L • 679 V in the example to the right • VPK-PK(L-L) = 2 * VPEAK(L-L)

600 400

VRMS =

1 V PK-PK 2 2

For one power cycle

VRMS = VAC2 For one power cycle

0

P≠V*I N

-800

Time

AC Three-Phase “Utility” Voltage 480VAC , Measured Line-Neutral

600 400 200 0

B

-400

B

IB

-600

Time

A-N Voltage B-N Voltage C-N Voltage Three-phase Rectified DC

IC

N

IA

C

9 6 3

Real Power • P, in Watts • = instantaneous V * I for a given power cycle

0 -3

I

P≠V*I

φ

N

V

Capacitive load

-6

Time A Current B Current C Current

A

Reactive Power • Q, in Volt-Amperes reactive, or VAr • Q = S2 - P2 • Does not “transfer” to load during a power cycle, just “moves around” in the circuit

10 ARMS Example

IA

Digital Sampling Technique for Power Calculations� Period 1 Mi = 18 points

B

Period 2 Mi = 18 points

Delta (∆) 3-phase Connection • Neutral is not present in the winding (in most cases)

A

mi = point 7

mi = point 25

V C-N

IB

N V A -N

• The digital samples are grouped into measurement cycles (periods) • For a given cycle index i….

• The digitally sampled voltage waveform is represented as having a set of sample points j in cycle index i • For a given cycle index i, there are Mi sample points beginning at mi and continuing through mi + Mi -1.

• Voltage, current, power, etc. values are calculated on each cycle index i from 1 to N cycles.

PTO TA L = VA -N * IA + VB-N * IB + VC-N * IC

IA PTO TA L ≠ VA -N * IA + VB-N * IB + VC-N * IC

V C-N

teledynelecroy.com/motor-drive-analyzer

IRMS

QB

Real Power for each Phase • P, in Watts • = instantaneous V * I for a given power cycle

VRMSi =

IRMSi =

Reactive Power for each Phase • Q, in Volt-Amperes reactive, or VAr • Q = S2 - P2

PB

φ

SB PA

SC

• PTOTAL = PA + PB + PC • STOTAL = SA + SB + SC • QTOTAL = QA + QB + QC

φ φ

QA

SA

PC QC

Line-Line Voltage Sensing Case

B IB VB-C

Current is measured L-N

N

IC

L-L voltages must be transformed to L-N reference:

B

VB-N

VA-B

IA

IB

A

N

IC

VA-N IA

A

VC-A

C

C

VC-N

Two Wattmeter Method – 2 Voltages, 2 Currents with Wye (Y or Star) or Delta (∆) Winding

Q

φ P

Real Power

Note: Any distortion present on the Line voltage and current waveforms will result in power measurement errors if real power (P) is calculated as |S|*cos(φ). To avoid measurement errors, a digital sampling technique for power calculations should be used, and this technique is also valid for pure sinusoidal waveforms.

Voltage is measured L-L on two phases • Note that the both voltages are measured with reference to C phase

mi + Mi - 1 1 V j2 Mi j=mi

Σ

mi + Mi - 1 1 I j2 Mi j=mi

Σ

Real Power (P, in Watts)

Mathematical assumptions: • Σ(IA + IB + IC) = 0 • Σ(VA-B + VB-C + VC-A) = 0

Pi =

Apparent Power (S, in VA)

Reactive Power (Q, in VAR)

PTOTAL = VA-C * IA + VB-C * IB STOTAL= VRMSA-C * IRMSA + VRMSB-C * IRMSB QTOTAL = STOTAL2 - PTOTAL2

Current is measured on two phases • The two that flow into the C phase

This is a widely used and valid method for a balanced three-phase system

Formulas Used for Per-cycle Digitally Sampled Calculations

VRMS

V A -N

φ

IC

Calculations are straightforward, as described above: • PTOTAL= PA + PB + PC • STOTAL = SA + SB + SC • QTOTAL = QA + QB + QC

S

-9

-15

C

Three-Phase Winding Connections

C

Apparent Power • |S|, in Volt-Amperes, or VA • = VRMS * IRMS for a given power cycle

15 12

-12

IB

V B-N

IA

N IC

Voltage is measured L-L • Neutral point may not be accessible, or • L-L voltage sensing may be preferred

Inductive load

Single-phase Real, Apparent and Reactive Power AC Three-Phase "Line" Currents

A IC

480 VAC Example

A

I

• For inductive loads • The current vector “lags” the voltage vector angle φ • Purely inductive load has angle φ = 90° • Capacitive Loads • The current vector “leads” the voltage vector by angle φ • Purely capacitive load has angle φ = 90°

Important to Know • Current is stated as “lAC”, but this is really IRMS • Line currents can represent either current through a coil, or current into a terminal (see image below) depending on the three-phase winding connection • IPEAK = 2 * IRMS • 14.14A for a 10 ARMS current in the example to the right • IPK-PK = 2 * IPEAK

A-B Voltage B-C Voltage C-A Voltage

-200

-800

V

φ

Line Current Measurements

-600

As with the single-phase case, Power is not the simple multiplication of voltage and current magnitudes, and subsequent summation for all three phases.

IB

Apparent Power for each Phase • |S|, in Volt-Amperes, or VA • = VRMS * IRMS for a given power cycle

Single-phase, Non-resistive Loads For capacitive and inductive loads • P ≠ V * I since voltage and current are not in phase

-400

800

If a neutral wire is present, three-phase voltages may also be measured Line-Neutral • VL-N = VL-L/ 3 • 277 VAC (VRMS) in this example • VPEAK = 2 * VL-N • 392 V in the example to the right • VPK-PK = 2 * VPEAK

C

A

120°

Current value = IX*sin(α) • IX = magnitude of line current vector • α = angle of rotation, in radians

200

-200

Line-Neutral Voltage Measurements

N

Neutral

Like voltage, the resulting time-varying “rotating” current vectors appear as three sinusoidal waveforms • Separated by 120° • Of equal peak amplitude for a balanced load

AC Three-Phase “Utility” Voltage 480VAC , Measured Line-Line

480 VAC Example

Wye (Y) 3-phase Connection • Neutral is present in the winding • But often is not accessible • Most common configuration

Power Factor (PF, or λ) • cos(φ) for purely sinusoidal waveforms • Unitless, 0 to 1, • 1 = V and I in phase, purely resistive load • 0 = 90° out of phase, purely capacitive or purely inductive load • Not typically “signed” – current either leads (capacitive load) or lags (inductive load) the voltage

C

VC

Three-phase, Non-resistive Loads

For purely resistive loads • PA = VA-N * IA • PB = VB-N * IB • PC = VC-N * IC • PTOTAL = PA + PB + PC V B-N

Voltage Current

120°

120°

VA-N

Line-Line Voltage Measurements

V

Resistive load

Three-phase, Resistive Loads

Three-phase, Any Load

ω (rad/s) or freq (Hz)

Like voltage, three-phase current has three different line current vectors that rotate at a given frequency • Typically, 50 or 60 Hz for utility-supplied voltage

VA

I

N

B

By definition, the system is “balanced” • Vectors are separated by 120˚ • Vectors are of equal magnitude • Sum of all three currents = O A at neutral (provided there is no leakage of current to ground)

B VPK-PK

Line

Neutral

P=V * I

Power Factor

Phase Angle (φ) • Indicates the angular difference between the current and voltage vectors • Degrees: - 90° to +90° • Or radians: -π/2 to + π/2

The resulting time-varying “rotating” voltage vectors appear as three sinusoidal waveforms • Separated by 120° • Of equal peak amplitude

Time

“Not True” RMS

For purely resistive loads • P = I2R = V2/R = V * I • The current vector and voltage vector are in perfect phase

Phase Angle ω (rad/s) or freq (Hz)

C

If all three phases are rectified and filtered • VDC = 2 * VL-N * 3 = VPEAK * 3 = 679 V in the example to the right

-50 -100

The resulting time-varying “rotating” current vector appears as a sinusoidal waveform

At any given moment in time, the current magnitude is I*sin(α) • I = magnitude of current vector • α = angle of rotation, in radians

A

120°

VB

Neutral

to receive a Power Basics

Neutral

120°

The three voltage vectors rotate at a given frequency • Typically, 50 or 60 Hz for utility-supplied voltage The single-phase voltage vector rotates at a given frequency • Typically, 50 or 60 Hz for utility-supplied voltage

120°

ω (rad/s) or freq (Hz)

Typically, the three phases are referred to as A, B, and C, but other conventions are also used: • 1, 2, and 3 • L1, L2, and L3 • R, S, and T

THREE-PHASE

Electric Power • “The rate at which energy is transferred to a circuit” • Units = Watts (one Joule/second)

Imaginary Power

Neutral

MDA800 Series Motor Drive Analyzers 8 channels, 12-bits, 1 GHz

SINGLE-PHASE

Like voltage, the single-phase current vector rotates at a given frequency • Typically, 50 or 60 Hz

Line Current (Peak)

• Magnitude (voltage) • Angle (phase) Typically, the single-phase is referred to as “Line” voltage, and is referenced to neutral.

LINE POWER

SINGLE-PHASE B

Volts (Peak), Line-Line

MDA800 Series and sign up

THREE-PHASE

Single-phase line voltage consists of one voltage vector with:

Volts (Peak), Line-Neutral

Learn more about the

LINE CURRENT

SINGLE-PHASE

mi + Mi - 1 1 Vj * Ij Mi j=mi

Σ

B

B

IB VB-C

C

Power Factor (λ)

N

IA VA-C

A

IB

VB-C

C

λi =

VA-C

A

IA

Pi Si

Si = VRMSi * IRMSi

magnitude Qi =

S i2 - P i2

Sign of Qi is positive if the fundamental voltage vector leads the fundamental current vector

Phase Angle (φ)

magnitude Φi = cos-1λi Sign of Φi is positive if the fundamental voltage vector leads the fundamental current vector

| teledynelecroy.com/contactus © 2015 Teledyne LeCroy, Inc. All rights reserved.

MDA800 Series 8 ch, 12-bit, 1 GHz Oscilloscope tlec-mda-poster-designworld-Q3.indd 1 V2.LE.indd 17 Pneumatic Actuators - MSCasebook 11-16

7/27/16 11:11 3:00 PM 11/8/16 AM

Motion System

APPLICATIONS

Better ballscrews, more applications BALLSCREWS SUIT APPLICATIONS needing light, smooth motion, applications requiring precise positioning, and when heavy loads must be moved.

Examples include machine tools, assembly devices, X-Y motion and robotics.

Factors such as lead accuracy, axial play and preload, and life-to-load relationship are most commonly used to classify ballscrews.

Lead accuracy is the degree to which the shaft’s rotational movements are translated into linear movement. With lead accuracy and axial play determined by the manufacturing method of the ballscrew shaft and the assembly of the nut, high lead accuracy and zero axial play is generally associated with relatively higher-cost, precision ground ballscrews, while lower lead accuracy and some axial play is associated with lower-cost, rolled ballscrews. Fabricated by rolling or other means, these ballscrew shafts yield a less precise, but mechanically efficient and less expensive ballscrew.

Specifying a ballscrew requires understanding the application criteria that the component needs to satisfy. There are several factors to consider and each one plays a role in the decision-making process. The most important factors are: • •

load—including the mass being moved and the forces involved in the machine’s processes orientation—for example, horizontal or vertical, which affects the need for load-bearing support

• • • • •

speed—velocity and acceleration travel—the stroke length precision—including positional accuracy and requirements for repeatability environment—special considerations for rugged or unique environments duty cycle—cycle rate

Recent advances in manufacturing and materials have improved ballscrew performance so machine designers today can get better linear motion at lower cost. Some improvements include the fact that the latest generation of ballscrews has more load density than ever, giving designers higher capacity from a smaller package. There is also a trend toward more miniaturization, as well as faster ballscrews using both rolled and ground screw manufacturing methods.

There is also a move toward more integration. For example, ballscrew-based linear actuators are readily available as all-in-one packages. The benefit here is that such integrated packages significantly reduce design time as well as time required for assembling a system and programming the actuator itself.

In applications requiring extreme precision, ballscrews play a key role here as well. A recent example comes from Satisloh GmbH, based in Wetzlar, Germany.

Satisloh makes machines for surface processing, such as grinding, polishing, coating and finishing of precisionoptical components. The company’s new grinding and polishing machines, the SPM-125/SPS-125 for production of lenses for precision optics, use controls and linear systems from Rexroth.

The SPM-125/SPS-125 machine is used for making concave and convex glass or ceramic lenses with 10 to 130-mm diameters. The machine features three linear axes, one swivel axis as well as one workpiece spindle.

It uses Rexroth’s Indramotion MTX CNC system, IndraDrive Cs servomotors (from 0.1 to 3.5 kW), and Rexroth ballscrews and ball rail systems.

The Satisloh SPM-125/SPS-125 features three linear axes, one swivel axis as well as one workpiece spindle. It uses Rexroth ballscrews and ball rail systems.

18

DESIGN WORLD — MOTION

Ballscrews - MSCasebook 11-16 V1.indd 18

11 • 2016

motioncontroltips.com | designworldonline.com

11/8/16 11:27 AM

100 YEARS OF INNOVATION.

For 100 years NSK has been proudly designing motion and control products that not only help increase productivity but also help make the world a more safe, reliable and comfortable place. Here’s to celebrating the past, innovating in the present and setting the future in motion.

877.994.6675

NSK_MSHandbook9-16.indd 19

www.nskamericas.com

11/8/16 12:57 PM

APPLICATIONS

Motion System

SKF S70 W series ball bearings are specifically designed for woodworking applications. The hybrid bearings reduce friction and increase maximum spindle speed.

Bearings uses are everywhere THERE ARE DIFFERENT TYPES OF BEARINGS specifically designed for applications depending on expected loads and the possibility of temperature fluctuations, contaminant exposure, and pressure.

For example, wind turbine bearings and slewing rings can be as large as 2 m in diameter and must often handle hundreds of tons. Conversely, there are bearings for medical applications that show up in smaller machine equipment requiring bearings only

20

DESIGN WORLD — MOTION

Bearings - MSCasebook 11-16 V3.indd 20

11 • 2016

a few millimeters in diameter. These applications might subject the bearing to washdown and therefore require treated steel subcomponents. For quiet or disposable designs, manufacturers use plastic as well. Similarly, industrial equipment that’s fast, hot or insufficiently lubricated under typical conditions can benefit from hybrid bearings. These are the bearings that make use of rollers, balls and steel raceways made of ceramic.

Balls provide the rolling element in ball bearings for low-friction motion between the two races of the bearing. Ball bearings are frequently cost effective and usually require low maintenance. These attributes, plus low heat generation make them widely selected for motion system applications. Ball bearings are in everything from turbine engines and skateboard wheels to medical equipment and aerospace applications.

motioncontroltips.com | designworldonline.com

11/8/16 10:28 AM

Linear Motion Systems

Ball

IKO’S SUPERIOR COMPONENTS HAVE ENDURED MARS—IMAGINE WHAT THEY CAN DO FOR YOU HERE ON EARTH...

To learn about customizable solutions for your specific application, or our maintenance-free (C-lube) lubrication (up to 5 years or 20,000 km), visit:

www.ikont.com

Roller

Ball Spline

New York: 800-922-0337 • Chicago: 800-323-6694 • Minneapolis: 800-252-3665 • Atlanta: 800-874-6445 Dallas: 800-295-7886 • Los Angeles: 800-252-3665 • Silicon Valley: 800-252-3665

IKO Int'l 6-16.indd 21

11/8/16 12:57 PM

Motion System

and reduce costs by 40%

APPLICATIONS

Replace your metal bearings

Reduce cost and increase technology with iglide® iglide® plastic bearings are 100% self-lubricating, maintenancefree, and available in a range of 40+ materials to suit even the most demanding applications.

With product selection tools, reliable lifetime calculation, CAD downloads, and more available online. Thousands of dimensions in stock and ready to ship as early as same-day.

Free samples available at www.igus.com/drytechbox

This NC rotary table from FIBROMAX is for rotary and multi-axis machining. It moves 400-ton loads with precision thanks in part to radial and axial concentricity in the micrometer range — and absorption of radial and axial forces through preloaded and generously dimensioned axialradial bearings. The indexing table carries load on the bearing through roller circulation shoes.

sales@igus.com 1.800.521.2747

22

Bearings - MSCasebook 11-16 V3.indd 22

Roller bearings have rollers of differing shape (spherical thrust, spherical, cylindrical) as opposed to balls for transmitting loads and reducing friction.

Because of this design, roller bearings have a larger surface contact area than ball bearings and can accommodate larger loads without deformation. This bearing more evenly distributes weight over cylinder line contacts, allowing moderate thrust loads. With ball bearings, the weight is distributed across sphere point contacts. Designers choose these bearings for turbine engines, conveyor belt rollers, gearboxes, and transmissions, as well as the mining, pulp and paper, food and beverage and waste-water industries.

A roller bearing with rollers whose length is at least four times their diameter is called a needle roller bearing. The larger surface area permits high radial loads in a limited space. Needle bearings are in rockerarm pivots, compressors, transmissions and pumps. A rear-wheel drive vehicle’s drive shaft often has no less than eight needle bearings (four in each U-joint). Often there are more. They are also common in agricultural equipment, construction equipment, two-cycle engines, and paper moving equipment.

Thrust ball bearings are for applications with primarily axial loads. They can also handle shaft misalignment. Additionally, the bearings excel in highspeed applications for the automotive and aerospace industries and spindles, machine tool tables, fluid control valves.

Thrust roller bearings transmit load between the bearing’s raceway to handle radial loads; these bearings can also self-align account for shaft deflection and alignment errors. Typical applications include: crane hooks, pulverizers, cone crushers and other heavy-load, medium-speed applications.

Tapered roller bearings use tapered rollers between tapered inner and outer ring raceways. These rollers are angled, so their surfaces converge at the bearing’s axis.

Unlike most bearings that accommodate either axial or radial loads, these bearings handle large loads in either direction.

Design engineers use these bearing for fuel pumps, helicopter transmissions, agricultural uses and others.

DESIGN WORLD — MOTION

11 • 2016

11/8/16 10:28 AM

Reduce cost and increase technology with iglide®

iglide® plastic bearings are 100% self-lubricating, maintenancefree, and available in a range of 40+ materials to suit even the most demanding applications.

With product selection tools, reliable lifetime calculation, CAD downloads, and more available online. Thousands of dimensions in stock and ready to ship as early as same-day.

Reduce cost andReduce increasecost and increase technology with technology iglide® with iglide®

iglide® plastic bearings iglide are®100% plastic bearings are 100% self-lubricating, maintenanceself-lubricating, maintenancefree, and available infree, a range and of available in a range of 40+ materials to suit 40+ even materials the to suit even the most demanding applications. most demanding applications.

With product selection With tools, product selection tools, reliable lifetime calculation, reliableCAD lifetime calculation, CAD downloads, and more downloads, available and more available online. Thousands of online. dimensions Thousands of dimensions in stock and ready in to stock ship as and ready to ship as early as same-day. early as same-day.

Reduce cost and increase technology with iglide®

iglide® plastic bearings are 100% self-lubricating, maintenancefree, and available in a range of 40+ materials to suit even the most demanding applications.

With product selection tools, reliable lifetime calculation, CAD downloads, and more available online. Thousands of dimensions in stock and ready to ship as early as same-day.

11 • 2016

Bearings - MSCasebook 11-16 V3.indd 23

DESIGN WORLD — MOTION

sales@igus.com 1.800.521.2747

Free samples available at www.igus.com/drytechbox

sales@igus.com 1.800.521.2747 sales@igus.com 1.800.521.2747

Reduce downtime and increase service life with Chainflex® cables

Unmatched testing, widest selection, and a full guarantee for up to 36 months make Chainflex a world leader in continuousflex cable performance. More than 1,200 cables in a range of types available from stock and ready to ship in as little as 24 hours. Never any cutting costs or minimum orders.

Free samples available at www.igus.com/cf-sample

sales@igus.com 1.800.521.2747

Case study: Bearings boost precision Bearings in machine-tool spindles need both speed and precision. High-speed capability and accuracy are critical for woodworking and other soft-material industries. Plus ever-increasing demands for productivity and efficiency mean bearings for electro-spindles always looking to boost quality.

SKF supplies bearings to High Speed Development, a producer of electro-spindles for woodworking applications.

Recently the companies collaborated on a new bearing design for woodworking applications. In the end, they designed S70 W series hybrid angular contact ball bearings with an 18° contact angle and are preloaded.

They come in sizes for 25 to 55 mm shaft diameters. An optimized PEEK cage reduces noise and vibration and low to medium speeds. It combines high stability at low to medium speeds — and has a speed factor to 1.6 million n·dm.

The bearing rolling elements have bearing grade silicon nitride Si3N4 and rings of bearing steel. They are resistant to damage during rapid starts and stops.

The bearings have noncontact seals fitted on both sides, and the seals hold lubricant inside, so don’t require lubrication after mounting.

This AE Series planetary gear reducer from Apex Dynamics includes three high-precision ball bearings.

In fact, the bearings are straddle mounted to carry high radial and axial loads.

Free samples available Free at samples available at www.igus.com/drytechbox www.igus.com/drytechbox

Plain bearings don’t have rolling elements. They’re compact and lower-cost bearings for many applications, but automotive and construction are some of the most common. Plain bearings go in steering cylinders, hydraulic excavators, and more.

Guaranteed for 36 months

Free samples available at www.igus.com/drytechbox

and reduce costs by 40%

and reduce costs and by 40% reduce costs by 40%

and reduce costs by 40%

Continuousflex cables

BEARINGS

sales@igus.com 1.800.521.2747

23

11/8/16 10:29 AM

APPLICATIONS

Motion System

Belts and pulleys in motion designs COMMON WHERE EFFICIENCY OR ACCURACY ARE OBJECTIVES are synchronous or high-torque drive belts. Applications from consumer-grade home printers to heavy industrial conveyors use these synchronous belts, because unlike V belts with trapezoidal cross-sections, they don’t slip.

Motion applications often need customized belts and sprockets in urethane, double-sided, mini-pitch, and made-to-order (MTO) versions.

Double-sided belts have covered teeth to transfer up to 100% of maximum-rated load from one or both belt sides. These come in trapezoidal timing configurations and HTD curvilinear tooth profiles.

Some run to 14,000 rpm with speed ratios to 10:1, which is enough to replace gearsets in some cases.

Double-sided belts also excel as serpentine drives in riding mowers with counter-rotating blades, printing presses, and textile machines. Urethane belts maximize motion transfer, especially when incorporating polyester or aramid tensile members.

Their tooth profile is a miniature version of belt with standard 40° angle teeth. Speed ratios reach 8:1 and torque output is to a couple lb-in. These belts excel on positioning axes, thanks to their low torque and minimal backlash — especially in printers and copiers that need clean operation.

Long belting (usually with L or H trapezoidal tooth or HTD profiles) can exceed 500 feet in some cases. They work for power transmission and axis synchronization — doing double duty as conveyors in many cases. Such belts complete with rack-andpinion sets in machine tools and X-ray equipment as a viable drive for linear strokes. One caveat: These belts spliced transmit a quarter less horsepower than a comparable endless belt.

This belt-drive application on a conveyor is a power-transmission and load-moving surface. It’s an Intralox ThermoDrive that (with durable construction and positive engagement between drive and belt) addresses problems of flat belting, including the need for tensioning adjustments and mistracking.

24

DESIGN WORLD — MOTION

Belts & Pulleys - MSCasebook 11-16 V3.indd 24

11 • 2016

motioncontroltips.com | designworldonline.com

11/7/16 5:03 PM

A A

TRADITION A TRADITION OF OF EXCELLENCE OF EXCELLENCE

Visit us in Booth #E-10319 at...

Pack Expo International Nov 6-9, 2016, Chicago, IL

STR3 Miniature Stepper Drive STR3 Miniature Stepper Drive Designed and Produced for OEMs STR3 Miniature Stepper Drive Designed and Produced for OEMs Designed and Produced for OEMs • Step & direction control • Step & direction control • Step & direction control • Premium performance • Premium performance • Premium performance • Ultra-compact footprint • Ultra-compact footprint • Ultra-compact footprint • Easy to set up with onboard dip switches • Easy to set up with onboard dip switches • Easy to set up with onboard dip switches

StepSERVO™ Integrated Motors

StepSERVO™ Integrated Motors The Next Evolution in Step Motor Technology StepSERVO™ Integrated Motors • Closed loop outperforms traditional, open loop step The Next Evolution in Step Motor Technology motors in every way The Next Evolution in Step Motor Technology • More torque • Closed loop outperforms traditional, open loop step • Better efficiency motors in every way • Closed loop outperforms traditional, open loop step • Cooler and quieter operation motors in every way • More torque • More torque • Better efficiency • Better efficiency • Cooler and quieter operation • Cooler and quieter operation

SV200 Servo Drives And J Series Servo Motors

• Full-featured servo systems • Competitive prices • Auto-tuning, anti-vibration and STO • Torque, velocity and positioning modes

SV200 Servo Drives SV200 Servo Drives And J Series Servo Motors And J Series Servo Motors • Full-featured servo systems

• Full-featured servo systems • Competitive prices • Competitive prices • Auto-tuning, anti-vibration and STO • Auto-tuning, anti-vibration and STO • Torque, velocity and positioning modes • Torque, velocity and positioning modes

Connected. Customized. Closed Loop.

Since 1978, developing motion control solutions that optimize machine performance and help you Make it Move.

www.applied-motion.com | 800.525.1609

Connected. Customized. Closed Loop.

Connected. Customized. Closed Loop.

Since 1978, developing motion control solutions that optimize Since 1978, developingand motion control solutions that optimize machine performance help you Make it Move. machine performance and help you Make it Move.

www.applied-motion.com | 800.525.1609 www.applied-motion.com | 800.525.1609 Applied Motion 7-16_Vs2C.indd 56 AppliedMotion_MSHandbook9-16.indd 25

8/1/16 12:58 2:43 PM 11/8/16 PM

APPLICATIONS

Motion System

Manufacturers of Power Transmission and Motion Control Components

Concentric Maxi Torque

Stock and Custom Keyless Hub-to-Shaft Connection System Email or call to get your

CMT Stock Products Catalog Order today. Ships today!

MTO belts are mostly trapezoidal and HTD. Those for applications involving the assembly or transport of electronics or explosive substances include a body and tooth-facing fabric made of conductive material such as carbon to prevent static discharge. In contrast, belts for power tools and appliances are often made of nonconductive materials that insulate internal components.

Belts that run in harsh environments incorporate oil-resistant and temperature-resistant compounds.

Elsewhere, tensile members of aramid withstand shock loads, and steel members help belts maintain positioning accuracy. Engineers can even customize the twist of members to alternate or go one way to satisfy tracking requirements. Another option is thick or backed belts to convey or grip objects in tandem with mating belt drives. Backings can also extend belt life and address vibration.

For industrial applications, most belt sprockets are made of either cast or ductile iron. That said, steel excels in designs that run at speeds exceeding those safe for iron pulleys — to 20,000 fpm. Likewise, aluminum pulleys run at high speed and have low inertia to boot. Another lightweight option is non-metallic pulleys — common in lawn equipment and power tools that transmit little torque and have relatively short design life. Other synchronous-sprocket options include specialty tooth profiles for better positioning accuracy or custom hub mounts and flanges.

Custom Synchronous Drives

Precise. Reliable. Cost Effective.

Shown here is a bucket elevator from Feeco International that uses an electric motor through a belt drive for operation.

Timing Pulley Stock

Guaranteed When You Need It.

Custom Machine & Tool Co., Inc. (800)355-5949 • sales@cmtco.com www.cmtco.com

Precise. Reliable. Trusted.

American Engineering • American Made © 2016 Custom Machine & Tool Co., Inc.

Belts & Pulleys - MSCasebook 11-16 V3.indd 26

26

DESIGN WORLD — MOTION

11 • 2016

11/9/16 2:40 PM

 BELTS & PULLEYS

Manufacturers of Power Transmission and Motion Control Components

LoPro is a guide-wheel-based linear actuator from BishopWisecarver Corp. featuring 90o steel guide tracks. The steel tracks can be up to 20 feet long and can be readily butt joined for longer lengths. A pair of opposing tracks are mounted to aluminum track plates in sections of about 10 feet long.

Polyurethane belting provides long mechanical actuation with good accuracy and high speed while generating little noise.

Application example: Tight pulley connection helps robotics profile brain function Now, BKIN Technologies sells machines that let neuroscientists and clinician scientists make scientific investigations into neurological conditions. The company’s KINARM is a robotic exoskeleton that moves with a patient’s arm to detect anomalies. When interacting with the robotic system, a patient either sits in a chair with robot arms affixed (in the case of a KINARM Exoskeleton Lab) or grasps two robotic manipulandums (in the case of a KINARM End-Point Lab). Then the setups run augmented reality software that creates virtual environments in which patients either direct hands to targets or interact with objects.

The robotic exoskeleton has a slotless motor that powers and drives the robot through a belt-and-pulley mechanism. The connection between motor and master pulley is critical, requiring zero backlash and no slippage.

Early KINARM Labs used a pulley that attached to the motor shaft using set screws, but constant changing of motor direction during operation subjected

11 • 2016

Belts & Pulleys - MSCasebook 11-16 V3.indd 27

this connection to high shock loads ... loosening the screws and allowing backlash, shaft damage, and system failure. Now BKIN uses a more reliable connection called the Concentric Maxi Torque bushing system from Custom Machine and Tool Co. (CMT). The bushing offers zero backlash and high clamping torques. A low profile allows for direct coupling to the motor shaft — eliminating the need for a custom-length shaft and bellows coupler on the motor.

The result of the mechanical shrink fit is ease of positioning and elimination of shaft damage.

In fact, CMT sells the pulley and bushing as an assembly. A mechanical shrink fit takes the form of a setscrew axial to the shaft that forces the tapered bushing into the hub’s matching taper. As the lever forces the two tapers together, the bushing slot compresses to clamp the pulley to the shaft. That same set screw can come off and go in the opposite hole to release the shrink fit and allow for removal or repositioning.

DESIGN WORLD — MOTION

27

Synchronous Timing Pulleys Featuring Concentric Maxi Torque, CMT’s Patented Keyless Hub to Shaft Connection System Email or call to get your CMT Stock Products Catalog Order today. Ships today!

Custom Machine & Tool Co., Inc. s SALES CMTCO COM www.cmtco.com

Precise. Reliable. Trusted.

!MERICAN %NGINEERING s !MERICAN -ADE Ăš #USTOM -ACHINE 4OOL #O )NC

11/7/16 5:03 PM

APPLICATIONS

Motion System

Cases of brake and clutch use BRAKES, CLUTCHES AND TORQUE LIMITERS WORK IN MEDICAL EQUIPMENT, packaging machinery, industrial hoists, and installations. Brakes stop and hold loads. Clutches and torque limiters disengage and engage power-transmission outputs to transfer torque from an input. Torque limiters modulate power transmission to protect mechanical equipment from overload.

When selecting clutches, brakes, and torque limiters for an application, options include mechanical, electric, fluidic or self-actuation. Electric brakes are easy to control and cycle, even to a couple thousand cycles per minute. In contrast, common air-actuated brakes and clutches run coolly and maintain hold with minimal power. Friction brakes with disc, drum and cone morphologies work well as emergency brakes because of their failsafe holding—essential on conveyors, escalators, airport-baggage handlers, elevators and other safety-critical designs.

The size and type of brake most suitable for a given design depend on whether the machine needs emergency stops or softer stops that sacrifice brakes to protect loads from shock. Then, other application criteria (including the machine envelope, thermal capacity, cycle rates, and inspection and repair schedules) dictate the final selection. In other machines, it’s more important that brakes prevent shifting loads and misalignment.

In most cases, it’s best to size brakes and clutches to the motor torque of the machine axis.

But especially for axes where the brake must stop a vertical load, engineers should account for the fact that motors can temporarily draw added current to output more than their rated torque.

28

DESIGN WORLD — MOTION

Brakes & Clutches - MSCasebook 11-16 V3.indd 28

11 • 2016

The JEB0325 by Carlyle Johnson is a low-backlash springset jaw holding brake which is often used for medicalimaging applications. By eliminating backlash, the brake ican smoothly stop an imaging unit from rotation and positioning sequences with no vibration or shaking. This allows for clear imaging.

motioncontroltips.com | designworldonline.com

11/7/16 3:50 PM

Power Transmission and Motion Control Solutions for Industrial Applications

The Power Brands in Power Transmission Ameridrives Couplings

Delroyd Worm Gear

Kilian Manufacturing

Svendborg Brakes

Ameridrives Power Tranmission

Formsprag Clutch

Lamiflex Couplings

TB Wood’s

Guardian Couplings

Marland Clutch

Twiflex Limited

Bauer Gear Motor

Huco Dynatork

Matrix International

Warner Electric

Bibby Turboflex

Industrial Clutch

Nuttall Gear

Warner Linear

Boston Gear

Inertia Dynamics

Stieber Clutch

Wichita Clutch

Altra_MSHandbook9-16.indd 29

www.AltraMotion.com 11/8/16 12:59 PM

APPLICATIONS

... or the largest.

Motion System

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

Posidyne long-coupled C-Face clutch brakes from Force Control Industries work because they eliminate common damage to keyways and motor shafts. The long-coupled Posidyne clutch-brake offers both the simplicity of C-Face mounting and a tight coupling. It uses oil-shear technology for rapid and precise stopping. This technology helps the brakes last up to 10 times longer than standard dry-friction brakes and abolish maintenance, adjustment, and disc replacement.

AS9100C:2009/Certified

Helpful resources include published performance curves from brake and clutch manufacturers. These list dynamic torque ratings for various operating speeds to help engineers match brakes and clutches to peak motor-output torque.

Beyond these general guidelines, fast, hot and other extreme applications require extra evaluation. Some tips: Spring-set brakes benefit motion designs that slow loads with the motor before the brake engages; they’re also suitable as holding mechanisms.

Machinery that runs beyond a few hundred cycles per minute may need brakes and clutches that are larger than performance curves indicate.

Industrial designs that operate in hot environments may benefit from friction brakes with specialty friction-surface geometries and materials (such as phenolic resin or ceramic). Motion applications

Clutches, Brakes & Power Transmission Products • electrical, mechanical, pneumatic & hydraulic models • system design and integration • expert engineers working on every order

Engineering Solutions for Clutches & Brakes

www.cjmco.com Phone: 860-643-1531 291 Boston Tpke, Bolton, CT 06043 30

Brakes & Clutches - MSCasebook 11-16 V3.indd 30

DESIGN WORLD — MOTION

that don’t get a lot of maintenance also benefit from the longer life these friction materials get. Brakes that use permanent magnets for operation automatically adjust for wear.

Brakes for high-cycle applications Where applications run at 50 to 300 cycles per minute (as in indexing with a clutch brake) each clutch engagement transfers a torque spike to the connection between the motor shaft and input shaft of the clutch brake. High-cycle applications can cause severe hammering on the motor’s shaft connection to the clutch. For convenience and ease of assembly, standard C-Face connections are most common — but loose fits can cause torque to transfer through the key and keyway and hasten failure. Here, clutches and brakes that connect with shrinkfit or clamping couplings for a 360° connection perform better.

11 • 2016

11/8/16 11:37 AM

BRAKES & CLUTCHES

In applications that must rapidly stop, start, reverse, and change speed, clutch brakes that use oil shear technology are also suitable. Here, a boundary layer of transmission fluid shears between friction discs and drive plates. As the parts come together, the fluid in shear transmits torque. This eliminates direct friction-disc contact during high-speed slip. Heat from the friction surface is dissipated as the fluid circulates to the housing. That’s useful on axes with start-stop cycles or cycle rates to 300 cycles per minute. Here, oil-shear brakes last five to ten times longer than dry clutch-brake offerings. Other clutch-brake features that boost design performance in high-cycle-rate applications include: • Low-inertia components that draw less motor horsepower to accelerate the load • Multiple-disc designs that produces high torque • Recirculating fluid to dissipate the heat of engagement • Simple actuation for accurate and easy adjustment for rapid starts and stops

Case in point: ROBA guidestop brakes from Mayr directly mount onto masses to be braked or held. This helps make gravity-loaded axes safer, as drive elements between the motor and moving mass (including spindles, spindle nuts, shaft couplings or gearboxes) have no influence on safety. That’s different than traditional motor brakes in which all drive elements transmit braking torque to the carriage. Plus all elements between the brake and carriage in these traditional arrangements degrade rigidity.

Braking on vertical axes is usually a fail-safe setup, so close when de-energized.

Another application challenge — vertical axes On machine tools and machining centers with vertical axes that need safety components to protect personnel from harm, profiled rail brakes are one option.

Suspended loads are a hazard in machines if people work below. Unintended fall or crashes of load must be stopped as quickly as possible to protect personnel and equipment. Here, safety brakes that work through backlash-free clamping of profiled rail guides. Some versions integrate condition monitoring with contactless proximity switch.

Vertical axes must have safety brakes.

ROBA-guidestop brakes from Mayr apply force directly to moving masses of vertical axes — to minimize risk to people pursuant to DIN EN ISO 13849-1. The brake comes in eight sizes to deliver holding forces from 5 to 34 kN.

motioncontroltips.com | designworldonline.com

Brakes & Clutches - MSCasebook 11-16 V3.indd 31

11 • 2016

DESIGN WORLD — MOTION

31

11/7/16 3:51 PM

APPLICATIONS

Motion System

Cables customized to specific applications

32

MORE THAN ANY OTHER COMPONENT, cables come in customized versions to satisfy specific application requirements. The number of conductors and strands to transmit power to motors and feedback to and from sensors and controllers are just a couple cable features designers match to designs.

Usually requiring UL listing, cables in motion-control applications must be able to handle tight bending radii, abrasion, flexing, and possibly even torsional movements. Some must also isolate the effects of strands conducting power. In VFD cables, for instance, a symmetrical ground design with three grounds and three power conductors offers a small outer diameter and less EMI. However, a four-conductor design with three power conductors and one ground is better for continuous flex applications. The latter are common in machine tools, assembly lines and industrial-production applications.

Jacket material must also be compatible with the application. The cable jacket protects conductors and insulation and may also provide a level of shielding. For example, cables used in harsh environments, such as on mobile machinery and machine tools, require special jacketing to withstand chemicals such as cutting fluids and oils and abrasion. Cables used in these tough environments or in welding applications may also require a flame-retardant jacket or low-smoke, zero-Halogen design.

Cables used in flexing and rotating applications, such as those on robots, must have high tensile strength and abrasion and flammability resistance. These are most often manufactured of polyvinyl chloride (PVC), chlorinated polyethylene (CPE), polyurethane (PUR) and thermoplastic elastomer (TPE).

On the other hand, cables used in medical applications must be biocompatible. The most common material used in cables for medical equipment is silicone, as it is durable and can be easily sterilized, disinfected and cleaned without disintegrating. Other medicalgrade materials include thermoplastic elastomers, thermoplastic polyurethanes and PVC. Still other cables are manufactured with antimicrobial jacket materials to prevent bacterial growth.

As mentioned, shielding and insulation are also applicationspecific. Shielding protects the cables from outside electromagnetic interference, but also protects users and machines from voltage spikes and other internal interferences. For cables that will be inside cabinets or machines, or those with light to medium loads, unshielded designs may be used, as they usually are smaller and offer a tighter bend radius.

But cables installed on machines that are in motion require shielding, especially when they connect to a motor or drive enclosure.

DESIGN WORLD — MOTION

Cables - MSCasebook 11-16 V3 MG.indd 32

11 • 2016

All-in-one integrated cable is increasingly common. Case in point: The new HIPERFACE Digital Servo Link (DSL) protocol is a standard for communication with electric motors using just two wires integrated in the motor cable. Here is an example from Kollmorgen, which recently expanded its range of single-cable motor-drive interconnection options with a new one-piece cable and connector assembly for Hiperface-DSL.

motioncontroltips.com | designworldonline.com

11/9/16 10:50 AM

CABLING When tasked with designing a new power cabling system for the tricable gondola lift at the Pardatschgratbahn in the ski resort of Ischgl, Austria, LÜTZE had to come up with completely custom designs to meet the many requirements in this mountainous application.

Custom cable design hits the slopes When tasked with designing the cabling for a new tricable gondola lift at the Pardatschgratbahn in the ski resort of Ischgl, Austria, LÜTZE Inc. had to think outside— and inside—the box to come up with a design that would meet all the tough requirements of the application. The seats on the new gondola cars are heated by up to three generators providing a continuous supply of power. This power source is also used for interior lighting, heating and screens.

When developing the new cabling system, LÜTZE worked closely with the Austrian gondola lift constructor company Doppelmayr to ensure the cables could withstand the extreme weather conditions and UV radiation from the mountains all while coping with perpetual movement in the car. It was clear from the beginning a standard solution was not going to fit the bill. The new combined cable would need to not only feed the voltage from the independent generators into the cabin, but also carry the signal for the thermo-sensors. The plans required additional signal lines and individual cables that could be connected at different points.

LÜTZE engineers opted for heavy-duty industrial plug connectors used with a cable featuring a black, halogen-free PUR sheath to ensure it could withstand extreme conditions and the high UV radiation in the mountains. This ensures reliable operation even in the case of temperature fluctuations between -40 and 80°C. The new PUR cable from LÜTZE allows a very small bending radius of up to a maximum of 10 times its own diameter for tight installation spaces and movements. This was necessary because the cables are always in motion as the cabin moves. Some of the completed assemblies were supplied with aluminum IP65 connectors and casings with a special surface finish making them highly suitable for outdoor applications.

motioncontroltips.com | designworldonline.com

Cables - MSCasebook 11-16 V3 MG.indd 33

The heated seats of the Pardatschgrat gondola require significant power generation, which is supplied by custom cable assemblies from LÜTZE.

11 • 2016

DESIGN WORLD — MOTION

33

11/9/16 3:33 PM

APPLICATIONS

Motion System

Applications where chain drives and actuators excel CHAINS ARE VERSATILE AND RELIABLE components that transmit power in machinery or convey products. Roller chains are mainly used with drives but also go in applications subject to weather, water and chemicals that make other options fail. Most drive applications use an ASME/ ANSI roller chain wrapped around a driver sprocket that is connected directly to the motor or reducer. This sprocket is usually connected to a machine’s conveyor head-shaft.

Conveyor chains go in applications that move product horizontally, vertically or around curved radii. Most common conveyor chains are ASME-style (ANSIstyle) attachment chains. Types include single-pitch and double-pitch attachment chain, hollow-pin chain, curvedattachment chain and plastic-sleeve chain. Attachments accommodate special fixtures or blocks for specific conveyor functions.

Accumulating conveyors use one conveyor-chain subtype for applications needing more control over product flow — in packaging or assembly, for example.

In contrast, rigid chain pairs with electric motors to push and pull loads.

Locking links form rigid series or coil upon retraction. Small consumer-grade applications for rigid chain include powered skylight mechanisms for opening and closing. Larger industrial applications include those for jacks and platforms, material handling, and actuation of vertical axes.

Some applications need guides to maintain stability and not buckle under angled loads. Otherwise, engineers can design the application to run the rigid

nis quis rum ex ma mnis m a olore at d sam o

del id upta

m s l e

d

nem

34

DESIGN WORLD — MOTION

Chain - MSCasebook 11-16 V3.indd 34

11 • 2016

Forklifts use chain drives for lift mechanisms. They’re rugged and deliver high load capacity.

motioncontroltips.com | designworldonline.com

11/7/16 3:54 PM

AN UNBEATABLE PACKAGE:

QUALITY, DEPENDABILITY, & ENGINEERING SUPPORT.

Crafted to excel in the toughest environments, including high-speed, wash down, vacuum sealing, high-temperature, food grade and many more. From standard chains to highly customized solutions, Tsubaki has the right chain for your packaging industry application. We understand the importance of your line’s uptime so save time and money by trusting in Tsubaki. And don’t forget Tsubaki’s full line-up of complementary products. Bundling options provide the flexibility to ensure optimum quality along your entire production line. At Tsubaki, we’ve got you covered.

ROLLER CHAINS • ENGINEERING CLASS CHAINS • BACKSTOPS • SPROCKETS • CABLE & HOSE CARRIERS • POWER TRANSMISSION PRODUCTS ROLLER CHAINS • ENGINEERING CLASS CHAINS • CAM CLUTCHES • SPROCKETS • CABLE & HOSE CARRIERS • PT COMPONENTS

Total Package USTSUBAKI.COM

©2015 U.S. Tsubaki Power Transmission, LLC All Rights Reserved.

US Tsubaki Motion Casebook 11-16.indd 35

11/8/16 1:00 PM

APPLICATIONS

Motion System

chain with links shoulders down. Standard rigid chain is carbon steel to withstand heat to 200°C, but some machinery benefits from stainless, high-temperature, and coated chain.

In a similar way, self-lubricating power-transmission chains excel in harsh environments or where regular maintenance is difficult. They are useful in applications in food and beverage, paper product or wood-processing industries where traditional lubrication presents too much of a contamination or clogging risk.

Chains are also available with specialty coatings for rugged environments. Stainless steel is a good choice in applications exposed to corrosion, but because this material cannot be hardened in the same manner as carbon steel, it doesn’t have the same load carrying capacity. Nickel-plated chains are another alternative, providing some protection for mildly corrosive environments.

Factors that can limit chain life are corrosion, wear and fatigue. If a chain application needs long life without contamination, pick chain with self-lubricating subcomponents. If the roller-chain application requires high precision, pick chain with precision roller bearings at each link connection.

This is a car lift used by Porsche in the company’s Leipzig showroom. The Grundei lift used rigid-chain actuators for stability and compactness.

SOLUTIONS FOR PRECISION MOVEMENT OF VERY HEAVY LOADS

QUICK DIE CHANGEപͳപSTAGE AND ORCHESTRA LIFTSപͳപCUSTOM ENGINEERED SYSTEMSപͳപINDUSTRIAL LIFTS LinkLiŌ liŌ columns

RollBeam Telescopic push-pull

LinearBeam guided push-pull Press-mounted dual push-pulls

SERAPID Inc. | 34100 Mound Rd. | Sterling Heights, MI | Tel +1 586-274-0774 | info-us@serapid.com | www.serapid.com

Chain - MSCasebook 11-16 V3.indd 36 DW half page rv.indd 1

11/7/16 3:55 PM 4/12/2016 2:17:33 PM

23,000+

Catalog Springs

Plus!

Custom Springs

To Meet Your Specification.

Request a FREE Catalog

More than 340 pages of parts, pricings and specifications Call: 888-SPRINGS (888-777-4647) Visit: leespring.com Fax: 888-426 6655 Email: sales@leespring.com ISO 9001 Registered Company

LeeSpring_MSHandbook9-16.indd 37

11/8/16 1:01 PM

APPLICATIONS

Motion System

Uses for compression springs are everywhere THE MOST COMMON APPLICATIONS for compression springs are variations to resist linear compressing forces (such as a push force) where space is limited, where the application needs uniform bearing pressures, or where an assembly needs less buckling. These ubiquitous motion components are in automotive applications such as seats, pedals, transmission springs, and windshield wipers. Building automation uses compression springs for industrial doors, fasteners, and dampers. Electric-distribution applications use compression springs for contactswitch functions and other electromechanical returns. Medical uses for compression springs also abound—in simple mechanical equipment (such as beds) to those in advanced actuators for precision medical devices. In consumer devices, springs abound in appliances, lawn mowers, and cell phones.

This Öhlin shock absorber for motorbikes incorporates a compression spring for better compression and rebound characteristics than standard TTX36 MkII designs. Damper function is more consistent than that of previous versions.

Called the TTX GP, the design goes into most racing bikes and some street bikes.

38

DESIGN WORLD — MOTION

Compression Springs - MSCasebook 11-16 V3.indd 38

11 • 2016

motioncontroltips.com | designworldonline.com

11/7/16 4:00 PM

CONTROLLERS

Range of applications for motion controllers MOTION CONTROLLERS RANGE from single-axis smarts to programmable automation controllers (PACs) that synchronize hundreds of axes and plant data communications. These precision command centers are central to today’s motion-system innovation.

Consider how last year, the Composite Material Laboratory at Inholland University in the Netherlands installed a Moog Portable Test Controller for analysis of composite materials. The 100-kN hydraulic bench quickly tests lightweight materials for all sorts of products — including everything from aerospace and car parts to consumer sports equipment such as hockey sticks.

The Moog test system includes hydraulic actuator, load frame, and controller The lab recently did full-scale testing on bio-composite scooter

parts to simulate road profiles. It’s also verified the ruggedness of cargo straps for aviation to show compliance with EASE regulations.

Software running on the controller gives engineers many options, so they can adjust the applied force during testing sequences.

Integrated Test Suite software is versatile, and the Moog test controller uses an EtherCAT fieldbus interface for connecting slave devices needing time synchronization. A Gantner Instruments Q.bloxx measurement system links to the test controller for a modular measurement setup to connect to the test controller over EtherCAT.

Active yaw systems on wind turbines use feedback from sensors to rotate the nacelle against the stationary tower (yaw bearing) to track wind direction. B&R offers azimuth controls to minimize wear by optimizing the yaw system.

More specifically, intelligent control via ACOPOS P3 servo drives eliminates motion errors and withstands harsh offshore conditions including 1-g vibrations. Its coated circuit boards are impervious to humid and salty air.

motioncontroltips.com | designworldonline.com

Controllers - MSCasebook 11-16 V3.indd 39

11 • 2016

DESIGN WORLD — MOTION

39

11/8/16 10:13 AM

Without use of vibration-suppression function block

APPLICATIONS

Inspection time per chip Travel time: 120 msec

Vibration settling time: 300 msec

Vision inspection

Handling time per pallet: 420 msec per chip x 400 chips =

Vision sensor

Servomotor

Pallet

XY stage

168 sec

With vibration suppression

Inspection time per chip Travel time: 120 msec

Servomotor

Vibration settling

time: 100 msec

Vision inspection

Motion System

Handling time per pallet: 220 msec per chip x 400 chips = 88

sec

A pallet for semiconductor-wafer inspection has a 20 x 20 grid of trays to hold 400 chips. The resonant frequency of the pallet is 30 Hz. Sysmac vibration-suppression function blocks from Omron Automation run on an NJ/NX controller to cut settling time after every pallet move and make wafer inspection 80 seconds faster.

The Ultimate I/O System 5 Reasons to Upgrade

Multifunction Analog/Digital I/O

Model 826

1 2 3 4 5 www.sensoray.com

Fail-Safe outputs Abundant I/O points Powerful event-driven API Diverse range of I/O functions Advanced counters with event FIFOs

for data acquisition & motion control

Other motion controllers use advanced function blocks to improve specific applications Consider how in some semiconductor-inspection machines, vibration-suppression function blocks can effectively shorten examination time. An X-Y stage moves a chip-carrying pallet so that a vision sensor can check chips one by one. After each pallet move, residual vibration persists — but the vision sensors can’t inspect chips until that vibration stops. Here, Sysmac Vibration Suppression library functions, a new addition to Sysmac Studio’s integrated development environment, from Omron Automation (running on the company’s NJ/NX controller) can trim settling time by two-thirds — for inspection cycles up to 100% faster than setups with no such suppression.

More specifically, Omron’s VSMoveParam1 calculates the S-curve parameters (including velocity, acceleration, and jerk) for suppressing vibration during single-axis positioning.

The programming then uses this data to suppress vibration at system resonant frequency through corrective oscillations via the servomotor driving the axis in question. That boost maximum axis travel speed and (in many cases) workpiece quality or overall throughput.

40

Sensoray_DW_1116.indd 1 Controllers - MSCasebook 11-16 V3.indd 40

DESIGN WORLD — MOTION

11 • 2016

10/14/2016 10:42:12 AM 11/8/16 10:13 AM

Galil Motion Control

ALL THE RIGHT MOVES...

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

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

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

galil.com 1.800.377.6329 Galil 5-15.indd 41

11/8/16 1:02 PM

APPLICATIONS

Motion System

DMG turning-milling centers use Siemens Sinumerik 840D sl CNC controllers to drive myriad turning and milling functions on a machine that makes medical implants. An MDynamics technology package maintains implant surface quality even during fast machining of difficult materials.

Here a Moog Portable Test Controller helps with single-axis testing of composite materials. It runs Integrated Test Suite software and uses an EtherCAT fieldbus interface for connecting EtherCAT compatible devices.

42

DESIGN WORLD — MOTION

Controllers - MSCasebook 11-16 V3.indd 42

11 • 2016

In contrast, the VSConstVelProfile1 function in Omron’s Sysmac Vibration Suppression library calculates a position profile with a specified velocity in constant-velocity zones. Then it calculates a smooth position profile for each stretch of acceleration and deceleration so as to reduce residual vibration at stops ... and suppress vibration during constant-velocity strokes. This particular function is useful when an application involves the handling of fragile items or liquids that can slosh or spill.

Controls in medical-implant manufacture Medical-implant manufacturers must document and validate their products, and now CNC-controlled machines to produce prosthetics are making that easier. German manufacturer implantcast Corp. uses a CNC controller for transfer of CAD/CAM data to the actual production ... including (among many other products) artificial titanium hip implants. The latter are mostly made through removal of material from stock.

Production of hip implants runs on DMG turning-milling centers with a Siemens CNC Sinumerik 840D sl. The machine also makes tailored instruments for the implantation surgery (including surgical rasps to prepare the bone). Fast data processing of the 840D sl helps in bulk manufacture of standard implants as well as custom patientimplants cut precisely to the associated bone structure with the help of a MRI or CT images. A Sinumerik Operate user interface integrates simple swivel commands that simplify setup. (Swivel functions are for swiveling a machine axis and an axis of the workpiece coordinate system.) The CNC also handles coordinate transformations. motioncontroltips.com | designworldonline.com

11/8/16 10:14 AM

Your Machine’s Motion, Simplified

You wouldn’t believe the things we do.

Mitsubishi Electric’s Motion Controllers make it easier than ever to replace complex mechanical systems with the flexibility of high-performance servo control. The Graphical Mechanical Editor software takes care of multi-axis synchronization automatically, eliminating the need for complex calculations and formulas in your programming code. Design your machine however you wish. Mitsubishi Electric makes the programming simple, so that you can go from concept to production in no time.

us.MitsubishiElectric.com/fa/en

Mitsubishi_MSHandbook9-16.indd 43

11/8/16 1:02 PM

CONVEYOR FUNCTIONS are as varied as the applications they complete. Conveyors for discrete product transport benefit from customization to satisfy requirements — including chain and belt size, morphology and material; support frames; controller, drive, and motor or motors; mode of engagement with the drive; encoder, vision, and switch feedback; tracks, bumpers, and gates; and HMIs and plant-level IT integration.

Consider warehouse automation where the objective is ultra-fast sorting and tracking. Such applications need conveyors with servomotor functionality integrated with inspection stations sporting machine vision. Pharmaceutical manufacturing — now a trillion-dollar industry — demands exacting conveyor designs as well, especially as standards such as FDA CGMP regulations are more stringent than ever. Here, conveyors must deliver top-notch warehouse automation functions and have stainless and aluminum parts to pose no risk of contamination to expensive pharmaceutical products such as pills. Likewise, medical-device manufacture must adhere to FDA regulations that dictate equipmentsterilization schedules, so conveyors in these applications withstand harsh washdowns.

Motion System

APPLICATIONS

Conveyor uses abound

Interroll MSC 50 magnetic speed controllers allow total control over material handling systems. They’re most cost-effective for controlling the speed of boxes and plastic trays traveling on gravity roller conveyors and spirals (or at sorter ends).

Conveyors are the main arteries of Amazon’s enormous fulfillment centers.

44

DESIGN WORLD — MOTION

Conveyors - MSCasebook 11-16 V4.LE.indd 44

This is an MBF-P 2040 horizontal belt conveyor from mk North America. Two units meet end to end. These conveyors feature a sidewall on one edge of the belt as well as a friction top on that edge of the belt. This is done for positive product placement and location.

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 9:58 AM

COUPLINGS

In one design, engineers replaced gear couplings with diaphragm couplings because the latter can run continuously and need no lubrication or maintenance.

Couplings for specific installation requirements COUPLING VARIATIONS COMPLEMENT MACHINE DYNAMICS to meet application criteria.

Misalignment, extreme temperatures, mechanical resonance and other factors make some couplings best suited for given applications.

Rigid couplings are torsionally stiff, but parallel shaft misalignment exceeding one thousandth of an inch will cause failure. Compression or clamp couplings offer torsional strength with a two-piece design that allows easy removal. Designers select rigid couplings for servo systems requiring moderate speed, high torque capacity, and reduced cost.

Flexible couplings damp vibrations in both continuous-motion and intermittent applications.

Prevalent in setups needing precision control and misalignment compensation, flexible bellows couplings work well in CNC machine, robotics, and encoder applications.

Jaw couplings are less stiff than other couplings, so work best in constant-motion applications.

Engineers often pick Oldham couplings over straight

motioncontroltips.com | designworldonline.com

Couplings - MSCasebook 11-16 V3.indd 45

jaw couplings for industrial equipment such as conveyors and gearboxes.

Their reliability is steadfast even under significant misalignment. Oldham couplings of various materials satisfy a multitude of demands, including vibration reduction and need for zero backlash. They also handle parallel misalignment and axial motion restriction.

Disc couplings are common for servomotor-driven setups because of their high torque transmission, capabilities under high or changing speed, and misalignment compensation.

Offset couplings let designers make machines smaller and more efficient. They can mount to shaft hubs or directly to machine flanges for shaft displacement from 0.156 to

11 • 2016

Miki Pulley CPU Pin-Type couplings damp vibration on packaging machinery. They have a pin-andbushing connection and handle angular misalignment of 4o (and parallel misalignment of 0.5 mm). Aluminum dissipates heat from adjacent sources.

Clamp-style hubs slip onto connecting shafts, and screws tighten them into place. The coupling runs to 4,000 rpm and transmits 2.2 to 25 Nm.

DESIGN WORLD — MOTION

45

11/9/16 2:42 PM

Motion System

APPLICATIONS

17.29 in. and torque capacities from 50 to 460,000 in.-lb. Here, one option is to combine zero-maintenance bearings with couplings to bolster uptime and decrease lubrication needs. Sealed bearings don’t have lube fittings, which streamlines geometry. Offset couplings work in presses, embossing systems, paper-production equipment, and pharmaceutical machinery.

Diaphragm coupling helps polymer resin pumps When a global petrochemical company had a coupling failure on a polymer pump in one of its larger resinprocessing facilities, the problem caused expensive, time-consuming production line shutdowns.

Ameridrives was asked to solve the problem and guarantee it would be the last time. Initially, gear couplings were on all polymer pumps between the gearboxes and pumps for this slow (50 rpm) and high-torque application.

Maintenance crews did their best but keeping pricey gear couplings lubricated globally proved to be hard.

This spindle uses a ROTEX GS coupling from KTR Corp. to damp vibration while connecting the toolpiece with clamping ring hubs that withstand circumferential speeds to 50 m/sec.

46

Couplings - MSCasebook 11-16 V3.indd 46

DESIGN WORLD — MOTION

11 • 2016

11/9/16 10:20 AM

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

SERVOMETER® Electrodeposited Metal Bellows

BELLOWSTECH Edge Welded Metal Bellows

Features: • Zero backlash • Thinnest high strength walls • Seamless construction • Premium alloy FlexNIckel® • Diameters as small as 0.020 in (5mm) • Highest cycle life • Design assistance for customization

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

Configure Your Couplings Online Now! servometer.com bellowstech.com

Servo.Bellows_MSHandbook9-16.indd 47

or Call 973.785.4630 And Speak With One of Our Bellows Experts

11/8/16 1:03 PM

Motion System

APPLICATIONS

WHEN SAFETY IS A REQUIREMENT 0.1-2,800 NM.

After review, the engineering team suggested swapping the gear couplings for diaphragm couplings to get a continuous running solution requiring no maintenance or lubrication (unlike the gear couplings' six-month maintenance intervals).

The Ameridrives team collaborated with industry professionals to create custom diaphragm couplings that met resin pump requirements. The custom components were delivered in several sizes and arrangements with torque ranges to 1,100,000 Nm (10,000,000 in.lb). One is a 10-ft long, 23-in. diameter coupling featuring split retaining rings on the gearbox end hubs, pump, multiple convoluted diaphragm pack flex elements at each end, and more.

An integral indexing and timing device also aligns the coupling with the mixing blades of the polymer pump.

This tabletop sample-processing machine includes an AllMotion EZServo4BLDC with on-board memory that runs commands to end effector. Notice in the red cage the servo coupling transmitting motor power to the linear axis.

WWW.RW-AMERICA.COM

48

Couplings - MSCasebook 11-16 V3.indd 48

DESIGN WORLD — MOTION

11 • 2016

11/9/16 10:21 AM

AC DRIVES

Improving energy efficiency with ac drives THE VARIETY OF AC DRIVES (including those known as variable frequency drives [VFDs]) satisfy a wide range of applications. The most common of these ac drives differ from those typical for precision motion control found in robotics, semiconductor fabrication, certain types of machining, and medical instruments to output motion to sub-mm to µm and even nm scales. That’s because common servo systems use feedback and an array of dc drives to control motor-driven axes, but the most common ac drives control induction and ac synchronous motors.

Some common applications include conveyor systems, lift and hoist machinery, grinding, fan, pump and compressor operations, and large machinery installations.

Typical ac drives run applications that need speed control, which is everything from basic functions to VFDs paired with induction motors or synchronous permanent-magnet types.

Such ac drives first convert ac to dc and then use switching techniques to vary voltage and frequency to the motor. Constant-voltage VFDs (which use pulse width modulation [PWM]) are

most common. These feed a train of dc pulses with different widths into the motor windings with a shaped current waveform.

Machine builders often use VFDs to boost energy efficiency.

Controlling current drawn by the motor can reduce energy bills because it prevents the motor from constantly running at full load. But VFDs help boost efficiency in other ways, too. With three-phase motors, they outperform single-phase induction motors (common in industrial washers and similar applications). In a similar way, VFD setups also outperform pairings of triac control with universal motors.

Applications, including vertical arrangements and those with frequent stopping and starting, benefit from regenerative braking possible with VFDs. Here, the drive’s solid-state components channel energy back into the ac mains or a braking resistor. That boosts design efficiency and lets machine axes slow down faster than they would if left to coast down.

Induction-motor-based motion designs that incorporate VFDs also avoid high in-rush currents at startup. That’s because VFDs make it so the motor’s input starts with low voltage and frequency. There’s also less mechanical wear, as eliminating startup in-rush currents prevents excessive torque and renders throttles, dampers and louvers unnecessary.

Regardless of the application, all ac drives must meet key parameters, including the power-supply configuration and input voltage (and whether the frequency is 50 or 60 Hz). Compatibility with the motor’s voltage,

The functions and power of the range of i500 frequency inverters can be tailored to virtually any machine application and industrial environment. Compliant with efficiency class IE2, Lenze i500 inverters feature a slim design and peak energy efficiency in the 0.33 to 60 hp (0.25 to 45 kW) power range.

motioncontroltips.com | designworldonline.com

AC Drives - MSCasebook 11-16 V1.indd 49

11 • 2016

DESIGN WORLD — MOTION

49

11/7/16 4:03 PM

APPLICATIONS

Motion System

current rating and horsepower, as well as what speed control the application needs (closed-loop vector, open-loop vector or volts/Hz), are other considerations. Note that VFDs can introduce harmonic distortion, which degrades power quality and machine performance. However, newer VFDs address this issue.

Also, many common ac-drive applications benefit from ac drives that deliver safety features (brake controls and stops, for example) and acceleration or speed monitoring and limiting.

Environmental factors may also be a consideration.

For instance, in some cases ac drives must withstand exposure to dust, extreme temperature and humidity. Here, drives with rated enclosures (NEMA 1 or NEMA 12 ventilated, for example) may be required.

Drive/motor combo cuts extruder energy usage by 9% Recently, Emerson Industrial Automation was able to help Stål & Plast, a Danish extrusion specialist, improve its production processes by replacing three worn-out dc electric motors with Dyneo PM motors and a Unidrive M variable speed drive at the company’s extruder plant.

Stål & Plast A/S of Denmark manufactures bench tray systems used in greenhouses and nurseries worldwide. The tray systems are manufactured on a fully automated vacuum forming machine. The raw plates are manufactured at a co-extrusion plant operated by three extruder motors, one 175-kW motor and two 71-kW motors.

The heart of the new drive/ motor combination is a Control Techniques Unidrive M700 variable speed drive, which helps reduce annual energy consumption by 9%.

Stål & Plast A/S manufactures its tray systems using high-impact polystyrene on modern fully automated vacuum forming machines.

50

DESIGN WORLD — MOTION

AC Drives - MSCasebook 11-16 V1.indd 50

The extruder plant’s three worn-out dc motors were due for extensive reconditioning or alternatively an expensive and time-consuming replacement, as new dc motors would have to be made to order.

Jacob Braa Sørensen, managing director of Stål & Plast, in consultation with Emerson Industrial Automation, decided to upgrade the extruder plant by purchasing highly efficient Dyneo PM motors from Leroy Somer, which are controlled by a Control Techniques Unidrive M700 variable speed drive.

The replacement involved collaboration with service partners Lindpro as the professional installer and automation provider for the project, and Ølgod Elektro, which routinely handled commissioning and running-in.

For Stål & Plast A/S, the main reason for choosing a motor technology with permanent magnets was, first of all, the long-term energy savings on power consumption but also the higher operating torque, the operational reliability of PM technology and the low maintenance costs compared with dc technology.

Calculations showed that Stål & Plast could reduce the annual energy consumption of the three motors by an average of 9%. The extruder accounts for 75% of the plant’s total energy costs, of which most is consumed by the extruder motors.

Over a period of 10 years, 95% of the total costs of an electric motor are directly attributable to the energy consumption, whereas the purchase price and the maintenance costs represent as little as 5% of the total costs of the investment.

11 • 2016

motioncontroltips.com | designworldonline.com

11/7/16 4:09 PM

READY FOR THE NEXT REVOLUTION?

Sigma-7 Unshackles Automation Productivity Planning innovations for years to come, or are you more focused on next week’s productivity numbers?

Either way, Yaskawa’s new Sigma-7 servo systems help you break free of yesterday’s standards. From the first spin of the rotor, Sigma-7 boosts precision and productivity. Yet its programming ease and performance make tomorrow’s automation ideas possible.

Don’t stay chained to legacy servo capability. Crank up to Sigma-7 the servo for the Next Revolution.

For more info: http://budurl.me/YAI929

YASKAWA AMERICA

Yaskawa_MSHandbook9-16.indd 51

DRIVES & MOTION DIVISION

YASKAWA.COM

1-800-YASKAWA

11/8/16 1:05 PM

APPLICATIONS

Motion System

Applications for dc drives DESIGNS BASED ON DC DRIVES excel in an array of industries. That’s because some applications benefit from dc drives and the distinct characteristics they offer—including simple speed control, cost-effective integration, and long life. Common dc-drive applications include the movement of axes on wire-drawing machinery, hoists and elevators, paper-web handing, extruding applications, spindle drives, and material handling.

Machines that use dc drives paired with brush motors for speed control incorporate a silicon controlled rectifier (SCR) for power conversion. This SCR or thyristor converts ac power input to adjustable-voltage output that goes to the motor armature. SCRs provide controllable power output by phase angle control, so called because the firing angle synchronizes with the ac source’s phase rotation.

Brushless dc motors paired with dc drives offer an alternative to conventional dc drives and ac inverters, marketed as dc-drive replacements. Of course, brushless dc motors have windings on the stator and permanent magnets on the rotor; rotor-position feedback from an encoder or Hall-effect sensors send speed information back to a controller as a way to facilitate adjustment of electronic commutation on the fly.

Chips for driving dc motors from Texas Instruments such as the 9 x 9-mm DRV8305-Q1 are available in a 48-pin thermally enhanced thin-quad flat pack (HTQFP) package, while the UCC27211A-Q1 is available in an eight-pin small outline integrated circuit (SOIC) package.

The advantages of dc drives include the ones just mentioned and wide speed ranges, good speed regulation, and starting and accelerating torques that exceed rated torque by 400% or more. Matching a dc drive to a given application ultimately depends on the application’s starting torque. Other relevant factors include input power factor, the need for dynamic braking, speed regulation, range, and need for high speed, and conduciveness to energy regeneration.

Drives for dc motors also come in chip-level packaging for placement on circuit boards. For example, two new motor drivers from Texas Instruments (TI) are specifically designed for automotive applications such as driving dc motors in various systems such as fans and pumps. They’re part of a growing trend toward smaller, more compact dc motor drivers designed to accommodate the growing number of applications for small dc motors.

The motor drivers support high-performance powertrain applications. The DRV8305-Q1, an integrated three-phase brushless DC gate driver, and the UCC27211A-Q1, a high-current half-bridge gate driver, improve system performance and provide design flexibility to meet a diverse range of automotive system requirements.

For powertrain applications such as transmission pumps or engine cooling fans, the DRV8305-Q1 features a smart gate-drive architecture with programmable slewrate control that allows easy optimization. It operates down to 4.4 V to support start-stop functionality, which lets car manufacturers meet strict fuel efficiency and carbon-dioxide emission standards. Also, an integrated 3.3-V or 5-V linear regulator, three currentsense amplifiers and smart gate-drive architecture reduce board size and eliminate up to 20 external components. Advanced on-chip protection with detailed fault diagnostics guard against overtemperature, undervoltage lockout, MOSFET shoot-through and overcurrent events.

The 100-V UCC27211A-Q1 half-bridge gate driver supports both brushed and brushless dc motor applications. The half-bridge design means gate drivers can be placed closer to the MOSFETs, minimizing parasitic inductances and simplifying overall board layout. It features a fast propagation delay of 15 nsec, rise and fall times of 7 nsec and a 4-A peak gate drive. A negative voltage rating of -12 V also protects the driver from potentially damaging voltage spikes.

52

DC Drives - MSCasebook 11-16 V1.indd 52

DESIGN WORLD — MOTION

11 • 2016

11/8/16 11:44 AM

ENCODERS

Encoders with Profinet interface from Posital Fraba play a key role in an upgraded automotive production line.

Encoders in motion applications

A workstation on an automotive production line shows the updated equipment including PLCs and HMIs which helped increase production.

THERE ARE AS MANY ENCODER CHOICES as there are design objectives. When encoders provide position feedback, it’s common to specify encoder resolution exceeding what the application requires as a way to address the partial count uncertainty of digital measurements.

Heavy industrial equipment for metal stamping, wind turbines, printing, and steel processing often uses high-speed rotary encoders that can reliably track speed and position even to 40,000 rpm. Other applications benefit from reflective encoders with interpolation for high-resolution measurement on small motors (usually closed-loop steppers) that drive axes on consumer products such as printers.

Other machines need rugged and rated encoders with oversized bearings, specialty seals, and reinforced housings. Industrial-rated encoders work in interior elevators, automated process machinery, and robot joints. In contrast, applications that expose encoders to liquid submersion, washdown, contaminants, shock and vibration, or EMI noise necessitate more rugged versions. These applications include those for off-road equipment, cranes, wind turbines, food-and-beverage machinery, and medical devices. Usually, it’s either the failure of the encoder’s bearing (in the case of rotary setups) or contamination and signal failure that takes the encoder out of commission. For example, wood processing tends to be dusty, while food applications and their cleaning cycles tend to be steamy and force humidity inside encoder housings.

In applications where the design must track position along a linear axis, linear encoders excel. Machine tools make copious use of linear encoders, especially for the manufacture of aerospace parts needing milling and finishing. motioncontroltips.com | designworldonline.com

Encoders - MSCasebook 11-16 V4.indd 53

11 • 2016

DESIGN WORLD — MOTION

53

11/9/16 3:39 PM

APPLICATIONS

Motion System

Bringing production lines up to speed One industry that undergoes frequent changes is the automotive industry, as carmakers must respond to evolving customer preferences and regulatory requirements. That means regular upgrades to their production facilities as well.

One U.S. automaker recently decided to retool a Michigan engine plant for a new production program and update an automation system controlling equipment on the shop floor. The automaker hired Canadian integrator DataRealm Inc. to design and implement a new solution.

The project included new IT interfaces, new PLCs, updated human-machine interfaces (HMI), new data communications and upgrades to sensors and actuators. The integrator was also responsible for programming and traceability.

The plant was once state-of-the-art with PLCs close to machinery they controlled and some units protected with IP67-rated housings. Communication between controllers and sensors and actuators was through a proprietary networking system. The integrators decided more powerful PLCs and new networking were needed.

The plant upgrade first saw IP67-rated PLCs from Phoenix Contact and an INTERBUS fieldbus network. Current upgrades include the installation of a PROFINET data communications network. PROFINET, a form of industrial Ethernet, will enhance system support of an unlimited smart devices (sensors and actuators) and communication with higher-level manufacturing management systems.

New encoders for the system had to deliver accuracy, reliability, and compatibility with the upgraded communications networks, plus compactness and IP67 ratings or better for installation on existing machinery.

POSITAL IXARC absolute rotary encoders met the requirements.

“POSITAL had products that met our specs and supplied adaptor plates that simplified swapping out the old sensors,” said Dave Fortin, President of DataRealm.

The availability of POSITAL encoders with both INTERBUS and PROFINET communication interfaces was another advantage.

The plant is successfully up and running with the new production program and the supporting automation system. In fact, it has emerged as the most productive plant of its type in the company.

Encoders help align telescopes doing dark energy research Another application relies on encoders for rotary and linear position feedback to precisely position a telescope’s optical system. HEIDENHAIN encoders work in the Hobby Eberly Telescope (HET) to help researchers study dark energy. In place at the University of Texas-Austin at the McDonald Observatory, this telescope will fill in the gap of reaching longer distances in the sky than currently possible.

Rho Rotary Encoder x6

Upper X Encoder

Hexapod Rotary Encoder x6

Two encoders from HEIDENHAIN go in the Hobby Eberly Telescope. The LB 382 linear scale is a reliable incremental-type steel tape scale with a grating period of 40 µm and accuracy of 5 µm. The EQN 437 is a multi-turn rotary encoder with integral bearings that boasts accuracy of ±20 arc-min.

Y Encoder

Lower X Encoder

54

DESIGN WORLD — MOTION

Encoders - MSCasebook 11-16 V4.indd 54

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 11:13 AM

Innovative Sensor Technology

Pulses for Automation Made possible by Kübler

LINEAR MEASUREMENT

COUNTERS AND PROCESS

FUNCTIONAL SAFETY

INCLINOMETERS

ROTARY ENCODERS

BEARINGLESS ENCODERS

SLIP RINGS

SOLUTIONS FOR INDUSTRIES WIND

ELEVATOR

Kübler Group Kuebler Inc. 10430-J Harris Oaks Boulevard Charlotte, NC 28269

MOBILE

MOTOR

SOLAR

STEEL

PACKAGING

CRANE

Tel +1 704 705 4710 Toll free +1 855 KUEBLER usa@kuebler.com

www.kuebler.com/usa Kuebler Motion Casebook 11-16.indd 55

11/9/16 4:01 PM

APPLICATIONS

Motion System

Dark energy is currently understood to be a mysterious force pushing the universe apart. Called cosmic acceleration, the gravitational dark energy force is pushing instead of pulling. The HET (operational since the 1990s) began upgrades in 2013 and should soon offer more insight into dark energy. Nearly-completed equipment at the top of the HET consists of a new optical system and spectrographs. Three HEIDENHAIN linear scales are part of the new optical system’s tracker, and six of the company’s rotary encoders are affixed to an adjoining six-leg hexapod on top of the HET. “HEIDENHAIN encoders give accurate position measurement on the HET,” said Herman Kriel, HET Project Manager. “This telescope is different from conventional ones, as it does not move. Instead a tracker atop the telescope moves and aligns with a mirror, so must be extremely accurate.”

The new optical system has six axes of freedom and moves some of the optics up and down to focus the telescope and in tip and tilt to keep it aligned with the primary mirror.

The rotation stage on top of the hexapod compensates for image rotation during tracks. Using HEIDENHAIN’s three LB 382 linear scales on the X and Y stages and eight EQN 437 rotary encoders on the hexapod and rotation stage, the HET tracker will move ±1.8 m in X and Y directions relative to the mirror, for a total travel of 3.6 m, and ±9.5 ˚ in tip and tilt and ±21.5 ˚ in rotation.

The HET (Hobby Eberly Telescope) at the University of Texas-Austin at the McDonald Observatory will help scientists uncover the secrets of dark energy.

The PROGRAMMABLE Size 25 shaft encoder that goes ANYWHERE Program your CPR, output, and waveform on-site!

EPC’s new Model 25SP Accu-CoderPro™ is the only Size 25 Shaft Encoder you’ll need. You’ll save time and money, and reduce your inventory, by keeping these on your shelf.

With the easy-to-use interface, you can program these specs on-site: CPR – any resolution from 1 to 65,536 Waveform – choose from 32 different waveforms Output type – 6 output options Designed for an industrial environment, the Model 25SP can operate in temperatures from -40º to 100º C, comes standard with dual bearings rated 80lbs axial or radial, and offers sealing up to IP67.

Call EPC today to learn how the Model 25SP can be your encoder solution.

1-800-366-5412 • www.encoder.com

Encoders - MSCasebook 11-16 V4.indd 56

11/9/16 11:14 AM

GEARING Shown here is a Big Ass Fan that incorporates a NitroSeal gearbox from STÖBER Drives. It pairs with a 1-to-2-hp motor run off a VFD to output airfoil speeds from 62 to 197 rpm.

Gearsets in action: Real-world uses

motioncontroltips.com | designworldonline.com

Gearing - MSCasebook 11-16 V3.indd 57

GEARS FUNCTION in an array of powertransmission applications. They are the natural complement to electric motors in industrial and consumer designs. Consider some examples: Amusement rides to consumer-grade home printers make use of spur gears. These roll through meshing for up to 98% or higher efficiency per reduction. The only caveat is that they exhibit tooth sliding and noise due to initial tooth-to-tooth contact and audible shock loads.

Helical gear reducers are costlier than spur sets, but work in designs needing high horsepower and efficiency. Textile machinery, conveyor drives, rolling mills, and elevators all use helical gearing to engage gradually over tooth faces for smooth operation and high load capacity. The only caveat is that the machine setup must include framing or supports to resolve thrust loads originating from the gears.

11 • 2016

DESIGN WORLD — MOTION

57

11/9/16 10:43 AM

APPLICATIONS

Motion System

Non-parallel and right-angle gears go into motion applications for material handling, aerospace and defense, packaging equipment and food-processing machinery. Input and output shafts protrude in different directions; gear teeth are worm, hypoid, bevel (straight, spiral or zerol), skew or crossed-axis helical. Common bevel gearsets often go into material-handling and packaging equipment.

Hypoid gears (useful for high-toque applications) are like spiral-bevel gearsets, but output and input shaft axes don’t intersect — and that simplifies integration of supports. Common in aerospace, zerol gearsets have curved teeth that align with the shaft to minimize thrust.

Speed reducers work with an array of motors.

These gearsets alter the torque of a motor—usually as an increase proportional to rpm reduction. Common in material-handling setups, shaft-mounted gear reducers come in designs that use special couplings to address reactionary torque. Other shaft-mounted reducers actually mount to the machine housing (especially in machine setups with surrounding enclosures) so the input shaft doesn’t support the reducer.

The American Gear Manufacturers Association (AGMA) defines the term speed reducer as sets with pitch-line velocities not exceeding 5,000 fpm or pinion speeds not exceeding 3,600 rpm.

Consider worm-gear reducers. These typically go into low to moderate-horsepower motion applications because they have high ratios and output torque, but are cost effective and compact. Most worm gears are cylindrical with teeth of consistent size; some wormbased reducers have double-enveloping tooth geometry (in which pitch diameter is deep and short and then deep again) to boost tooth engagement.

Metal cutting and forming machinery, construction equipment, and packaging machinery all benefit from the low backlash of this gearing type. To illustrate, printingpress rolls hold tight print registration at high speeds thanks to the ability of doubleenveloping worm gearing to withstand shock and extreme acceleration. The gearing’s low

Shown here is a Makita angle grinder.

The corded 9556NB model uses an 840-W brush motor that takes 220 Vac input. The gear housing can rotate to suit different cutting and grinding applications.

58

DESIGN WORLD — MOTION

Gearing - MSCasebook 11-16 V3.indd 58

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 10:43 AM

Call us: NC Facility 980-299-9800 Neugart Motion Casebook 11-16 .indd 59

11/8/16 1:09 PM

APPLICATIONS

Motion System

inertia also lets presses start and stop more quickly than those with multi-stage gearing.

Gearheads, much like gear reducers, are useful where applications call for high torque at low speed. They reduce a load’s reflected mass inertia, so ease the acceleration of big loads ... which in some cases, even lets machines run off smaller motors. Gearheads range from basic spur gearheads to complex planetary gearheads and harmonic gearheads, all exceling in select applications.

The latter (also called strain-wave gearing) is for special speed-reduction applications.

This gearing excels in robot-arm articulation, medical equipment, and offshore drilling.

(Strain-wave gearing sets are called Harmonic Drives, a registered trademark term of Harmonic Drive Systems.) Strain-wave gearing helps designs with zero backlash and high torque density.

Much machinery integrates servogears into application-specific electromechanical arrangements, and several of these arrangements are common enough to have their own labels. Gearmotors (most useful in machines that move heavy loads) include a

The Abrasive Power Tool Division of Suhner Industrial Products sells Rotomax hand tools for grinding, cutting, roughing, descaling, and polishing. The tools use gearing paired with single-phase ac motors with overload isolation and soft starting; IP45 protection; and active braking. The 2.0-to-4.7-hp flexible-shaft tool here has interchangeable attachments to work as an angle grinder, straight grinder, drum polisher, belt sander, tube polisher or die grinder. It runs at 500 to 15,000 rpm for applications in industrial steel fabrication, polishing, sheet-metal assembly, food processing, and appliance manufacturing.

60

Gearing - MSCasebook 11-16 V3.indd 60

DESIGN WORLD — MOTION

11 • 2016

11/9/16 10:44 AM

Small Size.

Big Performance.

The SPH Flange Gearbox is small in size, but achieves great performance due to a rigid housing, supported planet carrier, high precision gears, and optimized taper roller bearings. It is produced to the elevated standard of quality and reliability customers have come to expect from GAM’s high-performance SPH product line.

Toll Free 888.GAM.7117 | www.gamweb.com | info@gamweb.com

OTHER SPH PRODUCTS:

SPH-W

901 E. Business Center Drive, Mount Prospect, IL 60056

GAM_MSHandbook9-16.indd 61 16_GAM_026_Ad_H.indd 1

SPH-K

SPH-C

© 2016 GAM. ALL RIGHTS RESERVED

11/8/16 1:10 PM 5/16/16 12:37 PM

APPLICATIONS

Motion System

gear reducer integrated with an ac or dc electric motor. Gearboxes are contained gear trains; planetary gears are a common form. Planetary gears often go in servo systems. Usually, the planet gears mount on a movable arm that rotates relative to a sun gear. In most applications, an outer annulus meshes with planet gears.

Planetary gearsets offer applications advantages over other gearsets, including multiple kinematic combinations, power density, big reductions from compact setups, and pure torsional reactions. Planetary gearboxes also boost overall design efficiency. Losses never exceed 3% per stage, so the sets transmit most energy for productive motion output.

In applications driven by servo systems, gearboxes also reduce settling time (which is a problem when load inertia is high compared to motor inertia).

Application brief: Gearboxes in electric vehicles Electric adventure vehicles (EAVs) need light transmission components but lots of torque. So EAV maker Outrider USA recently sourced Neugart planetary gearboxes to get just that. Outrider makes several versions of an Alpha bike (for everyday use on gravel roads and streets) and a Horizon for offroad cycling. Each model has a drive to output 1 to 4 kWh. For high-speed road applications, Outrider chose a single-stage Neugart PLQE 60-mm gearbox with a 5:1 gear ratio. EAVs for lower-speed applications have a two-stage version with a 15:1 gear ratio.

Outrider briefly considered a two-stage belt drive, but this didn’t provide necessary reduction — and a three-stage belt drive would’ve taken up almost triple the space of the PLQE planetary gearbox.

One of the biggest challenges Outrider engineers had was finding a gearbox with enough torque density at 13,000 rpm. EAVs use performance motors, so the gearboxes had to meet output rpm and torque requirements. Smaller gearboxes can handle high speeds but not torque. In contrast, the PLQE 60 has

This Outrider electric adventure vehicle (EAV) is the Alpha for everyday use on gravel roads and streets. It uses a Neugart gearbox for high speed and torque density.

62

DESIGN WORLD — MOTION

Gearing - MSCasebook 11-16 V3.indd 62

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 10:45 AM

GEARMOTORS

FOR MORE DETAILS AND RESOURCES VISIT OUR WEBSITE AT WWW.GROSCHOPP.COM

712.722.4135 • 712.722.1445 (fax) • 420 15th St. NE, Sioux Center, IA 51250 USA • Registered ISO 9001:2008

Groschopp Motion Casebook 11-16.indd 63

COPYRIGHT © 2016 | DWGRMTR0716

11/8/16 1:11 PM

APPLICATIONS

Motion System

up to six planets for higher torque density in a given frame size than comparable gearboxes. The gearbox also accepts overloading to boost speeds and torque. Gearboxes in this size have a regular torque rating of 40 Nm. The PLQE 60 gearbox weighs about two pounds, so keeps drive weight low. In fact, the Outrider’s power-dense drive outputs about 5.5 hp out of a 7-lb package. Plus the PLQE 60 doesn’t need an adaptor, as it comes with a direct motor attachment for connecting to the EAV motor. That keeps the design footprint to a minimum. PLQE 60 millimeter gearboxes are (in a single stage) 97% efficient. Double-stage versions are 94% efficient.

For high-speed road applications, the singlestage version of the Neugart PLQE 60-mm gearbox excels. Designs for slower EAVs use a two-stage version with a 15:1 gear ratio.

DieQua has more Gearhead Solutions Different Technologies Provide Different Benefits

Are You Selecting The Correct Technology For Your Motion Profile?

Whether your application requires dynamic acceleration, precise positioning or simple motion control, several gear technologies can do the job. But which one does it best?

Planetary Designs

Precision Worm

Spiral Bevel

High Torque Helical

Precision Hypoid

Precision Cycloidal

Only DieQua offers you the widest range of servo motor gearhead designs, along with the experience and expertise to help select the optimal solution to satisfy your needs.

If you are specifying servo gearheads, you should be talking to DieQua!

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

64

DESIGN WORLD — MOTION

Gearing - MSCasebook 11-16 V3.indd 64

630-980-1133 10/25/16 9:20 AM

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 10:45 AM

Design World.indd 1 Harmonic Drive Motion Casebook 11-16.indd 65

9/21/16 8:16 AM 11/8/16 1:12 PM

APPLICATIONS

Motion System

Low-power applications benefit from gearmotors

66

APPLICATIONS THAT REQUIRE a lot of force to move heavy loads are the most common for gearmotors. Most industrial gearmotors incorporate fixed-speed ac motors. However, some gearmotors use dc motors, which are common in automotive applications, among others.

It’s possible to combine many different motors and gearsets. However, not just any one will work for every application because certain combinations are more efficient and cost-effective than others. This is why knowing the application and getting an accurate estimation of its required torque and operating speed is the foundation for successfully integrating a gearmotor into a system.

Gearmotors typically outperform other motorgear combinations. More importantly, gearmotors simplify design implementation because they save engineers from having to integrate motors with gears, which in turn reduces engineering costs. If the application requirements are known, engineers can order the right gearmotor directly from a supplier.

If a gearmotor is sized properly, having the right combination of motor and gearing can prolong design life and boost overall design efficiency. Gearmotors can also eliminate the need for couplings and potential alignment problems that come with those components. Such problems are common when a design includes the connection of a separate motor and gear reducer, which in turn increases the potential for misalignment and bearing failure.

As applications for gearmotors expand, manufacturers are seeing a change in expectations from end users. For instance, end users have an increased expectation for more integrated designs. Meanwhile, other companies have found that the design requests they’re receiving are becoming more complex, requiring more customization and creative thinking.

DESIGN WORLD — MOTION

Gearmotors - MSCasebook 11-16 V1.indd 66

11 • 2016

The Sinamics G110M from Siemens is a motor-integrated drive for Simogear gearmotors that is particularly well suited for material handling applications. It features IP66 protection as well as integral USS/Modbus RTU, Profibus and Profinet / EtherNet/IP communication profiles. Options like internal braking resistors and motor brakes and integrated features such as “Quick Stop” and a limit switch function are especially useful in conveyor applications.

The Hilti TE 1000-AVR rock breaker is a concrete-breaking power tool for professional demolition work. It incorporates a brushless switched-reluctance (SR) motor that, through a precision gearset, rocks a hammer piston for top power with minimum weight.

motioncontroltips.com | designworldonline.com

11/9/16 11:36 AM

GRIPPERS

Applications for end effectors and grippers ROBOTICS AND MATERIAL-HANDLING DESIGNS use end effectors — tools or devices connected to the end of a robot arm. End effectors can include cutting tools and drills, welding tools, brushes, screwdrivers, vacuum cups and grippers.

Grippers in robotics pick or place objects on assembly lines, conveyors, or other automated systems. Three common gripper types are parallel, three-finger and angled setups. Parallel designs with two fingers are most common. They close on workpieces or open to grip from within. Three-finger designs have three fingers offset by 120° to hold workpieces in a secure clasp. Angled robotic grippers feature jaws that work at

different angle openings. Other grippers that don’t fall into neat categories include magnetic grippers, single-jaw grippers, and bladder grippers that inflate around parts. (Refer to the section in this Casebook on pneumatic actuators for more information.)

Ultimately the workpiece size, force, and shape dictate the most suitable gripper style. End effectors and grippers usually run off pneumatic or electric power; hydraulic setups are rare.

Pneumatic grippers dominate industrial-assembly and robotic applications, as they’re reliable and grip quickly.

Electromechanical grippers use ballscrews, belts or racks and pinions to connect to the jaw or finger that is touching or gripping the part.

Here a Universal Robots setup uses grippers mounted on P/N 1530 T-slot aluminum profile from 80/20 Inc.

motioncontroltips.com | designworldonline.com

Grippers - MSCasebook 11-16 V3.indd 67

11 • 2016

DESIGN WORLD — MOTION

67

11/9/16 11:46 AM

Motion System

APPLICATIONS

ATI Industrial Automation’s Robotic Tool Changers are used in Electroimpact’s new method of automated carbon fiber assembly. Mounted in the head of the end-effector, ATI’s Tool Changers allow it to detach and replace with identical ones loaded with different tools. This lets the system efficiently change over jobs, allowing engineers to dream up dynamic options and enable quick implementation.

They run off a motor for tasks like loading and unloading machines to assembly lines. They can grip small parts such as IC chips or large items such as railroad-wheel assemblies of 3,000 lb or more. They’re suitable where applications need tight precision or lifting of heavy items. Normally, electromechanical grippers are aluminum and steel, though some are of carbon fiber and plastics.

A big driver of robotics and industrial gripper innovation is the automotive industry. Here, grippers operate at various stages of the manufacturing process (from painting to final assembly) to manipulate parts and panels.

Besides the automotive industry, another spurring changes in robotic gripper design is electronics, especially for consumer products. That’s because manufacturers must adapt quickly, with product lifecycles shorter than ever. For non-industrial applications, a growing area of specialized devices are prosthetic grippers. These grippers are by far the most sophisticated, with designs aiming to replicate the movement and functionality of a human hand.

Seeing is believing

UV CURABLE ADHESIVE UVLV Ideal for spin coating Low viscosity

70-120 cps The SCHUNK TENDO Platinum toolholder is easy to use but maintains precision for milling, drilling, and reaming applications. It’s made with tool steel and a brazing and hardening process to stay rigid and durable. Vibration damping and runout accuracy of less than 0.003 mm at 2.5 x clamping diameter helps the tool holder work with machine spindle and cutting tool to reduce wear and damage.

Outstanding optical clarity

Refractive Index 1.517

Thermally stable

Tg of 120°C Very low shrinkage upon cure

1-2%

Hackensack, NJ 07601 USA ∙ +1.201.343.8983 ∙ main@masterbond.com www.masterbond.com 68

Grippers - MSCasebook 11-16 V3.indd 68

DESIGN WORLD — MOTION

11 • 2016

11/9/16 11:48 AM

HMI HARDWARE

Human-machine interfaces — New uses for hardware HUMAN-MACHINE INTERFACES (HMIs) are spreading because multitouch screens are more cost effective than ever. There’s also been a shift from resistive to projected-capacitive displays and from proprietary to open HTML5 platforms. Industrial HMIs often incorporate capacitive displays because they’re fast. Many have bezel-free designs, so also help machinery meet cleanliness requirements in food and beverage and medical equipment.

What’s more, HMIs with capacitive displays have multi-touch capabilities that make industrial displays feel more like personal mobile devices, helping machine builders leverage familiarity many users already have with such interfaces.

Consumer-device design is spurring industrial-HMI innovation. In fact, the wireless communications, large displays, and significant processing power of today’s smartphones and tablets mean that they can function as HMIs in some applications.

Manufacturing today demands regular machine upgrades or changeover from one manufacturing operation to another.

Here, modular HMI hardware lets users make on-the-fly changes to machine operations to keep pace with varied production requirements. High-tech industries such as pharmaceutical and medical often incorporate the latest HMIs to differentiate builds in the marketplace. OEMs of such machines increasingly look to add features such as multitouch panels.

Application in food and beverage: Stainless HMI bodies Kilian Tableting of the Romaco Group recently saw an increase in sales thanks in part to its new KTP420X rotary tablet press. The machine incorporates a 21.5-in. hygienic stainless-steel HMI — a B&R Automation Panel with an Automation PC 910 and dual-core i7 processor. The HMI has hard buttons (not virtual ones on the screen) for key functions.

“We stopped using virtual keys for heavily used functions because of visible wear on our previous system,” said Kilian’s CTO Jens Carstens. “Unlike virtual keys, the hardware keys also provide tactile feedback to let operators keep their eye on the machine when working in jog mode.”

The HMI works well in pharmaceutical and food and beverage industries. Kilian programmed it to accept gesture controls ... even swiping gestures that are demanding on

motioncontroltips.com | designworldonline.com

HMI Hardware - MSCasebook 11-16 V2.LE.indd 69

computing and graphics. The volume of data produced by the tablet press puts heavy data load on the HMI. More specifically, the KTP420X can output 360,000 tablets per hour, and controls monitor, record, and display maximum pressing force for all of them in real time for quality assurance. The variety of configurations (including test sampling methods) makes the data-load larger. Fortunately, the HMI’s Automation Panel 900 communicates with the PC 910 via SDL3 for minimal latency. Applications and data run off a high-speed 128 GB solid-state drive, and Kilian uses an OPC interface between the control and HMI applications to simplify integration.

A new Kilian rotary tablet press includes an HMI display and illuminated ring keys to satisfy cleanliness standards. The B&R HMI has gesture control and an Automation PC 910 with a dual-core i7 processor and Automation Panel.

11 • 2016

DESIGN WORLD — MOTION

69

11/9/16 11:51 AM

Powerful Control Solutions for Any Industry Does your automation process require specific capabilities and customization?

8 Versatile Sizes: 7” – 21.5”

Maple’s OMI6000 Light Industrial Panel PC line offers powerful performance at excellent prices.

These modern, rugged units provide greater access and better control over your data.

Cast Aluminum Bezel and Chassis

Fast Dual-Core/Quad-Core Processors Windows OS and Data Storage Options IIoT and SCADA Software Ready

Take Your Industrial Control Further.

Your Industrial Control Solution www.maplesystems.com | 425.745.3229

Maple Systems Motion Casebook 11-16.indd 70

11/8/16 1:13 PM

HMI SOFTWARE

HMI software enabling new designs HUMAN MACHINE INTERFACE (HMI) SOFTWARE runs on HMI hardware to give machine operators a way to interact with and manage machine functions through a graphical user interface (GUI). Communication is to supervisory and machine-level functions.

Development of this software can be expensive upfront but ultimately lower long-term costs and redundancies.

Applications for HMIs dictate which software features are relevant. Some machines demand data collection and logging; others require that HMI software is programmed to show operators system parameters. Other pieces of HMI software to go on equipment with lots of changeovers are setup to let programmers or plant personnel switch modes on the fly. Choosing the right HMI software for an application starts with analysis of machine specifications — including system architecture, performance requirements, integration and cost of procurement and operations.

Most HMIs display data through the GUI. Some advanced HMIs even let operators view diagrams, photos, and system schematics.

For motion-control applications, visual GUIs can be simple text displays or color monitors with touchscreens. High-performance HMIs are usually custom to operator requirements.

Standard HMIs are common on setups that are less intensive.

Some HMI software works with portable platforms such as the Microsoft Windows CE, a scalable version of the Windows operating system for handheld devices. This trims cost, as the operating systems are distributed on machine-level embedded HMI, solid-state open HMI machines, distributed HMI servers and portable HMI devices. Also, some applications, such as pharmaceutical and medical machinery, use the latest HMI features to differentiate themselves from competitive offerings.

motioncontroltips.com | designworldonline.com

HMI Software - MSCasebook 11-16 V2.LE.indd 71

Case study of HMI use: HMI helps simplify blown-film production A manufacturer needing more flexible temperature control zones on its extrusion systems recently turned to Hosokawa Alpine American for upgrades. Now the machnes have real-time monitoring and allow on-the-fly adjustment of conditions.

Alpine, maker of blown-film extrusion setups for the plastics industry, supplied a new 9-Layer X-Die line system that delivers complete zone temperature control; remote I/O; and a touchscreen HMI to give operators in-process control and monitoring.

The HMI helps with componentfailure analysis, system-fault detection, and control of 120 separate zones. Typical systems allow for a 2 to 3° F variation, but the new machine keeps that to within 1° F. Plus an industrial flat panel on the PC has a wider screen for easy viewing; an auto-tune function and better CPU in the PLC boosts performance. Using a Siemens protocol again meant no significant software conversion was needed, and all data feeds are on Profinet.

Quick-connect I/O hardware reduces installation, commissioning and replacement time of hardware.

An open control architecture allows end-user adjustment of parameters to suit various applications and recipes. In addition, the Alpine team routinely customizes the frontend of the controller HMI for easier customer training and seamless transitions from legacy systems.

11 • 2016

This Hosokawa Alpine American blown-film machine is the X-Die. It has a Siemens motor and drive assembly as well as a PLC and HMI to control processing and recipe changes. Tight zone regulation boosts output film consistency.

DESIGN WORLD — MOTION

71

11/9/16 11:54 AM

APPLICATIONS

Motion System

Leadscrews: motion system mainstays AMONG THE METHODS AVAILABLE FOR CONVERTING ROTARY MOTION TO LINEAR, leadscrews are a mainstay. A leadscrew, or power screw, is a threaded rod or bar that translates rotational motion into linear motion. Leadscrews generate sliding rather than rolling friction between a nut and the screw. Consequently, higher friction means a lower overall efficiency. And efficiency, when talking about leadscrews, is simply the ability to convert torque to thrust while minimizing mechanical losses.

Many motion designs incorporate leadscrews, driving axes on machines big and small. They usually sport higher ratings than comparable ballscrews thanks to more contact between the nut and screw load surfaces. Recently, innovations in materials and helix geometry address old issues associated with leadscrew friction, bringing it down to better than 0.10 in some cases; making them a good fit for fast and dynamic applications. In fact, there’s also been an uptick in leadscrew use in machines for 3D printing, manufacturing and medical applications.

A host of different industries are adopting new leadscrew components and linear systems. Designers of kiosk and automated retail applications, for instance, are looking for ways to simplify machines, reduce design weight and simplify assembly and maintenance. In a similar way, both additive manufacturing (3D printing) and traditional subtractive processes (plasma cutter, laser and waterjet manufacturing) are driving new leadscrew uses. The same holds true for factory automation.

On this Roland MPX-90M direct part marking machine, an adjustable X-Y table holds flat and oddly-shaped parts. Leadscrews drive the marking head over the part during engraving.

72

DESIGN WORLD — MOTION

Leadscrews - MSCasebook 11-16 V2.indd 72

11 • 2016

Choosing the right leadscrew for a linear motion application involves several considerations including screw pitch and lead, thrust, speed, accuracy and repeatability.

The two most important factors in determining the performance of a leadscrew are the screw pitch and lead. The pitch is the linear distance between the threads, while the lead is the linear distance the nut travels. Speed is another critical parameter.

Leadscrews have a critical velocity, which is the rotational velocity limit of the screw. Reaching this limit induces vibrations in the leadscrew.

Accuracy and repeatability are also important factors to consider. The accuracy of a leadscrew is a measure of how close to a desired end point the assembly can move a load to within a given tolerance.

The accuracy of the leadscrew will mostly determine the system’s accuracy. On the other hand, repeatability is a measure of how well a leadscrew assembly can repeatedly move a load to the same position.

When it comes to the kinds of leadscrews engineers are specifying in their designs, there are clearly more integrated or pre-engineered systems being used. Choosing these types of systems can reduce engineering costs as well as design time.

One example of a leadscrew design in a medical application is a part-marking device from Roland.

The MPX-90M direct part-marking device allows for marking surgical instruments and tools with unique device identification (UDI) numbers as directed by the U.S. Food & Drug Administration (FDA). Unlike traditional dot-peen technology, the MPX-90M accurately imprints 2D DataMatrix barcodes down to 1 mm2 on hard metal medical instruments. In fact, the MPX-90M prints on materials ranging from surgical steel, titanium and aluminum to matte plastics and acrylic.

The marks, 30-µm deep, won’t scratch off either.

An automated head height function ensures proper image placement while an adjustable X-Y table holds flat and oddly shaped parts. Motor-driven leadscrews move the marking head over the part during engraving.

motioncontroltips.com | designworldonline.com

11/7/16 4:19 PM

Infinite Possibilities in Motion The global leader in Linear Actuators with the experience to deliver the right combination to suit your needs Infinite winding options Multiple encoder options

Multiple grease options 10 anti-backlash nut styles

60+ custom molded / machined material options

Limitless number of custom designs and shapes

Proximity sensors

Custom connectors and cabling

Other options • • • •

200+ lead-screw options

2 TFE coatings

15 customizable Hybrids (21 to 87 mm) 14 customizable Can-Stacks (15 to 46 mm)

Brushless options available “Clean motor” options for critical environments Special corrosion-resistant motors Custom end bells for special mounting requirements

Designed and manufactured by Haydon Kerk • Resources of a global company – colleagues, facilities and services • Nearly 100 years of experience

www.HaydonKerk.com

hkapplications @ ametek.com Call... United States : 1 8OO 243 2715 International : 1 203 756 7441

© 2016 by AMETEK Inc. All rights reserved.

Haydon Kerk 5-16.indd 73

11/8/16 1:14 PM

APPLICATIONS

Motion System

Applications for linear motion components LINEAR GUIDE SYSTEMS include guide rails, slides and ways. They are also categorized into a few basic types including profile rails, slides, linear bearings, guide wheels and plain bearings. A typical arrangement includes a rail or shaft and carriages and runner blocks. Linear systems are also based on sliding or rolling contact.

A major function of rolling guides is to reduce friction in machines. They go in applications ranging from advanced semiconductor manufacturing to large machine tools and construction equipment.

Semiconductor manufacturing equipment or inspection machines needing high-precision positioning are suitable applications for linear guides. In machine tools for cutting, linear guides work better than sliding-contact linear bearings, as they withstand heat and other problems associated with high feed speeds.

A classic application for profile rails is in the machine tool industry where load capacity, stiffness and accuracy are paramount. In medical equipment such as CAT scan, MRI and x-ray machines, square rails are more common.

Elsewhere, round rails offer several advantages, including the ability to run smoothly when mounted to less than perfect surfaces—defined as having a flatness error of over 150 μm/m.

Linear sections of this Festo Multi-Carrier System consist of linear motors and load supports, base profile, and roller conveyor. The setup is meant to complement traditional conveyor installations.

Integrated controls handle both transport and motion-control functions as well as the coordination of other machine modules.

74

DESIGN WORLD — MOTION

Linear Guides - MSCasebook 11-16 V2.LE.indd 74

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 11:56 AM

Built to Stand Up High Precision, Rigidity and Robust Performance.

MUK Series Linear Actuator Systems

High Precision High Load Capabilities

Class 7 ball screw standard

Loads up to 2500 lbs (11200 N)

Precisely aligned profile rail guideways.

Robust Performance Two to four recirculating ball bearing blocks Single and dual carriage options Dual carriage configuration

See all Mechatronics Enabled motion systems at www.pbclinear.com

6402 Rockton Road, Roscoe, IL 61073 USA 1-800-962-8979 • www.pbclinear.com

PBC Linear Motion Casebook 11-16.indd 75

11/8/16 1:15 PM

APPLICATIONS

Motion System

Manual adjustments (as those in kitchen equipment, headrests or fitness and rehabilitation equipment) use linear guides including ball-pretensioned positioning systems from igus (for stepped locking) as well as prism slides with pretensioned carriages. Integrated designs allow for easy adjustments without forcing engineers to resort to oversized linear guides.

For cleanroom and food-processing applications that can’t tolerate contamination, linear guides that use rolling elements (as well as plain bearing systems) are unsuitable because of their need for lubrication requirements.

Some applications demanding extremely high precision and accuracy use fluid-floated bearings for the highest accuracy and precision possible. These are hydrostatic or aerostatic bearings using a high-pressure fluid between the rail and carriage. They’re more expensive and harder to manufacture than other linear options, but get top precision and accuracy.

Important considerations for choosing a linear-motion rolling guide include loading (static and applied); stroke and speed; target precision and accuracy; and required life. Preloading is sometimes necessary depending on application requirements. Lubrication is another consideration, as are shields, bellows, seals, and covers for the linear guide system if contaminants are a threat.

This TourSpin Club Washer from Riveer Co. washes golf clubs — a full set of irons and hybrids in less than 60 seconds. The machine uses PBC Linear SIMO Series linear actuators to move the Venturi nozzles back and forth over loaded clubs. The actuators withstand the repetitive washdown.

This B&R SuperTrak conveyor has a modular design that includes 1,000-mm linear track sections.

76

DESIGN WORLD — MOTION

Linear Guides - MSCasebook 11-16 V2.LE.indd 76

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 10:30 AM

Save Time. Save Space.

Save Money.

CUS TO SLID M ES AVA ILAB LE

with Del-Tron’s DL Linear Actuators.

These lead screw and ball screw actuators offer the benefits of a space-saving design, fast and simple assembly, long life, and a competitive price. The rigid enclosed aluminum box structure provides a compact envelope that incorporates the linear bearing and drive mechanism.

Integrating all components into a single unit that includes the motor adaptor saves assembly time and eliminates the need to source additional parts. DL series linear actuators are offered in travel lengths up to 410 mm. The DL ball screw and lead screw actuators utilize recirculating guide technology to provide a low profile and compact design solution. Our DW series (double wide) is engineered to create a wider mounting platform while still maintaining the same low profile height as our standard width DL actuators. This double wide design is ideal for applications that need a greater carriage mounting area or where axial play must be minimized.

Precision Linear Motion Required. Del-Tron Preferred.

• Compact space saving design • Available with ball and lead screw technology • Standard selection of stepper and servo motor mounts provided • Manufactured from corrosion resistant aluminum and stainless steel materials • Covers, limit switches and other options available

Del-Tron Motion Casebook 11-16.indd 77

11/8/16 1:16 PM

APPLICATIONS

Uses for ac motors MOTORS THAT RUN ON AC POWER, especially induction

Motion System

motors, are common in many industrial applications, heating and ventilation systems, and refrigeration, as well as many household appliances. Their speed can be varied and controlled fairly easily and they are more reliable and require less maintenance compared with brush dc motors.

Knowing a few basic guidelines for selecting the right ac motor for an application ensures the best fit. Important parameters include knowing the operating speed, load torque and inertia of the system based on the motion requirements.

There are many online calculators that can help determine the right motor based on these specific application parameters.

Other important factors to consider may include the available input voltage, required functions, features and user preferences.

Aside from well-established industrial applications, medical equipment is driving new demand for ac motors that are smaller, lighter, more powerful and efficient and generate less noise. Regardless of application, however, designs incorporating ac motors are seeing requirements for smaller footprints to continue to decrease sizes of machines and systems as well as better efficiencies that can improve manufacturing production rates.

Together with improved drives and motion controllers, complete integrated systems with drives, controllers, motors and HMIs can simplify designs and improve production throughput on manufacturing or packaging lines as well as simplify overall operation.

And while a host of applications are taking advantage of improvements in ac motor design, some of the more interesting ones involve more energy-efficient production lines and a solar-powered flight around the world.

Switching a dairy production line to permanent magnet ac motors from Control Techniques and Leroy-Somer led to a sizable increase in energy efficiency.

78

DESIGN WORLD — MOTION

AC Motors - MSCasebook 11-16 V2.indd 78

11 • 2016

Dairy producer boosts energy efficiency with switch to permanent magnet motors

Inex, a Belgium-based producer of dairy products, is seeing energy savings of at least 18% from its refrigeration process as a result of switching to Dyneo permanent magnet motor technology from Control Techniques & Leroy-Somer. The solution, which also features a LeroySomer Powerdrive high-power modular drive, is being used in an industrial refrigeration system that cools milk after pasteurization or sterilization.

Because refrigeration is a key element in the manufacturing process, optimum operation and reliability is paramount. As part of a recent investment package, Inex acquired four new industrial refrigerator systems based on Sabroe SMC 106E reciprocating ammonia compressors. At the time, the company had heard good reports of permanent magnet motors and wanted to install one as a trial. As a result, three of the compressors were supplied with standard Leroy-Somer IE2 (90 kW) asynchronous AC motors, and one with a Leroy-Somer IE4 (105 kW) synchronous permanent magnet motor from the Dyneo range.

The refrigeration systems are used to cool water to 1°C, which in turns cools milk to around 4°C. The installation operates almost continuously, but at variable load. Here, the benefits of permanent magnet motors come to the fore as their performance retains almost constant partial load, unlike standard asynchronous motors, generally leading to a reduction in energy consumption.

Control Techniques and Leroy-Somer’s experts visited Inex after the installation was complete. They discovered that the refrigerator operating with the Dyneo permanent magnet motor was delivering significant energy savings. Using a digital energy analyzer, the drive and motor experts made a series of power measurements comparing two refrigeration units working at the same conditions. One featured the LSRPM280SC-T synchronous magnet motor (105 kW) running at 1500 rpm and Leroy-Somer Powerdrive, while the other housed the standard LSES280MK-T (90 kW) asynchronous motor running at 1487 rpm and a competitor drive.

They found significant energy savings from using the permanent magnet motor across a range of different load profiles.

Depending on the type of measure – involving number of pistons, speed, evaporation temperature and condensation

motioncontroltips.com | designworldonline.com

11/8/16 2:22 PM

吀栀 椀渀琀 挀漀

AC MOTORS

temperature – the calculated energy savings were between 18 and 21%, taking into account any losses from the drive and the motor.

Torque motor helps propel Solar Impulse 2

Earlier this year, the Solar Impulse 2 airplane finished its flight around the globe. It accomplished the feat with an airtime of over 500 hours and is the first plane to do so relying entirely on solar energy. The solar-powered flight launched from Abu Dhabi and flew across Asia, the Pacific Ocean, the United States, the Atlantic Ocean, and Europe before finishing where it began. The historic flight is a monumental achievement not just for the aviation industry but for the idea of clean energy as a technological driving force.

The Solar Impulse 2 was designed to have optimum performance-per-weight ratio so every component, down to the smallest screws, was made as light as possible. This also included the proper motor drive. A number of years ago ETEL was asked to contribute its expertise in direct drive technology to create a motor capable of an efficiency above 95% which proved vital in ensuring the solar power absorbed by the panels was used most efficiently.

The Solar Impulse 2, seen here flying over San Francisco on its historic around-the-world flight, features a diect-drive torque motor from ETEL. (Image © Solar Impulse | Revillard | Rezo.ch.)

Through a partnership with many vendors, the Solar Impulse 2 team was able to achieve their goals with ETEL’s motor being a significant part of the design effort. In the end, the airplane proved to successfully combine the most advanced scientific knowledge in terms of aeronautics, materials, photovoltaic energy, and electric motors.

The ETEL motor used in the Solar Impulse 2 is a torque motor characterized by having an optimized force density and high current efficiency. The motor in the Solar Impulse 2 was slightly modified from a standard motor in order to withstand the extreme environmental conditions unique to this challenge.

一攀眀 匀琀愀渀搀愀爀搀猀 昀漀爀 倀漀眀攀爀 愀渀搀 倀爀攀挀椀猀椀漀渀 椀渀 䴀椀挀爀漀 䴀漀琀椀漀渀

吀栀攀 䘀䄀唀䰀䠀䄀䈀䔀刀 䴀漀琀椀漀渀 䌀漀渀琀爀漀氀氀攀爀猀 嘀㌀⸀ Ⰰ 琀栀攀 渀攀眀 䴀䌀㌀⼀䴀䌀匀 洀漀琀椀漀渀 挀漀渀琀爀漀氀 昀愀洀椀氀礀Ⰰ 愀爀攀 栀椀最栀 瀀攀爀昀漀爀洀愀渀挀攀Ⰰ 椀渀琀攀氀氀椀最攀渀琀Ⰰ 渀攀琀眀漀爀欀攀搀 搀爀椀瘀攀猀 漀瀀琀椀洀椀稀攀搀 昀漀爀 戀漀琀栀 伀䔀䴀 愀渀搀 愀甀琀漀洀愀琀椀漀渀 愀瀀瀀氀椀挀愀琀椀漀渀猀⸀ 吀栀攀猀攀 栀椀最栀 戀愀渀搀眀椀搀琀栀 挀漀渀琀爀漀氀氀攀爀猀 昀攀愀琀甀爀攀 ㄀ 洀椀挀爀漀猀攀挀漀渀搀 猀愀洀瀀氀攀 琀椀洀攀 昀漀爀 瘀攀氀漀挀椀琀礀Ⰰ 瀀漀猀椀琀椀漀渀 愀渀搀 挀甀爀爀攀渀琀 昀攀攀搀戀愀挀欀⸀ 䤀渀搀甀猀琀爀礀 猀琀愀渀搀愀爀搀 渀攀琀眀漀爀欀 愀渀搀 挀漀渀琀爀漀氀 椀渀琀攀爀昀愀挀攀猀 ⠀䔀琀栀攀爀渀攀琀 昀椀攀氀搀戀甀猀 琀攀挀栀渀漀氀漀最礀Ⰰ 唀匀䈀Ⰰ 渀攀琀眀漀爀欀 挀漀洀洀甀渀椀挀愀琀椀漀渀 瀀爀漀琀漀挀漀氀猀 䌀䄀一漀瀀攀渀 愀渀搀 刀匀ⴀ㈀㌀㈀⤀ 刀漀戀甀猀琀 瀀漀眀攀爀 猀琀愀最攀 眀椀琀栀 攀砀琀攀渀猀椀瘀攀 琀爀愀渀猀椀攀渀琀 猀甀瀀瀀爀攀猀猀椀漀渀 愀渀搀 琀栀攀爀洀愀氀 瀀爀漀琀攀挀琀椀漀渀 ⠀甀瀀 琀漀 ㄀ 䄀 挀漀渀琀椀渀甀漀甀猀Ⰰ ㌀ 䄀 瀀攀愀欀⤀ 一攀眀 䘀䄀唀䰀䠀䄀䈀䔀刀 䴀漀琀椀漀渀 䴀愀渀愀最攀爀 㘀 猀攀琀甀瀀 眀椀稀愀爀搀 昀漀爀 猀椀洀瀀氀椀昀椀攀搀 甀猀攀 漀昀 䘀䄀唀䰀䠀䄀䈀䔀刀 瀀爀漀搀甀挀琀猀 䴀愀砀椀洀甀洀 瀀攀爀昀漀爀洀愀渀挀攀 愀渀搀 瀀爀攀挀椀猀椀漀渀 昀爀漀洀 愀氀氀 䘀䄀唀䰀䠀䄀䈀䔀刀 挀漀爀攀氀攀猀猀 䐀䌀 洀漀琀漀爀猀Ⰰ 戀爀甀猀栀氀攀猀猀 䐀䌀 洀漀琀漀爀猀Ⰰ 愀渀搀 氀椀渀攀愀爀 䐀䌀 猀攀爀瘀漀 洀漀琀漀爀猀 ⠀愀渀搀 攀砀挀攀氀氀攀渀琀 挀漀洀瀀愀琀椀戀椀氀椀琀礀 眀椀琀栀 愀 眀椀搀攀 爀愀渀最攀 漀昀 漀琀栀攀爀 洀漀琀漀爀猀 漀渀 琀栀攀 洀愀爀欀攀琀⤀ 䐀攀挀攀渀琀爀愀氀椀稀攀搀 椀渀琀攀氀氀椀最攀渀挀攀 瀀爀漀瘀椀搀攀猀 琀栀攀 愀戀椀氀椀琀礀 琀漀 猀愀瘀攀 瀀爀漀最爀愀洀 猀攀焀甀攀渀挀攀猀 ⠀甀瀀 琀漀 攀椀最栀琀 瀀爀漀最爀愀洀猀 挀愀渀 戀攀 甀猀攀搀 漀瘀攀爀 愀氀氀 椀渀琀攀爀昀愀挀攀 琀攀挀栀渀漀氀漀最椀攀猀⤀

AC Motors - MSCasebook 11-16 V2.indd 79

吀眀漀 挀栀愀渀渀攀氀 焀甀愀搀爀愀琀甀爀攀 猀椀最渀愀氀猀 愀渀搀 愀渀 愀搀搀椀琀椀漀渀愀氀 椀渀搀攀砀 猀椀最渀愀氀 ⸀㄀ 琀漀 ⸀㌀ 搀攀最爀攀攀 瀀漀猀椀琀椀漀渀椀渀最 愀挀挀甀爀愀挀礀 伀瀀琀漀ⴀ爀攀昀氀攀挀琀椀瘀攀 猀礀猀琀攀洀 愀猀 愀 猀椀渀最氀攀 挀栀椀瀀 猀漀氀甀琀椀漀渀 䠀椀最栀攀猀琀 爀攀猀漀氀甀琀椀漀渀 椀渀 椀琀猀 挀氀愀猀猀 ⠀甀瀀 琀漀 ㄀ Ⰰ 氀椀渀攀猀 瀀攀爀 爀攀瘀漀氀甀琀椀漀渀⤀ 䄀渀最甀氀愀爀 爀攀猀漀氀甀琀椀漀渀 漀昀 ⸀ 㤀 搀攀最爀攀攀猀 眀椀琀栀 琀栀攀 攀瘀愀氀甀愀琀椀漀渀 漀昀 㐀 Ⰰ 攀搀最攀猀 瀀攀爀 爀攀瘀漀氀甀琀椀漀渀 䌀漀洀瀀愀挀琀Ⰰ 氀椀最栀琀眀攀椀最栀琀 愀渀搀 椀搀攀愀氀 昀漀爀 愀 眀椀搀攀 爀愀渀最攀 漀昀 洀攀搀椀挀愀氀 琀攀挀栀渀漀氀漀最礀Ⰰ 愀甀琀漀洀愀琀椀漀渀Ⰰ 漀瀀琀椀挀猀Ⰰ 愀渀搀 爀漀戀漀琀椀挀猀 愀瀀瀀氀椀挀 愀瀀瀀氀椀挀愀琀椀漀渀猀 爀攀焀甀椀爀椀渀最 栀椀最栀 愀挀挀甀爀愀挀礀Ⰰ 爀攀瀀攀愀琀愀戀椀氀椀琀礀Ⰰ 愀渀搀 爀攀猀椀猀琀愀渀挀攀 琀漀 猀琀爀漀渀最 洀愀最渀攀琀椀挀 椀渀琀攀爀昀攀爀攀渀挀攀猀 䌀漀洀戀椀渀攀猀 眀椀琀栀 䘀䄀唀䰀䠀䄀䈀䔀刀 挀漀爀攀氀攀猀猀 䐀䌀 洀漀琀漀爀猀 愀渀搀 戀爀甀猀栀氀攀猀猀 䐀䌀 洀漀琀漀爀猀Ⰰ 愀猀 眀攀氀氀 愀猀 漀琀栀攀爀 䘀䄀唀䰀䠀䄀䈀䔀刀 洀漀琀椀漀渀 琀攀挀栀渀漀氀漀最椀攀猀Ⰰ 椀渀挀氀甀搀椀渀最 琀栀攀 䴀漀琀椀漀渀 䌀漀渀琀爀漀氀氀攀爀猀 嘀㌀⸀

⠀㠀 ⤀ 㠀 㜀ⴀ㤀㄀㘀㘀 眀眀眀⸀洀椀挀爀漀洀漀⸀挀漀洀 䌀氀攀愀爀眀愀琀攀爀Ⰰ 䘀䰀 唀匀䄀 䐀攀氀椀瘀攀爀礀 椀渀 琀栀爀攀攀 搀愀礀猀 漀爀 氀攀猀猀 椀猀 愀瘀愀椀氀愀戀氀攀 昀漀爀 洀愀渀礀 瀀爀漀搀甀挀琀猀⸀

11/9/16 2:46 PM

APPLICATIONS

Motion System

Applications using dc motors THERE ARE TWO BASIC TYPES OF DC MOTORS; brush and brushless.

Even with the known drawback of brush motors exhibiting wear at their brush-and-commutator interface, they are still widely used because of their high peak torques and the fact that they can be controlled by simple speed controllers. Plus, they are often less costly than other options, especially in large volumes.

Brush dc motors also have a linear torque-speed relationship, which makes them easier to control. These characteristics make them suitable for applications in consumer appliances, personal home goods and toys, and automotive designs. In fact, permanent-magnet brush dc motors are the most common electric motor in passenger vehicles where they’re used for driving windshield wipers, power windows and power seat positioners.

On the other hand, wound-field dc motors are common in household appliances such as vacuum cleaners, cordless power tools and food mixers. The only drawbacks are that they produce more audible noise and exhibit wear (at the brushes) so don’t work well in applications with high duty cycles.

Recently, many industry trends are pushing dc motors to be lighter, more powerful and portable.

So, for example, more and more miniature applications are using dc motors. Because of the need for power and precision in a small package, miniature dc motors are finding their way into medical applications such as remote surgical robots.

Case in point; voice coil actuator motors used in medical applications.

In a ventilator application, BEI Kimco’s Voice Coil Actuator (pictured) is able to control both the inhalation and exhalation valves with extreme precision.

80

DESIGN WORLD — MOTION

DC Motors - MSCasebook 11-16 V2.indd 80

11 • 2016

motioncontroltips.com | designworldonline.com

11/7/16 4:28 PM

maxon control electronics for strong DC brushed and brushless motors.

maxon motor control

Power under control.

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

Maxon_MSHandbook9-16.indd 81 228.6x276.225.indd 13

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

11/8/16 13:40:12 1:17 PM 04.08.2016

APPLICATIONS

Motion System

Multi-Axis Communications Just Got Simpler.

1 READY. Use our free SMI™ software to auto detect motors.

2 SET. Set CAN addresses and baud rate.

3 GO. Send commands; start talking.

Medical devices typically tend to be smaller and weigh less than the vast majority of applications that require some type of motion control simply because they are often portable and/or mobile, hand-carried or lifted. Internal components needed for these medical devices are chosen carefully in order to make for the smallest overall device footprint.

Linear voice coil actuators (VCA) from BEI Kimco provide precision linear motion control needed for ventilators and other delicate medical instruments in an extremely small size. The VCA is able to control both the inhalation and exhalation valves on ventilators with extreme precision, providing the exact amount of air specified and the necessary reliability for this life-critical application. Additionally, with its bi-directional capability and permanent magnet, the position will remain at one end or the other, even in a power failure.

The small LAH08-15-000A VCA has a diameter of 0.75 in. and weighs only 2.3 oz., helping to minimize additional weight to the ventilator. The VCA delivers a peak force of nearly 1.81 lb and has an operating stroke of ± 0.2 in. (total 0.4 in. stroke). It also provides low hysteresis, zero cogging, high acceleration, and long life cycle.

Same for 2 or 120 motors.

That’s all there is. Simple!

Metabo 1,700-W grinders incorporate motors that are better at dissipating heat while providing up to 50% more torque and 20% more power to the end user.

There's now 30% more resin at the rotor to prevent abrasion from dust ingress, as well as new field-coil technology and increased armature diameter for more torque.

Learn how our easily deployable programming language gets your machine to market faster at animatics.com/comm When Performance Really Matters®

+1 408 965 3320

|

DC Motors - MSCasebook 11-16 V2.indd 82

sales@animatics.com

82

DESIGN WORLD — MOTION

11 • 2016

11/7/16 4:30 PM

INTEGRATED INTELLIGENCE for

Dynamic Motion

Motion Solutions Made, Efficient, Maintenance-Free and on lowest cost of Ownership.

MODULAR SYSTEM Flexibility, delivery performance & complete motion solutions.

Standardized motors, gears and modular accessories are available with a higher degree of lexibility to address specific requirements in complete motion solutions.

Dunkermotoren_MCTrends_3-16.indd 83

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

11/8/16 1:18 PM

APPLICATIONS

Motion System

Clever uses for integrated motors INTEGRATED MOTORS, also called smart motors, include a motor rotor and stator (in a brushless dc, servomotor or stepper motor form) paired with other motion components.

About half of all integrated motors incorporate a brushless motor with permanent magnets on the rotors, though other formats exist.

The most basic integrated motors consist of just a motor and drive or a motor and controller. Other add-ons can include an encoder for feedback, power supplies, cabling, and communication ports. For the latter, common communication options include serial communication links such as RS232 or RS485 and advanced network topologies for complex motion control tasks—CANopen, DeviceNet, or Ethernet protocols.

The pre-engineered nature of smart motors lets application engineers use motor-based motion control with less effort. With fewer parts, integrated motors also boost reliability and minimize cabling, wiring, and overall design cost. Most integrated motors also program easily and quickly, which cuts development time.

For machine builders, integrated motors help reduce machine size and complexity. That’s because smart motors significantly reduce the amount of space required for a machine by consolidating components, eliminating cabling, and possibly the need for entire enclosures. Integrated motors can also eliminate external controllers such as PLCs. With the increased use of decentralized motion-control architectures, applications using integrated motors have only proliferated. As an alternative to centralized motion control, decentralized architectures distribute motion control to a number of individual motion axes (in this case, to individual integrated motors), eliminating the need for a central controller. This means that individual motors can execute the control closer to the actual axis of motion or load, thereby taking the computational burden off of a central controller and distributing it to individual integrated motors.

Integrated motors central to fast bottling machine Creating a fast bottle labeling (or cupping) machine requires the design and execution of complex and dynamic ECAM movements — especially with more than 60 integrated motor/drives on a rotating platform, transferring high power and high-speed EtherCAT communication through slip rings.

This type of design would require tackling manipulators using rapid and complex control of rotating mechanics with motors and drives that operate in a vibrating, humid and extreme temperature environment. In addition, Fast bottle labeling takes fast execution of dynamic ECAM movements. Integrated motor/drives from Elmo help speed the process and simplify design.

84

DESIGN WORLD — MOTION

Integrated Motors - MSCasebook 11-16 V2.indd 84

11 • 2016

motioncontroltips.com | designworldonline.com

11/7/16 4:43 PM

INTEGRATED MOTORS

Motors on a bottling platform integrate Gold Whistle servodrives from Elmo — so the rotating carousel is simpler and lighter — and only needs cabling to a dc bus and for EtherCAT communications..

there is the requirement of transmitting deterministic and signal-integritysensitive communication via the slip ring media. This could involve substantial time and many weeks of intensive work, requiring high-level expertise with considerable experience. But smart motors from Elmo shorten design time to less than three days.

Integrated into the motors are Gold Whistle servodrives. This simplifies the indexing table and minimizes cabling to only dc bus plus EtherCAT communication cables. So the electrical cabinet is smaller too — for less EMI. The servodrive is tuned for wide bandwidth and fast response by overcoming the non-linearity of the mechanical load, making operation more stable for higher throughput.

All 60 servodrives run off a Maestro multi-axis controller that controls and supervises the whole bottling process.

Bottles feed into a machine and transfer to the rotating platform, which consist of 60 small integrated drive/ motor components called DUETs. The DUETs fit in the rotating platform’s limited footprint. They all directly drive bottles, which ensure precision of rotation during camera image capturing.

Engineers designed the compact motor/high power drive for limited machine space using high-resolution absolute feedback for precision and servo control performance. The DUETs must be rugged enough to withstand the mechanical vibrations of the rotating platform. The minimum cabling used here results in minimal external noise and low EMI and RFI. Four cameras take snapshots of the bottles for a host computer to process and verify exact label position using an algorithm. Bottle rotation is controlled by the Maestro, which sets the initial target labeling position and waits for the ECAM execute operation to start. All subordinate units operate in the DS-402 standardized cyclic synchronized position mode of operation. The Maestro and EASII feature high interpolation levels for smooth motion trajectories with a minimum number of ECAM points. It enables fast dynamic table calculations, execution, table switching, multi-hierarchy topology building and virtual axis synchronization. The advanced EASII, Elmo Application Studio ECAM tool combined with Elmo's Motion Block Libraries (EMBLs), make testing of the ECAM trajectories faster to get machines up and running in a couple of days.

11 • 2016

DESIGN WORLD — MOTION

Integrated Motors - MSCasebook 11-16 V2.indd 85

85

11/7/16 4:44 PM

APPLICATIONS

Motion System

Where linear motors make designs better MACHINE-TOOL APPLICATIONS and the manufacture and assembly of semiconductor components account for more than half of all linear-motor use. That’s because linear motors are precise (albeit costly compared to other linear-motion options). Other applications for these relatively new motion components also include those that need fast and precise positioning or slow and extremely steady strokes.

Linear motor speeds range from a few inches to thousands of inches per second. The designs can deliver unlimited strokes and (with an encoder) accuracy to ±1 μm/100 mm. For this reason, a variety of medical, inspection and material-handling applications use linear motors to boost throughput.

Unlike rotary motors (which need mechanical rotary-to-linear devices

86

DESIGN WORLD — MOTION

Linear Motors - MSCasebook 11-16 V2.LE.indd 86

11 • 2016

to get straight moves) linear motors are direct drive. So, they avoid the gradual wear of traditional rack-and-pinion sets.

Linear motors also avoid drawbacks of rotary motors running belts and pulleys ... limited thrust because of tensile-strength limits; lengthy settling times; belt stretching, backlash and mechanical windup; and speed limits of 15 ft/sec or so. Plus linear motors avoid lead and ballscrew inefficiencies (about 50 and 90% respectively) as well as whip and vibration. They don’t force designers to sacrifice speed (with higher pitches) for lower resolution, either.

Multi-axis stages that use linear motors on each axis are more compact than traditional set-ups, so fit into smaller spaces. Their lower component count also boosts reliability. Here, the motors connect to regular drives, and (in servo operation) a motion controller closes the position loop.

motioncontroltips.com | designworldonline.com

11/9/16 1:09 PM

LINEAR MOTORS

Linear motors include a coil and stationary platform. Linear–motor subtypes include brushless ironcore and ironless designs as the ones from Chieftek Precision USA shown here.

11 • 2016

Linear Motors - MSCasebook 11-16 V2.LE.indd 87

DESIGN WORLD — MOTION

87

11/9/16 1:09 PM

APPLICATIONS

Motion System

Linear stepper motors deliver speeds to 70 in./sec, suitable for relatively quick-acting pick-and-place and inspection machines. Other applications include part-transfer stations. Some manufacturers sell twin linear steppers with a common forcer to form X-Y stages. These stages mount in any orientation and have high stiffness and flatness to a few nanometers for every hundred millimeters to output accurate moves.

Some cost-sensitive applications benefit from hybrid linear motors, as they have inexpensive ferromagnetic platens. Much like linear stepper motors, they vary magnetic saturation from the platen to shape opposition to magnetic flow. Feedback plus a PID loop with positioning control helps the motor output servo-grade performance. The only catch is that hybrid motors have limited output and exhibit cogging from coupling between forcer and platen. Two solutions are phase-teeth offset and driving for partial saturation of platen teeth and forcer teeth sections. Some hybrid motors also use external cooling to boost output during continuous operation.

Linear ac induction motors that run to 2,000 in./sec work for people movers, roller coasters and large aerospace applications.

Gen-eral-purpose types can move a few inches to 150 ft/sec or faster. Cylindrical linear motors have steel rods and a moving coil or rods filled with stacked magnets, so work in myriad ma-chines that need quick and accurate strokes. In a similar way, ironless-core (or air-core) line-ar motors output up to 3,000 N and speeds exceeding 230 in./sec. These capabilities make this linear-motor subtype indispensable in long-stroke pick-and-place applications, flyingshear setups, and laser and waterjet cutting.

Linear ac synchronous motors can output 7,000 N or more.

Some use water cooling to boost force output. Such designs find use in baggage-handling systems and amusement rides. Iron-core motors also work in machine tool and robotics applications.

Image courtesy of University of Wisconsin-Madison Plant Imaging Center and IntelLiDrives

Linear-motor application example: Researchers use XYZ robot to develop hardier crops Watching plants grow and develop roots can be tiresome, but tracking plant development reveals how genetically modified plants can give better yields than unaltered versions. Now, plantphysiology researchers at the University of Wisconsin-Madison are using automated image acquisition to make that easier.

Researchers place plant samples in an LED-illuminated 6x6 grid of Petri plates on a vertical tubular aluminum frame to conduct 36 experiments in parallel. Then robotic camera CCD imagers working off an XYZ vertical gantry create time-lapse movies of plant growth to give researchers better understanding of how genetic manipulations affect development.

The XYZ gantry consists of computer-controlled linear actuators, each integrating a brushless linear servo motor from IntelLiDrives with a high-resolution linear encoder. The gantry moves the CCD cameras over a 1-m-by-1-m area with positioning resolution of 10 µm. An extra linear axis lets the researchers change the camera’s field of view to get well-focused images of the seedlings in their Petri plates.

88

DESIGN WORLD — MOTION

Linear Motors - MSCasebook 11-16 V2.LE.indd 88

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 3:51 PM

LINEAR MOTORS

Robotic cameras and computerized motion control are helping researchers identify plant characteristics that improve hardiness. A robotic control XYZ gantry with linear-motor actuators from IntelLiDrives moves a pair of cameras between growing plant samples.

Infrared light-emitting diodes behind the fixture provide illumination.

The robotic camera snaps a picture every 30 seconds to capture the curling and twisting motion of germinating seeds putting out new roots.

After capture, the images go through analysis that determines cellular growth rates in the root as well as the angle and curvature of the root tip. Computer-vision algorithms study the camera’s time-lapse videos and measure (among other things) the sizes of seeds, plants’ cellular growth rates, and the angle and curvature of the roots.

Using this XYZ robot with computer vision gives researchers the ability to automate the plant growth timelapsed image acquisition and processing ... and increase throughput of experiments to track the plants growth and development. Now researchers can find the genes that control plant’s root growth and have fundamental importance to crop improvement. It lays the foundation for discoveries that could one day further improve plants for human consumption and other use.

11 • 2016

Linear Motors - MSCasebook 11-16 V2.LE.indd 89

DESIGN WORLD — MOTION

89

11/9/16 1:10 PM

APPLICATIONS

Motion System

The PR01 series electric motors from LinMot were specially developed for the closing and screwing process in a packaging application. They combine both a linear motor and a rotary direct drive in a compact housing.

Servomotors improve key applications HIGH-CAPACITY MANUFACTURING APPLICATIONS are leveraging servomotors and drives in their quest to achieve better efficiency with automation. This is because servomotors are one of the most commonly used motors for precision positioning and load-responsive motion.

Servomotors power applications in a wide range of industries, though are most suited for controlling the movement of machines in packaging, semiconductor manufacturing, as well as medical equipment and food and beverage production. Other common applications include robotics and positioning and tracking systems for solar panels. Here and elsewhere, servomotor technology can help boost accuracy and output.

Selecting the right servomotor for an application involves three important parameters: load, speed and torque.

Not only must acceleration, deceleration and running torque be taken into account, but also the ability of the servomotor to tightly control the load’s speed, position or torque. This means the peak torque measurements must be calculated, usually during acceleration or

90

DESIGN WORLD — MOTION

Servo Motors - MSCasebook 11-16 V3.indd 90

11 • 2016

deceleration, along with the running/normal torque. Also, the inertia of the system (the load’s resistance to change in speed) must be calculated to ensure that the motor/drive system will be able to control the load.

A motor’s continuous torque is its ability to produce the rated torque and speed without overheating. Intermittent torque indicates how much torque a motor can produce in a short period of time based on current limits of the drive and motor. The intermittent (or peak) torque of a motor can be much higher than its rated torque, and servo systems are usually designed to operate within that peak torque range when accelerating or decelerating the load.

Linear-rotary servomotors smooth out closure process In one packaging application, a unique servomotor helped to vastly simplify the design of the packaging machine.

Engineers from packaging machinery maker Tölke were looking to replace conventional cam-disc technology on their new filling and closing line. However, if the closing process itself needed to be modified for a product changeover, it was necessary to change out the mechanical cams involved in the screwing process, a time-consuming and costly process. As a result, Tölke built a carousel machine with 16 closing stations for an application with frequent product changeovers.

The entire screwing process now uses a model PR01-84 linear-rotary motor from LinMot at each station.

This electric motor, part of the PR01 series, was specially developed for the closing and screwing process. It combines both a linear motor and a rotary direct drive in a compact housing, each of which is controlled separately.

motioncontroltips.com | designworldonline.com

11/9/16 2:49 PM

What’s Inside Matters The PITTMAN Difference ®

On the outside, this looks like an ordinary DC motor. In fact, this particular motor is not a standard off-the-shelf part, but designed exactly to a customer’s specific technical requirements. PITTMAN has an experienced team of engineers focused on providing the perfect motor assembly to our customers demanding motion applications.

• • • • •

Special brush formulation for use in a very low humidity environment Bearing system to handle higher than normal axial loads Very tight balancing spec to minimize audible noise and vibration at high speeds Unique magnet charge pattern to minimize cogging at low speeds Specially chosen surface-mount components inside the motor to meet an aggressive EMC requirement • Numerous integrated spur and planetary gearboxes, encoders, brakes and drives

When evaluating DC motor choices, it’s what’s inside that matters.

www.Pittman–Motors.com 343 Godshall Drive, Harleysville, PA 19438 USA: +1 267 933 2105 Europe: +33 2 40 92 87 51 Asia: +86 21 5763 1258

Pittman (AMETEK) 3-16.indd 90

11/8/16 1:19 PM

Motion System

APPLICATIONS

New, however, is the use of an electronic linear axis in the closer. "The cap needs to be picked up, placed on the bottle, and then guided so as to provide optimal support for the rotary motion," said Markus Kröger, the Tölke project manager. "If this linear motion were controlled by a cam disc, then the heights at which the cap is picked up and placed down would be fixed, and the entire motion sequence would be defined."

If modifications to the motion sequence were required for a product changeover, then the mechanical solution would require different closure heads or even different cam discs to be installed; the machine builder would have to integrate adjustable cam discs. In some cases, a spring would also need to be installed to compensate for the weight of the head.

"With a direct drive and an electronic stroke curve, none of this is needed anymore," explained Kröger. With the right parameter sets for the programmed motion sequence, or by invoking a predefined recipe, the motion of the linear motor can be designed as needed."

As such, different types of closures, including screwon and press-on caps, can be processed on the same machine. Even different press forces or thread pitches, such as those found on containers with and without safety caps, can be handled by a linear drive without any mechanical reconfiguration.

In addition, a linear-rotary motor like the PR01, with its two independently controlled axes, can start the rotary motion during the linear stroke, decoupled from the position of the turntable.

To promote the modularization of the machine, Tölke engineers used the mechanical decoupling of the closing process from the carousel or turntable. If a screwing station was damaged, it could now be replaced in a short time, so the machine could get back to work much faster after a crash. In addition, because of the decoupling, the closing process can now be completed for all containers in the line prior to a planned machine stop.

In order to further reduce the downtime and monitor the screwing process, the information produced by the linear-rotary drive for each individual screwing process (torque, speed, angle, vertical position, linear speed, and force) can be analyzed.

The drive data for snap-on caps can also be usefully applied for monitoring purposes. An error message can be generated if a prescribed value for the snap-on force is exceeded due to an interfering injection point.

Due to these many advantages, Tölke had already developed a solution prior to the use of the PR01 linearrotary motor, wherein the linear motion was generated by a servomotor in conjunction with a ballscrew spindle. The ballscrew, however, had to be protected against dust, which requires additional design effort that is not necessary for the fully assembled linear-rotary motor. The linear-rotary motor is much simpler to use.

By using the linear-rotary motor from LinMot, Tölke was able to decouple the closing process from the motion of the turntable. This allows a closing station to be swapped out much faster in case of damage, thus minimizing downtime.

Photo courtesy Rossmann.

92

DESIGN WORLD — MOTION

Servo Motors - MSCasebook 11-16 V3.indd 92

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 11:34 AM

Im

ag

ec ou

rte

sy

Int

ral

ox

STEPPER MOTORS

Stepper motors excel in unique conveying application STEPPER MOTORS are common in positioning applications and have the advantage of being accurately controllable down to fractions of a degree, even without the use of feedback devices such as encoders or resolvers. They operate in open-loop (not closed-loop), without the need for tuning parameters as in closed-loop systems. Stepper motors are also relatively inexpensive.

Because speed is proportional to the frequency of the input pulses, they can attain a wide range of speeds.

Though stepper motors are capable of producing high torque at low speeds, they work best for lower power applications and not for applications requiring lots of torque to move heavier loads. They excel

motioncontroltips.com | designworldonline.com

Stepper Motors - MSCasebook 11-16 V2.LE.indd 93

in applications requiring the control of rotation angle, speed and position. Other drawbacks are that not properly controlling the motor can produce detrimental system resonance. Also, stepper motors are generally difficult to operate at extremely high speeds. Plus as motor speed increases, torque decreases.

Most applications for stepper motors leverage their superior positioning capabilities. For example, in optical systems and electronics assembly, accurate positioning is critical for maintaining high production standards. What’s more, using hollow-shaft stepper motors lets machine designers route wires and cables through the center of the shaft, which in turn saves valuable space and can reduce cable fatigue.

Other applications include surgical robots, some pick-and-place gantry systems as well as solar cell positioning and 3D printing.

11 • 2016

DESIGN WORLD — MOTION

93

11/9/16 11:26 AM

APPLICATIONS

Motion System

94

Stepper Motors - MSCasebook 11-16 V2.LE.indd 94

One application taking advantage of stepper motors comes from the world of material handling and conveying. A unique conveyor system from Intralox uses a series of integrated stepper motors as the primary actuation method. The company’s active roller belt, or ARB, technology executes a variety of moves on packages on a conveyor such as aligning, turning, merging, sorting, singulating, and more.

As explained by Eric Rice of Applied Motion Products, his company worked with Intralox to develop a new system that would improve upon an existing conveyor. The challenge was to increase accuracy, maintain high speed, and keep costs low. The engineers also switched from an analog control setup to a digital system with a new network connection.

The choice of network was fairly straightforward because in North America and even in Europe, Intralox mostly uses Rockwell controllers that have built-in EthernetIP masters ... and which Applied Motion Products’ integrated stepper motors also support.

Another requirement was to maintain high-speed operation.

The faster the packages are moving down the conveyor, the faster the control system must respond and sort packages. The feet per minute or packages per minute the systems handle is a key performance indicator. The existing analog positioning system updated motor position about every 2 msec. Here was a potential snag: The default update rate for devices on an EthernetIP network is about 10 msec, so this was a problem to be resolved.

In fact, after several tests Intralox determined that although the 2-msec update rate was attainable with the analog solution, something slower was acceptable for most applications, including higher-accuracy setups. More specifically, Intralox decided that an update rate of 4 msec would be acceptable. That was far more attainable using the integrated stepper motor.

The engineering department at Applied Motion Products then looked for ways to streamline the code. They determined that they could support a 4-msec update time for the network and still have plenty of time to handle other things the processor inside the integrated stepper motor does ... including trajectory generation, current control, program execution, and I/O control. There was enough time left over to get an EthernetIP message every 4 msec.

The final design objective was to keep costs low. Many motor and drive options on the market can accommodate the accuracy and high-speed requirements of the conveyor ... and many of them non-integrated servo systems. But to replace the low-cost integrated stepper motor with an extensive non-integrated servo system would likely cost significantly more. Just consider how there are installations that use Intralox conveyors 200 feet long running 100 axes. The control panel such a design would necessitate (to support 100 servo drives and then run 100 sets of cables to 200 motors) would be costly and complex. So the Applied Motion Products solution made sense for this financial reason as well.

DESIGN WORLD — MOTION

11 • 2016

11/9/16 11:27 AM

The Step Motor Specialists BACKED BY

GET THE EXACT STEP MOTOR POWERED

LINEAR ACTUATOR

YOU NEED IN YOUR DESIGN

EASY AS

1

2

3

√ Select Your Motor √ Select Your Screw √ Select Your Nut

Configure Online Now

www.LinEngineering.com/Actuators

DN_LIN_Ad_Linear_Actuators.indd 1 LinEngineering_MSHandbook9-16.indd 95

Or Call 408.919.0200

And Speak With One Of Our Application Specialists

9/6/2016 5:20:08 PMPM 11/8/16 1:21

APPLICATIONS

Motion System

Networks enable all-new motion designs ETHERNET IS INCREASINGLY COMMON for networking motors, drives and controls such as PLCs. Applications include pick and place assembly, conveying, and machining. In fact, all forms of networking will gain in importance with the rising Internet of Things (IoT). Gathering data is the new function for networks in motion, courtesy of all the smart chips going into motion components.

The aim is that new streams of data will come to improve the quality of motion applications. Many machines need tight coordination between axes to maximize quality and throughput. Case in point: Manufacture of flat-panel displays and batteries is increasingly complex as demand for lower cost necessitates increased efficiency. Here, coordinated motion courtesy of networks and controls delivers needed efficiency. But access to more process data may also come to help engineers use distilled information for improving operations.

Note that in some areas of motion control, it’s simpler and more precise to synchronize multiple actuators using a communication protocol such as Sercos than by conventional means.

Application example: Coating stainless appliances Polished stainless-steel components for home appliances, furniture, and automobiles are sensitive to scratches and fats, so German company Foilpuller sells automated machines to coat such surfaces with protective plastic films during manufacture.

Bosch Rexroth drives and controls run the machines.

The machines apply clear UV-hardened lacquer to stainless-steel components, and cut it for accurate removal from The IndraMotion MTX was the first CNC controller to get certification for open areas. conforming to the Ethernet standard Here, IndraMotion Sercos automation bus.

MTX CNC controls from Bosch Rexroth enable cutting of any geometrical shape by means of circular interpolation by multi-axis-coordinated IndraDrive compact drives. Dual-axis controllers significantly reduce required cabinet space but facilitate control of more than 20 axes.

Controllers and drives communicate through Sercos.

The drive level runs off G-Code, as users are familiar with this CNC language. Pre-programmed software components from Rexroth simplify custom configuration.

Overall data consistency allows cutting tasks just in time and without intermediate storage, which saves space and minimizes risk of damage to workpieces.

Foilpuller machines coat surfaces with protective plastic films.

Communication between its Bosch Rexroth controllers and drives is through Sercos.

96

DESIGN WORLD — MOTION

Networks - MSCasebook 11-16 V3.indd 96

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 12:02 PM

EK08__USA__Canada.indd 6 Beckhoff Motion Casebook 11-16.indd 97

10.03.15 09:20 11/8/16 1:22 PM

APPLICATIONS

Motion System 98

Applications for retaining rings MACHINE ASSEMBLIES AND SUBASSEMBLIES make copious use of retaining rings in everything from electric motors and gear retainers to solenoids to aircraft to door handles and sports equipment. These fasteners hold components together on shafts or in housings when installed in a groove. In fact, the automotive industry may make the most use of retaining rings, especially for assemblies in air bags, timing-belt pulleys, radiator hoses, turbo chargers, door locks, carburetor assemblies, drive shafts, and brakes.

Used in an array of oil-and-gas and other industry designs, tapered section rings have decreasing thickness from center to ends. They mount axially or radially, and the taper keeps full contact with the installation groove.

Common in assemblies for lawn mowers, hand and power tools, agricultural machinery, nuclear equipment, and even computer equipment, constant section retaining rings have a constant width around the circumference of the ring. When installed, these rings do not maintain uniform contact with the entire component.

They take on an elliptical shape and make contact with the groove at three points. Spiral retaining rings go into housings or on shafts with full contact with groove or component. Their grooves are shallow, so have less load bearing capability. So, spiral rings often go into applications that prioritize full contact with the retained component or lower axial profile.

DESIGN WORLD — MOTION

Retaining Rings - MSCasebook 11-16 V2.LE.indd 98

11 • 2016

Spiral rings go in torque converters, speed reducers, lamp assemblies, clutches, hinge pins, home appliances, robotic toys, pumps, couplings, valves, hydraulic equipment, and photography equipment.

They don’t have protruding ears to interfere with mating components. They also eliminate the need for machining and threading. Spiral retaining rings don’t necessitate special tools for removal and come standard with removal notches for extraction.

When selecting a retaining ring for an application, factors that dictate which retaining ring is most suitable include application environment (including temperature, speed, and thrust); critical dimensions (including the assembly’s housing or shaft diameter; and the installation-groove dimensions. In fact, maximum thrust is one of the most critical application parameters, as it dictates whether there’s risk of groove deformation or ring shear. Applications that run in corrosive environments may also need retaining rings made of specialty material.

Beveled retaining rings (such as the one on the right from Rotor Clip) eliminate endplay vibration and let the complementary angle of the beveled ring act as a replacement for a nut. That removes the need to torque parts or machine threads on the housing. The cost of the beveled ring is also lower than the nut alternative.

motioncontroltips.com | designworldonline.com

11/9/16 12:19 PM

SMALLEY WAVE SPRINGS: FORCE WITHOUT THE FOOTPRINT. REDUCE OPERATING HEIGHT BY UP TO 50% WITH THE SAME FORCE AND DEFLECTION AS COIL SPRINGS. Looking for a solution for tight spaces where a conventional coil spring simply doesn’t fit?

Smalley wave springs deliver precision and high performance in diameters now* down to 0.165". What’s more, a smaller assembly size and less material used means cost savings with no compromise in performance.

Let us customize the wave spring that meets your exact requirements.

All Springs Are Not Equal®

Free test samples for your next design are available at smalley.com/samples.

Ask Smalley. Our world-class team of engineers is always on call with free design consultation, downloadable CAD models or no-charge samples for evaluation and prototyping.

THE ENGINEER’S CHOICE™ * Small part manufacturing requires close collaboration when determining design criteria. Please consult Smalley on your next application.

Smalley_Product_Ads_Full_Page_Master.indd 3 Smalley 8-16.indd 99

3/10/2016 9:40:50 AM 11/8/16 1:24 PM

APPLICATIONS

Motion System

Shock and vibrationdamping applications SHOCK AND VIBRATION-DAMPING components are as varied as the designs in which they work. That ranges from heavy-duty machine tools to delicate designs that assemble semiconductor components. Addressing these oscillations lets machines run faster, for more throughput and higherquality (more accurate) moves. For example, the automotive manufacturing and packaging industries make copious use of mid-bore and smaller-bore hydraulic dampers.

Consider how bottle-blowing machine builders use adjustable shock absorbers instead of rubber bumpers or springs to increase glass and plastic bottle production. The shock absorbers protect the bottle’s neck and opening against stress fracture during manufacturing, even in hot and dirty environments. The shock absorbers in this application sport reinforced bodies to withstand more energy per second as well as Teflon-coated piston rings and piston rod seals formulated to withstand heat.

Shocks and vibration dampers excel in designs that are engineered to avoid the structures’ natural frequencies during operation. Adding mass with heavy bases or mounting machines into steel or concrete flooring is one approach. In applications where this is not possible or sufficient, vibrationisolating components and other passive dampers can absorb

Snubbers and Axial Isolators from LORD Corp. are components in the company’s multistage downhole isolation system product family that reduce the magnitude and occurrence of shock and vibration transmitted to the tool string from drill string excitations. Users regularly report a greater than 80% reduction in axial shock events more than 30 g.

100

DESIGN WORLD — MOTION

Shocks - MSCasebook 11-16 V2.indd 100

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 2:50 PM

ITT Enidine Motion Casebook 11-16.indd 101

11/8/16 1:25 PM

Motion Control Motion Custom Control control Custom control of hand forces of hand forces Vibration Control Vibration Control Isolate unwanted Isolate unwanted vibrations vibrations

Safety Safety Products Products Protection Protection for all for all machine machine designs under designs under any condition any condition

Motion System

Expect more more Expect than Automation Automation than Control!

Control!

APPLICATIONS

Deceleration & Vibration Deceleration Technology: & Vibration Technology:

Automation Automation Control Control Optimum Optimum tuning for tuning for any design any design

or attenuate vibrations. Here, the components bear the whole machine weight to shift excitation off the natural frequency. As a general rule of thumb, isolators should shift a design’s natural frequency so it’s no more than one-third of the excitation frequency. One caveat is that overly compliant isolators can actually increase the magnitude of motion. One solution where this is an issue is hydraulic or magneto-rheological setups that damp at system natural frequency but isolate like undamped designs.

In contrast, active vibration controls use actuators and sensors to counteract vibrations with motion having an out-of-phase frequency. One such design is a negative-stiffness mechanism from Minus K, which adjusts horizontal and vertical resonant frequencies separately. Such technology is particularly useful in aerospace and semiconductor applications with nanometer-level and better accuracy demands.

Mechanical subcomponents in the form of wave springs and compliant couplings are still other options to isolate vibrations, in everything from precision electric-motordriven machinery to those that run off internal-combustion setups.

As mentioned, one semi-active product to damp vibrations is magneto-rheologic fluid from Lord Corp., a blend of magnetic powder in oil, water or glycol that reversibly changes from free-flowing to semi-solid under an electromagnetic field. Particularly useful in automotive applications that must accommodate changing road and driving conditions, magneto-rheologic components can replace traditional hydraulic fluid in shock absorbers.

No matter the subtype, shocks and vibration-damping components have a reputation for being a commodity component. In fact, these devices are highly engineered and customized to very specific loads, impacts and machine geometries, and affect overall equipment performance.

by ACE

by ACE

Like the snubbers and axial isolators, the new Generation 3.0 prototypes of the SoftShoe product line from LORD Corp. are used in oil and gas downhole systems to protect probe-style MWD tool strings from high-energy axial shock. A dual compression compliance element provides additional longevity.

800-521-3320 800-521-3320 shocks@acecontrols.com shocks@acecontrols.com Download a CAD file or our product Download a CADat: filewww.acecontrols.com or our product sizing software sizing software at: www.acecontrols.com

Shocks - MSCasebook 11-16 V2.indd 102

1.3_vertical_ACEfamily.indd 1

102

DESIGN WORLD — MOTION

11 • 2016

11/9/16 11:21 AM

10/17/2016 1:49:38 PM

ROBOTICS

Robotics in motion: Common applications ROBOTIC PLATFORMS abound in Cartesian setups, delta subtypes, and six-axis selective-compliance-articulated robot arms (SCARAs). They’re more common than ever for machining, packaging, palleting, machine tending, welding, and assembly.

But no matter the application, the robot morphology must match the task at hand.

Case study: Quadrupled production capacity with collaborative robots Contract manufacturer Dynamic Group had difficulty staffing injection-molding production and wanted to employ their labor force with less menial tasks, so recently bought three collaborative robot arms from Universal Robots.

One robot picks and places frames to hold pieces and transport them to a trimming fixture. Then the robot places the parts in front of an operator for further handling before he or she pushes a button to reactivate the cycle. The setup makes medical-device pieces that are heat sensitive, so cycle times must be consistent from part to part. Before, Dynamic Group was having trouble making one good part with manual labor, especially with various shifts tending the machine cycle differently.

“Universal Robots’ UR10 robot arm gave us a consistent cycle,” said CEO Joe McGillivray. We went from having three operators on a single shift to running three shifts per day with just one operator. So we essentially quadrupled production capacity and scrap went from significant to near zero.”

The second injection-molding application uses a traditional Cartesian robot that drops a molded piece down a slide where the UR robot picks it up and places it in a degating fixture ... then palletizes the part on a table in front of an inspector. The old setup had parts fall onto a conveyor, which sometimes caused damage unless the operator caught them before they unloaded.

The new setup lets the inspector walk away to do other things and come back at will.

A third robot works on a kitting application. Using a vacuum gripper, a UR10 picks up a clamshell (the bottom part of a plastic box) then loads sterile wipes and saline solution into it before putting the container on a conveyor. Before the UR10, Dynamic Group tasked six to seven employees at once to do kit assembly.

“Our return on investment was less than two months, and we can quickly adapt the robots to other products,” said McGillivray.

He assumed Dynamic Group would need an expensive programmer or engineer to install the robots. “I’m not an engineer but within an hour of delivery, I had them setup and running test tasks,” said McGillivray. “Their user interface made

motioncontroltips.com | designworldonline.com

Robotics - MSCasebook 11-16 V2.LE.indd 103

them easy to program — so my initial assumptions about investment and extra hires were completely wrong.”

It took Travis Oksendahl, automation engineer at Dynamic Group, about two days to get the robots programmed once the cell was setup.

“Compared to traditional robots, the UR robots are easier to teach and program from drag-and-drop applications. In Teach Mode one simply grabs the robot arm and move it. Once points are set, simply hit play and the robot runs through these.”

All three UR robot models (UR3, UR5 and UR10) use technology that measures electrical current in the joints to determine force and movement. If the robot arm measures a force exceeding programmed force (down to 50 N in the UR3) it automatically stops.

“When Universal Robots distributor Braas Co. first showed me the robot, I asked them to pummel me with it. They wrote a program that let me walk in its way. It didn’t hurt, sensed me immediately, and stopped just like I’d want,” added McGillivray.

Having robots take over tasks previously handled by employees didn’t lead to staff layoffs. “We needed to make better use of our team, so instead of using our employees as labor, we needed to use their brains. That’s what Universal Robots helped us do.” The injection molder is now training employees to operate and program the UR robots. McGillivray and his team are also working on getting more UR robots into their production — including a UR with a structured lighting system for doing micron-level inspection 360° around a part.

Robot I/Os (and ease of access to them) allow quick tool changes, which serve the manufacturer’s high-mix low-volume situation.

11 • 2016

DESIGN WORLD — MOTION

103

11/9/16 12:13 PM

APPLICATIONS

Motion System

Linear stages and rotary tables used in all industries POSITIONING STAGES AND ROTARY TABLES lead the move to integrated designs in motion applications.

Just consider how fiber optic, test and measurement, and semiconductor machines (as those for assembly) all use precision stages and tables to boost throughput and quality. More specifically, the manufacture of flat-panel displays has spurred ever-larger motion-stage formats with linear-motor actuation and air-bearing load carrying. Elsewhere, belt-driven stages satisfy the need for long strokes but avoid ballscrew support challenges and the cost of linear motors.

Another growth industry using positioning stages is additive manufacturing. Here, everimproving materials and layup techniques demand new stages at all performance levels. Many basic maker-level machines use stages with synchronous belt-driven axes. More demanding applications (such as those for research and prototyping, medical, and small-batch manufacturing) commonly use positioning stages with motor-driven ballscrews to coordinate motion. In the same way, medical and life-research applications make use of ultra-precision stages that deliver performance motion profiles impossible a decade ago. Here, piezomotors, miniature linear supports and coarse-and-fine tandem actuators are increasingly common options.

Pre-engineered positioning stages dominate packaging, as this industry often forces integrators to satisfy design schedules that bar design and setup of multi-axis functions in house. Likewise, the machine-tool industry is making more use of customThis Motion Index Drives programmable built positioning stages (in laser-cutting and similar RT400-Flex has a barrel-cam and cammachines, for example). These and the stages for follower mechanism preloaded for zero backlash. Unlike gear reducers needing CNC applications are increasingly customized to backlash to work, the barrel cam specific motion tasks. That helps them deliver on requires the opposite. dynamic parameters at lower cost and without the

104

DESIGN WORLD — MOTION

Stages & Gantries - MSCasebook 11-16 V3.indd 104

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 12:30 PM

The Standard in High-Performance Linear Motion Just Got Better Aerotech’s new and improved PRO-Series stages

• Performance specifications improved by as much as 98% • New linear-motor stage sizes – PRO115LM and PRO190LM • Linear motor stages now with an absolute encoder option • Ball-screw stages now available with a linear encoder option • Direct mounting to English or metric optical tables Proven linear motor and ball-screw positioning stages now with new sizes, features, and improved performance. Call or email an Aerotech Applications Engineer today to discuss your requirements, or go to www.aerotech.com to request a quote.

Ph: 412-963-7470 • Email: sales@aerotech.com • www.aerotech.com WORLD HEADQUARTERS: USA THE AMERICAS • EUROPE & MIDDLE EAST • ASIA-PACIFIC

Dedicated to the Science of Motion AF0416B-RAD

AF0416B-RAD-PRO Series-Gen 2-9x10_875.indd 1 Aerotech Motion Casebook 11-16.indd 105

9/29/2016 10:54:50 AM 11/8/16 1:25 PM

APPLICATIONS

Motion System

Piezo-based nanopositioning systems such as these from PI (Physik Instrumente) are suitable for OEM production automation, metrology, scientific research, and lab automation.

hassle of reformatting or retrofitting stock setups. Enabling this newer approach are proliferating software tools that let OEMs and end users manipulate initial design iterations within virtual environments that have accurate models of real-world stage components.

Assembly is different. Here, semi-custom Cartesian stages excel for pick-and-place and inspection via machine vision. More typical in these setups are traditional rotary motors paired with rotary-to-linear devices (ballscrews, for example) and controllers that compensate for system dynamics to get accuracy to a few micrometers or better.

Automotive applications vary widely. For example, the large scale of sheet metal and body-assembly tasks present unique challenges that, in some cases, only overhead stages (or those with rack-and-pinion sets) satisfy. At the opposite end of the spectrum, stages that carry inspection instrumentation to detect part features on a nanometer scale often take the form of direct-drive axis assemblies driven by a precision controller that even corrects for environmental fluctuations.

106

DESIGN WORLD — MOTION

Stages & Gantries - MSCasebook 11-16 V3.indd 106

11 • 2016

Application examples: Rotary table and indexers improve medical and aerospace manufacturing Consider one example of an indexing-drive application. An integrator building a system for Boeing was asked to deliver a zero-backlash rotation system for positioning reverse-thruster parts for assembly. Complicating the design was that thruster and carriage are 140 x 80 x 60 in. and weigh 4,000 lb — and the user wanted a 5:1 safety factor. The positioner also had to allow for misalignment.

In the end, the integrator chose a Motion Index Drives programmable RT400-Flex machine. Its barrel-cam and camfollower mechanism are preloaded for zero backlash. Casehardened barrel cams and needleless cylindrical cam followers maximize torque. A custom bearing assembly on the tail accommodates any structural size differences from expansion and contraction. The RT400-Flex that Boeing uses also has a safety lockout and custom output flange for engagement at multiple angles.

In another indexing application, a medical-parts manufacturer had to find a new way to make closed female luer valves that connect bags, injection sites, and sampling tubes. The valves improve patient outcomes by minimizing motioncontroltips.com | designworldonline.com

11/9/16 3:55 PM

PERFORMANCE P

STAGES & TABLES

MATTERS M

bacterial ingress that can cause bloodstream infections and prevent exposure to infectious diseases or hazardous drugs.

To create the valve-making machine, the company sought the help of WEISS and WEISS North America. The supplier built three TR1100 ring-style systems — including ring indexer, stationary plates, and riser in an octagon-shaped frame design. A ringshaped design allows free design space and adjusts to various diameters and thicknesses.

Dial-ring outside diameter had to be at least 1,100 mm; inside diameter had to be to 800 mm; and indexing precision had to be within ±18 in. The medical-device company also had WEISS mount HP70 pick-and-place direct-drive components inside the guarding frame. The HP70s make 70-mm vertical strokes and 225-mm horizontal strokes with more than 100 cycles per minute and repeatability to within 0.01 mm. Here, a drive works with two linear motor axes featuring a knuckle on the Y-Z axis so there’s no need for a Z-axis linear motor.

At Primatics, when we tell you that our precision

This integrated machine from ISTHMUS Engineering & Mfg. makes cabinets out of sheet metal. It performs material handling, robotic integration, and processing tasks to present sheet-metal subcomponents to a universal assembly fixture preprogrammed on a PLC for 35 different cabinet configurations. It uses servo-driven axes to move cabinets to a robotic fastening station. Two six-axis robots equipped with TOX clinching heads then join liner components into a completed cabinet. Notice the overhead actuators using rackand-pinion sets to transport the sheet metal.

11 • 2016

DESIGN WORLD — MOTION

Stages & Gantries - MSCasebook 11-16 V3.indd 107

107

A

motion products will perform to specification, you can be certain they will do just that. And, we have the data to back it up.

We build high performance motion solutions that integrate easily and function seamlessly with complex automated systems.

Our clients experience a high correlation between the test data we provide and the performance they are measuring in the field.

m c t W in c O t a

When performance matters, Primatics delivers!

W P

The PXL33B is small form factor linear stage, optimized for higher accuracy, repeatability, and nanometer level minimum incremental motion.

T o n

primatics.com • 541-791-9678

p

11/9/16 3:56 PM

APPLICATIONS

Motion System

Motion applications for transducers and sensors TRANSDUCERS AND SENSORS ARE ESSENTIAL COMPONENTS for data collection, systems monitoring, and control feedback. In motion-control applications, transducers take the form of rotary or linear encoders for position feedback, sensors such as tachometers for speed sensing, and even proximity switches to initiate or halt some machine action. In hydraulic motion control systems, for instance, pressure transducers are a key part of the control.

Another common position measuring sensor is the magnetostrictive linear displacement transducer (MLDT). MLDTs have the advantage of using moving magnets that don’t come in contact with the sensor tube, avoiding mechanical wear, and providing absolute position readout.

Transducers abound in industrial designs, consumer products, and everything in between.

And with the rise of the IoT and IIoT (industrial internet of things), they’re poised to make their way into even more applications.

For instance, in the gaming world, Silicon-Valley-based Titanium Falcon sells a wearable smart ring. Called the Talon, it lets mobile gamers play games without touching their mobile devices, and see more of the screen as a result. “Traditionally, about 30% of gaming screen is blocked by the user’s hand or fingers,” said Titanium Falcon's Co-founder and CEO Juan Guo. Using real-time 3D tracking, the Talon outperforms onscreen 2D controls to let gamers use quick and easy waves and gestures to control the application.

The Talon's electronic innards include a microcontroller and a motion sensor that tracks rotational and lateral motion (in nine degrees of freedom). In contrast, traditional motion controls in gaming equipment such as the Xbox Kinect use motion-capture technology with limited accuracy and predefined set spaces. The Talon is also 90% smaller than traditional interfaces.

Through-shaft sensor offers position accuracy in harsh conditions In steer-by-wire applications, Piher’s hollow shaft PST-360 contactless Hall-effect magnetic sensor provides accurate pedal or brake position. The sensor’s through-shaft technology lets it wrap anywhere around the shaft, enabling sensing directly at the source. It lets engineers integrate a fully featured rotary sensor directly on existing shafts without the packaging issues such as gears that typically accompany encoders or

A trio of sensor offerings from SIKO including wire-actuated encoders, angle sensors and tilt angle sensors are designed for industrial trucks like forklifts.

108

DESIGN WORLD — MOTION

Transducers - MSCasebook 11-16 V1.indd 108

11 • 2016

motioncontroltips.com | designworldonline.com

11/7/16 4:48 PM

TRANSDUCERS

Piher’s PST-360 Contactless Hall-effect Magnetic Sensor is a fully featured rotary sensor used for accurate pedal or brake positioning in on-road and off-road vehicle steer-by-wire applications.

other through-shaft sensing devices. With no mechanical interfaces, this type of ‘clean’ configuration helps obtain an accurate and precise output signal over the complete life of the sensor, which is 50 million cycles that includes IP67 protection sealing.

The sensor element is a rotating ring magnet. Internally, there are only two main non-contacting components - the magnet (the only moving component) and the electronics. Since the ring magnet never comes into contact with the sensing electronics, it has no sensitivity to dust or dirt and can therefore tolerate high vibration cycles.

The PST-360 was especially conceived for extreme environment applications in onroad and off-road vehicles such as tractors, forklifts, trucks, racing cars and many others.

Smart sensors enable smart forklift trucks Industrial trucks such as forklifts, reach stackers or Automated Guided Vehicles (AGV) rely on intelligent sensors. The absolute measurement of position, angle, tilt, speed and lifting height is becoming more and more an integral part of intelligent industrial trucks.

Sensors help save time, reduce human error, improve productivity and above all ensure an increased level of safety.

Procedures can be automated, or useful information, such as lifting height, fork

motioncontroltips.com | designworldonline.com

Transducers - MSCasebook 11-16 V1.indd 109

position or the tilt of the lifting mast, can be displayed to the driver. In order to be able to implement these functions safely and easily, companies like SIKO GmbH offer wire-actuated encoders, angle sensors and tilt sensors.

Newly redundant wire actuated encoders meet the safety requirements in the whole system in line with SIL 2 and performance level d. The newly redundant wire actuated encoders SG32, SG42 and SG62 are used in forklifts and AGV systems to make them more reliable in measuring the height of the lift mast.

The SG32, SG42 and SG62 wireactuated encoders offer improved safety by means of a special and complete redundant sensor technology, which is employed to measure the absolute position.

Two completely separate sensor systems measure the absolute position and give it out separately as analog signals. With a measuring range between 3 and 6 m, these wire-actuated encoders are best suited for measuring the absolute height of the lift mast on driverless transport systems.

For forklifts, versions for up to 15 m are available. All sensors are available with the redundant interface, potentiometer, analog current or voltage, as well as CANopen.

Complementing these encoders are angle sensors. The first is a space-saving and robust angle sensor called the AH25S

11 • 2016

specifically for measuring the steering angle on driverless transport systems.

An exact miniature angle sensor with a blind-hole hollow shaft was developed in close collaboration with designers of such systems, making them easy to assemble and, with its robust die-cast housing, offering a real alternative to existing sensors made of plastic. The precision sensing gives absolute measurements over 360° with a resolution of 12 bits and gives the angle position over the analog interface with no time delay.

Lastly, in order to reliably detect the tilt angle of the lift mast, as well as the whole vehicle, SIKO offers two robust inclinometers with its tilt angle sensors, IK360 and IK360L. The MEMS-based tilt angle sensors are fully enclosed with their high IP69K protection rating, and are available in two precision variants (0.1° as well as 0.5°). Both sensors are available as a single-axis variant (0 to 360°) or a two-axis variant (+/- 80°).

DESIGN WORLD — MOTION

109

11/7/16 4:48 PM

APPLICATIONS

Motion System

110

Wave-spring uses abound in motion designs ALTHOUGH OFTEN BURIED IN ASSEMBLIES, wave springs are essential to motion-control applications, ranging from gearboxes, actuators, rotary unions, and clutches to an array of consumer products.

Wave springs operate as load bearing devices.

They suit applications with special space needs to take up play or compensate for dimensional variations within assemblies. They also work in designs that need loads to move either gradually or abruptly to reach a predetermined working height.

A wave spring always applies load in an axial direction. Wave springs also apply consistent loads within a small tolerance range at different work heights. These capabilities let design engineers adjust the application to meet given requirements when needed.

DESIGN WORLD — MOTION

Wave Springs - MSCasebook 11-16 V2.LE.indd 110

11 • 2016

One wave spring is the single-turn.

Versions with overlapping ends save axial space so there’s more space for travel. Here, the spring clings to the bore. In contrast, nested wave springs suit applications requiring higher forces to meet safety regulations, such as those in government or military applications.

A nested-wave spring provides a higher load than a single-turn wave spring (a stamped wave washer) and uses the same radial space as a single-turn design.

Use of multiple-turn wave springs can save 50% in axial space compared to a traditional coil spring. What’s more, these springs eliminate the risk of torsional movements during compression to work height.

motioncontroltips.com | designworldonline.com

11/9/16 12:34 PM

RotorClip_MSHandbook9-16.indd 111

11/8/16 1:26 PM

MOTION SYSTEM

APPLICATIONS

MOTIONCONTROLTIPS.COM

Ad Index ACE Controls Inc. ............................................................................ 102 Aereotech, Inc. ................................................................................ 105 All Motion .......................................................................................... 94 Altra Industrial Motion Corp. ............................................................. 29 AMETEK PMC ..................................................................................... 1 AMETEK/DFS .................................................................................... 15 Applied Motion Products .................................................................. 25 AutomationDirect ............................................................................ IFC Beckhoff Automation ......................................................................... 97 BellowsTech, LLC. .............................................................................. 47 Bison Gear & Engineering Corp. ..................................................... IBC Brogan & Patrick Manufacturing .......................................................... 8 Carlyle Johnson ................................................................................. 30 CGI .............................................................................................. 10, 11 Chieftek Precision USA .......................................................... 85, 87, 89 Custom Machine and Tool Co. Inc. ............................................. 26, 27 Del-tron Precision, Inc. ...................................................................... 77 DIEQUA Corporation ........................................................................ 64 Dunkermotoren, part of AMETEK ..................................................... 83 Encoder Products Company .............................................................. 56 Festo ................................................................................................. BC Galil ................................................................................................... 41 GAM Gear ......................................................................................... 61 Groschopp. Inc .................................................................................. 63 Harmonic Drive .................................................................................. 65 Haydon/Kerk, part of AMETEK .......................................................... 73 Helical Products Company .................................................................. 5 igus, inc. ...................................................................................... 22, 23 IKO .................................................................................................... 21 Intech ................................................................................................. 60

ITT Enidine ...................................................................................... 101 KHK USA Inc. ....................................................................................... 9 Kuebler Inc. ....................................................................................... 55 Lee Spring ......................................................................................... 37 Lin Engineering ................................................................................. 95 Maple Systems Inc. ............................................................................ 70 Master Bond ...................................................................................... 67 Maxon Motors ................................................................................... 81 MicroMo ............................................................................................ 79 Mitsubishi Electric .............................................................................. 43 Moog Animatics ................................................................................ 82 NBK America LLC .............................................................................. 46 Neugart USA Corp. ........................................................................... 59 NSK Precision .................................................................................... 19 PBC Linear ......................................................................................... 75 PITTMAN, part of AMETEK ............................................................... 90 Primatics, Inc. .................................................................................. 107 R+W America .................................................................................... 48 Rotor Clip Company, Inc. ................................................................ 111 Sensoray ............................................................................................ 40 Serapid Inc. ....................................................................................... 36 Servometer® ..................................................................................... 47 Smalley Steel Ring Company............................................................. 99 Teledyne LeCroy ................................................................................ 17 THK America, Inc. ................................................................................ 3 Tolomatic ........................................................................................... 13 US Tsubaki ......................................................................................... 35 Yaskawa America, Inc......................................................................... 51 Zero-Max, Inc. ...................................................................................... 7

SALES Mike Caruso mcaruso@wtwhmedia.com 469.855.7344

LEADERSHIP TEAM Michelle Flando mflando@wtwhmedia.com 440.670.4772 @mflando

Garrett Cona gcona@wtwhmedia.com 213.219.5663 Jessica East jeast@wtwhmedia.com 330-319-1253 @wtwh_MsMedia Michael Ference mference@wtwhmedia.com 408.769.1188 @mrference

WTWH Media, LLC 6555 Carnegie Ave., Suite 300 Cleveland, OH 44103 Ph: 888.543.2447 FAX: 888.543.2447

Mike Francesconi mfrancesconi@wtwhmedia.com 630.488.9029 David Geltman dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david Neel Gleason ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

Tom Lazar tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom

Publisher Mike Emich memich@wtwhmedia.com 508.446.1823 @wtwh_memich

Jim Powers jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

Managing Director Scott McCafferty smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty

Courtney Seel cseel@wtwhmedia.com 440.523.1685

EVP Marshall Matheson mmatheson@wtwhmedia.com

@wtwh_CSeel

805.895.3609

@mmatheson

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© 2016 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

Subscription Rates: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only.

Subscriber Services: To order a subscription or change your address, please email: designworld@halldata.com, or visit our web site at www.designworldonline.com POSTMASTER: Send address changes to: Design World, 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

112

DESIGN WORLD — MOTION

Ad Index Motion Casebook 11-16.indd 112

11 • 2016

motioncontroltips.com | designworldonline.com

11/9/16 12:54 PM

THE BEST JUST GOT BETTER...

DC

AC Runs Cooler & Longer Lasting than Traditional Right Angle Gearmotors AC and DC options available now 1/15 - 1/2 HP; 35-1780 in-lbs • AC MOTOR OPTIONS: 115V 1PH, 115/230V 1PH 230V 3PH Inverter Duty, 230/400-460 50/60HZ 3PH • DC MOTOR OPTIONS 720 frame size: 12V, 24V, 90V, 130V and 180V 725 frame size: 12V, 24V, 90V, 130V and 180V 730 frame size: 24V, 90V and 130V • Maximum power density means a compact profile without compromising performance • Ground gearing provides whisper quiet operation, low backlash precision • Latest hypoid gear technology ensures less friction/heat and extends product life • Versatile mounting interchangeability to easily upgrade your installed drives • Exclusive PowerSTAR® EP lubricant for extended life To learn more about PowerSTAR® right-angle gearmotors, please visit Bison’s NEW WEBSITE at www.bisongear.com or call 1-800-AT-BISON.

©2014 Bison Gear and Engineering Corp.

BisonGear_MSHandbook8-16.indd 1

We make your products go.™

11/8/16 1:27 PM

Introducing the FAST App The Festo Mobile App gives you quick and easy access to our FAST catalog which features a complete line of automation components with “Same Day”, “3 Day” and “5 Day” availability.

• On-the-go access to the FAST catalog • Tracking and managing orders • Notification of shipments

Download today and get started!

festo.us/mobileapp

Festo Motion Casebook 11-16.indd 114

11/8/16 1:28 PM