Design World November 2017

www.designworldonline.com

November 2017

inside: Motion Control: Functional safety: Coming to

a machine near you

p. 78

Industrial Ethernet: Industrial Ethernet—a

version for every application

p. 86

Mechanical: Guide to ball bearing

Bad robot: Will you trust your autonomous vehicle?

118

materials and applications

p. 108

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and I came away very impressed. Jabil, sometimes called the $20 billion company that no one’s heard of, is one of the three biggest contract manufacturers in the world—and is the largest such firm that is U.S. based.

“We try to keep a low profile,” said John Dulchinos, VP of Digital Manufacturing. “We try to stay below the radar, not disrupt the supply chain or get in the news.”

Jabil has an impressive 101 factories in 30 different countries, and 170,000 employees.

But the company realized that they needed a place where they could bring all of their capabilities together and show customers what they can do at their various facilities. So, they opened Blue Sky two years ago.

One of the things that most impressed me was their command center, which looked like a junior version of NASA’s Mission Control. Monitors showed everything from weather to worldwide seismic situations and currency exchange rates to the price of gas.

Earthquake in Italy? Maybe that means switching manufacturing for a particular product to the Czech Republic. The yen is spiking? Maybe that means switching suppliers for a project to South Korea. When I think of interconnected systems, I admit that I’ve never thought this big about it.

Jabil is thinking big about 3D printing and how it relates to manufacturing, too— as evidenced by their being a foundational partner with HP for its Multi Jet Fusion technology. While the company realizes that digital manufacturing is mostly prototyping now, that situation is rapidly evolving. Among other things, 3D printing allows for digitalization in many aspects.

“We’re heading to the digital factory,” Dulchinos said. “We’ll be flipping your manufacturing from one part of the world to another with the flip of a digital switch.”

He explained that in some industries, from mining to fighter jets, 3D printing will allow for converting physical inventory into digital inventory, where parts can be produced as needed.

“That would be groundbreaking—and a huge cost savings,” he said.

Jabil sees it coming from their customers, as well—the company represents some 250 top brands. Dulchinos said that the leaders in every industry “are looking at 3D printing.”

But it’s not just the 800-lb gorillas of the world that are looking at this technology.

Smaller and medium-sized companies are looking at digital manufacturing to disrupt business models and industries. As opposed to traditional manufacturing, complexity can be almost free with 3D printing—for example, it’s no harder to print a more complex manifold. In fact, it could be cheaper, as less material is being used … and the build time would be shorter than building a solid block of material.

Jabil is also seriously getting into—and investing in—printed electronics, which might be thought of as a sister technology to 3D printing.

“We think the two will converge over time,” Dulchinos said.

One thing’s for sure: the manufacturing plant of today, while not going away any time soon, will be undergoing some significant shifts in both processes and operation over the next decade. Plants that turn a blind eye to these changes will soon be so far behind that they won’t be able to compete—or even catch up. DW Paul J. Heney - Editorial Director pheney@wtwhmedia.com On Twitter @ DW—Editor

4 November 2017 www.designworldonline.com DESIGN WORLD

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Teschler on Topic The cost of having a manager

annoy you

A lot of engineers get annoyed when a supervisor wants to spend time reviewing some aspect of their job. If you find yourself thinking these meetings are usually a colossal waste of time, you may find solace from a recent report in the Harvard Business

Review. There Professors Gary Hamel and Michele Zanini estimated that the cost of excess bureaucracy in the U.S. economy amounts to more than $3 trillion in lost economic output, or about 17% of gross domestic product.

They reached this conclusion after reviewing U.S. Bureau of Labor Statistics data which said there were 23.8 million managers, firstline supervisors, and administrators in the American workforce in 2014.

That works out to one manager and administrator for every 4.7 employees. Overall, managers and administrators made up 17.6% of the U.S. workforce and accounted for nearly 30% of all salaries and benefits.

These statistics made the Harvard professors wonder how much of this supervision we really need. They

concluded that we ought to double the ratio of employees to managers and administrators so there is one manager for every 10 employees. This would free up 12.5 million individuals for doing real work instead of pestering their direct reports.

The shift in human resources would also make line-level employees more productive. The professors say it is reasonable to assume that as much as 50% of all internal compliance activity, such as budgeting and performance reviews, is of questionable value. Studies show that American workers who are not managerial spend about 16% of their time on these sorts of tasks. Cutting that time in half would annually save about 8.9 million worker-years.

The professors concluded these changes are feasible based on their analysis of a few plants where there is a minimum of supervisory personnel.

These plants include those of Nucor (America’s most profitable steel maker), W.L. Gore (famous for its Gore-Tex fabrics), Sun Hydraulics (a manufacturer of hydraulic components), and General Electric’s jet engine plant in Durham, N.C. At the GE Durham plant, for example, a single supervisor — the plant manager— oversees more than 300 technicians. The facility is more than twice as productive as other GE Aviation plants.

You might wonder whether the GE plant and the other establishments held up as role models are just anomalies. After all, there have been numerous studies claiming that better management — sometimes equated with more management — is the key to productivity. One in particular — done by economists from Stanford, MIT, the U.S. Census Bureau, and LSE, Centre for Economic Performance — looked at 30,000 manufacturing firms and claimed that those with more structured management practices were more productive, innovative, and had faster employment growth.

But a close reading of this study reveals that the “structured management” practices it mentions have nothing to do with supervisors.

Most of the rise in structured management, say the authors, has come in data-driven performance monitoring.

That’s a scenario where workers can see for themselves how they stack up just by checking statistics on a computer screen — no need for badgering from management.

In other words, less time spent dealing with administrators translated into more time being productive. That’s an enlightened way of running things that, unfortunately, too few facilities adhere to. DW

Leland Teschler • Executive Editor lteschler@wtwhmedia.com On Twitter @ DW—LeeTeschler

6

November 2017 www.designworldonline.com

Lee Teschler Column 11-17_Vs3.LL.indd 6

DESIGN WORLD

11/6/17 2:44 PM

The RSM2800 Magnetic Encoder counts turns, measures angles down to the last degree, and remembers shaft positions without power Don’t try this with other encoders: imagine your machine with the RSM2800 inside both lose power and are still turning without power; when power is restored, the RSM2800 reports the correct position including the counts that occurred with no power!

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Technology Forward Do designers need to get physical?

As powerful and feature-rich as CAD programs have become, you can argue that there’s a missing element to the design experience. Even augmented reality does not deliver the needed experience, yet.

The experience is actually touching a physical, three-dimensional model of the designed object.

The digital world is working hard to replicate such an experience as best as it can, but nothing quite succeeds like holding the object in your hands and examining and testing it. Simulations are great, and quite mature, but something is still lacking.

That is one of the reasons behind the trend to offer a fabrication lab experience to CAD designers.

Dassault Systemes in Waltham, Mass., recently gave a tour of its new fab lab within the headquarters building.

Noted Abhishek Bali, 3DExperience Lab manager, this facility helps CAD software designers, as well as customers, test and play with equipment to learn more about how a design could or should be manufactured and what future features to include in SOLIDWORKS to make the process more efficient.

Part of the focus of the new features in SOLIDWORKS 2018 is on shrinking the steps it takes to go from design to actual product production.

This lab has a range of equipment, notably several versions of desktop 3D printers, such as Formlabs and Ultimaker, a Tormach mini CNC mill, a

Roland SRM-20 for circuit design and test, a Shopbot CNC router, and even a small robot arm.

Said Bali, “Engineers are doing more physical prototyping, rather than just working with software.”

The trend for design engineers is to become multi-faceted, performing a range of tasks more involved with physical product development. So in a sense, everyone is becoming a “maker.”

Some of this shift into making is due to 3D printing / additive manufacturing.

“3D printing has made a lot more engineers think about manufacturing,” said Craig Therrien, senior product manager for SOLIDWORKS. With this increase in skills, comes the need for better communications between design and manufacturing.

The two groups still often speak in different “languages.” Dassault hopes to change that by promoting SOLIDWORKS 2018 as a common language between manufacturing and design, even across the enterprise.

One takeaway from the meeting is that everything—from design through manufacturing through use—is connected; we just need to figure out how to fully benefit from this connectivity. This is where future advances lie. DW

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

8

November 2017 www.designworldonline.com

Leslie Column 11-17_Vs2.LL.indd 8

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Green Engineering Jonathan Wilkins

• Marketing Director • EU Automation

Making industrial robots more

green

Manufacturers are introducing more automated and robotic systems to the factory floor to streamline the production line and efficiently deliver products to customers. However, as the factory increases its automated processes, it requires more energy to complete production.

With energy efficiency standards becoming stricter, manufacturers aim to reduce carbon emissions across the factory. The introduction of standards, such as ISO 50001, encourages manufacturers to improve energy performance and identify areas where they can reduce energy consumption.

Manufacturers can then monitor each asset on the assembly line to determine where they can best save energy.

VSDs Most industrial machines operate using motors, and around 65% of energy consumption in industry is attributed to these parts. When monitoring equipment, manufacturers may find that the motors are working faster than required and might even be running when the machine is not in use.

Installing a variable speed drive (VSD) is the best way to reduce motor speed to align with production. This equipment regulates speed and force of an electric motor to adjust the speed based on that of the assembly line. Using this technology prevents unnecessary energy consumption when the machine is working at a slower production rate.

EOT It is a common misconception that only new equipment will be energy efficient.

Manufacturers that use older equipment also have the opportunity to reduce energy consumption. While obsolete parts

12

are no longer produced by the original equipment manufacturer, it does not mean that they are not energy efficient.

Some industries, such as the pharmaceutical sector, rely on obsolete parts to keep systems running but also want to ensure that their processes are cost and energy efficient. Technology is advancing quickly, meaning that parts can easily become obsolete.

Many of these parts meet current energy efficiency standards, despite no longer being produced, meaning that manufacturers can use them, rather than replacing an entire system.

Relying on parts suppliers can ease the process of sourcing obsolete equipment, as it can be difficult to find the correct component. Using obsolete parts allows manufacturers to optimize their current system, rather than replacing it. Sourcing obsolete also promotes a circular economy as parts are given a longer lifecycle, rather than being disposed of in a landfill.

November 2017 www.designworldonline.com

Green Engineering 11-17 Vs2.LL.indd 12

Software It is important for robots to run efficiently and use only the required power. However, if the software programming is not frequently updated, the machine will still use excessive amounts of power.

Introducing new software can also improve the energy efficiency of a robot. Manufacturers can monitor and manipulate any asset by creating a digital twin using real-time analytical data. The manufacturer can then determine if the machine is using excessive energy and try to solve the issue using the digital twin before adapting the physical machine, efficiently reducing energy consumption.

These technologies ensure that manufacturers can run efficient machines, providing the best products to customers at the lowest cost and with little impact on the environment. DW

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Contents 11 • 2017

•

vol 12 no 11

•

designworldonline.com

ASRS

ASRS Automated Storage Retrieval Systems

www.designworldonline.com

A Supplement to Design World - November 2017

Covering the latest motion and control components, equipment and systems in ASRS design

120

ASRS COVER 11-17_FINAL.indd 54

Inside: 130/ Collaborative robots triple 3D printing production • 134/ Epson all-in-one SCARA • and more

| istockphoto.com

www.designworldonline.com

72 _MOTION CONTROL

94 _SENSORS

How to get a variable frequency drive (VFD) running with minimal effort

Achieving precision with limit switches

Here we cover the specifics of how variable frequency drives (VFDs) operate and ways to simplify their installation and setup.

78 _MOTION CONTROL Functional safety: Coming to a machine near you As

functional safety plays an increasing role in machine-tool manufacture, more emphasis is placed on encoders correctly and accurately measuring position data and handling encoder diagnostics and mechanical fault exclusion.

86 _INDUSTRIAL ETHERNET Industrial Ethernet—a version for every application

bigger Everything’s

in Texas China 114

choices for detecting presence and position, limit switches are often the best option for high precision needs.

Robotics Cover_11-17_FINAL.indd 112

112-147 10/31/17 12:04 PM

102 _ELECTRONICS Cheap Lidar will pave the way for autonomous vehicles

Innovations in sensing technology that won’t break the bank promise to help robotically piloted vehicles understand their surroundings.

108 _MECHANICAL Guide to ball bearing materials and applications

Ball bearings can be used in a range of applications, from medical and packaging technology to electronics and office technology.

ON THE COVER With new sensors, driverless vehicles may understand their surroundings for safer driving. | istockphoto.com

A | S | B | P|E

A | S | B | P|E

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CONTENTS 11-17_Vs4.LL.indd 14

A Supplement to Design World - November 2017

Among all the

Ethernet, in its many versions, continues to spread as the network of choice for industrial applications.

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November 2017

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Follow the whole team on twitter @DesignWorld

DESIGN & PRODUCTION SERVICES

EDITORIAL

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

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison Traffic Manager Mary Heideloff mheideloff@wtwhmedia.com Production Associate Tracy Powers tpowers@wtwhmedia.com DIGITAL MEDIA/WEB/ BUSINESS DEVELOPMENT

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November 2017

17

11/6/17 3:04 PM

Design for Industry O f f- s h o r e

Pressure transmitter with

low-power output

When low-power consumption is critical for off-shore applications, this low-power pressure transmitter may be a good choice. The PMP71 pressure transmitter has a 1-5 Vdc Low Power output option that draws only 17 milliwatts of power at 9 V, thus it consumes less power during operation than other voltage-output pressure transmitters in the market. This low-power draw makes the PMP71 suited for battery- and solar-powered applications, such as remote oil & gas wellheads, offshore platforms or pumping stations where low power consumption is critical.

The PMP71 measures absolute and gauge pressure of gas, steam or liquid and has built-in algorithms to calculate level, volume and mass of liquids.

Measuring spans are available in ranges from -6 to +6 psi up to -15 to 10,500 psi. For safe operation at process temperatures up to 752°F, it has a piezo resistive measuring cell and metallic welded process isolating diaphragm.

The PMP71 has ATEX, FM, CSA, NEPSI, IECEx approvals and is suitable for use in up to SIL3 hazardous applications.

The voltage output version is available with the CSA C/US XP approval in North America. DW

Connect and discuss this and other engineering design issues with thousands of professionals online

Endress+Hauser | www.us.endress.com/PMP71

November 2017 www.designworldonline.com 18

DFI 11-17_Vs3.LL.indd 18

WHAT DO YOU THINK?

DESIGN WORLD

10/31/17 1:58 PM

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

Sensor delivers linear

position feedback and takes up minimal space With the Internet of Things requiring sensors on nearly everything, situations arise that could use a sensor, but the space available for one is minimal. The BIP04 Compact Inductive Linear Position Sensor, however, delivers accurate, continuous linear position feedback over a 17 mm range, in a compact form factor.

The BIP04 is for position feedback on machine tool clamping spindles, pneumatic grippers, and any other application requiring linear position feedback in a confined space.

The sensor is available in analog 0-10 V, analog 4-20 mA, and IO-Link interface versions.

Features include: • Non-contact inductive technology ensures dependable operation and long service life.

• Field-teachable measuring range offers maximum flexibility and customization possibilities.

• Fully potted housing provides protection against damage in harsh machine environments. DW

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DESIGN WORLD

DFI 11-17_Vs3.LL.indd 19

November 2017

19

10/31/17 1:58 PM

Forming the Future

LEADING THE

INDUSTRY

Design for Industry Packaging

Pressure vacuum pumps Vacuum pumps can be a key component in packaging applications. The 2755 series variants are: 2755BE75, 2755BGHI75, 2755CE60, 2755CGHI60, 2755TE48/40.

2755TGHI52/48, 2755VEF75, 2755VHI75. These oil-less twin WOB-L piston units are RoHS compliant and designed for single stage vacuum, two stage vacuum, single stage compressor, or two stage compressor operation. They are designed for applications including blood or laboratory analyzers to ozone generators to packaging equipment, just to name a few.

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For more than a century Newcomb Spring has been recognized as the industry leader, with unmatched capabilities and expert services.

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• The 2755BE75 (115/60/1) is UL approved and provides an open flow of 7.5 cfm (212.4 l/min) and can operate up to 93% of local barometer continuously.

It weighs 21.5 lb (9.8 kgs) and measures (L x W x H) 10.35 in.

(262.9 mm) x 5.37 in. (136.4 mm) x 9.32” (236.7mm).

• The 2755BGHI75 (230/60/1 & 220-240/50/1) is TUV approved and provides an open flow of 7.5/6.6 cfm (212.4/186.9 l/min) and can operate up to 93% of local barometer continuously. It weighs 22.6 lb (10.3 kgs) and measures (L x W x H) 10.35 in. (262.9 mm) x 5.37 in. (136.4 mm) x 9.32 in. (236.7mm).

• The 2755CE60 (115/60/1) is UL approved and provides an open flow of 6.5 cfm (184.0 l/min) and can operate up to 15 psi (1.0 bar) or 91% of local barometer continuously. It weighs 21.5 lb (9.8 kgs) and measures (L x W x H) 10.35 in. (262.9 mm) x 5.37 in. (136.4 mm) x 9.32 in. (236.7mm).

newcombspring.com DFI 11-17_Vs3.LL.indd 20

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• The 2755CGHI60 (230/60/1 & 220-240/50/1) is TUV

approved and provides an open flow of 6.5/5.6 cfm (184.0/158.6 l/min) and can operate up to 91% of local barometer continuously. It weighs 22.6 lb (10.3 kgs) and measures (L x W x H) 10.35 in. (262.9 mm) x 5.37 in.

(136.4 mm) x 9.32 in. (236.7mm).

• The 2755TE48/40 (115/60/1) is UL approved and provides

an open flow of 2.6 cfm (73.6 l/min) and can operate up to 160 psi (11.0 bar). It weighs 21.7 lb (9.8 kgs) and measures (L x W x H) 10.75 in. (273.1 mm) x 5.37 in.

(136.4 mm) x 9.32 in. (236.7mm). Unit comes standard with fan guards and ground wire.

• The 2755TGHI52/48 (230/60/1 & 220-240/50/1) is TUV

approved and provides an open flow of 2.75/2.30 cfm (77.9/65.1 l/min) and can operate up to 175 psi (12.1 bar continuously. It weighs 23.0 lb (10.4 kgs) and measures (L x W x H) 10.75 in. (273.1 mm) x 5.37 in.

(136.4 mm) x 9.32 in. (236.7mm). Unit comes standard with fan guards and ground wire.

• The 2755VEF75 (115/60/1 & 110/50/1) is UL approved and

provides an open flow of 3.9/3.4 cfm (110.4/96.3 l/min) and can operate up to 98% of local barometer continuously.

It weighs 21.5 lb (9.8 kgs) and measures (L x W x H) 10.35 in.

(262.9 mm) x 5.37 in. (136.4 mm) x 9.32 in. (236.7mm).

• The 2755VHI75 (220-240/50/1) is TUV approved and

provides an open flow of 3.4 cfm (96.3 l/min) and can operate up to 98% of local barometer continuously. It weighs 22.6 lb (10.3 kgs) and measures (L x W x H) 10.35 in.

(262.9 mm) x 5.37 in. (136.4 mm) x 9.32 in. (236.7mm).

Units include a cathodic epoxy coated monolithic head, cathodic epoxy coated wetted parts, quality die-cast aluminum components, as well as more robust design features that utilize best practices from other product series. Supplied standard with each unit is a capacitor, capacitor insulator boot, and intake filter. DW

Gardner Denver THOMAS | www.gd-thomas.com

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Design for Industry Aerospace/military

Stainless steel flush nuts for thin

metal sheets won’t mar surfaces The design challenge is to fasten thin metal sheets in a manner that assures load-bearing threads that are stronger than tapped holes. In addition, the fastening cannot protrude on either side of the sheet. One solution is the PEMSERT self-clinching flush nut. These nuts can be installed before sheet bending and forming to provide threads for mating hardware in sections that otherwise would be inaccessible for fastener installation after chassis are formed. Their hexagonal head and clinch technology ensures high axial and torsional strength in service.

Ultimately, the nuts install permanently, will never loosen or fall out, and leave surfaces unmarred to enhance the functional and cosmetic qualities of assemblies.

The product line includes PEMSERT F 300 Series stainless steel types for installation into steel or aluminum sheets and PEMSERT F4 heat-treated 400 Series stainless steel versions specifically designed for installation into

300 Series stainless steel sheets. Both types are available in thread sizes #2-56 through ¼-20 and M2 through M6. Sheets can be as thin as 0.060 in./1.53 mm. For aerospace applications, F nuts can be ordered to conform with US NASM45938/4 aerospace standards.

Installation is accomplished easily by squeezing the nut into a round hole using sufficient force to embed its hexagonal head flush in the sheet. The metal displaced by the head then flows evenly around the back-tapered shank of the fastener to securely lock the nut permanently into place. Both the hexagonal head and the fastener’s self-clinching design combine to deliver high pullout and torque out resistances. Only a mating screw is required to complete final component attachment. DW

PennEngineering | www.pemnet.com

1.800.933.4915 22

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POWER TRANSMISSION

Design f o r I n d u s t r y

RETAINING DEVICES &

Safety

maintenance & assembly tools BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

Safety valve for

machine guarding The safe operation of machinery is always a priority. The M35 Series safety exhaust (dump) valve is for Category-4, PL e machine guarding applications. The safety function of the valve is to shut off supply of pneumatic energy and to exhaust any pneumatic energy from downstream of the valve.

The M35 Series double valve includes the 3/2 normally closed

function, dual poppet design, and is based on the technology of the SERPAR Crossflow family of double valves.

This control-reliable double valve is designed with external

PRECISION NUTS & WASHERS

monitoring for safe redundant operation, and is available with or without EEZ-ON (soft start) function. The EEZ-ON (soft start) up. The M35 Series valve is enhanced with a modular mounting

Materials of: ALLUMINUM and CORROSION RESISTANT STEEL

DW

Ross Controls | www.rosscontrols.com

ADAPTER SLEEVE ASSEMBLIES

Materials of: CARBON, ALLOY and HARDENED ALLOY STEELS

module option allows slower build-up of pressure during startdesign, allowing flexible air entry system assembly.

INCH and METRIC THREADS LEFT HANDED as well as RIGHT -HANDED

NUTS & WASHERS

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

W

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WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly.

Visit our website–whittet-higgins.com–to peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local

or a good distributor.

DESIGN WORLD

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33 Higginson Avenue, Central Falls, Rhode Island 02863 Telephone: (401) 728-0700 • FAX: (401) 728-0703 E-mail: info@whittet-higgins.com Web: www.whittet-higgins.com

10/31/17 2:00 PM

Design for Industry Safety

Power distribution blocks reduce costs

and improve safety

The design of the IP 20 Power Distribution (WPD) Blocks incorporates finger safety and offers reduced installation cost, when compared to conventional terminal blocks, by joining individual blocks to create small bus modules in the control cabinet.

The new compact, single bus modules have the ability to manage multiple load connections from one to nine poles. This unique design provides space-savings in the cabinet, while the transparent top cover offers a clear view of wire termination points and bussing configurations. The WPD blocks can be DIN-rail or direct mounted and ganged together via built-in joiners to create multi-pole assemblies of two- and three-phase groupings.

The WPD blocks are for power source distribution in low voltage applications (UL - 600V / 30 – 310 A, ac/dc) and accommodate a range of wire sizes from AWG 14 – 3/0.

Constructed of UL 94 V0 halogen free materials, the WPD blocks provide safe and advanced technology connections to deliver power and performance for a wide range of industrial applications. DW Weidmuller | www.weidmuller.com

Break the Chains of Maintenance CONTI® SYNCHROCHAIN CARBON is among the world’s highest-performing belts. Its incredible strength gives it the power to replace chain drives in the same space and frees you from the need to lubricate or re-tension the drive, saving maintenance cost, increasing uptime and improving efficiency. www.contitech.us

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To learn more, contact customer service at (800) 235-4632.

November 2017 www.designworldonline.com

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11/6/17 11:37 AM

Opto 22_new ad 11-17_main issue.indd 25

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Design Notes Edited by: Mike Santora • Associate Editor

Stepper motor steps in for discontinued product line

Quadrel Labeling Systems designs and builds all of their

ck The TechLine Front/Ba Inline Labeling System tems features from Quadrel Labeling Sys or interface, a color touchscreen operat steel PLC control, and stainlessup to construction with speeds . ute min 275 products per

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stepper-based Pressure Sensitive and Shrink Sleeve Labeling Systems using stepper motor technologies and has been doing so since the late 1980s.

Certain situations can prompt a company to change components within a system. For example, when a supplier is sold to a larger company, which then discontinues the product line being used. Quadrel had this occur with their motion system components, which meant that they needed to find another vendor with a product of equal or greater capabilities.

The motion product selected was Applied Motion Products’s STAC6-S advanced microstep drive with encoder input. The STAC6-S stepper drive is a two-phase, bipolar step motor drive specifically for high-speed, high-torque applications. It uses current control for smoothness over a wide speed range. The STAC6-S operates on singlephase 120 Vac and outputs up to 6.0 A/phase (peak-ofsine) to the step motor and features over-voltage, overtemperature, and over-current protection and is complemented by a specially matched set of low-loss NEMA 23 and NEMA 34 frame step motors.

The STAC6-S was able to duplicate the performance, match the footprint, and offer programmable features and IO at basically the same price as the discontinued product. Further, the STM-24 integrated drive and motor was also used to replace a bulky synchronous stepping motor, which allowed Quadrel to offer programmable variable speed for their TableTop systems at basically the same price as the synchronous motors.

A few of the features of the STAC6 that make it a good fit for Quadrel’s Labeling Systems include anti-resonance, torque ripple smoothing, and microstepping. Additionally, the company gained a bonus capability—the STAC6 product line is fully programmable, which offers the company’s engineering team high levels of flexibility with their stepping motor applications. And, there is no need to provide additional electrical components to gain this flexibility.

The drives have simple and intuitive fault protection that designers as well as users can implement when debugging controls. Simple multicolor blinking LEDs with a printed decode chart right on the controller case makes it easy for the team to

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Y

CM

MY

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Design Notes All of the Quadrel Labeling Systems are designed and manufactured in-house using CAD technology.

Complete Motion Solutions Pneumatic, Electric & Hydraulic Actuators

find wiring errors, missing motor fields, low input voltages, and much more.

While in operation, the resolution, direction, output torque, and integrated programmable inputs and outputs offer plenty of application flexibility to use the component in most of Quadrel’s wide variety of Pressure Sensitive and Shrink Sleeve Labeling system designs.

Quadrel’s electronic architecture sends step pulse signals via high-speed I/O ports to different components during operation. The STAC6-S stepper drive comes with an RS-232 port for

A few features that make the STAC6 a good fit for Quadrel’s Labeling Systems include antiresonance, torque ripple smoothing, and microstepping.

PHD offers an extensive line of pneumatic actuators that are known for long life and high quality. Over our 60 years of innovation, we have extended our product offerings to include built-to-need components, price alternative components, electric actuators, specialty workholding clamps, and motion control robots.

From single actuator solutions, to multi-unit systems, PHD and Yamaha Robotics can provide complete solutions for practically any application requirement.

To order a catalog, visit

phdinc.com/complete • 1-800-624-8511

configuration and programming. It also provides an RS-485 port for streaming serial (SCL) and Q commands over serial networks with up to 32 axes.

Accelerations and decelerations, profile, and multiple continuous control data following pulse trains are sent to the drives. When a servo application is too expensive for one of Quadrel’s customers, the company will essentially mimic the servo application using the STAC6 controller, and do so at a much lower price point for the customer.

Nearly all of the company’s labeling applications only need 1000 steps per revolution, but labeling requires high current and low inertia to cycle the label drive system and precisely control the label movement. Each STAC6 drive

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Design Notes 11-17_Vs3.LL.indd 28

November 2017 DESIGN WORLD

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The STAC6-S AC advanced microstep drive with encoder input is a two-phase, bipolar step motor drive designed specifically for high-speed, high-torque applications.

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Motor Feedback Systems for linear and rotative drives

comes with an encoder feedback connector for applications such as these that demand high levels of position accuracy not typically available when using typical open-loop step motor systems.

Through the use of a double-shaft step motors with incremental encoders Stall Detection or Stall Prevention can be activated in the drive.

The STAC6-S Advanced Microstep Drives have three pulse-based control modes, including step and direction, A/B quadrature, and CW/ CCW pulse; as well as velocity control mode with joystick operation; streaming serial command mode for commands sent from a host PC or PLC using serial communications ports; multi-axis stored program mode; seven digital inputs and three digital outputs that are all optically isolated; two analog inputs; torque ripple smoothing; and microstepping to 51,200 steps per revolution. UL Recognized (File No. E310506), CE approved, and RoHS compliant. DW

10/9/17 9:18 AM

Absolute and incremental magnetic measurement ■ ■ ■ ■ ■

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

Applied Motion Products www.applied-motion.com

DESIGN WORLD

Design Notes 11-17_Vs3.LL.indd 29

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

11/6/17 11:43 AM

Design Notes Edited by: Mike Santora • Associate Editor

Support bearings help fabric roll keep turning out products

The fabric roll shaft rests on a Vesconite Hilube support bearing.

Dam linings, billboards, butchery aprons, and many others are just some of the items that Arthur Dowson (Pty) Ltd. will start producing at the end of October in Johannesburg, South Africa. The laminating and coating factory is establishing a production line that will be introducing Vesconite Hilube support bearings for its fabric roll shaft.

Arthur Dowson maintenance manager Roy Rodgers says that the company had previously used teflon and nylon support bearings before switching to Vesconite, a self-lubricating high-load-bearing polymer.

Vesconite proved to have increased wear resistance compared to alternatives which tended to be ground down by the rolling action that they were exposed to, he says.

Upon deciding to re-establish the laminating and coating factory, after a temporary closure and relocation of equipment, Arthur Dowson made the decision to change to Vesconite Hilube, the more advanced version of the polymer Vesconite that has a lower co-efficient of friction and requires less lubrication.

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Design Notes Rodgers explains that, at the start of the production process, the fabric roll shaft, with the raw material around it, will rest on a new support bearing.

This curtain-like material will roll off the fabric shaft at 12m/min and then be coated with an anchor coat, or bonding coat, before it receives a top coat that is set in an oven.

Once it has received the coatings on the one side, the material is rolled onto another fabric roll shaft that is supported at the other end of the production line with more of the support bearings.

1000m of the roll is typically transported back to the start of the production line so that the reverse of the material can also be coated.

The process is then repeated, and the roll of fabric gains in weight and volume as it receives additional coatings.

Rodgers reports that the fabric rolls can weigh up to 2t after coating, with some clients requiring more coatings that result in an even greater fabric weight.

The decision to use the current plain support bearing design was motivated by the fact that roller bearings have to be removed with the fabric shaft, while the current design, which is a block shape with an open end that allows the fabric shaft to be lowered onto it and move on it, is a simpler easier-to-operate design, explains Vesconite Bearings mechanical engineer Juan van Wyk. For Arthur Dowson, the bearings also allow easy cleaning, since the polymers are resistant to many acids and alkalis, including acetone, paraffin and turpentine.

Rodgers says that the material coating company lubricated the previous support bearings to reduce wear and is likely to continue the practice with the Vesconite Hilube support bearings.

Wear becomes particularly important on the support bearings at the end of the production line, since the coupling of the driveend attachment and the material shaft have a small range for engagement, he says.

Rodgers reports that the company had three production lines running 24 hours a day previously, and that the coating firm will expand according to need following the successful reimplementation of an initial production line. DW

Vesconite Bearings | www.vesconite.com

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Design Notes 11-17_Vs3.LL.indd 32

32 November 2017 DESIGN WORLD

10/31/17 2:16 PM

Design Notes Edited by: Mike Santora • Associate Editor

Produced by Karma Culture LLC, Karma Wellness Water features a patented cap that protects dry probiotic cultures to maintain the highest efficacy without the need for refrigeration.

Spin-welding technology helps

redesign bottle cap

Produced by Karma Culture LLC, Karma Wellness Water features a patented cap that protects dry probiotic cultures to maintain the highest efficacy without the need for refrigeration. This product is just one of the latest examples in increasing package complexity fueled by demand for more convenient, on-the-go products. For Karma, that meant finding a way to successfully execute production of its complex cap design.

DESIGN WORLD

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November 2017

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OF MANUFACTURING CUSTOM CABLES

NORTHWIRE.COM

•

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+1 715.294.2121

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The KarmaCap uses a screw-on base with a sealed upper capsule that contains the probiotics and can be activated with the push of a button. The sealed upper capsule works because spin-welding technology joins circular thermoplastic parts by applying pressure and a spinning motion that generates heat to melt and fuse them together without impacting the probiotics inside.

To create a bottle cap that dispenses the probiotics with the push of a button, Karma Culture called on Emerson and its Branson spin-welding technology.

“The KarmaCap design, sealed with Branson spin-welding technology, has been vital to our ability to deliver the only shelfstable probiotic water available,” says C.J. Rapp, CEO of Karma Culture LLC. Probiotic cultures, known as “good bacteria,” are typically premixed with water before bottling as the probiotic ingredients are prone to deteriorate due to moisture, UV rays, oxygen, or heat. Premixed products like this require refrigeration or special handling to slow deterioration, but cannot stop it.

The KarmaCap overcomes these obstacles by using a screwon base with a sealed upper capsule that contains the probiotics until the consumer chooses to mix with the push of a button. The sealed upper capsule works because spin-welding technology joins circular thermoplastic parts by applying pressure and a spinning motion that generates heat to melt and fuse them together without impacting the probiotics inside. The result is an airtight seal between the upper capsule and the screw-on cap base that prevents premature mixing or leaking.

Today, the KarmaCap manufacturing process uses Emerson’s Branson SW300 servo-driven spin welders to produce caps that are free from the issues associated with snap-fit seals – dramatically improving production efficiency and eliminating nearly all rejects. DW

Two Part Adhesive with LOW THERMAL RESISTANCE EP30TC Epoxy Passes NASA Low Outgassing Tests

Exceptionally low thermal resistance 7-10 x 10-6 K•m2/W Superb thermal conductivity 18-20 BTU•in/ft2•hr•°F Ultra thin bond lines 5-15 microns

Emerson | www.emerson.com/packaging

154 Hobart St., Hackensack, NJ 07601 USA • +1.201.343.8983 • main@masterbond.com

www.masterbond.com

DESIGN WORLD

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10/31/17 2:19 PM

Internet of Things

Go wireless with fluorescent light tubes Here’s an interesting approach to wireless, and potentially IoT, technology.

LiFi (light fidelity) has advanced to the point of introducing a new form of mainstream implementation. This technology uses the same LED lights that illuminate a work space to transmit secure, high speed, wireless data at rates that can go beyond those possible with Wi-Fi. This new development results from the introduction of the first LED “light bar” fixtures equipped with the required transmission technology and designed to replace fluorescent tubes.

With an estimated 3-4 billion installed fluorescent tubes throughout the world, the integration of built-in LiFi transmission technology in new and retrofit LED light bars is moving LiFi beyond the pilot stage to full-scale implementation in offices, schools, warehouses and other facilities.

“LiFi is not a concept, it is really here,” says Harald Haas, co-founder and Chief Science Officer of pureLiFi, a company spearheading the development of the

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File access is permitted only if a device is connected to the LiFi network. Once a user connects to a LiFi network, they can download and modify certain files.

DESIGN WORLD

10/31/17 2:47 PM

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Internet of Things

With the implementation of LiFi in LED lightbars, the technology is now

technology. “If people want to engage, they can purchase the products right now.”

commercially available.

What is LiFi? LiFi is a high-speed, secure, fully networked wireless communication technology similar to Wi-Fi. However, LiFi uses the entire light spectrum where Wi-Fi uses radio frequencies (RF).

To do this, the LED light fixtures used in homes and offices are outfitted with a module that controls the light for optical data transmission. The high speed light pulses are invisible to the naked eye, yet can be used to transmit data at high speeds to a receiving device located in a laptop, computer tower, cell phone or other smart device.

In the future, LiFi will be embedded into the mobile devices we use every day, as well as play a key role in machine-to-machine communication and the Internet of Things (IoT).

The use of visible light provides a host of intriguing benefits that outpace what is currently possible with the radio frequency waves used by Wi-Fi and cellular networks.

Standard Parts.

Winco.

J.W. Winco’s immense offering of leveling devices include… · Inch and Metric sizes · Tapped or Stud Type · Steel, Stainless Steel and Plastic Bases · Plain, Anti-Vibration and Non-Skid Pads · A multitude of load ratings for light to heavy duty loads Explore Winco’s full product line of standard machine components for industry by visiting www.jwwinco.com or by contacting us with your application requirements.

Sales@jwwinco.com • Phone: 800-877-8351 Fax: 800-472-0670

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Internet of Things

When compared to the overloaded full RF spectrum, the light spectrum is 1,000 times larger and is currently unregulated with no licensing fees.

In lab conditions the technology is already capable of 10 Gbps speeds, and with the available bandwidth potential, data transmission speeds up to 100 times faster will be possible in the near future as the technology advances.

StepSERVO

TM

Integrated Motors

LED lighting manufacturers push LiFi forward According to Haas, who is considered the “father of LiFi” and has been working in the field for the past 15 years, the implementation of the technology into lighting fixtures has necessitated a close partnership with LED light manufacturers.

“The lighting manufacturers are very important to move LiFi forward,” says Haas.

“They know how to design lights and fixtures and we know what needs to be done to create high speed data networks out of light and add communication capability to it.”

Until recently, most of these fixtures were small lamps or recessed can lights. Now, one of its partners, Linmore LED, is introducing the first LiFi enabled LED light bars designed to replace fluorescent tube lighting.

With the technology, data speeds have been clocked at 43 Megabits-per-second (Mbps) up and down.

“Linmore LED is the first company to bring this technology not only into new light bar fixtures, but also be able to retrofit linear fluorescent fixtures to use the LiFi technology,” says Haas.

Linmore LED originally built its reputation in the retrofit market, uses its own proprietary designs involving optics, thermal dissipation and a number of other techniques to ensure its LED products perform in the top 1% in energy efficient in the industry.

According to Paul Chamberlain, CEO of Linmore LED, the product’s design allowed for the integration of the LiFi modules in the ideal position on the light bar, without affecting critical aspects such as lighting distribution, thermal dissipation or overall performance.

Retrofit fixtures, even those that are not LiFi enabled, are in great demand as many facilities seek to drive down energy costs by as much as 70-80% by converting to LED technology. This trend is also driven by the increased operating life of LEDs and concerns about the toxic

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Internet of Things

LiFi takes advantage of its limited transmission distance to offer better security.

mercury used within fluorescent lamps that complicates disposal.

“Businesses want to leverage an LED upgrade and get more than just lighting, says Paul Chamberlain, CEO of Linmore LED. “Using an existing part of a building’s infrastructure – lighting – opens up endless possibilities for many other technologies to have a deployment backbone. Internet of Things (IoT), RFID, product and people movement systems, facility maintenance, and a host of other technologies are taken to the next level with LiFi available throughout a facility.”

Security benefits Among the expected early adopters of the technology are those that seek greater security of data transmission. Initial markets expected to adopt LiFi technology include

federal government and defense, banking, financial institutions and hospitals.

Distance has always been viewed as a limitation in many communication systems, with considerable effort taken to enhance the ability of a network to send data over longer distances. LiFi takes advantage of its limited transmission distance to offer better transmission security. With LiFi, a receiving device must be directly within the cone of light to receive a broadcasted signal. Visible light, including near-infrared wavelengths, cannot penetrate opaque objects such as walls, which means that the wireless signal is constrained to within a strictly defined area of illumination.

In a man-in-the-middle attack the attacker must be able to intercept all relevant messages passing between the

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two victims and inject new ones. This is straightforward in many circumstances; for example, an attacker within reception range of an unencrypted wireless access point (Wi-Fi) can insert itself as a man-in-the-middle.

Because visible light is easily containable within a space, it could eliminate classic man-in-the-middle attacks where eavesdroppers located outside an area are able to intercept communications from radio waves emanating outside building.

Traditional encryption and authentication protocols used for Wi-Fi provide an additional layer of security for the LiFi network.

The ability to direct or shape light into defined areas of illumination allows precise partitioning of any environment.

File access is permitted only if a device is connected to the LiFi network. Once a user connects to the LiFi network, they can download and modify certain files. It is also impossible for a nearby employee to intercept information sent to the server/ network by another employee, since the uplink communication is on a different frequency from the downlink.

Further increasing security, every device that can connect to the network can be localized and tracked using the technology.

The same LiFi module enables “communication on the move” by tracking the transmission source electronically, with no moving parts.

“You can walk through a building, into different [light] zones and it will keep you connected the entire time as you move along in the building,” says Haas.

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The future The technology is expected to continue to advance under an “aggressive strategy of miniaturization and lower costs,” says Haas.

Although current technology requires use of a dongle, much like early Wi-Fi, Haas says the major mobile device manufacturers are already expecting to adopt the technology within the next 3-5 years. DW

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Internet of Things

What is the missing link in the Industrial Internet of Things?

Robert Miller CLPA-Americas Director

Much of the promise of Industry 4.0 is based upon seamless interconnectivity between production machines, enterprise systems and sources of data in the wider world. The Industrial Internet of Things (IIoT) is a key foundation of that interconnectivity through low cost, easily integrated sensors, actuators and systems.

Yet in most production environments today, true integration is rarely realized.

Production networks need to communicate a variety of data, from critical realtime machine control signals to high volumes of recorded data from quality control systems and machine monitoring technologies. The differing technical requirements of these diverse data types can lead many organizations to implement multiple data networks. That adds complexity to system design, construction and maintenance. It makes data sharing across different types of equipment more challenging too.

To overcome these difficulties, manufacturers need a different kind of communication network. We at CC-Link believe that network is CC-Link IE, an open industrial network offering gigabit Ethernet performance.

CC-Link IE solves the first critical challenge facing the new generation of connected factories: bandwidth. At 1 Gbps, it offers performance up to 10 times that of similar protocols available today, enough to satisfy the most data-hungry modern manufacturing processes. The 1Gbps network is not all about the speed – but the data capacity allowed by the increased bandwidth; this provides for true Industry 4.0 capability.

CC-Link IE is based on standard IEEE 802.3 Ethernet, and offers flexibility in network design, including ring, line and star topologies. The line and star topologies 42

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CC-Link IE can help manufacturers reap the benefits of greater connectivity across their processes, with improved network performance delivering tighter control, greater data throughput at high speed, deterministic performance and inherent security.

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can be combined to provide systems that offer the maximum application flexibility.

The ring and line connections are also attractive, as they permit simple “daisy chaining” of devices, meaning the added cost and complexity of network switches can be avoided.

CC-Link IE also allows considerable application flexibility by supporting multiple protocol types on the same network. This reduces costs and increases maintainability. In addition to the standard I/O control, it offers safety (SIL3) and motion control on the same cable. This allows the CLPA to offer a cost-effective, simplified, flat network architecture that meets the needs of nearly all applications in the discrete sector.

The network uses commercially available Ethernet infrastructure, such as standard gigabit switches, Cat5E cable and RJ45 connectors. A single network can incorporate a total of 120 stations with up to 100 m of Cat5E cable between each station. As many as 239 networks can be interconnected. To further increase the network possibilities for end users and machine builders, CCLink Partner Association has worked with PROFINET International (PI) to produce a specification for a “coupler” device that will allow these previously incompatible networks to be freely interoperable.

Moreover, the CLPA is working with the OPC Foundation to develop support for OPC-UA with CC-Link IE.

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Unlike industrial protocols built on the standard TCP/IP (UDP/IP) stack, CC-Link IE combines the physical and data-link layers of the OSI hierarchy with an open protocol that extends from the network to application layers. The result is inherent cybersecurity, thanks to an open, but controlled knowledge base that CLPA partners are free to implement, but reduces the exposure to unauthorized use.

Critically for applications that combine industrial automation with enterprise systems and cloud or internet-based technologies, CC-Link IE can encapsulate TCP/IP (UDP/IP) packets for transmission across the network, allowing this traffic to “tunnel” through the CC-Link IE system.

CC-Link IE’s basic communication technique is based on a shared memory model. All the devices on the network occupy an area of the controller’s memory. To communicate with them, simply change the value of the data in the area corresponding to the relevant device. The network automatically handles the traffic with the standard “cyclic” (synchronous) communication.

The same process happens in reverse for communication to the controller from devices. For high priority, unscheduled events such as alarms, or lower priority non-cyclic transmissions such as diagnostic information, an alternative “transient” (asynchronous) communication method is available. www.designworldonline.com

The gigabit bandwidth means that even high levels of transient traffic do not impact the deterministic regular cyclic communication, meaning normal system functions are not impaired and the scan cycle is completely deterministic.

Deterministic performance is achieved with a token passing method, allowing dependable system operation. In practice, this allows network update times to occur in a few tens of microseconds, depending on system size and configuration. CC-Link IE also offers the ability for redundant controllers, so even a controller failure will not necessarily result in lost production.

CC-Link IE can help manufacturers reap the benefits of greater connectivity across their processes, with improved network performance delivering tighter control, greater data throughput at high speed, deterministic performance and inherent security. It is set to play a key role as manufacturers adopt Industry 4.0 models to address the production challenges of tomorrow. DW

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Internet of Things

MindSphere—platform services for the IoT For companies seeking to perfect their entire value chain from design, production planning, engineering and manufacturing to a full range of aftersale, maintenance and upgrade services, there’s MindSphere. This platform is part of the Digital Enterprise Software Suite, Siemens Cloud for Industry.

MindSphere is a platform as a service (PaaS) concept with a wide range of services for manufacturing companies on the path to Industry 4.0. It is an open operating system for IoT, allowing

a custom platform for recording and analyzing large volumes of plantwide production data. A customer can integrate with Siemens or third-party providers for predictive maintenance services, energy data management and resource optimization development applications.

MindSphere interlinks physical products and production facilities with digital data, enabling the implementation of innovative solutions plus the ability to bring products onto the market faster

and more efficiently.

It is based on an open infrastructure on SAP HANA and allows the creation of new digital services ongoing for the customer.

This data hosting platform combines device management, connectivity, all necessary data storage and the associated infrastructure, providing virtualized data management that can be deployed quickly. DW

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Internet of Things News Intel offers approach to IoT scaling and security While earlier reports claimed that we will see 50 billion devices connected through the IoT by 2020, the reality is we are nowhere close to reaching those numbers. In fact, recent research reports are far more tempered and predict closer to 30 billion devices by the same timeframe. The reason for the scaled down outlook is because of the real-time issues of scaling deployments and security.

Today, provisioning and management of devices is a huge challenge, as IoT devices are added manually. It involves coordination between installation technicians, IT network operations, and operational technology teams and can typically take more than 20 minutes for a single device. Imagine installing 10,000 “smart IoT” light bulbs – at present, it could take two years to complete the process. This is to say nothing of the effort required to maintain device privacy and security.

To solve these complex issues, Intel announced the launch of Intel Secure Device Onboard (Intel SDO). This technology securely automates and brings IoT devices online within seconds rather than hours. Intel SDO is offered to IoT platform providers as a service

they can provide to customers who wish to onboard thousands of connected devices.

Intel SDO’s “zero touch” model allows devices to dynamically discover the customer’s IoT platform account at power-on for automatic registration.

It offers a one-to-many, one-time enablement approach that can be integrated into almost any device or IoT platform, eliminating the need to custom pre-load provisioning configurations for each IoT implementation.

The Intel SDO also leverages Intel’s privacy-preserving IoT identity solution, the Intel Enhanced Privacy ID (Intel EPID), to anonymously authenticate the device and establish an encrypted communication tunnel, preventing hackers from tracing the device from

factory to owner. Intel EPID establishes a best practice identity model for IoT onboarding.

Intel SDO is integrated with Wind River Helix Device Cloud, its device lifecycle management platform that enables IoT devices to securely connect, monitor, manage and service devices.

With the integration of Intel SDO, Wind River’s latest release of Device Cloud includes zero touch onboarding designed to mitigate the risk of security attacks to a device, ensure privacy, and deliver automation that dramatically reduces installation and onboarding time to seconds. DW

Intel | Intel.com/ securedeviceonboard

The Industrial Internet Consortium and oneM2M partner on IIoT The Industrial Internet Consortium (IIC), a leading organization transforming business and society by accelerating the adoption of the Industrial Internet of Things (IIoT), and oneM2M, a global IoT standards initiative, announced they have agreed to work together to contribute to the creation and development of the Industrial Internet. Under this agreement, the organizations will work to prevent fragmentation and to harmonize various aspects of the IIoT. Joint activities between the IIC and the oneM2M will include:

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News

• Collaboration, review and two-way feedback pertaining to IoT use cases, requirements and reference architectures.

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testbeds and interoperability events.

• Feedback from oneM2M to IIC Industrial Internet Reference Architecture.

• Joint workshops, showcases and interoperability events.

“The Industrial IoT brings a whole new set of specific requirements in comparison to consumer IoT. Deriving those specific requirements from market driven use cases as well as lessons learnt from operational driven testbeds, such as those developed

by IIC, is the only viable option to develop the set of standards needed for IIoT,” said oneM2M’s Technical Plenary Chair Dr. Omar Elloumi, of Nokia. “Formalizing our cooperation with the IIC is an important step in meeting these requirements. oneM2M has built an interoperability framework that’s applicable within and across IoT application domains. We are excited to have the opportunity to work with the IIC to extend our footprint of standards” “Horizontal technologies that enable scalability across a variety of industrial verticals are essential to the widespread adoption IIoT,” said Wael William Diab, IIC Chair of the Liaison Working Group. “We are excited about working with oneM2M to ensure that interoperability remains a core tenet of the IIoT as we look to accelerate the growth of IIoT applications.”

The IIC Liaison Working Group is the gateway for formal relationships with standards and open-source organizations, consortia, alliances, certification and testing bodies and government entities/agencies. The agreement with the oneM2M is one of a number of agreements made by the IIC Liaison Working Group. DW

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CAE Solutions

Easier integration of

electronics into everday products

Detailed performance simulation in context of vehicle to vehicle communication.

The Simcenter portfolio will include features that give engineers the ability to engineer the electromagnetic performance of systems with regard to antenna design and installation, EM Compatibility (EMC), EM Interference (EMI), EM hazards and more. These features are the result of a partnership Siemens has entered into with Ingegneria Dei Sistemi (IDS), an independent engineering and systems technologies company based in Italy to provide high-frequency electromagnetic (EM) engineering solutions to the market.

With the increasing integration of electronics into everyday products and increased connection to IoT, fast, accurate representations of how products will perform in real-life situations helps ensure design success. This large increase of electronics, specifically wireless devices, creates a likelihood of EM interference and potential system malfunctions, but also allows the opportunity for new product functions if properly managed in the design stage.

In automotive, autonomous driving presents a higher stakes circumstance where reliability and safety require highquality EM sensor behavior for obstacle detection and collision avoidance, both long and short range, but also V2X. IDS solutions provide realistic predictive engineering, on scalable virtual models ranging from individual sensors through full systems integrated into virtual cars.

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simulations into driving scenarios, car manufacturers will be able to increase the safety and performance of autonomous vehicles. DW

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Electro-Magnetic Compatibility (EMC) Analysis of the front part of an aircraft | courtesy of Piaggio Aerospace & HIRF-SE Project

November 2017 www.designworldonline.com

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CAE Solutions

MapleSim 2017 eases the

creation of digital twins and other virtual prototypes

MapleSim models multidomain systems, supporting the rapid creation and testing of initial concepts. These capabilities help users identify and prevent unexpected interactions between different domains, and generate computationally efficient models in less time.

MapleSim is used across a variety of applications and industries, including the creation of physics-based Digital Twins. Digital Twins do not require test data to predict behavior, so they can be used for conceptual design as well as validating product performance, design changes, and diagnostics. The latest release provides new and improved model development and analysis tools, expands modeling scope, introduces new deployment options, and strengthens toolchain connectivity.

MapleSim 2017 includes:

• the Initialization Diagnostics App provides insight into the initialization process to help users determine how the initial values are computed and what actions are needed to adjust them.

• the Modal Analysis App helps users explore and understand the natural

vibration modes of their mechanism, so they can identify which modes will have the biggest impact on the design and determine how to reduce the vibration in the final product.Â

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a c i r e m 4.

A n i e 3 d 9 a 1 m e c n Y i s R VE MapleSim is used across a variety of applications and industries, including the creation of physics-based Digital Twins.

Other improvements include more than 100 new components, including expansions to the Electrical and Magnetic libraries.

MapleSim 2017 also provides a new Modelica code editor that makes it easier to create Modelica-based custom components, new options that simplify the creation of custom analysis tools, and enhanced support for connectivity with other modeling tools through FMI export. The MapleSim family of products also includes MapleSim Explorer, which enables users to make the knowledge embedded in their MapleSim models available to more people.

In addition, the new MapleSim 2017 release includes a new add-on component library. The MapleSim Heat Transfer Library from CYBERNET provides a comprehensive view into the heat transfer effects present in a model, enabling users to refine their design to improve performance and avoid overheating. The MapleSim Heat Transfer Library from CYBERNET is useful for any situation where heat generation is a concern, especially when there are moving boundaries between heat generating components, such as motors, batteries, printers, and manufacturing equipment. DW

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CAE Solutions

A glimpse at what’s new in COMSOL Multiphysics

COMSOL, a leading provider of software solutions for multiphysics modeling and simulation app deployment, provided attendees with a sneak preview of the latest updates of the COMSOL Multiphysics and COMSOL Server products at the annual COMSOL Conference in Boston. Attendees learned about current and future developments of the software from Svante Littmarck, President and CEO, COMSOL, Inc. during his keynote address.

“Our customers are at the forefront of innovation behind the products that will shape our future,” says Littmarck. “We work tirelessly to support their efforts by increasing the modeling power of the COMSOL software and by making collaboration among simulation experts and their colleagues the core of everything we do. This annual event is our opportunity to connect and exchange knowledge within the COMSOL community on multiphysics modeling.”

Looking ahead at the upcoming release • Acoustics and acoustic-structure interactions based on a hybrid boundary element-finite element (BEM-FEM) method • Impulse response for ray acoustics • Magnetostatics based a hybrid boundary element-finite element (BEM-FEM) method • Shape memory alloy (SMA) materials for structural analysis • Revolutionary new method for capacitively-coupled plasma (CCP) simulations • Support for 3DConnexion SpaceMouse devices

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• Turbulent-flow enabled inlets for CFD simulations • 150 new materials and 1300 new material properties in the Material Library product • More than 60 substrate material properties for RF and microwave analysis “We are excited to now offer acoustics analysis based also on the boundary element method. It’s a great addition that many of our users have been waiting for”, says Mads Jensen, Technical Product Manager, Acoustics, at COMSOL. “By combining boundary element, finite element, and ray acoustics analysis in a multiphysics environment, our users get unprecedented modeling power. Users can now efficiently analyze the full range of acoustic frequencies from the lowest bass notes to ultrasound.

Not to mention all the possible multiphysics couplings.”

Those in attendance had the opportunity to test the beta version of the software to try out this new feature, along with many updates to be announced later this year. DW

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Simple support structure

improves warehouse packaging efficiency An improvement in packaging efficiency required attention to ergonomics, ease of assembly, and cost efficiency.

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A S / R S

• Though limited by challenging design constraints, engineers created a supporting structure that mounts underneath the existing module and integrates an arrangement of plywood, aluminum extrusions and linear bearings, an achievement that required attention to ergonomics, ease of assembly

A

and cost efficiency.

Automation is changing how traditional distribution centers operate as companies search for new ways to maximize their efficiency, increase order accuracy and fulfill customer demand. When it comes to automated technology, most people tend to think about robots, automated guide vehicles and pickand-place systems. But just as important are the smaller, simpler structures that must be engineered to interface with the high-tech systems. And their designs present their own set of challenges.

Demonstrating this point, systems integrator N-III, Inc. recently devised a simple, yet large-scale solution to improve the efficiency of an existing warehouse packaging staging module. Though limited by challenging design constraints, the company created a supporting structure that mounts underneath the existing module and integrates an arrangement of plywood, aluminum extrusions and linear bearings, an achievement that required attention to ergonomics, ease of assembly and cost efficiency.

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www.designworldonline.com

Edited by Danielle Collins Senior Editor

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A S / R S

•

To improve a packaging station, N-III engineers created tables made of strong ply capped with an ABS plastic. The tables were then mounted onto a linear slider, which was mounted simply into a standard aluminum extrusion.

Engineering challenges.

“Automation is changing how traditional distribution centers operate as companies search for new ways to maximize their efficiency, increase order accuracy and fulfill customer demand.”

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In this recent application, an automated package distribution center was looking to improve its packaging modules.

Each module is made up of four chutes that feed packages from the top of the system down to the station operator.

The operator is notified of an order and, from there, can pull it out, package it and place it onto a conveyor belt beneath the chutes. The customer wanted to incorporate support platforms onto the design of this existing structure, which the operators could use to box the finished orders.

A few solutions were initially proposed, including a scissor lift, a drop shelf and a motorized, wheeled cart. However, all of these systems would operate apart from the existing module without having to mechanically interface with it. These ideas were ultimately scrapped because they were too costly or had ergonomic problems associated with them, requiring workers, for example, to twist, running the risk of injury.

N-III ended up solving these issues with a simple design that connects to the module and even uses its existing boltholes. For a work surface, the engineers created tables made of strong ply, which they capped with an ABS

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plastic. These ABS “tops” were water jet cut and served as the template to rout the tables from the ply. The tables were then mounted onto a linear slider, which was mounted simply into a standard aluminum extrusion.

From there, workers can slide a table along the length of the chutes to where it is needed—a taping station, for example. While there is one table per four modules, tables can travel freely across up to 12 modules, maximizing design flexibility and minimizing the number of tables that need to be installed.

Structural engineering required.

The success of N-III’s solution is owed, in part, to engineers’ flexibility over the course of the design process. For example, it became apparent that the use of a 1 x 1 inch lateral bar would not be able to accommodate the moment loads created by the weight of the packages on the tabletops. A 100 lb package placed at the end of a table would create a 600 lb load on the supporting structure, pulling the bearing out of the rear track. To ensure that the system could hold up to these loads, engineers first ran a finite element analysis (FEA) test to analyze and compare system stress under loads using a 1 x 1 in. and 1 x 2 in. lateral bar. Whereas the 1 x 1 in. bar deflected, engineers discovered that the 1 x 2 in. bar could handle the high loads

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Rollon compact rail combats misalignment Bearings that aren’t aligned properly during installation can cause problems on any precision machine, resulting in wear or even reduced bearing life. The Rollon Compact Rail system is inherently tolerant of misalignment, thanks to a rail geometry that can absorb alignment errors in one or two axes.

Whereas ultra-high precision guides of the heavy packages. They therefore integrated this new component into their design.

measure acceptable misalignment in arc minutes and microns, the Compact Rail measures it in degrees and millimeters.

Designed for assembly.

For example, Compact Rail N-III’s solution overcame several rollers can rotate up to 2 design constraints, all of which degrees relative to the rail were dictated by the existing without affecting function packaging structure. For one, or increasing wear. For engineers had to figure out a way to attach the tables to the structure machine builders, having a without any additional drilling or the self-aligning system results use of T-nuts. Besides being more in greater design freedom expensive than the aluminum sliders and cost reduction. Simple themselves, logistically, incorporating spacing tools make T-nuts would have been a design installing to the proper nightmare. Instead, the engineers designed pre-drilled and tapped bars tolerance easy. that, once inserted into the extrusions, readily aligned with the track’s 4,000 existing boltholes.

It was also important that the design maintain a certain height so as not to impede the conveyor belt beneath the staging module once it was attached. N-III’s solution added only four inches to the vertical space between the module and the conveyor underneath.

Though limited by challenging design constraints, N-III created a supporting structure that mounts underneath a distribution center packaging module, integrating an arrangement of plywood, aluminum extrusions and Rollon linear bearings.

The linear bearings used in the packaging module had to handle very high loads. A 150 lb package placed at the end of a table, for example, would create a 600 lb moment load on the supporting structure.

N-III’s solution added only four inches to the vertical space between the module and the conveyor underneath.

Cost savings.

Additionally, unlike the motorized, wheeled cart originally proposed, N-III’s final design included no complex moving parts. It integrated a simple, space-efficient structure that could be attached to the existing staging module using the structural members, bolt holes and brackets from the existing structure for seamless integration— reducing overall implementation costs by 40%. l AS/RS

Rollon Corp. | Rollon.com

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The packaging module includes tables, which are made of strong ply and are capped with an ABS plastic. The tables were mounted onto a Rollon linear guide, which was inserted into a standard aluminum extrusion.

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How to

manage backpressure from accumulation

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A S / R S

A

Accumulation conveyors

provide buffer zones in material handling systems to manage product flow, which is especially important when there is an imbalance between upstream and downstream capacity. But accumulation often results in backpressure, which can damage products or cause downstream operational problems.

Common drawbacks of product accumulation

The right conveyor will ensure product is transported through a warehouse or facility without the damage often caused by accumulation.

Danielle Collins

Traditional conveying systems experience backpressure during product accumulation due to upstream pallets successively bumping into each other as they stack up behind the lead pallet. This backpressure can generate hundreds of pounds of force and, more importantly, compromise the integrity and quality of the products being accumulated.

In addition, a traditional conveyor system typically runs non-stop, regardless of the actual production requirements.

This means the conveying media – belt or chain – also runs continuously beneath the product, even during accumulation, while the product is stationary. Not only does this cause unnecessary wear and tear on the conveyor and the motor, it also wastes energy.

Senior Editor

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The team at Glide-Line has seen the consequences of traditional accumulation—including wear and tear on conveyor belts and chains that move underneath stationary pallets.

A better alternative: zero pressure accumulation The traditional solution

“Although not the most desirable solution, until now, up-sizing the conveyor system has been the easiest and most effective way to handle the consequences of product accumulation.”

So, how do conveyor designers and manufacturers typically deal with the extra loads, friction, and wear and tear that occur during accumulation? Simple: up-size the conveyor system.

Of course, this means heavier-duty (and sometimes larger) components, which adds cost, both in terms of the conveyor itself and in higher energy usage. Plus, accumulation and backpressure still have to be managed with pneumatic stops and eyes, which require PLC I/O, wiring, and code development, driving extra costs and effort into the project.

Accumulation is a necessary part of many processes, but if it damages the product or jeopardizes previous assembly or other operations, it’s a detriment to the overall production and quality - not to mention the economic impact of scrap, rework and stopped production. Unfortunately, this is often the case with traditional accumulation, due to the impacts and shock loads the products experience as they “pile up” behind one another.

The solution: individually managed accumulation zones Referred to as “zero pressure accumulation,” a conveying system with individually managed accumulation zones ensures there’s always a gap between products, which provides gentle product handling by eliminating the hundreds of pounds of backpressure that can cause product damage. Each individual zone can handle up to 200 lb, so the ability to transport heavy loads is not compromised.

•

The team decided there must be a better solution. That’s why they’ve designed a zero pressure accumulation option for Glide-Line conveyors.

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No more damaged product, scrap, rework, and stopped production due to the bumps and shocks that products endure during traditional accumulation. Instead of increasing cost, as many product “improvements” do, Glide-Line ZP reduces cost through energy savings, fewer wear parts, and reduced maintenance.

Zero pressure accumulation eliminates wear and tear due to friction by dividing the conveying system into multiple zones and operating each zone only as the process requires.

This means that the conveyor media stops during accumulation rather than running continuously under the stopped product. Eliminating friction and running the motors and conveyor media only when needed drastically reduces energy consumption and wear and tear on the conveyor.

How zero pressure accumulation works To manage each zone individually, the single ac motor used on a traditional conveyor is replaced by multiple, small 24 V brushless dc motors – one for each zone. Each motor incorporates a driver card with integrated “zero pressure” logic, and the motors are daisy-chained together to ensure that each zone operates only when needed. Pallet sensors are wired directly to the driver card for the motor, which means even less I/O, fewer motor starters or VFDs, less code development, simpler wiring and reduced overall effort. Not only does this simplify the control scheme and hardware costs, it significantly reduces wear and replacement parts.

The dc motors used in Glide-Line ZP zero pressure accumulation, for example, are compact and have virtually silent operation, making them suitable for noise-sensitive environments (or those where noise is already at or near

maximum acceptable levels). Not only does individual zone management reduce wear and tear on the conveyor, the 24 Vdc motors are constructed with bearings that have a 300,000 hour lifespan, which virtually eliminates the need to replace motors during the conveyor’s operational life. Despite the use of multiple motors, ZP conveyors have lower maintenance requirements and higher reliability than traditional conveyors. l AS/RS

Glide-Line | glide-line.com

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HIGH LOADS. LONGER LIFE. EXTREME RELIABILITY. NH/NS SERIES LINEAR GUIDES NSK’s NH/NNS Series linear guides equipped with K1™ Lubrication Units deliver a maintenance-free solution to extend operating life. Engineered to deliver extremely high load ratings, NSK NH/NS linear guides can be designed for a wide range of applications. If you’re looking for smooth operation, reduced noise and increased durability, trust NSK.

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Gearmotors

on the move: Driving AGVs When someone uses the term “driverless vehicle,” what probably comes to mind is some iteration of the driverless cars that auto manufacturers and technology companies have been testing for the past few years. But driverless vehicles have been around since the 1950s, when wireguided vehicles, now known as “AGVs,” were first used for industrial applications.

• The term “AGV,” or automatic guided vehicle, didn’t come into use until the 1980s.

Prior to that, these automated material handling systems were generally referred to as “driverless vehicles.”

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Danielle Collins | Senior Editor

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•

Right angle gearmotors meet the size constraints inherent to AGV applications, and Bodine chose gearmotors that would also reduce power consumption and maintenance, with low-voltage, brushless dc motors.

A

According to the Material Handling Institute, an AGV “consists of one of more computer controlled, wheel based load carriers (normally battery powered) that run on the plant floor (or if outdoors, on a paved area) without the need for an onboard operator or driver.” Navigation can be achieved by following a path indicated by buried inductive wires, surface-mounted magnetic or optical strips, or by way of inertial or laser guidance.

As part of an automated storage and retrieval system (ASRS), automatic guided vehicles (AGVs) provide “hands-off” material management for pallet handling, truck and trailer loading and unloading, material movement, and of course, material storage and retrieval. Where AGVs excel are applications with repetitive delivery of fixed loads or volumes, those where on-time delivery (to a manufacturing or shipping station, for example) is critical, and those where material tracking is important.

AGV applications pose challenges If you look under the hood of an AGV, you will likely find one or more gearmotors, providing locomotion to the AGV itself or helping to lift and rotate the load that’s being carried.

There are several requirements that gearmotors must meet in AGV applications. First and foremost, size matters, so the gearmotor should be as compact as possible. Space for motion and control components is at a premium in an AGV, since the

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middle portion of the robot needs to remain unobstructed for placement of the batteries. And because AGVs are batterypowered, power consumption needs to be kept to a minimum. Monitoring and maintenance of the robot should be simple, despite the fact that it will be subjected to extremely heavy loads, vibrations and shocks, and possible adverse environmental conditions.

But while these requirements present challenges, as Terry Auchstetter, Business Development Manager for Bodine Electric points out, they’re not showstoppers.

Solution: Right-angle gearmotors The space constraints posed by AGV applications often necessitate the use of right-angle gearmotors, to “tuck” the gearmotor along the side of the robot and eliminate any encroachment on the center portion, where the batteries reside. In one application, Bodine designed a right-angle gearmotor with a driveshaft that acts as the axle for the robot wheels, further reducing components and minimizing space.

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“Space for motion and

control components is at a premium in an AGV, since the middle portion is needed for battery placement.”

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Because the gearmotors drive the robot’s wheels, they have to not only support the load being moved, but also the weight of the robot itself. This means the gearmotor driveshaft has to deal with very large radial and axial loads, so Bodine modified the bearings and bearing housings to ensure the driveshaft could support these high loads. The customer also required electromagnetic fail-safe brakes on the gearmotors, which increase the length of the assembly. By using right-angle gearboxes, however, this added length didn’t interfere with the space for the batteries, as it would have with a parallel-shaft gearbox arrangement.

Along with size constraints, weight – which directly affects power consumption – was also at a premium.

To keep power consumption in check, low-voltage dc motors were paired with high-efficiency gearboxes. And the dc motors have a higher peak torque for a given size, so a smaller frame – and therefore, lighter – motor was able to meet the peak and RMS torque requirements.

Bodine specifically chose brushless motors for the application, greatly reducing maintenance, since there was no need to monitor or replace motor brushes. Brushless motors also

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eliminated electromagnetic interference (EMI) issues, which are a particular concern in automated warehouses, where much of the communication is done wirelessly. Temperature sensors were integrated into the gearmotor for monitoring and to prevent overloads that could damage the motors or even the robots.

AGVs often need to meet specific design criteria and size restrictions imposed by existing warehouse, distribution, and ASRS layouts. But as Auchstetter points out, it is possible to work within these constraints when sizing and selecting a gearmotor, without requiring new product development, which can be costly and require long lead times. The key is for manufacturers to be flexible, using modified standard designs and ensuring that every design element – from the major components to the mounting interface – is optimized to meet the specifications for size, weight, and energy consumption. l AS/RS

Bodine Electric Company | www.bodine-electric.com

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IKO is a world renowned producer of quality needle bearings, linear motion rolling guides, precision positioning tables & machine components.

Only IKO offers C-Lube — a 5 year or 12,500 miles maintenance-free lubrication in M series linear ways & maintenance-free cam followers.

IKO offers specialized solutions for many unique manufacturing situations including: clean rooms, vacuum environments, high temperature areas and dust or spatter protection.

IKO products are highly regarded in the worldwide marketplace and the company strives to live up to the inspiration for the name IKO: Innovation — our employees are constantly striving to develop new technologies.

Know-How — our extensive technical knowledge is applied to every situation to determine an optimal solution.

Originality — our creativity allows us to continuously improve the performance of our products.

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11/1/17 9:09 AM

AS/RS

The NH/NS Series Linear Guide features a new ball groove geometry that distributes contact surface pressure more evenly to increase overall load rating capacity. This optimized design achieves significant increases in reliability and service life for high-precision linear motion applications. Delivering longer service life, increased production speed and higher load ratings, the NH/NS Series is an optimal solution for Automated Storage & Retrieval Systems.

NSK can customize a solution to ensure material is moved in and out of storage areas precisely.

• Interchangeable rails and ball slides.

• Different ball slide types, accuracy grades and preload combinations available.

• Long-term, maintenance-free operation with optional K1™ Lubrication Unit.

• High accuracy

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Linear Motion for Robotic Handling in Automated Warehouses Rollon is a manufacturer of linear guides, telescopic rails, linear actuators and Cartesian systems. Our products are designed to meet the requirements of engineers designing and configuring applications in industrial automation, automated storage and retrieval systems and robotics.

Rollon’s engineers are experienced in creating solutions and custom products for OEM’s and machine builders everywhere to solve unique and difficult applications.

Rollon Corp.

101 Bilby Road, Suite B Hackettstown, NJ 07840 U.S.A. 1.877.976.5566 Email: info@rolloncorp.com

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How to get

a variable frequency drive (VFD) running with minimal effort Here we cover the specifics of how variable frequency drives (VFDs) operate and ways to simplify their installation and setup.

Bob Bonczar | Yaskawa America | Technical Training Services

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C o n t r o l

VARIABLE FREQUENCY DRIVE (VFD) AC

DC

AC

M

S

Variable frequency drives or VFDs — which we call simply drives in this context — operate in a wide array of industries. They’re often behind the scenes. Nevertheless, drives impart a cost-effective and reliable level of sophistication to motor-driven applications, so deserve careful consideration and installation. Here are six tasks for OEMs and other design engineers to satisfy before initial drive startup and for some operational situations.

1. Understand what a drive is.

A drive is an electric and electronic device that controls a motor’s speed by changing its frequency. Applications in which drives operate vary greatly. With some changes in the wiring and programming, a drive’s purpose can change completely.

The way in which a drive changes a motor’s frequency effectively expands the usefulness of that motor, as VFD-run motors are freed from the limiting setup of only being turned on or off. The drive lets the motor quickly or slowly accelerate to reach target speed … as well as decelerate slowly or

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Once it’s been established that a given drive is appropriate for the application at hand, end users only need to address a few details to get that drive running.

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C o n t r o l

quickly. It works like this: The drive first takes line power and converts it to direct current (dc) voltage. It then inverts it back to a simulated alternating current (ac) or pulse-width modulated (PWM) signal. The biggest benefit of drives is that they can save money by freeing the motor from needing to run at one speed all the time.

2. Understand how drives are applied.

Drive applications range from pumps and fans to conveyors and extruders — and in fact are virtually limitless. Knowledge of the application at hand helps OEMs select the right drive for the job. Myriad drives exist — so the size and voltage as well as necessary options (such as the inclusion of dynamic braking or a given network interface) impact drive selection. Ultimately these variations also dictate the proper methods to setup and operate the drive.

Displays such as monitors can show values such as current to help end users ensure the drive is running optimally.

drive will need during setup. For example, is the drive running alone and spinning a large fan? Such an application may seem quite simple, but even here it might be necessary to interface the drive to other equipment such as a programmable logic controller or PLC. Ask: What else is included in the system? Drives are just one piece of the design puzzle.

4. What wiring is necessary?

Wiring a drive can be dangerous if the installer is unfamiliar with the product, so have a qualified electrician help or execute the entire the install.

3. Understand how the drive is expected to perform for the application.

Tip: During drive setup, develop an understanding of what’s expected from the drive and how well it must perform. Such information partially indicates what a given

Here’s an example motor nameplate from which we collect parameters. V is the voltage. A is the FL AMPS. Frequency f is 60 in the Hz column.

DRIVE, SWITCH, POTENTIOMETER, AND MOTOR This is a typical wiring setup of a motor, drive, potentiometer, and switch. Control schematics simplify identification of how to connect the drive in such an arrangement.

VFD AC INPUT VOLTAGE L1 L2 L3 MOTOR OUTPUT T1 RUN COMMAND

T2

COMMON

T3

MOTOR

+VDC FREQUENCY REFERENCE COMMON

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When it comes to the installation of VFDs, safety is a must. Shown

LINEAR SLIDE ASSEMBLY?

here are the drive’s motor terminals — through which the actual motioninducing current will flow to the motor.

Of course when the connections are complete, power is applied to the drive. During this step, wear personal protective equipment (or PPE including gloves, a jacket, and eye protection) to avoid injury.

Another tip: Be sure to correctly read motor and drive schematics so that the line power is connected to the correct drive terminals … and the power-output terminals are properly connected to the motor.

Otherwise, there’s a risk of damage to the drive or individual harm.

Besides wiring for power, drives require another set of wiring — the control wiring. It’s through these connections that controls will tell the drive when to start and stop — along with how fast it needs to run. Here, account for how the drive is being controlled.

If it’s being run and monitored over a network, have full understanding of how the network option installs and how to initialize it. Case in point: If using Ethernet, the PLC or computer system with which the drive interfaces also needs parameter setting for communications with the drive. Doing this correctly may necessitate contacting a system specialist during drive setup.

Consider one simple example of a machine design that incorporates a VFD using a startstop switch input and an analog reference.

Study of the control schematic will indicate where the connections are and how they’re designated. As in an exercise common in DESIGN WORLD

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Based in the United States and more than 40 years of experience, we have been providing our customers with design assistance, product prototyping and full service manufacturing for custom linear ball slides, crossed roller slides, positioning stages and complete linear positioning systems. Ranging anywhere from a standard ball or crossed roller slide requiring custom holes or special materials to a complex positioning system, Del-Tron Linear Engineering can help.

Utilizing our customized or standard slides, let one of our knowledgeable engineers provide you with immediate technical assistance, enabling you to find work-arounds to design and develop unique out-of-the-box solutions. Call us today. You’ll find we’re always ready to help and offer personalized attention that’s unparalleled in the industry. We expect you’ll experience a level of responsiveness you just won’t see anywhere else.

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C o n t r o l Control:

Run source (start and stop) • Frequency or speed reference source Using a Yaskawa 1000 series drive, these settings are …

• b1-01 frequency reference source (defaulted for terminals) • b1-02 run source (defaulted for terminals) • E1-04 maximum output frequency • E1-05 maximum output voltage • E2-01 motor FLA

Here are the control terminals on a drive. It’s through these connections that control signals will command the drive through stops, starts, and speed settings.

children’s magazines, the goal is to connect items on the left of the page to like items on the right.

So in the case of VFD setup, the connections are made with shielded wiring: Items on the left are the switch and potentiometer, and the items on the right are the drive terminals.

5. What programming is necessary?

Until this point, drive setup is dominated by physical-installation considerations and manual connections. But drives are intelligent devices that need programming — much like new smartphones or even archaic VCRs of yore. A list of parameters must be set for the drive to understand control signals and how to respond to them. As mentioned, there are various ways to control an industriala drive — including via a network interface such as Ethernet or through switches and potentiometers. Drives have parameters to which the end user must program the design … as drives operate to satisfy commands based on fixed system settings and inputs and outputs. The following are the minimum parameters to be set:

In this example, the switch and potentiometer connect to the drive’s control terminals. The switch starts and stops the drive and the potentiometer adjusts the speed. Sometimes drives come defaulted to this type of interface so end users can easily install and start the drive with minimum effort.

6. Is there anything else?

Once the drive is connected and networked, does the motor rotate in the correct direction? If not, then a couple of the drive output leads may need to be swapped — but not the input. This is because the input line power isn’t directly connected to the output.

Is there an alarm or fault showing? The display on the drive may show a message that indicates if there’s a condition

Motor name plate data:

Full load amps (FLA) • Voltage • Maximum frequency (or speed in RPM to calculate the frequency in Hz)

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preventing the drive from running.

For example, this might be an overload condition. Here, the load to which the motor is connected will need inspection. Is it too heavy or accelerating too fast? This might necessitate physical adjustment or tuning of a parameter to start it more slowly.

In fact, other displays such as monitors can show activity such as current to help end users ensure that the drive is running optimally.

Is the drive’s output drawing excessive current? Is a digital input closure not taking effect? Here, the input will need monitoring for changes. In fact, a drive that stops or faults requires continuous monitoring so that it doesn’t stop again and spur more problems.

There are other considerations. What if a drive in service failed and needs replacing?

Addressing this issue is a often simple matter of getting an exact replacement and reprogramming it. Recent parameters will need resetting to get the drive back to the condition it’s meant to operate. For this, follow the guidelines on programming during setup.

One warning to close: If drive selection and installation are new and unfamiliar, contact a local vendor for support. Drive installation and setup can be dangerous if done incorrectly, so it’s always best to involve a designer or installer qualified to execute the process. DW Yaskawa America | yaskawa.com/ support-training

Shown here is a Yaskawa A1000 drive. Due to the involvement of electrical connections, drive installation always poses danger. That’s why it’s critical to follow setup instructions and involve professionals where required.

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Functional safety: Coming to a machine near you Functional safety is playing an increasingly important role in many machines, including machine-tool manufacture. For encoders, that means correctly and accurately measuring position data and transferring it to machine control, as well as encoder diagnostics and mechanical fault exclusion.

Jonathan Dougherty | Product Specialist | HEIDENHAIN Corporation

Machines and manufacturing plants are becoming faster and more flexible, but also more sophisticated and expensive. This applies for machine tools as much as for pick-and-place machines in automation or diecast systems for plastic processing. In view of the high investment costs for such high-tech machines, owners expect high availability and predictability of their plants and processes. At the same time, legal safety regulations for the operation of the systems are increasing. The result of this development is the growing significance of functional safety.

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The scale drum (center) of the HEIDENHAIN ECI 4000 is securely connected to the motor mechanics (left) thanks to a keyway on the right, as part of the scanning unit.

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M o t i o n

C o n t r o l

In addition to providing safety in standard optical rotary encoders, there are also a wide range of products and scanning interfaces available made for safety related applications such as magnetic angle encoders or absolute sealed linear encoders, which provide solutions to a wide range of applications in machines and systems.

Magnetic angle encoders and inductive rotary encoders are particularly suitable for use in production machines that expose their components to high mechanical loads.

HEIDENHAIN’s ECN 400 and EQN 400 encoders come with functionally safe mounting.

Safe mechanical connection Safe connection of the measuring device to the drive is a key element of functional safety requirements. There are now rotary encoders that offer a functionally safe hollow shaft connection with mechanical fault exclusion for their blind hollow shafts with various diameters. This mechanical fault exclusion avoids faults that cannot be detected by the controller, such as slippage of a frictional connection. The safe mechanical connection covers a wide range of shaft sizes from 6 mm up to 512 mm served by various functional safety encoders.

Functional safety is playing an increasingly important role in many machines, including machine-tool manufacture.

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Uniform diagnostic data A key component of functional safety is also the diagnostic information provided from the component. Some information that an interface should transmit which are relevant for plant availability are:

• The error message, which has to lead to a safe system condition. At the same time, this means that it causes a system shutdown.

• A warning, which indicates that an internal function limit has been reached. It serves as an early warning system for preventive and projectable maintenance without triggering immediate machine downtime.

• Diagnostic data, which provides detailed information on the position encoder’s functional reserve.

For functionally safe applications, designers should look for encoders that provide comprehensive diagnostics that are conducted in the encoder, so that warnings and error messages are generated. Error messages can then be transmitted with high priority with each position value transmission to the subsequent electronics.

What’s more, in order to evaluate the functional reserve in closed-loop operation, encoders should generate so-called evaluation numbers. The easy-to-understand valuation numbers should provide detailed information about the state of the internal incremental and absolute scanning signals

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C o n t r o l

Functional safety Considerations for machines

S

Safety is always important in machining and

automation, but at the end of 2009, the European Machinery Directive 2006/42/EC took effect, establishing more stringent rules and regulations in this area. Along with this directive, new safety standards including EN 61508 and/or EN ISO 13849 termed “Functional Safety” also went into effect. These standards require fundamental changes in the design and qualification of safety-related manufacturing facilities and affect all components of a machine that contribute to a safe function.

As a result of these directives, European manufacturers of

machines and machine systems are now obligated to use stateof-the-art technology to minimize danger to humans and the environment. Products for machining are not permitted to be marketed in the European Economic Area (EEA) unless they meet the requirements of all applicable EC directives. Because of this, these requirements are becoming more commonly accepted at facilities throughout the world, and a trend is in

Functionally safe machines can feature open workspaces, such as the one seen here, where operators can have access to equipment for troubleshooting, maintenance, and/or programming.

motion.

For instance, in a functionally safe machining scenario,

it’s beneficial to have an open workspace so that operators can get in or out of the equipment to manage material, troubleshoot, or develop programmed motions. In some cases, it’s desirable to have the machine actually powered, but moving slowly, in a safe manner, so the operator can be inside the workspace.

It may not be enough for the tools to have a scanner

identify the safety critical zone. All that this could support would be emergency shutdown. To allow for equipment to be active when operators are in this area, motion control specifically developed to support safety critical applications has to be used.

These controls will include redundancies in both the controller and the feedback so that when a stop is commanded, it’s absolutely sure the motion has stopped, or when an area of motion is not allowed, then it’s guaranteed to not go there.

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In addition to providing safety in standard optical rotary encoders, there are also a wide range of products and scanning interfaces available.

Bring Your Design To Life.

as well as the position value formation and thus information on the current condition of the encoder. Controls or inverters can use this data to make conclusions about the functional reserve. These values can then be transmitted in the closed control loop and should not burden the time for position transmission. Thus, the load on the subsequent electronics’ resources is relatively small, because it will only need to display numerical values. The availability of the valuation numbers and access to them depends on the respective customer-specific interface.

A range of angle and linear encoders is available from HEIDENHAIN for safetyrelated applications.

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C o n t r o l

Simple commissioning A digital interface for position data also enables the transmission of the so-called electronic ID label, i.e., data for commissioning the encoder and the controller. Some interfaces also transmit additional data such as the winding temperature of the drive or diagnostic data. The transmitted data is dependent on the interface.

For example, the EnDat 2.2 interface allows information about the functional state of the position encoder to be transmitted quickly and reliably during operation, regular maintenance or in the event of a fault. Such factors represent important basis data for condition monitoring or for making statements concerning the capacity and planning of systems and processes.

The unique combination of high-accuracy position measurement requirement, and a large number of available interfaces while trying to maintain simple diagnostic features can make the selection and identification of functional safety products seem daunting. However, by focusing on the above key components and having open discussions with the encoder manufacturer one can simplify the process and quickly find the right product to suit the application in even the most highly dynamic and highly accurate machines and systems. DW HEIDENHAIN Corporation | www.heidenhain.us

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I n d u s t r i a l

E t h e r n e t

Industrial Ethernet—

a version for every application

Leslie Langnau | Managing Editor

Ethernet, in its many versions, continues to spread as the network of choice for industrial applications.

Industrial Ethernet-based networks are almost 40% of all industrial communication networks, and growing, outpacing many older fieldbus type networks. Drivers behind this growth include the ubiquity of Ethernet, it’s an established standard protocol, it has widespread support, is easy to obtain, and offers economies of scale, use and familiarity.

Six versions of Industrial Ethernet are CC-Link Industrial Ethernet, EtherCAT, EtherNet/IP, Ethernet Powerlink, Profinet IRT, and Sercos III. Each offers different performance parameters.

Data transmission speed and data reliability are probably the most important capabilities in an industrial network. Each network takes a different approach to deliver data within a given time frame, so understanding that approach will factor into your choice.

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E t h e r n e t

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1 ms

<1 ms

100 Mbits/sec

Ethernet Powerlink

<1 ms

<1 ms

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<0.5 ms

< 0.1 ms

100 Mbits/sec

Sercos III

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The hardware used in most Ethernet based networks is the same; network interface cards (NICs) and CAT5 Ethernet cables are quite capable of delivering data quickly and reliably. The key will be the realtime protocol used by the specific network. A typical protocol like TCP/ UDP/IP, for example, which would ride over the Ethernet hardware and standard layers, does not deliver data at the speeds often needed by machine tools, but is perfectly adequate for other applications.

Thus, many industrial networks use one of three main approaches to deliver determinism in an Ethernet infrastructure.

The first approach is standard software and standard Ethernet. This approach uses TCP/IP layers with real-time mechanisms added to the top layer.

The second approach is “open” software with standard Ethernet.

(Check with the controlling organization about how open it is; some are only open in parts.) The Ethernet protocol really covers just the cabling and how packets of data are arranged and transmitted through the cabling. With the open software and standard Ethernet approach, software protocols are implemented over the standard Ethernet protocol.

The determinism often comes from proprietary portions of the software that schedules transmission of the data packets in specific times or setups. This software often resides at what is known as OSI Layer 3 and 4.

The third approach is open software and modified Ethernet. This approach often results in a new standard for Ethernet, such as IEEE 802. xxxxx. In some cases, this approach demands new hardware to execute the needed capabilities. The open software is often free and available in a public domain.

Now, let’s look at specific details of each network.

CC-Link Industrial Ethernet • CC-Link of the CC-Link Partner Association (CLPA) is an open protocol used by many manufacturers. There are a number of variations for specific application needs: CC-Link/LT, CC-Link Safety, and CC-Link Industrial Ethernet (IE) Control and Field. Most versions offer speeds to 10 Mbps at 100 m.

• CC-Link IE Field supports the demands of advanced automation. It leverages Gigabit Ethernet, so it can handle IIoT data quantities and speeds. The network links field-level devices to controllers,

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E t h e r n e t

Industrial Ethernet-based networks are almost 40% of all industrial communication networks, and growing, outpacing many older fieldbus type networks.

connects controllers to other controllers and provides deterministic commun- ications without the use of switches.

Users do not need detailed knowledge of Ethernet to use. It is a token-based communication approach, which means each device gets control of the network for a specific period of time.

EtherCAT The EtherCAT protocol was developed

by Beckhoff Automation. The EtherCAT Technology Group (ETG) now has responsibility and control over the development of this protocol.

It takes an open software and modified Ethernet protocol approach. EtherCAT delivers deterministic response; it is able to process 1,000 I/O points in 32.5 μs, or data from 100 axes in 125 μs.

It uses a bus master (central controller) in a ring formation of connected devices.

While EtherCAT uses the telegram structure of Ethernet, only one telegram is sent to all connected stations and slaves. The telegrams, or packets are divided into real-time and general data sections. As a packet travels around the ring, relevant output data are extracted by connected devices or input data are inserted into the packet. Very large data packets can be distributed across multiple EtherCAT frames.

EtherCAT is compatible with most drives and motion systems, regardless of manufacturer. More than 500 drive vendors have adopted EtherCAT compatibility as one of their network offerings.

Ethernet/IP Ethernet/IP was developed by Allen-Bradley (Rockwell Automation) and then turned over DESIGN WORLD

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to the Open DeviceNet Vendors Association (ODVA). It follows the standard software and standard Ethernet approach.

EtherNet/IP is an application-layer protocol on top of TCP/IP. The Common Industrial Protocol (CIP) software is a part of EtherNet/IP. The CIP Sync code is used to distribute IEEE 1588 compliant time information throughout the network. In this manner, EtherNet/IP maintains 100% compatibility with Ethernet yet still delivers fast data update times and deterministic transmission.

Communication with devices, or nodes, is handled by CIP over the TCP connection.

Multiple CIP connections can be handled over one TCP connection.

Through switches, EtherNet/IP can support an almost unlimited number of nodes. This protocol uses a producerconsumer services model for efficient slave peer-to-peer communications.

Ethernet/IP is time-based, which means control commands are received by the field stations in time. This method is how the protocol achieves determinism. Real-time delivery is safeguarded by three standards: UDP, Quality of Service (prioritization), and IEEE1588. Accessible bandwidth is limited to avoid contention and latency.

Ethernet Powerlink B&R developed ETHERNET Powerlink to provide standard Ethernet with real-time properties for motion applications. Now, the ETHERNET Powerlink Standardization Group (EPSG) manages this protocol. It uses the open software and standard Ethernet approach.

ETHERNET Powerlink is a cyclical protocol that organizes access to a network

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The hardware used in most Ethernet based networks is the same; network interface cards (NICs) and CAT5 Ethernet cables are quite capable of delivering data quickly and reliably. and the data synchronization of the devices.

Based on a more traditional version of Ethernet, Ethernet Powerlink must work around the Carrier-Sense Multiple Access with Collision Detection (CSMA/ CD) method of data packet transmission.

CSMA/CD does not deliver determinism.

If two packets transmit from different nodes at the same time, they can “collide,” scrambling data. When CAMA/CD detects such a collision, it picks a random time to re-transmit one of the packets through the network. The randomness of the re-transmit time eliminates any determinism.

To solve this issue, Ethernet Powerlink imposes a time slot for critical data, which eliminates any possibility of collision. A software-based master controls the timing on the network and the master authorizes individual nodes to send data. The master (controller) polls the slaves (drives) within a specific portion of the communication cycle, known as the isochronous phase.

Asynchronous data traffic can transmit over the remaining cycle time.

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E t h e r n e t

Profinet IRT PROFINET comes in two flavors; PROFINET RT for soft real-time requirements and PROFINET IRT (IRT = isochronous real time) for what is referred to as “hard real-time” performance. Siemens developed this protocol with members of the Profibus organization.

Profinet IRT is an open software and modified Ethernet approach.

PROFINET uses the producer/consumer model with additional protocols and services.

Time critical data travel in Ethernet frames with virtual local area network prioritization.

Other data, such as diagnostics and configuration data, are sent through UDP/ IP. This arrangement means Profinet can offer cycle times of around 10 ms for I/O applications.

Profitnet IRT can deliver cycle times below one millisecond. The protocol uses a time multiplex mode based on managed, hardware-synchronized switches. It also uses a time slot mechanism, which works like this: a certain bandwidth is reserved for the real-time data traffic, and the remaining bandwidth is available for non-critical data transmissions.

The nodes are connected to special switches rather than standard Ethernet switches. These special integrated switches use a special ASIC to control two or four ports at a data rate of 100 Mbps.

PROFINET is widely used by Siemens and GE, and is embedded in their controllers and equipment.

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I n d u s t r i a l

E t h e r n e t

more drop-in interchanges

SERCOS III is an open protocol for high-speed serial communication of standard closed-loop real-time data over Industrial Ethernet cable.

• SERCOS III uses 100 Mbps Ethernet

and the Ethernet telegram.

Determinism comes from the time slot approach in which bandwidth is reserved for the isochronous (real-time channel) and asynchronous (IP channel) data traffic.

• SERCOS-III works without hubs or switches. Each station has an integrated ASIC or FPGA with two communication ports. This protocol can be arranged as either a line or ring topology.

Specific hardware is needed for the slaves on this network, but it is possible to use software for the network master.

It enables rich I/O communication and efficient transmission of all conventional protocols over the same Ethernet network—in parallel—with SERCOS real time communication. It has cycles times of 31.25 usec. It can support 511 slave devices in each network, with multiple networks possible in an installation. DW

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CC-Link Partner Association www.cc-link.org EtherCAT Technology Group www.ethercat.org ETHERNET Powerlink Standardization Group www.ethernet-powerlink.org ODVA | www.odva.org Profibus | www.profibus.com Sercos | www.sercos.org

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S e n s o r s

Achieving

precision with limit switches There are many choices for detecting presence and position in machine automation applications, but limit switches are often the best option when high precision is required.

Tim Wheeler | Technical Applications Engineer | AutomationDirect

Many types of sensors are available for detecting presence and position in industrial automation applications, from course to fine precision.

Photo eyes and inductive switches are commonly used, but when a high degree of accuracy is needed, precision limit switches are often a better option because they provide repeatable accuracy down to the sub-micron level.

Hereâ&#x20AC;&#x2122;s a look at the different types of position sensing switches, and how limit switches can be used to achieve precision in robotic and machine tool applications.

Industry workhorse Industrial limit switches are the battleships of the sensor world and have been used in manual, semi-automatic and automated machinery applications for more than 100 years to detect presence and position of parts and mechanisms.

These sensors come in several configurations including NEMA, heavy-duty

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Figure 1: These limit switches are available in a variety of shapes and sizes to Figures, all courtesy of AutomationDirect. fit a wide range of applications.

IEC, double-insulated IEC, compact, miniature and precision, Figure 1.

The major difference between NEMA and IEC limit switch is the robustness, a common distinguisher in these comparisons.

The NEMA is designed for demanding applications such as in heavy machinery, foundries and mining, and tends to be more expensive. In applications such as material handling and gantry equipment, a similar but more cost-effective heavy-duty IEC limit switch is usually suitable. Both the NEMA and heavy-duty IEC housings are typically made of metal, die-cast zinc alloy or aluminum depending on the device.

Double-insulated IEC limit switches are typically made of plastic, and the compact IEC switches are made of plastic or metal.

Many of the precision touch limit switches are made of stainless steel. Precision limit switches have a barrel design, similar to a very small (M5 x 0.5) proximity switch.

These stainless steel, plunger actuation

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switches have a high degree of repeatable accuracy.

It is worth mentioning that safety switches are used to protect personnel and equipment from hazards by monitoring the position of movable guarding. They are often used on hinged guard doors where an actuator key engages the switch body when the guard is closed. Cable-operated safety switches are also used to activate an emergency stop when the cable is pulled.

Key selection considerations Limit switches are suitable for use in a range of applications and harsh environments on the factory floor due to their ease of installation, reliable operation and rugged design, Figure 2. Limit switches are typically used in physical contact applications that cause wear and tear on the switch actuator and electrical contacts, so exceeding two operations per second should be avoided.

When selecting a limit switch, consider the www.designworldonline.comâ&#x20AC;&#x192;â&#x20AC;&#x192;

It is worth mentioning that safety switches are used to protect personnel and equipment from hazards by monitoring the position of movable guarding.

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S e n s o r s

application and actuation method first, as often they are the clearer determining factors.

Other sensing options include inductive proximity switches and photo eyes, both of which are a touch-free method to sense position and presence. An inductive proximity (prox) switch detects ferrous and non-ferrous metals with no mechanical contact needed. A prox switch typically has a solid-state output, instead of mechanical contacts as with a limit switch.

Its non-contact sensing method and solid-state output make it a good choice for high cycle-rate applications, and when debris may interfere with limit switch actuation.

However, there are many quality and longlasting limit switches available. With a properly specified limit switch, it’s not unusual for it to have a mechanical life of 30 million actuations, and an electrical life of 5 million operations.

The limiting factor is often electrical contact life, but replacement contact blocks are available for quick replacement at a low cost with some limit switches.

Figure 2: Prewired limit switches provide easy integration into most industrial environments.

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NEMA and heavy-duty IEC limit switches are both suitable for used in harsh environments. Foundries, shipping and dockside operations are common applications.

They are also found in machines in industries such as automotive, food and beverage, and pulp and paper, and power. These switches also work well on large conveyors and welding equipment.

Limit switches are also used in more medium-duty applications such as earth moving equipment, agricultural machinery, and farm and tractor implements. Other medium-duty applications include CNC machine tools, overhead hoists, large cranes, and textile and printing machinery, Figure 3.

Limit switches are often used in consumer grade machines and equipment such as escalators and elevators, industrial automatic doors, aircraft access platforms, point-of-

sale dispensing kiosks, scissor lifts and slot machines. With careful design, limit switches work well in most of these applications, and are easily interfaced to programmable logic controllers.

Limit Switch Selection Criteria The leading limit switch selection criteria are listed in Table 1 and explained below.

Table 1, Limit switch selection criteria

• Actuation method • Repeatability • Travel to operate and reset • Force to operate • Contact configuration • Environment requirements

Limit switches are actuated several ways including side rotary, top and side push, and

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S e n s o r s

wobble stick. These actuators are often mounted onto 90° adjustable heads. Travel to operate contacts and the amount of force needed varies, and should be determined with a high degree of certainty before selecting a switch.

Levers are adjustable to any angle on the operating shaft and need around 5° rotation, from a total of 90° travel or more, in either direction to operate contacts.

Typical actuator types include various length stainless steel levers with nylon or metal rollers. Spring stainless steel rods (whiskers), and loops of nylon or metal cable, are available as well.

Push-operated (plunger type) limit switches are top or side actuation in a pushbutton or roller style to operate contacts, and require 2 mm or less travel.

Wobble head limit switches are typically top operated using different rod-type operators such as a nylon rod, stainless steel rod or

Figure 4: Precision limit switches can be used to home motion stages, often providing better repeatable accuracy than photo electric and inductive sensors.

spring steel—and will operate with about 10° of actuation, perpendicular to the rod, from any direction.

The repeatability of an assembled limit switch is determined by the type of

operating head used. The switches with the best repeatability are the direct-operated pushbutton or plunger type, typically 0.003-in. or less repeatable accuracy. The addition of rollers and operating levers

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adds tolerance stickup due to concentricity. The tolerance can easily double when rollers are used.

Limit switch operation starts at an initial, normal position at rest. When operated they move through a pretravel range to an operating point, where the electrical contacts close, and then into the overtravel range. The travel to operate and the travel to reset are different. There is hysteresis in limit switch actuation. It may take 1 to 2 mm, or 5° to 10° of pretravel, to operate a limit switch’s contacts, but only half of that to reset upon return, but precision limit switches often have zero pretravel.

The force to operate a limit switch varies widely depending on the device. Many heavy-duty switches require 4 lb or more to operate the contacts. Small, precision limit switches may only take 0.1 lb to operate.

Many limit switches have single-pole, singlethrow electrical contact configuration, either normally open or closed. Some have more contact configurations available. Snap-action contacts are available where the contact motion is independent of the speed of the actuator. The contacts will still close quickly even with very slow-moving actuators.

Alternatively, slow-make/slow-break contacts are available where contact motion is dependent on actuator speed.

A limit switch will operate reliably in extreme environments; at high or low temperatures; and in moist, wet or contaminated areas. Degree of protection varies from IP40 to IP67/NEMA/UL. Common enclosure Types are 1, 3, 3S, 4, 4X, 6 and 6P. Design considerations Limit switch design considerations listed in Table 2 and can affect the operation and reliability, but careful design can mitigate potential problems.

Table 2, Limit switch design considerations

• Mechanical life • Sensor impact • Switching frequency • Maximum actuation speed

Mechanical life of a limit switch can be extended by adhering to these guidelines. Limiting the severity of the impact of the target material on the limit switch operator is important, as is limiting the overtravel of the switch during operation as much as possible. There is no need to rotate or push

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Limit switches are also used in more mediumduty applications such as earth moving equipment, agricultural machinery, and farm and tractor implements. the switch actuator more than necessary for reliable actuation, and levers are adjustable to any angle on the operating shaft to minimize impact and overtravel. Pressing a limit switch plunger to the stroke end may cause malfunction due to the impact, but this can be mitigated by installing a hard stop.

Some limit switches allow right-angle operation to the plunger with an appropriate lead in cam angle, often 30°. However, many limit switches require contact with the object at a right angle or within a few degrees. Action is limited between the tip end and the edge of the internal bearing, but side loads can cause damage to the switch over time. The end of the housing may deform if impacted, causing failure in the return.

Shock and vibration specifications should be carefully considered during design. When severe, it could operate the switch and cause a fault. Mounting a limit switch out in the open where it can be accidently impacted, placing a side load on the axis of rotation, or causing overtravel of the plunger should be avoided.

As discussed previously, switching frequency must be less than 2 cycles per second as mechanical and electrical activations are limited. The actuation speed of a limit switch can be too fast or too slow as well. If

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activated too fast, the switch could bounce or wear quickly. Slow activation, less than 50 mm/minute, can cause repeatability errors, especially in precision limit switches.

Precision Limit Switches Traditional limit switches, proximity sensors and photo eyes are somewhat limited in terms of accuracy and repeatability, typically in the 25- to 100-µm range depending on the device.

However, there are some cost-effective and ultra-precise mechanical limit switches with repeatability in the 0.5- to 10-µm range, Figure 4. Considering a human hair is typically 50- to 60-µm in diameter, that’s precise sensing.

These precision limit switches are often used to replace fiber sensors used for positioning parts. When using a photo eye, uneven surfaces, water droplets and even fingerprints on the part can make precision position sensing less accurate.

However, since the precision limit switch contacts the part, it minimizes the effects of an uneven surface, and can push through a water drop or fingerprint.

In a sheet thickness application, such as detecting a double-fed label, designers may consider limit switches unsuitable for detection of an extra label due to low repeatability. However, newer high precision touch and tool setter switches are capable of 0.5 µm repeatability, and can reliably detect 50 µm or thinner sheets. Take-up material can be checked to ensure the label was removed.

These precision limit switches can be used in harsh environments including CNC machine tools with coolant spray and metal shavings, and in motion control and robotic automation. In these applications, the switches are typically used to find a home position, an edge of the tooling, or an edge on a part. Applications include finding the soldering tool tip to adjust the z-axis on a robot, homing x-y tables, and detecting the edge(s) of a grinding wheel in a CNC grinding application On automated machines and robots, there are many sensors such as vision

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systems, lasers and photo eyes. Finding the position of the tooling or part is often critical to operation. Precision limit switches are an excellent option to find a repeatable home or start position. Finding a position within 0.5 micron, 1/2000 of a millimeter, with a mechanical switch adds the word precision in front of machining and assembly.

Limit switches are tried and true in machine automation applications, and you have probably used them before. Don’t run a switch too hard or fast, and use the correct activation method. And don’t forget about the precision limit switch.

With repeatability starting well under one thousandth of an inch (10 µm), and down to sub-micron repeatable accuracy, finding precise position has never been easier. DW Automationdirect | Automationdirect.com

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cheap lidar will pave the way for autonomous vehicles Innovations in sensing technology that wonâ&#x20AC;&#x2122;t break the bank promise to help robotically piloted vehicles understand their surroundings.

Leland Teschler | Executive Editor

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Look at one of the prototype autonomous

vehicles cruising the highways and you may see a spinning cylinder perched atop the roof. This cylinder houses a light distancing and ranging (lidar) sensor. Initially, lidar sensors were used to generate digital maps for navigation software.

Now they are a critical part of the plan for how future generations of autonomous vehicles will sense what’s happening around them to prevent collisions.

Lidar units basically bounce a laser beam off a target and use the return time to measure distance. This time-of-flight (TOF) measurement can resolve the dimensions of objects as far as 300 m away to within a few centimeters, and they can provide this information in milliseconds.

One problem: Lidar units have historically been expensive. For example, consider the Lidar units that sat atop entries in the 2005 Darpa Grand Challenge, the event credited with launching autonomous vehicle technology.

Developed by industry pioneer Velodyne LiDAR, their cost was in the $10,000 range largely because they used a precision rotating platform to move their laser beams and detectors across the surroundings.

Lidar units used for digital mapping produce a characteristic 3D display defined by laser pulses reflecting from objects in the field of view. This display was generated by Velodyne LiDAR unit having a 360° field of view.

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One way manufacturers are reducing lidar cost is by eliminating the need for a precision spinning platform as found in Darpa Challenge lidars.

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Range determines sensor technology in lidar units

Measurement accuracy

Different lidars units employ different kinds of light detectors and detection techniques depending on the ranges involved, as summarized by light detector supplier Hamamatsu. Besides making time-of-flight measurements, lidar optimized for short-range use (a few tens of meters) may implement a triangulation scheme that measures the position of the reflected light relative to the light source. Also used are indirect methods that measure the phase difference between the laser and the returning light. Detectors for shortrange lidar units tend to be silicon PIN photodiodes.

As detection range rises the intensity of the laser light backscattered from targets falls off. Thus mediumrange lidar tends to use avalanche photodiode detectors because they can provide signal gains in the 10 to 100 range. Lidar units ranging out to hundreds of meters may use silicon photomultiplier detectors.

These are basically avalanche photodiodes operating in what’s called Geiger mode: A single photon causes avalanche current through a p-n junction that is reverse-biased well above the breakdown voltage. The signal gain for such devices can be on the order of 106.

Triangulation

Proximity

Short range

Long range

Si PD

APD

Clearly, this kind of price point won’t work for mass-produced autonomous vehicles. So today, manufacturers are devising lidar units that are more economical than those guiding the Darpa Challenge cars. Lidar designs targeting mass-produced autonomous vehicles have been announced costing a few hundred dollars or less.

One way manufacturers are reducing lidar cost is by eliminating the need for a precision spinning platform as found in Darpa Challenge lidars. The spinning optical platform approach has the advantage that it can create a 360° field of view (FOV). Lidars employing spinning platforms are still in use but now tend to mainly show up in aerial mapping or in inspecting vegetation as carried out by quadcopter drones.

But many lidar units now on the drawing boards for automotive use don’t employ a 360° FOV. Instead they look out in one direction with an FOV of perhaps 100° horizontally. To get a 360° coverage area, autonomous cars will likely carry three or four of these limited-view lidar units.

There are several ways of realizing limited FOV lidar. One technique, sometimes dubbed flash lidar, captures an entire scene with a single array of laser

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TOF

MPPC

diodes. It generally uses a 3D array of pixels, analogous to that in ordinary digital cameras but with the additional ability to record a 3D depth and intensity. Each pixel records the time the laser pulse takes to bounce back to the sensor. So each pixel records the depth and location as well as reflective intensity of the reflection it sees. A high-speed processor calculates the physical range of the objects in front of the camera. In lidar parlance, the resulting information is called a 3D point cloud frame and it is generated at video rates, generally up to 60 frames/sec.

Another technique for generating limited FOV lidar uses a MEMS micromirror to steer a laser beam across a scene in the style of a raster pattern. An example of such a system is that devised

by LeddarTech. It uses a pulsed laser diode whose beam bounces off an MEMS micromirror which oscillates rapidly on a single axis at a time. The micromirror sends the beam to a diffuser lens which doubles the angle of orientation of the beam and diffuses the laser pulse so it hits targets on the vertical FOV. A photodiode array detects the backscatter light coming from the targets. Meanwhile, the micromirror movement and laser diode pulses are synchronized with the movement of DESIGN WORLD

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Industry pioneer Velodyne LiDAR developed the first lidar units for the Darpa autonomous vehicle Grand Challenge. The 360° field-of-view that characterized the early lidar units is still available in modern units such as Velodyne’s Puck LITE. As in the Grand Challenge lidar, the Puck LITE rotates both its lasers and detectors. The rotation rate of the head is programmable and effectively sets the frame-rate of the resulting video. A lower rotation rate gives a higher effective horizontal resolution, but a lower frame rate, and vice versa.

A rotation sensor allows the end user to manage this trade-off. The units can rotate from a 5 to a 20-Hz rate.

the micromirror in a way that scans the horizontal FOV in multiple lines, raster style. The detector array segments each vertical signal in multiple individual measurements to build a 3D matrix representing the targets in the FOV. GM buys a lidar maker Unfortunately, the time-of-flight measurements implemented by traditional lidar units have their share of issues. For example, simple TOF measurements are prone to interference from other signal sources, and the interference worsens with distance because of the weaker signals involved. And the useful range of TOF lidars depends on how well they detect the relatively faint reflected signals. Making the lidar photodetectors more sensitive also makes them more susceptible to interfering signals.

Difficulties inherent in ordinary lidar may be one reason General Motors recently acquired Strobe Inc., a small California startup developing a sub-$100 solidstate lidar for self-driving cars. Strobe’s approach to lidar differs from that of other manufacturers. It produces brief chirps of frequency-modulated (FM) laser light in the style of chirped radar, where the frequency within each chirp varies linearly. Detectors

measure the phase and frequency of the echoing chirp. This gives information not only about the distance of targets but also their relative velocity. Moreover, the returns are said to be less susceptible to interference (because interfering signals are generally not modulated) and can be detected with photodetectors that needn’t be super sensitive.

The idea of FM chirp-based lidar isn’t new, but it has depended on factors that include the linewidth limitations of the

Some lidar units use micromirrors to scan their laser across targets. An example of a device implementing this technique is one from LeddarTech. Its scanning-type lidar unit covers a FOV of 60°×20° with a resolution of 0.25°×0.3° and can detect pedestrians more than 200 m away. In operation, a laser diode pulses a collimated beam towards the micromirror which is oscillating at a high frequency on a single axis. The laser diode synchronizes it’s pulses with the micromirror in a way that results in multiple scans of the horizontal FOV when the micromirror redirects the beam toward a diffuser lens. The lens doubles the angle of orientation of the beam and diffuses the laser pulse vertically. Targets in the FOV reflect back light that gets captured by a receiver lens and redirected to an array of photodiodes. The array segments each vertical signal into multiple individual measurements to build a 3D matrix covering the entire FOV. The resulting information is digitized and sent to an image processor.

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Oewaves lidar as applied in an ADAS application Point cloud

Chirp generator Scan clock

Data processing engine

optical resonator

Optical scanner

FM laser

FFT engine

ADAS engine

Photocell/amp assembly

You can get general sense of how Strobe lidar works by reviewing the Oewaves patent.

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Optical switch

emitting laser, the range of frequencies within the chirp, the linearity of the frequency change during each chirp, and the reproducibility of individual chirps.

Improving one of these factors tends to make the others worse. And FM lidar systems developed to date generally have relied on relatively large laser sources and on a carefully modulated, low-noise local oscillator with the FM provided by a relatively large interferometer. All in all, these setups have been complicated and bulky.

The Strobe lidar gets around the bulkiness problem by using a technique devised by another company called Oewaves, Inc. which was founded by one of Strobe’s principals. Called a “whispering gallery mode” optical resonator (i.e. resonating optical cavity), it reduces the laser’s linewidth via light feedback. The “whispering gallery” refers to a type of wave that can travel around a concave surface.

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Here is how the Oewaves patent describes a lidar system built around its FM chirp scheme for an advanced driver assistance system (ADAS). An FM laser couples to an optical resonator which can support one or more whispering gallery propagation modes. Light couples out of the optical resonator to provide optical injection locking of the FM laser and substantially reduce its linewidth. To FM the laser, the optical properties of the optical resonator are changed (for example by heat via a resistance heater, pressure via a piezoelectric device, and/or the application of a voltage potential via an electrode), to alter the wavelength associated with a whispering gallery mode. The resulting light frequency is fed back to the laser via injection locking to alter the laser light output frequency. A chirp generator is employed to produce optical frequency chirps from the FM laser. An optical switch directs the transmitted optical frequency chirp to an optical scanner. A scan clock controls the scanning rate and/or chirp generation rate and can make adjustments depending on environmental and/or traffic conditions. Chirps reflected from targets are directed by the scanner to a photocell/ amplifier. Amplified electrical signals corresponding to the reflected and retained chirp are processed in a fast Fourier transform engine and go to a data processing engine that estimates both the distance between the lidar emitter and the reflective object and their relative velocity.

Though the idea originated with sound waves in cathedrals, it can apply to light waves circulating with little attenuation inside tiny glass spheres or toruses.

You can get general sense of how the Strobe lidar works by reviewing the Oewaves patent. As the patent describes, light from the laser couples into the whispering gallery mode optical resonator and then couples back out as a returning counterpropagating wave that has a frequency equal to that of the optical resonator’s standing wave frequency. This returning wave gets injected into the laser and has the effect of locking it to the resonator frequency. It also reduces variations in the amplitude of the laser light (relative intensity noise, or RIN) which can degrade FM lidar performance.

So far so good. What’s noteworthy about the technique is that it seems to be a way of modulating the optical properties of the whispering gallery mode optical resonator.

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optical properties is what provides a method for producing highly linear and reproducible optical chirps for the lidar system.

As is often the case with patent applications, several of the technical details in Oewaves’ lidar scheme are only vaguely described. For example, regarding the FM technique, it only says that a transducer (via electrodes, resistive heater, and/or piezoelectric device) can alter an optical property (for example, the refractive index) of the whispering gallery mode optical resonator. In any event, Oewaves says all these components, even the spherical or torus-shaped resonator, can reside on a single substrate.

The patent also says the linewidth of the optical-injection-locked laser can be less than 100 Hz in some cases.

This is important because the narrow linewidth helps maintain light frequency reproducibility from one chirp to the next.

Such a laser source can provide linear chirps

with large bandwidths of 15 GHz or more which can make for lidar able to resolve distances down to less than a centimeter is some cases.

It looks as though we won’t have long to wait to see lidar with these capabilities.

Strobe has said it expects to produce its first commercial product next spring. DW References LeddarTech, http://leddartech.com/ Strobe Inc., https://www.strobeinc. com/welcome-2/ Velodyne LiDAR Inc., http:// velodynelidar.com/

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Injection locking technique using an optical resonator (Based on Oewaves patent drawing) Controller Phase rotator Optical coupler Lens

Light feedback

Modulator laser output

Laser

Reflected light beam

WHAT DO YOU THINK?

Whispering gallery mode optical resonator

Output light beam

The Oewaves patent describes the operation of its whispering gallery mode optical resonator – likely to be incorporated in the Strobe lidar system -- using this arrangement. A source laser beam couples into a whispering gallery mode resonator using an optical coupler such as a prism through a phase rotator and a lens. A subset of the frequencies represented in the laser beam propagates as a self-reinforcing whispering gallery mode wave a through the resonator that is “captured” in the whispering gallery mode. A portion of this propagated light couples out of the resonator by a second optical coupler. The output light beam gets reflected by a mirror to provide a reflected light beam. The reflected light beam couples back into the resonator to form a counterpropagating wave. This wave couples out of the resonator via the first optical coupler and returns to the source laser as a feedback light, which narrows the linewidth of the laser output. The narrowed linewidth output of the source laser can be output through an exposed facet of the first prism and used in a lidar system.

Feedback optics Optical coupler

Mirror Lens

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Guide to ball bearing materials and applications Preston Souza | Product Specialist

Ball bearings can be used in a range of applications, from medical and

packaging technology to electronics and office technology. Because these components are available in different types of materials, each with their own set of features and benefits, weighing the pros and cons of a specific kind of ball bearing can become an important part of the design process. Ball bearings are most commonly made of steel, ceramic or plastic. While every ball bearing is comprised of four main partsâ&#x20AC;&#x201D;an outer race, an inner race, a cage and ballsâ&#x20AC;&#x201D;each has its own set of unique characteristics.

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Steel ball bearings are used for extremely high load, fast RPM applications. They can, however, be noisy and they require constant lubrication.

Steel Ball Bearings Partly because they are an older technology, steel ball bearings are a trusted solution for many design engineers. Typically, these types of bearings are comprised of all-steel parts, but are available with different types of steel races and balls, or with a phenolic cage.

Steel ball bearings are ideal for robust

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applications handling extremely high loads, and fast rotations per minute, and some feature a radial load capacity of up to 30,000 pounds. Another advantage of steel ball bearings is that they tend to be very precise because of the clearance that can be created during the manufacturing process.

But steel ball bearings can also be heavy and noisy.

Additionally, depending on the grade of steel, they can

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The most common type of ceramic ball bearing is often considered a “hybrid,” which indicates that the outer race, inner race, and cage of the bearing are comprised of steel, while the balls are made from ceramic. also lack chemical resistance. They require constant lubrication, which can mean added maintenance concerns. Steel is susceptible to corrosion in humid or wet environments. Due to the need for lubrication, most steel ball bearings must also be sealed to eliminate dirt and debris from getting in and lubricant from getting out. Failure to seal them adequately can lead to bearing failure. Furthermore, in medical applications, their magnetic properties can cause problems.

In addition, the large number of steel ball bearing manufacturers leads to tremendous price variances, ranging from inexpensive to costly.

Ceramic Ball Bearings The most common type of ceramic ball bearing is often considered a “hybrid,” which indicates that the outer race, inner race, and cage of the bearing are comprised of steel, while the balls are made from ceramic. The ceramic material enables the bearing to run faster while maintaining a cooler operating temperature and simultaneously reducing noise, vibration, and wear. Since they are a hybrid design and still contain steel races, hybrid ceramic ball bearings are as equally susceptible to corrosion as steel ball bearings.

Fully ceramic ball bearings tend to be more corrosion resistant, more rigid, and lighter in weight than most steel ball bearings. Additionally, fully ceramic ball bearings are nonmagnetic, which is useful for applications where this might be critical (e.g. MRI equipment). Lower coefficients of friction and higher RPMs are also possible and, since they are nonconductive, ceramic ball bearings can be used in electrical applications. In addition, most ceramic balls bearings can operate in temperatures up to 1,800° F. With these advantages, ceramic ball bearings are an attractive solution. However, these types of bearings are extremely expensive, which is a strong argument in itself for seeking out an alternative solution when extremely high speeds and high temperatures are not needed.

Plastic Ball Bearings While plastic ball bearings are a newer technology, they do have certain advantages. Plastic ball bearings are comprised of all-plastic races and a plastic cage,

Plastic ball bearings are comprised of all-plastic races and a plastic cage, and are typically available with a choice of three different types of balls: plastic, glass or stainless steel. The choice of material is often dependent on the environment in which the bearing will be used.

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M e c h a n i c a l

Xiros ball bearings from Igus.

and are typically available with a choice of three different types of balls: plastic, glass, or stainless steel.

The choice of material is often dependent on the environment in which the bearing will be used.

The most common ball material within a ball bearing is stainless steel. Stainless steel balls are the most cost-effective choice, but they are heavier than both the plastic and glass options, and they are magnetic, which can be a detriment to some applications. Glass balls are better suited when a metal-free solution is needed. Glass balls also offer chemical resistance and weigh less than the steel balls.

Plastic balls are another suitable option. They weigh less than both the steel and glass balls, and provide wear resistance while still being resistant to a variety of chemicals.

Whatever configuration is selected, plastic ball bearings are suitable for applications with normal to high speeds and have a number of additional features.

Due to their plastic construction, plastic ball bearings are self-lubricating, corrosion resistant and they deliver a quiet operation. Another major advantage is that they are lightweight.

There are a few different plastic ball bearing manufacturers on the market. Some are producing plastic ball bearings typically made with acetal, and others are producing bearings with homogeneously blended materials including a base plastic, solid lubricants, fibers and filaments. Application specifics would indicate if using a simple plastic is sufficient, as it offers a lightweight quiet solution and corrosion resistance. If wear is a serious concern, a thermoplastic might be more advantageous.

Still, there are instances where plastic ball bearings should not be used, including applications with high loads or long-term temperatures exceeding 300° F. Ball bearings are manufactured with myriad features. Manufacturers of steel ball bearings, for example, often offer their bearings in a number of different types of steel, including a 300 series (soft stainless), a 400 series, or chrome steel. DW Igus | www.igus.com

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The Robot Report

By Frank Tobe • Founder of the Robot Report

Everything’s bigger in Texas China

R

Recent news about growth of Chinese robotics and related AI indicate

just how massive their investments are and how well they are paying off. For example, 90% of the personal robots on display at the IFA consumer electronics trade show held in Berlin in September were developed and manufactured by

Further, Preqin reported that Q3 venture-backed deals totaled $49 billion.

Included in the top 10 deals were Uber-competitor Grab’s raising $2 billion from SoftBank and Didi Chuxing and Alibaba’s $1.1 billion investment in eBay-like Tokopedia and $0.8 billion to Cainiao. Half of the top 10 were in Asia; only three were for U.S.-based companies.

Three Chinese companies stand out with Texas-size robotics-related activity: Midea/Kuka is planning to sell 50-55% of its annual $3 billion output in China by 2020; Siasun’s robots are exported to 30+ countries; and Alibaba is investing $15 billion over five years in internal logistics for their growing e-commerce business.

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| istockphoto.com

Chinese companies.

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Alibaba Amazon take note: China’s largest smart warehouse is manned by mobile robots moving shelves to picking and packing stations—and they look amazingly similar to Amazon’s Kiva robots.

Alibaba is emulating Amazon in putting robots into the logistics warehouses it operates for sorting, picking and moving applications. Through its investment in logistics company Cainiao, and similar investments in local startups Geek+ and Quicktron, both of which make Kiva-like mobile robots and provide extensive network and traffic management software for e-commerce distribution centers. Cainiao currently executes 57 million deliveries a day.

Alibaba, which had owned 47% of Cainiao, has invested a further $807 million to increase its stake to 51%.

Alibaba’s goal for Cainiao is to deliver anywhere in China within 24 hours and anywhere in the world within 72 hours.

Warehousing robots aren’t Alibaba’s only play. They are also investing in service robots through their joint venture with SoftBank Robotics and Foxconn and also augmented reality big-data-driven logistics navigation and picking solutions as well as other types of AGVs for towing, moving and sorting pallets, boxed goods and shelves.

In addition to the Cainiao investment, Alibaba also invested $1.1 billion in PT Tokopedia, a large e-Bay-like service covering Indonesia. Overall, Alibaba has committed $15 billion over the next five years to build out a global logistics network.

Midea Group Midea, China’s 4th largest consumer products manufacturer, and the country’s biggest maker of air conditioners, refrigerators and appliances, has a masterplan to revamp itself into China’s leading robot manufacturer. Last year, for around $4.5 billion, they acquired the world’s 4th largest robot manufacturer, Germany-based Kuka AG. At their air conditioner plant, Midea has deployed 800 robots and replaced 24,000 workers in their quest to improve quality and reduce costs. In another

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factory, Midea engineers have made it so six robots produce and assemble remote control devices every seven seconds, with 100% quality.

Early this year they set up an alliance with Israel-based advanced motion control and automation systems company Servotronix. Then they invested another $1.5 billion in a new factory in southern China to manufacturer and assemble service and industrial robots (7,000 and 2,000 per year respectively).

These robots will be for sale—as well as

restaurants, public spaces and indoor cleaning and security. Online retailer JD.com has teamed up with Siasun to automate JD’s logistic network and JD says that it also plans to develop delivery drones and driverless vehicles.

Qu Daokui, president of Siasun, said the company is looking to invest in robot technology in Europe and the United States, with acquisitions starting from at least $1 billion. “We are interested in companies that have state-of-the-art technologies or have a key presence in

Recent news about growth of Chinese robotics and related AI indicate how massive their investments are and how well they are paying off. for internal use—and the goal is that by 2025, 17,000 industrial robots will be produced at that factory in addition to Kuka’s goals at Kuka’s separate facilities.

Kuka plans to sell 50-55% of its annual output ($3 billion+) in China by 2020. Midea is doubling the number of research engineers working on product development and AI. Research projects include robotic bartenders, consumer food processors and industrial-grade food production robots. Midea’s investments and strategic alliances underscore their ambition to lead in automation and robotics within China and, later, globally.

Siasun Robot & Automation According to The Wall Street Journal, Siasun’s 2016 revenue was $2.02 billion, which was 20.47% greater than FY 2015. Forbes rates Siasun as #20 on the Innovative Growth Companies list with a market cap of $5.1 billion and 2,500 employees.

Siasun focuses on four verticals: advanced manufacturing equipment, rail transit automation, autonomous energy equipment and advanced robotics (across all divisions). In addition to fixed and mobile industrial robots, Siasun has a line of clean room robots and a new collaborative robot. They also have an extensive line of mobile robots for material handling, warehouses,

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the industry chain,” Qu said recently at the 2017 World Robot Conference in Beijing.

Currently, the Shenyang-based company’s industrial robots and other products are exported to more than 30 countries and regions. Moreover, twothirds of Siasun’s customers are foreign companies. According to China Daily, Siasun robots are at work in Ford and General Motors auto plants in the U.S. Last year, Siasun teamed up with Israeli companies and universities in a China-Israel robot research institute in Guangzhou where they are jointly working on artificial intelligence, which Qu billed as of great importance to robots by giving them “wings.”

Bottom line Many critics and pundits warn that the free-flowing incentives China has been giving to affect its five-year plans and Made in China 2025 program has produced fraud, false figures and unknown results. They worry about overcapacity and that many of the new companies involved in robotics are just in it to get the subsidies and tax breaks.

Nevertheless, the three companies profiled above attest to the fact that China’s overall goal to become a hightech maker and user of robotics and AI is working … and working BIG. Texas BIG. DW

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Consumer Robotics Paul J. Heney • Editorial Director

Disney and robotics

are a magical combination

T

The so-called “imagineers” who work at Walt Disney World and Disneyland have long been at the forefront using robotics to replicate humanlike movement … as well

At a recent event, Martin Buehler, Executive R&D Imagineer, Walt Disney Imagineering,

discussed what the company is doing. His team’s most newsworthy project is likely the new Pandora: The World of Avatar, located at Disney’s Animal Kingdom in Orlando, which

| Courtesy Disney

as creature-like movement, I suppose, given their vast catalog of characters.

recently debuted to the public with rave reviews.

Buehler said the attraction’s Na’vi the Shaman of Songs character is the latest and most expressive character they have done to date. Disney’s most advanced character previously had 16 functions—motors or movements— while the Na’vi has 40 movements, all in her head, “to make her super expressive.” In fact, when video of the character was released, it unleashed many debates about whether it was real or CGI. A big part of a robotic build like this, Buehler said, is reliability. In their world, many of the individual pieces of an attraction are critical—if they go down, the whole ride has to be shut down.

“She is now performing day after day, 18 hours a day, seven days a week, every day of the year. No breaks. So, we all went to incredible lengths testing cables, wires, motors, to make sure that she runs reliably … we make sure our characters, that we only build one of, are very reliable, and easy to repair.”

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This brings to mind the issue of a robot being a character. Buehler said he feels it isn’t only important for Disney.

“We really want to interact with characters,” he said. “We know how to interact with them. They understand us when we talk to them. They can see us. And that’s becoming more and more possible now. We talk to our devices. They can now safely recognize us with the latest iPhone. Who wants to type in a password? You want your bot to recognize you. And when that happens, we are more willing to welcome them. We’re more willing to accept some of the limitations. Even help them out. You ever stand in front of a closed door? I’d be the first one to open the door for [a robot].”

This has implications for other social interactions, such as when we invite robots in our home, whether it be as companions, for elder care

November 2017 www.designworldonline.com

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or as personal assistants. Buehler stressed that experiences are a critical component of our interaction with robots.

“What about the next experiences?” he said. “Are we innovative in using self-driving cars?

Once we’re inside these cars and don’t have any driving to do, what are we going to do? We’re going to be entertained—especially sitting in the traffic for a couple of hours a day. What are you going to do?

You’ve been sitting in this confined space. You may want to turn your car into an office. But we also want to play. Maybe with all those screens, you can turn the vehicle into an amazing automatic reality—a virtual reality cabin. Or go completely online and have amazing battles.

Star Wars battles or galactic battles against your friends or your fellow commuters. The possibilities out there are endless.” DW

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Autonomous Vehicles Leland Teschler | Executive Editor

Bad robot: Will you trust your

| istockphoto.com

autonomous vehicle?

I

If you believe the hype coming out of Silicon Valley start-ups, we are on the verge of seeing highways filled with fully robotic drivers. But numerous well-chronicled accidents among semi-autonomous vehicles have brought many questions about whether people should trust artificially intelligent cars to make good decisions.

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We don’t have to speculate about how people will react to new driver assistance technology. The market research firm J.D. Power recently surveyed consumers on their experiences with advanced features such as blind spot warning systems and lane-centering systems. It is illuminating to read the feedback they received. The lesson seems to be that today’s driver assistance tech is a reality check for what the future holds.

Comments coming back to J.D. Power about lane-centering were particularly noteworthy in that this feature takes control of the car’s steering – thus lanecentering is a harbinger of what may be in store when fully automatic steering debuts. “Nice try. It works sometimes,” was one comment. “Doesn’t work fast enough and makes wrong control inputs at times. Works best on highways and otherwise I’m very attentive. The system hasn’t gained my confidence.”

November 2017 www.designworldonline.com

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â&#x20AC;&#x153;I thought that the car would correct itself but it does not seem like it does,â&#x20AC;? went another. â&#x20AC;&#x153;Lane keeping is not consistent. Sometimes (rarely) the corrections are applied to the steering, but more often just get an alert in the instrument display. Unreliable. Not useful,â&#x20AC;? the driver continued.

With these sorts of comments, it is unsurprising that drivers often choose not to use lane centering. Only a bit over half (57%) of drivers reported keeping the lane-keeping function switched on all the time. About 20% say they tried it and stopped using it, never tried it, or used less than half the time.

The statistics are better for blind sport warnings, perhaps because these are alerts for the human driver rather than a system that takes control of the steering wheel. More than 80% of drivers have the warnings switched on constantly. Only about 5% donâ&#x20AC;&#x2122;t bother with it much of the time.

Drivers also gave J.D. Power opinions about where these advanced features needed improvement. Almost half said lane-keeping systems just werenâ&#x20AC;&#x2122;t accurate enough and needed better customization.

Youâ&#x20AC;&#x2122;d have to say that so far, opinions about driver assistance functions arenâ&#x20AC;&#x2122;t exactly a ringing endorsement for the more complicated systems now on the drawing boards. That skepticism is reflected in the responses J.D. Powers got when it asked drivers whether they would trust fully automated self-driving cars. Even premium car owners who own vehicles likely to sport driver assistance features are skeptical of self-driving cars. More than 50% of them said they definitely or probably wouldnâ&#x20AC;&#x2122;t trust self-driving vehicles. An even higher percentage of people who drive ordinary cars say they wouldnâ&#x20AC;&#x2122;t trust robotic drivers.

All in all, youâ&#x20AC;&#x2122;d have to say the automated driving features that have debuted so far arenâ&#x20AC;&#x2122;t exactly a big hit with the driving public. They often seem to be pretty fragile. It will take a lot of positive experiences rather than just hype to convince the public that robotic driving is an option worth paying for. DW

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Artificial Intelligence

| istockphoto.com

Leslie Langnau • Managing Editor

How AI will change the engineering skill set

I

In the 1950s, manufacturing employed about 38% of the U.S. workforce (Bureau of Labor Statistics). Today, that number has shrunk to 9% (Economic Policy Institute). The skill set for manufacturing was not difficult to obtain and often involved more brawn than advanced brain power. Automation of all types, including in the form of robots, played a huge role in taking over that skill set.

The next technology to impact skill sets will be Artificial Intelligence (AI). In fact, futurists think AI will be as prevalent as electricity—you will simply “plug in.”

This technology will likely eliminate many jobs that require skills involving linear or logical thinking. According to Accenture PLC, more than 1,000 large companies are testing or using AI and machine learning systems. In a few years, say forecasters, the main products of large companies will be their AI offerings.

Transportation is currently undergoing such a shift because of AI with driverless trucks, although some believe the changes won’t happen as fast as predicted.

Machine learning, the IoT, and AI enabled robots will continue to shift the skill set needed for manufacturing tasks.

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A number of CAD design tasks will be automated as well. Take a look at many of the new CAD programs coming out. More of them offer some kind of design assistance—suggestions from the software on how to improve your design in some way. Today, these programs use statistical and rapid stress and strain analyses to develop the suggestions. But the day is coming where your interaction with CAD programs will be in the form of asking questions or issuing commands, such as, “design an actuator with the following constraints on load, movement, and time,” and then you will examine what the program delivers.

AI is already demonstrating its ability to evolve. These systems are using all the terabytes of data Google, Facebook, and IoT applications are gathering to “learn.”

Then, these systems are taking that learning and using it to code and upgrade themselves with new features. You can expect that needed skill sets will change as quickly.

The future goes to the quick Who would have thought about a decade ago that you could have a job handling social media tasks on Facebook? That new skill set went to the young, who were so familiar with social content. And search engine optimization—another new skill set, courtesy of digital advances.

The new skills needed to work with the changes brought about by AI, however, are skills most people don’t have today.

According to futurists, these new skills will be based on empathy, big picture thinking, the ability to explain new technology to potential users, train AI systems, and prevent AI from decisions and actions with unintended consequences. You will need to work well with AI-based systems and you will need to think differently.

In transportation, for example, former drivers may need skills that tweak traffic algorithms for the best use of time and fuel.

In other industries, engineers will be making jobs for robots and intelligent products, says Kevin Kelly in his book The Inevitable: Understanding the 12

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The next technology to impact skill sets will be Artificial Intelligence (AI).

In fact futurists think AI will be as prevalent as electricity—you will simply plug in.

Technological Forces That Will Shape Our Future. Kelly optimistically says that job will never be finished. Notes Kelley, “We will cognify everything.”

Needed skills According to a global study some of the new categories of jobs will take many companies by surprise. The skills mentioned earlier can be grouped into the broader categories of training, explaining, and sustaining.

So what might be involved with training? One example includes jobs that require people to teach AI systems, such as Chatbots, how to work with human customers. Chatbots need to learn natural language processing and how to understand human behavior, including frustration, misunderstanding, and even sarcasm.

Skills will be needed to teach AI systems to mimic empathy and show compassion in a more realistic way.

People with these skill sets are being labeled “empathy trainers.” Today’s digital assistants, like Apple’s Siri and Amazon’s Alexa, should evolve to answer questions with compassion (and maybe even humor). But empathy trainers will also need to correct the digital assistants when they respond inappropriately.

The skill to explain Explainers will speak to both technologists and business leaders, facilitating understanding between them.

For non-technical people, AI is often viewed as a mysterious black box, so they won’t necessarily agree with decisions made on a purely algorithmic basis. For example, AI systems can handle some

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legal situations and offer an arbitrated settlement, but the parties may not wish to take the recommendation. Explainers can help in those types of situations.

Explainers will be called upon to explain the inner workings of complex algorithms. On example of an explainer would be an algorithm forensic analyst.

When an AI system makes a decision that leads to negative consequences, the analyst would examine the event and facilitate a correction. Analysts will need skills to conduct such research and explain the results to non-technical people.

Keeping it ethical The sustainers will be the ones who ensure AI systems operate as designed. They will help handle unintended consequences. Even though companies are proceeding quickly on AI development, developers are not necessarily confident in their ability to properly audit their systems, especially when it involves ethics.

Sustainers will act as watchdogs looking out for unconsciously programmed bias. While efforts will be made to develop algorithms without habitual perceptions, the AI systems may “learn” bias through their own observations relating to their selfprogramming. Sustainers, who might have such titles as “human ethics compliance managers,” along with algorithm forensics analysts will be called in to correct such issues. The goal is for AI systems to be fair, transparent, and auditable.

On the positive side, not all of these news skills will need degrees. So, despite the fears around AI, it could open a range of jobs at every economic level. DW

Sources • MIT SMR initiative • Accenture PLC’s • Daniel Pink, author of A Whole New Mind; Why Right-Brainers will rule the future • Kevin Kelly, author of The Inevitable: Understanding the 12 Technological Forces That Will Shape Our Future.

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Medical Robotics Brad Perriello | Life Sciences Executive Editor

Robotics in

| istockphoto.com

medicine

A look at 29 companies using robotics to address a variety of conditions, ranging from heart failure and joint replacement to cancer and even hair loss

T

The first surgical robot hit the U.S. market nearly 20 years ago and enjoyed a long run as the marketâ&#x20AC;&#x2122;s sole player. And although Intuitive Surgical is still the undisputed market leader, as of this writing TransEnterix had just entered the arena after winning FDA clearance for its Senhance device, with a slew of other prospects waiting in the wings.

These firms cover a wide swath of medical specialties, ranging from the traditional medtech strongholds of cardiology and orthopedics to abdominal surgeries and even hair loss. Hereâ&#x20AC;&#x2122;s a look at 29 companies working to apply robotics to medicine:

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Medical Robotics

• Auris Surgical: Founder Dr. Frederic Moll (a co-founder of Intuitive Surgical and several other medical robotics firms) last year paid $80 million for Hansen Medical and its Magellan and Sensie X devices for cardiovascular procedures; Auris is focused on lung cancer.

• Intuitive Surgical: First to market with the original da Vinci platform in 2000; won FDA nod clearance for latest-generation da Vinci X in May 2017.

• TransEnterix: Second to market in the abdominal surgery market; won FDA clearance in October 2017 for the Senhance system it acquired for $100 million from Italy’s Sofar in 2015; tabled the SurgiBot in 2016 after the FDA denied its clearance bid.

• Corindus Vascular Robotics: Makes the CorPath 200 device percutaneous coronary interventions via a radiation-shielded “cockpit” for the surgeon.

• Stereotaxis: Makes the Epoch platform, using both the Niobe and Vdrive navigation systems; Niobe uses two magnets on pivoted arms to magnetically control the instrument; Vdrive is used to control diagnostic and ablation devices.

• Verb Surgical: A joint venture between Johnson & Johnson and Google that’s been coy about its product; CEO Scott Huennekens calls Verb’s approach “Surgery 4.0,” saying that it integrates robotics, data analytics, machine learning, advanced instrumentation, and advanced visualization.

• Stryker: Took the lead in the robotics pack for the orthopedics space with its 2013 buyout of Mako Surgical and its partial knee and partial hip replacement systems; a total knee system hit the market in 2017.

• Mazor Robotics: Makes the Renaissance and Mazor X platforms; inked a strategic partnership with Medtronic, which paid $72 million for the distribution rights to Mazor X and a 10.6% stake in the Caesarea, Israel-based company.

• Zimmer Biomet: The orthopedics giant entered the robotic surgery field by snagging French robotics firm Medtech Innovative Surgical Technology and its Rosa Brain and Rosa Spine platforms.

• Titan Medical: The nearest rival to TransEnterix with its single-port Sport platform; ran into a major financial speed bump, forcing it to halt development until it raised nearly $7.9 million to jumpstart the program.

• Smith & Nephew: Got into the robotic surgical market with the acquisition of Blue Belt Technologies and its Navio device, which is designed to work with eight different knee systems from it and other manufacturers; the company has said it plans to expand the Navio platform into total, bi-cruciate retaining and revision knee implants and, eventually, total hip arthroplasty and sports medicine.

• Globus Medical: The fourth major player in orthopedic robotics, entered the market in 2014 via the buyout of Excelsius and its eponymous platform for orthopedic and neurosurgical procedures; Excelsius this year won FDA clearance in the U.S. and CE Mark approval in the European Union.

| istockphoto.com

• Medrobotics: Makes the Flex system, designed to provide access to hard-to-reach anatomical locations in the oropharynx, hypopharynx and larynx; won 510(k) clearance from the FDA in July 2015.

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• Restoration Robotics: Another startup co-founded by Fred Moll, Restoration Robotics this year raised $25 million in an initial public offering for the Artas system, designed to harvest follicular units for hair transplantation procedures. The system received FDA 510(k) approval in 2011.

November 2017 www.designworldonline.com

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Medical Robotics

• ReWalk Robotics: Makes robotic exoskeletons for stroke and spinal injury rehabilitation; plans a 2018 debut for its Restore soft exoskeleton; previously known as Argo Medical Technology, raised $36 million in a 2014 IPO.

• Reactive Robotics: This German medical robotics start-up raised a seven-figure round for the robotic intelligent therapy device it’s developing to replace manual Very Early Mobilization therapy for use with intensive care patients.

• Myomo: Another player in the robotic rehabilitation arena, Myomo makes the MyoPro line of powered orthotic devices for patients with neuro- muscular disorders.

• IotaMotion: The Iowa City-based company, spun out from the University of Iowa’s otolaryngology department, is developing a robotic-assisted insertion device designed to aid surgeons in advancing cochlear implant electrodes; raised $2 million in a seed financing round in August 2017.

• Wandercraft: Paris-based company raised $17.8 million in a Series B funding round in October 2017 to fund certifications and regulatory clearances for its rehab exoskeleton, designed to replicate the human gait; aims for CE Mark approval in the European Union next year.

• Bionik Laboratories: Is developing the Arke robotic rehabilitation device and recently integrated Amazon‘s Echo and Alexa voice technology into the lower body exoskeleton.

• Bioservo Technologies: This Swedish company makes the RoboGlove device for rehabilitation and is exploring the technology for possible soft exoskeleton applications.

• Robocath: Developing the R-one robotic platform for interventional cardiology; pursuing CE Mark approval in the European Union; raised $5.2 million (EU €4.7 million) in May 2017.

• Superflex: A spin-off of research group SRI International focused on developing wearable robotics designed to enhance the human musculoskeletal system; raised $10.2 million in May 2017.

• Medineering: Backed by Brainlab, is developing a platform endo and transnasal surgery.

• Synaptive: Toronto-based company makes the BrightMatter neurosurgery platform, including the Modus V digital microscope and robotic arm, that it calls “a GPS system for the brain.”

• Procept BioRobotics: Is developing the AquaBram system for treating benign prostatic hyperplasia using the Aquablation high-pressure waterjet to ablate prostate tissue.

• Cambridge Medical Robotics: Is developing the Versius robot-assisted surgical arm; added $26 million to its Series A round it plans to use on validation studies and further production.

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• Xenex Disinfection Services: Makes the LightStrike “germ-zapping” robot, which uses pulsed xenon to create full spectrum, high-intensity UV light to destroy the germs that create hospital- acquired infections; raised a $38 million funding round in February 2017.

• Cambridge Consultants: Is developing the Axsis micro-sized robotic surgical unit for cataract surgery, which measures 1.8mm in diameter and features two robotic arms with tendon- like cables measuring just 110 microns in diameter, approximately the same as a human hair. DW

November 2017 www.designworldonline.com

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Unmanned Vehicles/Drones Leland Teschler | Executive Editor

Gawking from drones:

Why geofences are the coming thing in UAVs

O

Owners of some 20 vehicles who were recently cornered by wild fires on a freeway near Los Angeles probably don’t have much good to say about aerial drones. For up to 20 minutes, five hobbyist drones prevented California firefighters from sending helicopters with water buckets over a stretch of I-5 while the flames raged. The consequence was several torched cars and “panic among motorists who fled on foot,” according to CNN. Fire fighters aren’t the only ones having problems with errant UAVs. Recently a Skyjet Aviation flight hit a drone while on approach to Jean Lesage Airport in Canada’s Quebec City. Fortunately the aircraft suffered only minor damage and no one was injured. The incident appears to have violated numerous regulations aimed at preventing such mishaps. Canadian authorities report that to date there have been 1,596 drone incidents reported in that country.

Civil penalties for flying a UAV in a fire zone under FAA flight restrictions can reach $27,500, and perpetrators also run the risk of doing prison time. But apparently such threats aren’t enough to stop aerial gawkers. That is one reason

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why The U.S. Interior Dept. recently partnered with drone makers and digital mapping firms to come up with a prototype warning system that provides realtime alerts and alarms about firefighting operations.

The agency developed the test system with drone maker DJI and navigational service providers AirMap and Skyward. Given the growing dangers of drones flying through forbidden air space, the Interior Dept.’s program could be harbinger of measures that could be adopted nationwide.

The Interior Dept.’s so-called geofencing system builds on one already installed on DJI UAVs. Today, DJI drones will, by default, not fly into or take off in locations that raise safety or security concerns.

But users who have verified DJI accounts can temporarily unlock or self-authorize flights in some of those locations, though not in prohibited areas or sensitive national-security locations such as Washington, D.C. To interact with a geofence, a drone must contain a GPS and autopilot software. During or before flight, it must download nearby “no-fly-zone” information in terms of latitudes and longitudes. As the drone flies, its autopilot continually computes the distance from the drone to forbidden areas.

When it reaches a boundary, the autopilot must either stop, maneuver away, and/or tell the operator to do something.

Future versions of geofencing may allow authorities to ground drones if they enter restricted airspace. But there are problems with geofencing.

One is that the boundaries of prohibited areas sometimes overlap in complicated ways. Many no-fly areas are not simple geometric shapes and straight lines but instead follow rivers, roads, or other geographical features. So the no-fly zones end up looking like ink blots on Rorschach tests.

Navigating through the resulting mazes can be tricky.

There are other difficulties as well. Aviation industry observers point out that sometimes GPS reception can be unreliable. The FAA will issue Notice to Airmen (NOTAMs) about GPS degradation in specific areas, but it is not clear how many drone operators are savvy enough to check for NOTAMs before they fly. Additionally, an operator may lose control of a drone if the automatic control kicks in during a brush with a no-fly boundary. That could be a problem if the drone needs to be maneuvered suddenly to avoid a mid-air collision.

Finally, manually controlled drones lacking GPS can’t observe geofences. So get ready for simple drones to either start carrying more expensive navigation gear or be legislated out of the sky. DW DESIGN WORLD

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The Robot Report Edited by Paul J. Heney | Editorial Director

Brooklyn manufacturer

triples 3D printing production with collaborative robots

Voodoo Manufacturing urgently needed to automate the manual loading and unloading of plates in their printers.

The robot arm gently places a plate with an orange Pokémon figure on a conveyor, picks up a new blank plate from a hopper, places it back in the 3D printer, and queues the system to start a new build. Toys are serious business here at Voodoo Manufacturing, a Brooklyn-based startup that has created a niche for itself producing plastic parts in runs of fewer than 10,000 items using an army of 160 3D printers. Products ranging from prosthetic hands to protective dog eyewear are now produced in this setup, called “Project Skywalker,” that the company believes is the first-ever robot-operated cluster of 3D printers.

The UR10 collaborative robot is helping Voodoo Manufacturing take 3D printing from a technology mostly used for producing prototypes and high-value components to become a viable alternative to the mass production of plastic parts done through injection molding, a more cost-intensive production process.

“When we were looking for a robotic arm, we were looking for one that could do the tasks, but would also be easily programmable and get up and running very quickly. For us, Universal Robots’ UR10 was a great option,” said Jonathan Schwartz, Chief Product Officer of Voodoo, adding that the collaborative safety features were imperative.

The robots are classified as “collaborative” due to their built-in safety system that makes the arm stop operating if

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it encounters objects or people within its route. This feature enables humans and robots to literally work side-by-side— with no fencing as is generally required with traditional industrial robots.

“So instead of building a factory with caged-off areas and potential hazards, we are now able to create a friendly workplace with continuous and spontaneous improvement and interaction between humans and robots,” said Schwartz.

Voodoo Manufacturing estimates that the cost of implementing a UR robot was about five times less expensive than a traditional industrial robot, due to the quick integration that did not involve safety cages, light curtains, and other safety measures usually needed when robots are at work in a factory setting.

November 2017 www.designworldonline.com

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The Robot Report

Fast integration Getting a proof of concept for Project Skywalker was a race against time as Voodoo Manufacturing was pitching investors.

“We didn’t have a couple of years to put something through R&D, we needed it here and now. We got the UR10 out of the box and were able to get it running within just a few hours,” said Schwartz, who also needed a gripper that could be seamlessly integrated at the end of the robot arm. “One important aspect for choosing the UR10 was that there were really good peripherals that we could use with it,” said Schwartz, who chose a twofingered gripper from Robotiq.

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The gripper is part of the rapidly expanding Universal Robots+ platform that features plug-and-play products for the company’s robots. Cynthia Kradjel, Account Manager with Universal Robots distributor Axis New Jersey, recommended the Robotiq gripper as she knew its UR+ certification meant hassle-free integration. “A UR+ product is tested and proven, the gripper software has even been integrated right on the robot’s own touch screen, which eliminated countless hours of trial and error, scripting code,” she said.

Charlie Fenwick, industrial engineer at Voodoo, emphasized how the integration ended up being the deciding factor in choosing the right robot solution. “We looked at different robot arms, but none of them had the ability to easily interface with the peripherals required to get the complete application up and running,” he said. “Getting the

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Voodoo chose the UR10 robot arm, as it interfaced seamlessly with the Robotiq gripper through the UR+ platform.

The Brooklyn startup 3D printed their own extensions to the gripper, enabling it to grab the build plates.

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The Robot Report Getting a product printed at Voodoo Manufacturing just requires sending the company a 3D file

“When we were looking for a robotic arm, we were looking for one that could do the tasks, but would also be easily programmable and get up and running very quickly.”

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gripper to work with the arm was almost like building a Power Point slide, by just dragging blocks of information onto the screen. All you have to do is link up the different blocks and it basically runs itself,” said Fenwick, adding that his team unexpectedly finished the project ahead of schedule.

Harvesting—the low hanging fruit The UR10’s work assignment of loading and unloading plates is called “harvesting,” which took up to 10% of all labor hours.

This low-value-added activity is what Schwartz describes as “a perfect and almost quantifiable task” that he felt confident in being able to automate with speed, accuracy, and precision.

Voodoo has 160 3D printers. By placing the UR10 on a mobile base roaming the 18,000 square feet factory, the company will be able to use the collaborative robot to tend 100 printers. By adding another UR10 to its fleet, Schwartz will take the startup from 30–40% printer usage up to 90%. “And from here on out as we scale, we can just buy more arms as we have more and more printers,” said Schwartz, who is not hesitant to call Project Skywalker “a massive success,” adding that “even though we shouldn’t have been surprised by the results, we all had this strong realization of how much of a gamechanger this would be.”

The key to tripling output is the fact that the robot can run overnight. “We can

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monitor the robot through our own software and access the status of any given printer to see whether it’s printing or idle, which means we can deploy this in our factory and run it 24/7 without any human oversight,” said Schwartz, who describes it as “magical” first morning he came in to find more than 30 completed print runs handled by the robot overnight.

Voodoo’s three-year goal is to reduce cost by 90%. The increased output compared with the reduction in labor cost provided by the company’s first UR10 means that the robot will pay itself back in less than six months. “If we’re going to increase our output ten-fold over the next couple of years, we have to do that without increasing our costs by 10x and the robots will be instrumental in achieving this,” said Schwartz, emphasizing that automating the harvesting was just the first step. “Beyond this, there are many other opportunities in our factory to automate; whether it is removing parts from the build plates, or cleaning them, or inspecting them for quality, or eventually even packing and shipping.”

Right now, Voodoo can compete with low-volume injection molded parts, but if the company is to compete at higher volumes such as batches of 100,000, they need to continue executing their automation strategy. In the long term,

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Schwartz envisions Voodoo scaling up its operation to around 10,000 3D printers. These printers will be able to use new materials and make products that you can’t see are 3D-printed. For the Brooklyn startup, automation is more than simply a way of cutting costs.

“It’s the only way we’ll survive to be a large company that employs hundreds, if not thousands, of people,” said Schwartz.

“In taking on such massive and deeply entrenched industry such as injection molding, automation is going to be our primary weapon.”

This weapon is not one that will kill jobs, Schwartz feels.

“The UR robots free our employees from a lot of the tedious tasks that we currently do in our factory and move them into higher-value positions that require more critical thinking,” said Schwartz. “Over the past 30 years, manufacturing has left the United States mainly because of the very cheap

Voodoo chose the UR10 robot arm, as it interfaced seamlessly with the Robotiq gripper through the UR+ platform. The Brooklyn startup 3D printed their own extensions to the gripper, enabling it to grab the build plates.

labor costs overseas; but we feel that is changing with new technology such as this robotic arm. Now we can build a factory that can actually compete on cost with Chinese factories. In the next ten years, we’re going to see manufacturing come back to the United States, and I predict an increase in manufacturing jobs available right here.” DW Universal Robots | www.universal-robots.com Voodoo Manufacturing | www.voodoomfg.com

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Epson all-in-one SCARA

A

to compete against Cartesians and serve mid-range applications

At the recent Pack Expo, Epson Robots announced an expansion of its industrial SCARA robot line with new T-Series all-in-one robots with built-in controllers. The design (with a price starting at around $7,500, according to early sources) reduces space requirements and simplifies setup.

The first available robot of the series is the T3 — a cost-effective and simple-tointegrate automation robot for basic applications such as pick and place, assembly, parts handling, and dispensing applications in electronic components and industrial automotive, medical development, lab automation, and consumer-electronics applications.

Epson Robots supplies PC-controlled precision factory automation with an installed base of more than 55,000 robots and hundreds of products that include SCARA, Cartesian and 6-Axis robots based on a common PC platform. T-Series robots are available now.

“The T3 has the same intuitive software and features of our high-end robots, which lends power and simplicity to even simple applications,” said Rick Brookshire, senior manager at EPSON Robots. “The miniaturization of many of its components plus the elimination of a controller chassis and other components also helps reduce overall cost.”

Variations of the T3 also leverage the manufacturer’s feedback offerings. “Conveyor tracking and machine vision allow the robots to visually monitor environments … and in fact, one of the claims to fame is built-in vision that lets users calibrate the vison to the robot without having to go outside into a separate programming environment,” noted Brookshire. That makes it easier for users to

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install vision-guided robot systems so ubiquitous in packaging.

When pressed on the accuracy of these variations, Brookshire was quick to underscore the T-Series competitive performance. “When assembling electronics such as cellphones, one might need 30-µm precision to put the amplifiers and speakers and all the rest into the unit correctly. In contrast, when putting that cellphone in a box for retail sale, 200 to 300 µm is often plenty sufficient. Our vision systems are precise and robust enough to satisfy both types of tasks,” said Brookshire.

The T3 robot includes a built-in controller (conveniently housed in the robot’s base) and runs at 110 or 220 V with no battery required for its encoders.

That in turn reduces factory downtime for maintenance (and battery swaps). The compact robot also reduces total cost of installation and integration for factory automation projects — and is suitable for simple applications. In fact, it’s even more

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The Robot Report THERE IS NO NEED FOR A SEPARATE CONTROLLER ...

THE EPSON T3 SCARA HAS A BUILT-IN CONTROLLER.

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ITS DIRECT CONNECTION SIMPLIFIES CABLING.

The T3 robot includes a built-in controller (conveniently housed in the robot’s base) and runs at 110 or 220 V with no battery required for its encoders.

cost-effective than Cartesian setups using multi-axis linear slides.

“Our T3 is a powerful, low-cost automation setup designed for easy integration, which helps lower the total cost of ownership versus current products for manufacturers and system integrators,” said Gregg Brunnick, director of product management for Epson Robots. “It’s suitable for customers looking to automate their factories without wasting time or money on complex slide-based setups.”

Here’s a rundown of the T3’s features: Efficient operation means it fits seamlessly into automation workflows

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and demands less time and money for system integration than most other setups. It installs in minutes, unlike linear slide-based systems. As mentioned, there’s an integrated vision-guidance option specifically for robot guidance; that makes it easy to automate simple applications when vision is required. The T3 is a tabletop mount; the arm length of joints 1 and 2 is 400 mm; its payload rating is to 1 kg, with a maximum to 3 kg.

Repeatability of joints 1 and 2 is to ±0.02 mm; of joint 3 is to ±0.02 mm; of joint 4 is to ±0.02° — and standard cycle time is 0.54 sec. Maximum ranges of motion for the four axes is ±132°and ±141° and 150 mm and ±360° — with the total weight of

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the T3 (not including cables) of 35 lb. Its built-in controller is housed in the base; the T3 also comes in variations to allow for connectivity via Ethernet/IP, EtherCAT, DeviceNet, PROFIBUS, PROFINET, and CC-Link fieldbus — plus a GUI Builder and other integrated options to help reduce development time; and the T3 takes less space than linear-slide setups but delivers a large work envelope.

Epson’s existing lineup of 3-kg-payload SCARA robots includes the G-Series, RS-Series, and LS-Series for industrial use. The G-Series robots deliver industry-known speed, precision, and low vibration … RS-Series robots

“With the T-Series robot setups, users don’t have to worry about performance or cost and can maximize productivity, said Brunnick.

“Feedback from many key customers, including manufacturers and system integrators, has been positive — with some already moving to replace slide-based systems with the all-inone T3.” DW

mount overhead for maximum work envelope thanks to their unique arm design. In contrast, the LS-Series robots deliver performance at low cost. Addition of the T-Series (and competitive price) means the Epson lineup meets even more application requirements.

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Robot Transfer Unit / 7th Axis Slide Utilizing a direct drive gear reducer and gear rack, we achieve higher accuracy and better performance with less components.

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Robots

could soon use new form of actuator: Genesis Robotics CEO explains In a recent interview, we spoke with Mike Hilton, CEO of startup Genesis Robotics. This spinoff of Genesis Advanced Technology focuses on R&D in robotics, oil and gas, medical, human performance, and clean-energy industries. The company recently announced an actuator that’s particularly suitable for powering the joints in SCARA robot arms and other kinematic setups.

Called the LiveDrive, the actuator delivers three times more torque than conventional direct-drive motors. Innovations include amplified magnetics (with a design that doubles the effective force of alreadystrong neodymium permanent magnets), a structure to resist internal collapse from the tremendous magnetic forces, and good thermodynamic design for heat dissipation.

Eitel: Genesis Robotics has a direct-drive offering called LiveDrive, and we’d like to know more about whether this constitutes a torque motor.

Hilton: Genesis Robotics is a R&D company, so we don’t actually commercialize components. Instead we do contract R&D and assume R&D projects and then move developments off to commercialization.

We began R&D on the LiveDrive with the intent of building a better actuator, as we saw tremendous inefficiencies in robotics and industrial automation. So we worked through gear designs for it, but realized the real limiting factor was motors: Engineers

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often can’t get enough torque out of motors, so must add complex gear systems to their assemblies. That led us to investigate ways to build better motors.

After some discoveries, we came to build a specialized brushless dc motor — but with our IP to impart very high torque. We realized our motor could (for some applications) actually eliminate the gearbox altogether. After all, in most industrial-automation scenarios, engineers would prefer to use direct-drive motors — as such drives avoid the issues of backlash, boost output-motion precision, and allow for backdriving.

For applications where even the LiveDrive can’t produce sufficient torque, we wanted to allow for use of the lowest-ratio gearboxes possible — to get the benefits of low or no backlash and full backdrivability.

Eitel: Tell us more about your motor’s high pole count and the patents you hold on variations that take the form of radial-flux and linear-motor arrangements as well as axialflux (pancake or Lorenz-force) motors.

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Hilton: We amplify the available magnetic force with magnet geometry and orientation to nearly double the flux that’s available out of the magnets.

Consider our reference design — a 25-cm axial-flux motor we’ve built for demonstrating to the industry what’s possible with our technology. The 25cm design delivers nearly 2,000 lb or 1,000 kg of force between the rotor and the stator. It has a structure that includes a solid stator and a solid rotor.

That’s in contrast with motors that use laminates to manage eddy currents in the stator.

More specifically, the LiveDrive stator structure uses a solid piece of material (of high-carbon steel or cast iron) with numerous poles that are very short — so these stator poles can actually behave as laminates (to minimize eddy currents). But the solid material sustains the magnets’ effective force. Actually, their shortness also allows for less distance between the copper and the back iron for more efficient heat extraction — so the motor can also be run more aggressively.

Eitel: Getting back to robotics applications: You made the actuators to be low cost and gracefully fit into existing robotic and industrial automation designs.

Hilton: That’s why we made the motor as simple as possible — and avoided exotic controls. For our own testing and prototype builds we use drives and controllers from Elmo Motion Control, though one can use any number of motion controllers and drivers with the LiveDrive. Our motor presents to motion controls as a brushless dc motor, but one can also run it as a stepper motor.

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To promote commercialization of our design, we’ve built reference designs and SCARA demonstration robots. For the latter, we’ve simulated 300 picks per minute and shown how our actuator’s high toqueto-inertia ratio allows for quick acceleration that’s typical of SCARA applications. We’ve also just completed a delta (spider) robot reference design incorporating LiveDrive — also a gearless setup. This is all part of an outreach effort to find a large global partner to help commercialize the LiveDrive — whether in the form of an acquisition, investment, licensing arrangement, or joint venture.

Eitel: Some literature compares the LiveDrive to setups incorporating strain-wave gearing. Why is that? Also tell me about the gears one might pair with a LiveDrive if more torque were needed.

Hilton: That’s been a hurdle for us, as comparing our gearless LiveDrive setups to designs with gearboxes and strain-wave or cycloidal actuators are applesto-oranges comparisons. So we underscore torque density and torque-to-weight values — and our motors have torque-toweight ratios that are similar to those of today’s geared systems.

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Voodoo chose the UR10 robot arm, as it interfaced seamlessly with the Robotiq gripper through.

But for circumstances where the torque requirement is huge, the LiveDrive pairs nicely with gearing. In fact, our team has a background in gear systems, and we’re currently building our own low-ratio backdrivable gearboxes with zero backlash for pairing with the LiveDrive.

In this conversation, we’re focusing on robotics and industrial automation.

But just consider automated valve systems in undersea oil and gas installations, or oil refineries and watertreatment plants. These valve systems require very high-torque actuators for closing, as they must cut through highpressure screens — even to 20,000 Nm. Even here our high-torque motors can dramatically reduce the gearbox ratios needed.

Another potential application is in the automotive industry as cars go to semi-autonomous and autonomous control. Such designs need actuators in the steering column. In fact, LiveDrive excels here because it delivers the high torque needed for the actual steering control plus works as a mirrored actuator to provide haptic feedback.

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Eitel: You use common “off the shelf” neodymium permanent magnets in your motor. How do you get more force out of them?

Hilton: We give the magnets special geometry and orient them in a special way in the rotor; the rotor mechanism I described earlier also helps amplify those magnetic forces. Reconsider the thinness of the LiveDrive — especially for axialflux designs having 2-cm thickness. Such compactness is useful in exoskeletons and walking robots.

The gearless nature of the LiveDrive also helps address the impact forces of walking. Consider how when a foot or a leg makes contact with the ground, there’s a jarring force that travels up the leg. Many walking robots use pneumatic or hydraulic actuators because gearboxes of traditional motor-driven systems can’t sustain such impact. In contrast, directdrive motors easily withstand these forces.

Eitel: How does the form factor affect the morphology of robots?

Hilton: Most multi-axis robots today have 90° joints — so a collaborative robot is usually just a series of 90°

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“Called the LiveDrive, the actuator delivers three times more torque than conventional direct-drive motors.”

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247 Lynnfield Street, Peabody, MA 01960 • 800.921.3332 • www.HarmonicDrive.net Harmonic Drive is a registered trademark of Harmonic Drive LLC. Robonaut image courtesy of NASA/JPL-Caltech.

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The Robot Report

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linkages. The challenges here are how torque must be on the rotary axis at that 90° point — and (from a safety perspective) how these joints act as a bunch of pinch points as linkages cross over each other. The latter means arms and hands can get trapped when the robot moves.

In contrast, our actuator has a thin form factor to actually rotate the axis in the joint to vertical. Then wedges between each actuator can effectively create a series of rotating inclined planes to do two things. First, they change the arm movement while eliminating pinch points. Second, they impart mechanical advantage. To illustrate, if one rotates two ramps against each other, not only does that change the ramp angle, but using two ramps creates a mechanical advantage that almost functions as an external gearbox. Again, only very thin actuators such as LiveDrive allow this.

Eitel: One of the main design objectives with collaborative robots is safety, so this mode of actuation is helpful.

Hilton: Yes, that’s why we get so excited about this application.

We’ve solved a fundamental safety problem in cobot design — and plants can let cobots that are inherently safer run faster for higher throughput. In fact, this relates to another design — what we call assist robotics. Here, the robot doesn’t follow preprogrammed motion paths, but rather follows the commands of a human on the fly. Because LiveDrive is so responsive (thanks to the low inertia of the gearless setup) it excels here.

Eitel: Think of the fictional exoskeleton Power Loader that Ellen Ripley wears in the movie Aliens.

Hilton: It’s the same basic concept. Instead of having preprogrammed motion points, handheld controls at the end of the robot arm let the operator take full control of the arm and use it as an augmented-strength device. So now in a highly customized manufacturing environments instead of worrying about slow preprogrammed collaborative motion paths, an operator can simply grab the robot arm ends and use the robot to lift heavy items — for a zero-gravity and zero-inertia floor mounted exoskeleton arm to do heavy lifting. Then they can release the arm and go do something else — getting the assistive-robot benefit without the complexity of motioncontrol programming. DW Universal Robots | www.universal-robots.com Voodoo Manufacturing | www.voodoomfg.com

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Robotics Robotics

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AEROTECH ​​ Superior motion is at the heart of all controls development for Aerotech. Users can program in a variety of languages including G code, PLC (ladder, function block, and structured text), .NET (C#, VB.NET), C, MATLAB®, or LabVIEW®. All parameters and variables are settable or gettable at runtime and can be initialized statically with an off-line configurator.

Aerotech will customize the controller for your needs with our plug-in architecture that allows special algorithms to be placed at the firmware, real-time OS, or the application layers. Plug-ins we already created include bar code algorithms, special encoder algorithms, and multiple settling criteria that can be monitored in your application code.

Aerotech’s standard controller can control motion in seven segments for precise position, velocity, and acceleration. However, if this is not enough, we can create special trajectories that you can call from your program and that meet your exact motion needs.​

Contact Info: Phone: 412.963.7470 Email: sales@aerotech.com www.aerotech.com

DieQua Corporation Robotic Joints Need High Rigidity and Torque Density Robots and robotic positioners are required to provide precise movements to achieve their task. With cantilevered loads and quick movements, mechanical play and material torsion are enemies of accuracy. To maximize load capacity and increase cycle times you need a reduction unit with high torque density, zero backlash, and high rigidity for it’s size. The Spinea Twinspin is the solution.

This revolutionary design has zero backlash along with high transmittable torque and the best rigidity for their size. 3 models are the smallest cycloidal reducers in the world, down to 50 mm diameter, which provides 3 times the end of arm performance over flex spline alternatives. 7 larger models, up to 300 mm diameter, are ideal for controlling axis motion in the other joints of robots with multiple degrees of freedom.

Contact Info: DieQua Corporation 180 Covington Drive Bloomingdale, IL 60108 Phone: 630.980.1133 www.diequa.com

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Robotics Robotics

Harmonic Drive Supermini Rotary Actuator

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These extremely small servo actuators utilize zero backlash Harmonic Drive® precision gears, a brushless servo motor and an incremental encoder to deliver high precision motion control. The RSF Supermini series is designed to operate with a wide range of third party drivers as well as Harmonic Drive LLC’s DCJ Series, DDP Series, DEP Series, and HA680 drivers. The compact design and exceptional positioning accuracy make these actuators perfect for small robot joints. The units are small enough to fit inside the finger of a robotic hand.

Contact info: Harmonic Drive LLC 247 Lynnfield Street Peabody, MA 01960 Tel: 978-532-1800 marketing@harmonicdrive.net www.harmonicdrive.net

igus Customize low-cost robotic joints and complete arm assemblies The new robolink designer is an online configurator tool from igus® that allows users to quickly and easily configure individual robotic systems. With the tool, users can select robolink components individually and configure a robotic arm step by step. They can also configure the length of the arm to match the dimensions a specific work environment, as well as simulate motion of the robot through rotating its joints. Furthermore, a parts lists can be saved for future reference, and a quote can be requested for the configured system.

The digital design tool uses an intuitive CAD interface suitable for both desktops and tablets.

Try it for yourself at http://robolink-designer.igus.tools

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Contact info: igus® inc.

P.O. Box 14349 East Providence, R.I. 02914 Phone: +1 800.521.2747

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Robotics Robotics

LazerArc by Motion Index Drives LazerArc is a manufacturer of Single Axis, 2 – Axis, 3 – Axis and 4 and 5 Axis positioning systems. Developed as a division of Motion Index Drives Inc., LazerArc specializes in handling custom engineered solutions. For over 46 years Motion Index Drives has been manufacturing and engineering high precision indexing equipment and have expanded to meet the demand in custom automation technology. Our systems can be equipped with servo motors or robot motors to act as a 7th axis or integrated with welding robots, tooling fixtures and more.

• Innovation: LazerArc customizes our products to fit your application needs without compromising our unmatched precision and accuracy.

• Reliability: Our indexers have operated in various industries; running 15 years or more, without having one minute of downtime resulting from any type of failure from our equipment.

• Quality: Most our products are free of backlash allowing for smooth, continuous and maintenance free operation eliminating the need for shot pins to get high accuracy and repeatability.

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LazerArc by Motion Index Drives 1204 East Maple Rd. Troy, MI 48083 Phone: 877.519.4639 Fax: 248.743.0749 info@lazerarc.com www.lazerarc.com

maxon precision motors, inc.

Frameless motors in robotics Applications in robotics often require high torque in order to not only move joints, but also do so with sufficient force. In some cases, minimizing the weight of each component is also critical.

In order to achieve the optimum of high torque density and minimum installation volume, a frameless solution should be considered.

This means the rotor and stator are delivered separate without bearings or motor shaft and allowing the motor to be integrated optimally in the structure of the robot. If saving space and weight in your robotic application is crucial, maxon engineers will work with you in finding the right solution.

• High level of integration in the structure of the machine

• High torques through multi-pole external rotor

• Low cogging torque

• Plenty of space for cable glands

• High overload capacity

• Equipped with hall sensors and thermal sensors (NTC) Learn more about the maxon solutions and visit www.maxonmotorusa.com

maxon precision motors, inc.

101 Waldron Road Fall River, MA 02720 Tel: 508-677-0520

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MICROMO 24% More Torque Per Watt â&#x20AC;&#x201C; in a Powerful 10 mm Package MICROMO launches the new FAULHABER 1016 SR series. At 10 mm in diameter and 16 mm in length, the 1016 SR series small dc motor delivers over 24% more torque per watt than competitive motors with the same dimensions. Additional strengths include low power consumption, high energy-efficiency and minimal vibration & low audible noise, making it well suited for applications with small dimensions and very high requirements such as those in autonomous robot systems, electro-mechanical systems, unmanned equipment, ROVs, and exoskeletons.

As the exclusive provider of FAULHABER motion products to North America, MICROMO creates value through advanced design and engineering services.

Contact Information: MICROMO 14881 Evergreen Ave Clearwater, FL 33762 Phone: (800) 807-9166 www.micromo.com

TAMURA Tamura Hall Effect Current Sensors for Robotic applications

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Tamura Hall Effect Current Sensors are suitable for factory automation robotics applications.

Our Fluxgate type sensors (rated current 6A to 100A, temperature range up to 105C) are suitable for motors to manipulate robotic arms. http://www.tamura-ss.co.jp/electronics/current_sensor/ pdf/f03p_s05_e.pdf And our Open Loop type sensors (rated current 50A to 800A) are used in amplifiers for spindle motors in robotics. Both types have an accuracy range of 1% or greater.

If you need more information about our current sensors, go to our Web-site http://www.tamura-ss.co.jp/ electronics/en/currentsensors/ You can get Fluxgate, Open and Closed Loop sensors information in our electrical components website.

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Robotics Robotics

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Universal Robots Robotics Within Reach Universal Robots has reinvented industrial robotics with flexible, collaborative robot arms. Innovative forcesensing technology makes the robot stops operating when encountering an employee, eliminating the need for safety guarding in most scenarios.

Unlike traditional industrial robots that stay hardwired in a cage, the lightweight UR Robots can be moved around, automating high mix low volume production runs.

Programming is intuitive; simply grab the robot arm to teach the desired movement, or use the touch screen.

The Polyscope GUI runs on a Linux OS platform for easy customization of specific tasks and tools. Product portfolio includes the UR3, UR5 and UR10 robot arms named after their payloads in kilos, they all feature 0.1 mm repeatability and span in reach from 19.7” in to 51.2”. Since the first collaborative robot was launched in 2008, the company has experienced considerable growth with the user-friendly cobot now sold in more than 50 countries worldwide. U.S. regional offices are located in Ann Arbor, MI, Long Island, NY, Irvine, CA and Dallas, TX.

Contact info: Universal Robots USA, Inc. 5430 Data Court, Suite 300 Ann Arbor, Michigan 48108 United States Phone: +1 844.462.6268 Email: ur.na@universal-robots.com

Visumatic Advanced Robotic Fastening & Joining Assembly Technology When most engineers think about flexible assembly, they imagine robots.

Robots can perform a wide variety of repeatable tasks during their long life.

Which is great, since manufacturers are faced with assembling an expanding mix of products in a shrinking number of plants.

Visumatic’s Viper MBC screw driving robot was developed to meet these challenges. It is an engineered feed and install system for projects that require quick and accurate fastening. The lean, flexible design allows placement in a variety of assembly processes. This robot package is modular and extremely durable for rapid assembly line deployment.

Engineered for your parts and your business, every system is backed by the strongest guarantee in the business. Visumatic’s breadth of robotic expertise means you can rely on them to handle every fastening challenge your company faces – today and forever.

Visumatic Industrial Products 856 Porter Place Lexington, KY 40508 USA 859-255-7907 www.visumatic.com

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Product World Electrically and thermally conductive grease

Food safe stainless steel motors

Epoxy Set epoxyset.com

Baldor-Reliance Food Safe motors

CTG-81 is an electrically and thermally conductive non-silicone grease. This grease provides heat dissipation with a thermal conductivity of 7.2 W/m°K and an electrical resistance of <.01 ohm-cm. It is suitable for high-end applications where maximization of heat transfer is essential.

This non-curing hydrocarbon can withstand 200°C continuously and will not dry out

Baldor Electric Company baldor.com

exceed IP69K for water to maximize motor life in high-pressure, sanitary cleaning environments. The high ingress protection rated enclosures have fully encapsulated windings, sealing the motor inside and out. Combined with a laser marked nameplate and a footless mounting design, crevices are kept to a minimum and allows the motor to withstand clean-in-place procedures.

A 3 piece-rotatable conduit box allows workers easier access to route incoming power

supply. Color-coded leads also help to quickly, and correctly tie the motor into the electrical system, using the waterproof heat shrink connectors. On larger frame sizes, lift lugs are fully welded to the frame to easily set the motor in place before attaching to the driven equipment.

or melt producing optimum stability over a lifetime of use.

The CTG-81 can be used in

applications requiring electrical contact where no stress to the electrical pads can

Ac-powered STR stepper drives Applied Motion Products applied-motion.com

be tolerated. It is a free-flowing paste that can easily be dispensed from syringes or

The STR Stepper Drives line has been expanded with the release of new drives for use

cartridges. It can be supplied in any size

in ac powered applications. STR stepper drives are designed for smooth motion and high

syringe or cartridge as well as jars or cans.

torque over a wide speed range. Two new ac powered STRAC drives expand the offering to cover larger motors and applications where maximum power is required.

Features: • Advanced functions for step and direction applications • Support for both step and direction and pulse/pulse control • Supply voltages from 90 to 240 volts ac • Up to 2.2 A/phase (STRAC2) or 8.0 A/phase (STRAC8) output current, peak of sine • Easy setup via dip switches and rotary switches … no software required • Air cooled enclosures — so no fans or

moving parts • UL Recognized, CE certified, and RoHS

compliant

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Design World 2017-18 FPB.pdf

Design-2-Part Show 8-17.indd 149

1

6/29/17

8:51 AM

10/31/17 12:47 PM

Product World Direct drive torque motors Allied Motion alliedmotion.com Smaller frame sizes have been added to the Megaflux Frameless Direct Drive Torque Motors line. Motors are now available in sizes ranging from 60 to 792 mm in outside diameter, with multiple stack lengths for each diameter.

Megaflux highlights include: • 12 standard frame sizes from 60 to 792 mm (2.4 to 31.2-in.) outside diameter • Continuous stall torque from 0.3 up to 2020 Nm (1490 lb-ft) • Clear ID aperture from 36.2 up to 582 mm (22.9 in) • Three winding designs: 48, 150, and 300 Vdc

Industrial Cat5e M12 ethernet patch cables AutomationDirect automationdirect.com These high flex, shielded M12 Ethernet CAT5E patch cables have a TPE (thermoplastic elastomer) jacket suitable for typical industrial applications. This Ethernet cable is flame retardant, chemical resistant and resistant to welding sparks.

The data rate for these Ethernet

cables is 100Mbps full duplex, making them suitable for devices that support Ethernet communications.

Several connection choices are

available including male straight to male straight, male straight to male 90°, male straight to RJ45, and male 90° to RJ45.

The cables are available in 0.6m, 1m and 3m lengths and have a -40° to +80°C (-40° to +176°F) temperature rating.

Weight processing modules Hardy hardysolutions.com The HI 1734-WS POINT I/O weight processing modules were recently released to replace older analog strain gage conditioners used to measure force on a pipe extrusion machine. The HI 1734-WS modules reduced calibration and set-up time versus the older analog strain gage conditioners.

The HI 1734-WS is suitable for applications where fast, stable weight data

and low cost of ownership are important. It is designed to be a high-performance replacement for analog transmitters with the advantages of noise filtering and vastly superior scale settling times.

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1 step

Infrared temperature sensor Balluff balluff.com Housed in a rugged M30 stainless steel housing with IP67 protection, this sensor features a multi-function display with auto-rotation. The menus

nameplate fastening!

No prep. No drilling.

No metal chips.

GRIPNAIL

aid in configuration and setup of the sensor. In addition, the optional IOLink interface lets users parameterize the sensor remotely with enhanced functionality to solve a wide variety of applications.

Features:

Metal-Tacks® are engineered to attach nameplates, wiring clips and components to pressurized devices and equipment — without drilling. Drive into virtually any metal to create a durable blind displacement anchor that will hold over 200 lbs. Metal-Tack fasteners also ensure that your product will never be compromised by over penetration.

• Temperature range 250…1250 °C (482...2282 °F) • Reliably detects moving objects • IO-Link interface provides additional functionalities

401 216 7900 Visit Gripnail.com for a video demo

• Available with 4...20 mA

MADE IN USA

INDUSTRIAL MICROHYDRAULICS

interface or discrete setpoints

Bulkhead housings Harting harting.com In accordance with IEC 60529, these bulkhead housings protect interior parts against strong water spray (IP66 degree of protection) and against temporary immersion in water to a depth of one meter (IP67 degree of protection). The flange of the Han M die-cast aluminium housing prevents water from penetrating into the connector.

The new housings of the Han M series complete the

housing range in sizes 6 B, 10 B, 16 B and 24 B. Applications are better protected against external influences. In addition, the Han M provides space savings of almost one-third compared to housings with protection class IP68, which are significantly larger.

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High Flow,

Compact Size Smallest 6 GPM Check Valve Ever!

• Save Space – Most Compact Design in its Class • Low Leakage Metal-to-Metal Seat • 100% Performance Tested • Easy to Install Innovation in Miniature

November 2017

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

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Product World

4-Wire complementary output inductive proximity sensors Gavazzi GavazziOnline.com The ICB Series with Complementary Output provides both a normally open and normally closed output in the same package for easy replacement, without compromising performance. Based on the ICB Series platform, the 4-wire dc sensors are offered in:

• Short or long barrel

• Flush or non-flush mounting

• NPN or PNP type

The 4-Wire Complementary Output Inductive Proximity Sensors also feature:

• Integrated diagnostics LED

• IP67 rating to protect against water and

humidity penetration

• Built-in microcontroller for accurate and

repeatable operation

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Product World

Absolute linear encoder Heidenhain www.heidenhain.us The LIC 4100 V linear encoder for vacuum environments is a new

equipment with a clamping system. The glass scales

addition to the LIC 4100 linear absolute kit style encoder system.

can be up to 3 meters in length. For longer lengths

With several technical considerations, these encoders can operate

of up to 27 meters, a stainless-steel tape scale can

down to 6*10-7 mbar, survive a 100oC bake out, and have low

be used with an extrusion that is screwed to the

outgassing. Industries that could take advantage of this encoder

machine axis. Accuracies of the glass scale can be to

are semiconductor and carbon fiber manufacturing.

+/- 3 microns, and the longer length tape scales can

be to +/- 5 microns per meter.

The LIC 4100 V encoder system uses a glass scale that can

be of a normal or zero thermal growth material attached to the

3GHz 75 OHM coaxial contact LEMO lemo.com

Stepper motor drivers Toshiba toshiba.semicon-storage.com These three stepping motor drivers detect excessive load on a motor

This 3GHZ coaxial contact

and automatically adjust power to the motor to accommodate this

can be used in various

load. The TB67S249FTG, TB67S279FTG, and TB67S289FTG enable

broadcast connector

motors to move with precision at rapid speeds under various

configurations (indoor and outdoor applications) and

loads - all while minimizing power consumption, heat generation,

combines multiple HD-SDI BNC type connectors into one. It

and system costs.

is particularly well-suited for 3x coaxial (HD), 4x coaxial (4K)

and 10x coaxial (8K) applications taking multiple HD-SDI

TB67S249FTG drives a 4.5 amps maximum current, while the

BNC type connectors into one integrated connector, making

TB67S289FTG and TB67S279FTG drive 3.0 and 2.0 amps,

interconnections simpler and more compact.

respectively. In addition, these motor drivers include the Advanced

Current Detection System (ACDS), which eliminates the need for a

The 3GHZ 75 Ohm coaxial contact is designed for RG179

Supporting a maximum operating voltage of 50 volts, the

B/U type cables, LEMOâ&#x20AC;&#x2122;s smallest 75 Ohm for multi-coax and

large, expensive high-power sense resistor to save PCB space and

hybrid coax connectors, providing signal integrity for video

lower system cost. To decrease noise and vibration, these devices

applications. This new contact can be used in various insulator

offer step resolutions of full, half, quarter, 1/8, 1/16 and 1/32 steps,

configurations as well as in combinations of coaxial and low

enabling fast, precise movements. They also identify a variety of error

voltage signal contacts, providing a perfect solution for the

conditions (thermal, over-current, under-voltage lock out, and motor

broadcast market as an alternative to HD-SDI.

load open detection) that improve system safety and reliability.

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Teal ethernet cat5e cable

Miniature, lightweight hybrid sensors

Lutze lutze.com

Micro-Measurements www.micro-measurements.com This hybrid sensor range incorporates precision foil strain gages adhesively bonded to flat substrates constructed of either metal, composite, or polymer. Hybrid sensors are manufactured using the same high-volume production equipment as those used to create its precision strain gages. The result is a cost-effective family of strain-gage based hybrid sensors with consistent batch-tobatch performance characteristics. Users may further incorporate an optional miniature signal amplifier, as either a stand-alone component or attached to

The Cat5e AWM 600V Ethernet cable

the sensor.

(part#104349) is designed to protect data from harmful interference ensuring uninterrupted data transmission and long term network reliability. This

The Pioneer in High-Performance PCB Wireform Technology

cable adds a teal colored, foil and braid shielded, 4-pair Cat5e. Flexible copper stranding makes installation and routing easy and small OD makes field wiring IDC connectors simple. This cable is suitable for most industrial Ethernet applications, where up to 1Gb/s speed is needed and flexibility or ease of routing is a primary consideration.

Specifications: • Cat5e #104349, AWM 600V, PLTC • Stranding: 22/7 stranding and smaller OD

For over 70 years, Components Corporation’s PCB Interconnect Products have ensured the highest standards of performance in the most demanding wireform interconnect and testing challenges.

• PCB test points

• Card edge connectors

• Preform jumpers

• Custom wireform manufacturing

• Battery contacts

for flexibility where easy routing is a requirement • Shielding: 100% Foil + 85% Braid • Jacket: Teal PVC (RAL 5021) • Max. Speed: 1 Gigabit/second • Bandwidth: 100 MHz per Cat5e

DESIGNED FOR VALUE. VALUED FOR PERFORMANCE.

cc

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COMPONENTS CORPORATION

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

11/1/17 1:13 PM

Product World One component, high temperature resistant epoxy Master Bond masterbond.com With a coefficient of thermal expansion of 15-20 x 10-6 in/ in/°C, EP13LTE is a one part epoxy for structural bonding applications.

EP13LTE is convenient to use, because it doesn’t require mixing, and has an unlimited working life at room temperature. Besides being easy to handle, this system also offers resistance to high temperatures, with a glass transition temperature of approximately 160°C. EP13LTE cures readily in 1-2 hours at 300-350°F. This epoxy paste has limited flow while curing. It bonds well to many substrates such as metals, glass, composites, ceramics and plastics. Once cured, EP13LTE has a strength profile delivering a tensile lap shear strength of 2,6002,800 psi, a compressive strength of 24,000-26,000 psi and a tensile modulus of 500,000-550,000 psi. This dimensionally stable system is able to withstand 1,000 hours at 85°C/85% RH and maintain a Shore D hardness of 90.

Compact touchless position sensors Novotechnik novotechnik.com/tfd40

Drop-in replacement to the common MCB NOARK na.noark-electric.com The UL 489 B1NQ, a recyclable, quickconnect breaker, is available in three curves (B, C and D), ranges from 0.5 to 63 A, and is compliant with UL/CSA/IEC standards for branch circuit protection in commercial and residential applications.

While designed and engineered for the

The TFD series of touchless linear

HVAC market, the HACR compatible MCB

position sensors provide wear-free

is also suited for a host of industrial

operation in tight spaces. Maximum

applications and other component

sensor dimensions are 40 x 27 x 7

sub-assembly designs. The current-

mm thin. The TFD-4000 Series uses

limiting B1NQ is thermal-magnetic

a magnetic position marker to provide

and protects against short circuit and

a touchless measurement range of 0 to 14, 24 or 50 mm—depending on model.

overload conditions. The 1- and 2-pole

These sensors take measurements through air and non-magnetic materials. Magnetic

breaker, offered at 120/240 Vac provides

position marker mount to the user’s application.

protection for branch and control circuits.

Key TFD-4000 Series specifications include ingress protection from liquids and

NOARK offers exceptional value with local

dust to IP 67, resolution of 12 bits, repeatability of ≤0.1% of full scale and optional

support and inventory for a wide range of

second channel for applications requiring redundancy. TFD-4000 Series sensors also

UL 508A panel designs, all backed by the

have analog voltage output and an operating temperature range of –40 to +125°C.

industry’s first 5-year limited warranty.

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High torque brushless dc motor Portescap portescap.com

4mm pitch target connector Mill-Max mill-max.com This target connector on 4 mm pitch is designed for rugged applications incorporating a flanged base and

These brushless dc slotted miniature

hardware options for secure mounting.

motors for surgical power tools are

This target connector series is the

designed and manufactured using a

mating half to the recently released

process that encapsulates and protect

858 series ruggedized spring-loaded

stators windings and electronics

connector.

from harsh external environments like

autoclave and dish wash witnessed

pin versions, this target connector series has a high temperature molded Nylon

by these applications. In addition, the

46 housing that is compatible with RoHS soldering processes. Mounting tabs,

windings are insulated per the medical

integrated into the housing, provide a means for secure attachment to the PCB

safety requirements for hi-voltage

or product assembly. The tab holes may be specified with threaded inserts or left

protection that is mandatory for

empty for other hardware requirements. The flanged base provides stability for

surgical powered hand tools. This is a

the connector. The pins are plated with 10 micro inches hard gold over nickel for

surgical motor solution for large bone

durability and excellent conductivity.

Offered in 2-6 positions in through-hole, SMT and SMT with alignment

orthopedic powered hand tools. The new size 12 (31.5 mm diameter) mini motor is available in 9.6V, 12V and 14.4V versions with cannulated and non-cannulated options, these motors can deliver peak torques of up to 1,720 mNm in a compact envelope.

Pressure/vacuum pumps Thomas gd-thomas.com These oil-less twin WOB-L piston units are RoHS compliant and are designed for single stage vacuum, two stage vacuum, single stage compressor, or two stage compressor operation. They are designed for a wide array of applications such as blood or laboratory analyzers to ozone generators to packaging equipment, just to name a few.

The 2755BE75 (115/60/1) is UL approved and provides an open flow

of 7.5 cfm (212.4 l/min) and can operate up to 93% of local barometer continuously. It weighs 21.5 lbs. (9.8 kgs) and measures (L x W x H) 10.35” (262.9 mm) x 5.37” (136.4 mm) x 9.32” (236.7mm).

DESIGN WORLD

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November 2017

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Product World Ball bearing linear guide stages OES oewincorp.com The AQ140 Series and the AQ150 Series of linear stages are available off-the-shelf in travel lengths of: 50 mm (1.969 in), 100 mm (3.937 in), 150 mm (5.905 in), 200 mm (7.874 in), 300 mm (11.811 in), 400 mm (15.748 in), 500 mm (19.685 in). These 2 µ resolution stages (achieved with a 10 micro-steps per step stepper motor driver) are suitable for: Laser machining, testing, pick-and-place, inspection, sorting, wafer handling, semiconductor, assembly, metrology, and photonics in industrial, laboratory, and medical applications.

The tables, depending on length of travel, measure 120 x 120 mm, 150 x 150 mm,

and 160 x160 mm. The AQ150 Series has top and side rail covers. With a 4 mm per turn, 2 µ backlash lead screw, typical performance specifications of the AQ140 and AQ150 linear stages include: repeatability of 5 µ, positional accuracy 8 µ, straightness 6 µ, driving parallelism 15 µ, pitching 25 arc seconds, and deflection 25 arc seconds.

Modular double valves ROSS Controls rosscontrols.com The safety function of the M35 Series valve is to shut off supply of pneumatic energy and to exhaust any pneumatic energy from downstream of the valve.

The M35 Series safety exhaust (dump)

Wireless 2.4 GHz I/O and Wi-Fi gateway modem Weidmuller www.weidmuller.com

valve is for Category-4, PL e machine guarding applications.

The ROSS M35 Series double valve

includes the 3/2 normally closed function, dual poppet design, and are based on the proven technology of the SERPAR® Crossflow family of double valves.

The WI-I/O-2-E-N-GBL, is a wireless networking I/O and Wi-Fi gateway that

accommodates multiple I/O nodes and extends communications to sensors

double valve is designed with external

and actuators in local, remote, or difficult to reach locations.

monitoring for safe redundant operation,

and is available with or without EEZ-ON

The WI-I/O-2-E-N-GBL offers wireless technology for industrial

The M35 Series control-reliable

applications including a simple web-based user interface, and a standards-

(soft start) function. The EEZ-ON (soft

based wireless protocol with a networking topology that is simple to use and

start) module option allows slower build-

configure. The WI-I/O-2-E-N-GBL can provide IP-based networking across

up of pressure during start-up. The M35

sprawling industrial environments and includes built-in I/O capability for digital

Series valve is enhanced with a modular

and analog inputs and outputs. The modem can be easily configured for use

mounting design, allowing flexible air

globally via a built-in webserver.

entry system assembly.

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It’s not a web page, it’s an industry information site Stay current with the latest electronic tips, resources, and news, visit eeworldonline.com and stay on Twitter, Google plus, Facebook and Linkedin. It’s updated regularly with relevant technical information and other significant news to the electrical design engineering community.

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EE Online house ad 11-17.indd 159

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Ad Index Aggressive Hydraulics ............................................................. 99 Aignep USA .................................................................................. 35,41 All Motion ...................................................................................... 4 Allied Electronics ............................................................ Cover,3,90 Altech Corporation .................................................................... 19,21 Anderson Metals ........................................................................ 153 Applied Motion Products, Inc. ............................................... 39 Aurora Bearing Company ....................................................... 41 AutomationDirect ....................................................................... 13 Bimba Manufacturing Company ........................................... 11 Bishop-Wisecarver ..................................................................... 81 Bison Gear .................................................................................... IBC Boker’s Inc. .................................................................................... 29 Canfield Industries ..................................................................... 38 Centritec Seals - A Carlyle Johnson Company ............... 16 CGI ................................................................................................... 49 Chem-Trend L.P. .......................................................................... 32 Components Corporation ....................................................... 155 ContiTech ...................................................................................... 24 Del-tron Precision, Inc. .............................................................. 75 Design-2-Part Shows ................................................................ 149 Digi-Key Electronics ................................................................... 15 Elesa USA Corporation ............................................................ 30 Endress+Hauser ......................................................................... 53 EXAIR Corporation ..................................................................... 5 EZAutomation ............................................................................. 1 Fabco-Air .............................................................................89,91,93 GRIPNAIL Corporation .............................................................. 151 Hyde Tools .................................................................................... 88 igus Inc. .......................................................................................... 31 Indium Corporation .................................................................... 51 IXYS ................................................................................................. 40 J.W. Winco, Inc. ............................................................................ 38 Keller America Inc ....................................................................... 111 Key Bellevilles Inc. ...................................................................... 88 Lenze .............................................................................................. 44 Magnet Applications ................................................................. 83 Master Bond ................................................................................ 35 METCASE ...................................................................................... 17 Miki Pulley US .............................................................................. 97 MW Industries Aerospace Solutions ................................... 84 NBK America LLC ........................................................................ 100 Newcomb Spring Corp............................................................... 20 NorthWire....................................................................................... 34 Novotechnik ................................................................................. 7 ON Semiconductor .................................................................... 77 Opto 22 ......................................................................................... 25 Penn Engineering ...................................................................... 47 PHD Inc. ......................................................................................... 28 Proto Labs .................................................................................... 9 Rutronik ......................................................................................... 85 SAB North America .................................................................. 92 SDP/SI-Stock Drive Product .................................................... 53 SEW-EURODRIVE ....................................................................... BC SIKO Products .............................................................................. 29 Smalley Steel Rings .................................................................. 10 The Arthur G. Russell Co., Inc. ............................................... 98 The Lee Company ..................................................................... 151 THK .................................................................................................. IFC Tompkins Industries .................................................................. 2 Trim Lok .......................................................................................... 22 Visumatics Industrial Products ............................................. 45 WAGO ............................................................................................. 37 Weintek USA Inc. ........................................................................ 27 Whittet-Higgins ........................................................................... 23 Xcentric Mold & Engineering .................................................. 96 AS/RS Supplement IKO USA .......................................................................................... 55 ITT Enidine .................................................................................... 63 NSK Precision .............................................................................. 65 Rollon .............................................................................................. 69 Robotics Report Supplement Aerotech......................................................................................... 127 C-Flex .............................................................................................. 142 Diequa ............................................................................................ 133 Harmonic Drive............................................................................. 141 igus Inc. .......................................................................................... 125 maxon precision motors .......................................................... 113 Micromo ......................................................................................... 123 Motion Index Drives .................................................................. 137 New England Wire Technologies/Catheter ....................... 129 Tamura Corporation of America ........................................... 142 Universal Robots USA, Inc. ..................................................... 117 Visumatics Industrial Products ............................................. 119

160

SALES

Mike Caruso

Statement of Ownership, Management, and Circulation (Requester Publications Only) 1. Publication Title

3. Filing Date

0 2 5 _- 1 4 6

4. Issue Frequency

Garrett Cona

WTWH Media, LLC 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

10/3/17

5. Number of Issues Published Annually

Monthly

12

gcona@wtwhmedia.com 213.219.5663 @wtwh_gcona

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6. Annual Subscription Price (if any)

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7. Complete Mailing Address of Known Office of Publication (Not printer) (Street, city, county, state, and ZIP+4®)

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Telephone (Include area code)

(888) 543-2447

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WTWH Media, LLC 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

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WTWH Media, LLC

6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

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6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

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6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

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Neel Gleason

ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

12. Tax Status (For completion by nonprofit organizations authorized to mail at nonprofit rates) (Check one) The purpose, function, and nonprofit status of this organization and the exempt status for federal income tax purposes:

N/A

Has Not Changed During Preceding 12 Months Has Changed During Preceding 12 Months (Publisher must submit explanation of change with this statement)

PS Form 3526-R, September 2007 (Page 1 of 3 (Instructions Page 3)) PSN: 7530-09-000-8855 PRIVACY NOTICE: See our privacy policy on www.usps.com PS Form 3526-R, July 2014 [ page 1 of 4 (see instructions page 4) ] PSN: 7530-09-000-8855 PRIVACY NOTICE: See our privacy policy on www.usps.com

13. Publication Title

Design World

15. Extent and Nature of Circulation

14. Issue Date for Circulation Data Below

September 2017

Average No. Copies Each No. Copies of Single Issue Published Issue During Preceding Nearest to Filing Date 12 Months

a. Total Number of Copies (Net press run)

Tom Lazar

tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom

Jim Powers

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

Courtney Seel

cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

LEADERSHIP TEAM

Publisher Mike Emich

memich@wtwhmedia.com 508.446.1823 @wtwh_memich

Managing Director Scott McCafferty

smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty

EVP Marshall Matheson

mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541.

(Include direct written request from recipient, telemarketing and Internet re(1) quest s from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser’s proof copies, and exchange copies.) b. Legitimate Paid and/or 13. Publication Title In-County Paid/Requested Mail Subscriptions stated on PS Form 3541.

Requested (Include direct written request from recipient, telemarketing and Internet reDistribution (2) quests from recipient, paid subscriptions including nominal rate subscriptions, (By Mail employer requests, advertiser’s proof copies, and exchange copies.)

15.and Extent and Nature of Circulation Outside Sales Through Dealers and Carriers, Street Vendors, Counter the Mail) (3) Sales, and Other Paid or Requested Distribution Outside USPS®

34,997

0

Nonrequested Distributed Outside the on MailPS (Include Pickup Stands, Outside CountyCopies Nonrequested Copies Stated Form 3541 (include (4) Shows, Showrooms and Other Sources) Sample copies, Requests Over 3 years old, Requests induced by a (1) Trade Premium, Bulk Sales and Requests including Association Requests, Names obtained from Business Directories, Lists, and other sources) Total Nonrequested Distribution (Sum of 15d (1), (2), (3) and (4))

d. Nonref.

In-County Nonrequested Copies Stated on PS Form 3541 (include Total Distribution (Sum of 15c and e) quested (2) Sample copies, Requests Over 3 years old, Requests induced by a Distribution Premium, Bulk Sales and Requests including Association Requests, g. (By Copies (See Instructions to Publishers #4, (page #3))and other sources) Mail not Distributed Names obtained from Business Directories, Lists, and Outside h. the Total (Sum of 15f and g) Mail) Nonrequested Copies Distributed Through the USPS by Other Classes of (3) Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% Requested Limit mailed atCirculation Standard Mail® or Package Services Rates) i. Percent Paid and/or (15c divided by f times 100) Nonrequested Copies Distributed Outside the Mail (Include Pickup Stands, (4) Trade Shows, Showrooms and Other Sources) Electronic Copy Circulation 16. Publication 16. of Statement of Ownership for a Requester Publication is required and will be printed in the issue of this publication. e. a.

Total Nonrequested Distribution (Sum of 15d (1), (2), (3) and (4)) Requested and Paid Electronic Copies 17. Signature and Title of Editor, Publisher, Business Manager, or Owner f.

38,359

34,998

0

Average No. Copies Each No. Copies of Single Issue Published Issue During Preceding Nearest to Filing Date 12 Months

Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541. c. Total Paid and/or Requested Circulation of 15b (2), (3),telemarketing and (4)) (Include direct written (Sum request from(1), recipient, and Internet re(1) quest s from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser’s proof copies, and exchange copies.)

Outside County Nonrequested Copies Stated on PS Form 3541 (include b. Legitimate Sample copies, Requests Over 3 years old, Requests induced by a Paid and/or (1) In-County Paid/Requested Mail Subscriptions stated on PS Form 3541.

Premium, Bulk Sales and Requests including Association Requests, Requested (Include direct written recipient,Lists, telemarketing Internet reNames obtained from request Businessfrom Directories, and otherand sources) Distribution (2) quests from recipient, paid subscriptions including nominal rate subscriptions, (By Mail employer requests, advertiser’s proof copies, and exchange copies.) and d. NonreIn-County Nonrequested Copies Stated on PS Form 3541 (include Outside quested Sample copies, Requests Over 3 years old, Requests induced by a Sales Through Dealers and Carriers, Street Vendors, Counter (2) the Mail) Distribution (3) Premium, Sales Requests including Association Requests, Sales, andBulk Other Paidand or Requested Distribution Outside USPS® (By Mail Names obtained from Business Directories, Lists, and other sources) and (4) Requested Copies Distributed by Other Mail Classes Through the USPS Outside (e.g. First-Class Mail®) the Mail) Nonrequested Copies Distributed Through the USPS by Other Classes of (3) Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% c. Total Paid and/or Requested Circulation (Sum of 15b (1), (2), (3), and (4)) Limit mailed at Standard Mail® or Package Services Rates)

e.

37,784

14. Issue Date for Circulation Data Below

a. Total Number of Copies (Net press run) (4) Requested Copies Distributed by Other Mail Classes Through the USPS (e.g. First-Class Mail®)

Total Distribution (Sum 15cPrint and e) b.

Total Requested andofPaid Copies (15c) + Requested/Paid Electronic copies (16a)

0

0

0

0

34,998

34,997

1,736

2,403

0

0

0

0

469

509

2,205

2,912

37,203

37,909

581

450

37,784

38,359

94.1%

92.3%

5,000 39,998

Date

5,000 39,997

42,203

42,909

94.8%

93.2%

Total Requested Copy distribution (15f) + Requested/Paid Electronic copies (16a) g. c.

Copies not Distributed (See Instructions to Publishers #4, (page #3)) I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form d. or Percent who omits material information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil Paid and/ororRequested Circulation h. Total (Sum of & 15f and g) copies (16b divided By 16c x 100) sanctions (including civil penalties).

(Both print electronic PS Form 3526-R, September 2007 (Page 2 of 3) i. Percent Paid and/or Requested Circulation (15c divided by foftimes 100) X I certify that 50% all my distributed copies (electronic and print) are legitimate requests or paid copies.

17.

16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the issue of this publication.

17. Signature and Title of Editor, Publisher, Business Manager, or Owner 18.

Pat Curran, Business Development Manager

November 2017 Date

10/3/17

I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties).

PS Form Form3526-R, 3526-R, September July 2014 2007 (page(Page 2 of 2 4)of 3)

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© 2017 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

Subscription Rates: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each.

Subscriptions are prepaid, and check or money orders only.

Subscriber Services: To order a subscription or change your address, please email: designworld@halldata.com, or visit our web site at www.designworldonline.com DESIGN WORLD (ISSN 1941-7217) is published monthly by: WTWH Media, LLC; 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103. Periodicals postage paid at Cleveland, OH & additional mailing offices.

POSTMASTER: Send address changes to: Design World, 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

November 2017 www.designworldonline.com

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2. Publication Number

Design World

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