Design World April 2018

www.designworldonline.com

April 2018

inside: Motion Control: How to design gearmotors for

extreme ambient conditions

p. 54

Linear Motion: Robot-transfer unit and

other linear-transfer system considerations

p. 60

3D CAD: CFD helps sports fans

keep cool

p. 72

Tubingversus hose in mobile machinery p. 66

APRIL DW COVER GATEFOLD 4-18_FINAL.indd 1

4/4/18 4:43 PM

The super compact, super capable PLC The Productivity1000 series PLC is the super compact yet highly capable member of our Productivity controller family and is packed with many of the features you love about the Productivity series including tag name programming, built-in data logging, multiple communication options, 50MB of user memory and an integrated web server. Housed in a smaller, slimmer design and with a CPU price of $169, the Productivity1000 PLC will deliver the time, space, and budget savings your project needs.

Built-in Communication:

Data Logging:

The Productivity1000 allows for up to 32GB of historical data to be saved to a removable micro SD card micro (sold separately).

The Productivity1000 comes with 4 built-in communication ports for easy connectivity to your PC or various industrial networks.

Micro USB MicroB USB port for easy plug-and-play programming

Serial RS-485 4-pin serial Modbus RTU/ASCII or custom protocol connection

Serial RS-232 RJ12 serial Modbus RTU/ASCII or custom protocol connection

Ethernet 10/100Mbps RJ45 Ethernet port for PLC programming and/or Modbus TCP, EtherNet/IP, custom UDP/ TCP connections

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Tag name Programming The Productivity Suite software is available for download free of charge and features tag name memory addressing with user friendly function blocks.

I/O EXPANSION MODULES STARTING AT

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4/2/18 3:42 PM

0 allows torical a card

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micro SD

The single top-side latch on every I/O module provides free and clear access to the latching mechanism when adding/ removing I/O modules.

•

The pivoting wire cover on each I/O module displays the wire label in any position so it’s visible at all times.

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ansion:

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4/2/18 3:43 PM

A little

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Affordable automation for everyone Are you dealing with tight budget constraints? Are you tired of getting squeezed for every last PLC dollar you have? If so, then the Productivity series of PLCs has a solution for you.

With a focus on customer satisfaction, the new space-saving Productivity1000 PLC was designed to provide the features you need at a price anyone, not just the big guys, but anyone can afford. Here’s just some of what Productivity1000 has to offer: • Built-in data logging • Easy plug and play programming • Robust communication with Modbus, ASCII and • FREE advanced software EtherNet/IP support with tag name memory addressing • Web server and mobile access • 50MB of user memory

On top of all that you also get FREE tech support for the life of the product and many other extras to help you smoothly and successfully complete your PLC project on-time and under-budget.

Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2017 AutomationDirect, Cumming, GA USA. All rights reserved.

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CPU and I/O Comparison CPU/PLC (with Ethernet)

(40) 24VDC Inputs (Built-in I/O included)

(32) 24VDC Outputs

AutomationDirect

Allen-Bradley

Productivity1000

Micro850

Allen-Bradley MicroLogix 1100

$169.00 P1-540

$442.00 2080-LC50-24QVB

$704.00

$295.00 (5) P1-15CDD1 combo

$586.00 (1) 2085-IQ32 + (2) 2085-OV16

$872.00 (1) 1762-IQ32T + (1) 1762-OB32T

$67.00 (1) P1-04ADL-1

$222.00 (1) 2085-IF4

$95.00 (1) P1-04DAL-1

$222.00 (1) 2085-OF4

$119.00 (1) P1-04THM

$343.00 (1) 2085-IRT4

$564.00

170mm [6.7”]

349mm [15.50”]

270mm [10.63”]

$787.50 FREE PS-PGMSW

$1,830.20 FREE Connected Component WB

$2,545.00 $5,890.00 9324-RL0700NXENE*

1763-L16BBB

(Built-in I/O included)

(4) Analog Inputs (Built-in I/O included)

(4) Analog Outputs (Built-in I/O included)

(4) Temperature Inputs (Based on thermocouple inputs)

Total Length DINrail space consumed mm [in]

Total Hardware Cost

Includes required terminal blocks, end caps, terminators, etc.

Programming Software

$405.00 (1) 1762-IF2OF2 combo (1) 1762-IT4

All prices are U.S. published estimated retail prices. AutomationDirect prices as of 12/13/2017. Allen-Bradley hardware prices taken from www.radwell.com 10/11/2017.

Allen-Bradley software price taken from www.rexelusa.com 10/11/2017. * The price for the MicroLogix 1100 software assumes the professional version, which includes RSNetWorx for EtherNet/IP configuration. No EtherNet/IP = $2,670

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• 2” or 50mm body diameter • 2.5” removable flange on select models • 8mm solid or hollow shafts or ⅜” solid shafts • Resolutions from 3 to 5000 ppr • Line driver (5 VDC) or totem pole output (5-30 VDC sink/source) • Up to 100 kHz (totem pole) or 200 kHz (line driver) response frequency • IP50 or IP65 environmental rating • 2m cable or Military-Style (MS) connectors (mating connectors and pre-made cables sold separately)

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Taming

your whirlwind

When I was still in college, before I had my first “real” job, my grandfather implored me to always “pay myself first.” That was his savings mentality, and it has served me well. What he meant was to put money toward the future before I ever saw it in my bank account—contribute to 401(k) plans, round my mortgage and car payment up to the next hundred dollars each month, that sort of thing. That little bit extra would make a real difference someday.

Now, each year, the National Fluid Power Association presents some fantastic speakers at their Annual Conference. The 2018 event certainly did not disappoint, but I was surprised to make a connection with my grandfather’s sage advice from all those years ago. Chris McChesney, one of the authors of The 4 Disciplines of Execution, spoke about leadership and execution. He delved into a lot of different areas, but one struck me as particularly noteworthy: the whirlwind.

According to McChesney, inside of every organization, there’s a conflict between two forces. On one side is your day job, which he calls the whirlwind. On the other are new projects, goals, more strategic issues— all the activities for moving forward, for innovating. But the whirlwind is where the problem lies for most of us.

“There is an enormous amount of energy spent to just keep the operation going,” he said. “Forget doing anything new.”

The key is that both things are necessary for you to be successful. An organization has to create and educate new leaders, come up with new products and innovations, break into new markets, and so on. And whether we’re managers or not, we have to participate in these sorts of initiatives. However, these tasks aren’t the same as the daily whirlwind—the emails, the reports, the meetings that you have to deal with.

This struck a chord with me. The whirlwind items compete for your time, energy, and attention, McChesney said. Every day. It’s relentless. If you let it, the whirlwind will take up 100% of your time and energy at the office. Our goal, he said, should be to keep it at 80%—actively take 20% of your time to dedicate toward bigger goals.

That’s easy to say, but how does one go about it? McChesney suggests simplicity.

You can’t have 8 or 10 big goals over the course of a year. Companies that he’s studied show that too many goals are subject to the law of diminishing returns.

“Organizations down at the team level that have two to three things they’re trying to do in addition to that day job, in addition to that whirlwind, are actually, over the course of a year, in a really good position to get those two to three new things done,” he said.

So, I propose to you today that you take five minutes, close your email, and think.

What one or two or three initiatives could you work on over the coming year that would really make a difference for your job or your team or your organization? Jot them down and tape that paper to the corner of your monitor. Stare at it every day when the whirlwind threatens to overtake you. And “pay yourself first,” so to speak.

Invest that 20% of time—or whatever you can afford—to make your job more efficient, more well-run, more successful in both the near and distant future. DW Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com On Twitter @ DW—Editor

4 April 2018 www.designworldonline.com DESIGN WORLD

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Teschler on Topic

A bridge too far?

I once worked on a project that went badly off track. It involved a digital communication system conceived back in the days when radios were usually analog devices. The digital approach, it was thought, could be better on a variety of fronts. Working with bits would be easier and quicker than trying to tweak analog signal paths.

The idea of an easier way to design radios sounded great; Management constantly griped about how long it took to perfect designs. So the whole effort was put on an accelerated development schedule.

Yeah, right. Optimism faded fast with the release of the first hardware prototypes. In a nutshell, they only worked on the test bench. In the real world, the noise environment cut the effective range to a laughable figure.

The fundamental problem with the whole effort was that we underestimated what we didn’t know.

Digital radio was a relatively new idea.

A lot of the know-how about how to do it hadn’t migrated much past academic papers. It was also tricky to get digital RF to work back then because discrete components made

up most of the circuitry. After a lot of wheel spinning, gnashing of teeth, and embarrassment among project managers, the so-called accelerated schedule turned into one extending about twice as long as a normal.

These bad memories came back as I learned about the collapse of the pedestrian bridge at Florida International University. The method used to construct the bridge had the unfortunate moniker of “accelerated bridge construction,” or ABC. The “acceleration” simply refers to the practice of building the span near the bridge site, then moving it into place onto its supports, thereby minimizing road-closure time.

Ironically, ABC arose partly to boost bridge safety – with one in nine U.S. bridges rated as structurally deficient, there’s a need for methods that help replace them economically.

And with 87,606 vehicle crashes in work zones during 2010, methods that minimize work zone disruptions also reduce traffic fatalities.

One of the unintended consequences from the FIU bridge catastrophe is likely to be malevolent undertones attached to anything with the label of “accelerated.” The tenor of some media reports written

in the heat of the tragedy might lead readers to think an accelerated method is one that is slapdash. This isn’t at all the case for ABC, a fact that becomes clear from a review of the website for FIU’s Center for ABC. It’s clear that ABC technology is much farther along than the digital radio concepts that tripped us up many years ago. On the FIU ABC site you can see studies of ABC techniques done on shake tables, in wind tunnels, in seismic regions, and in other situations that demand a careful assessment of risks. There is nothing hurried or haphazard about ABC. The loss of life at FIU is tragic. There should be sympathy not only for the victims and their families, but also for the engineers and construction personnel involved. I’ve seen first hand the kind of stomach acid that a major project-gone-bad can bring even when the only casualties involved are careers and egos. Undoubtedly the professionals associated with the FIU bridge collapse are experiencing nightmarish levels of stress and self doubt.

Readers with religious beliefs might consider remembering both victims and bridge builders in their prayers. DW

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

6

April 2018 www.designworldonline.com

Lee Teschler Column 4-18_Vs2.LL.indd 6

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Technology Forward Additive manufacturing

will remake manufacturing tools Imagine what would happen if designers used additive manufacturing to remake traditional manufacturing assist tools?

Eckhart, a company that has been building the tools that manufacturers use to make their production lines safe and efficient for more than 60 years will take up that challenge.

Eckhart’s ergonomic lift-assist and torque-mitigating tools allow a technician to perform tasks like lifting and positioning a car engine while it is bolted to the chassis. Its tools are used in industries such as automotive, aerospace, heavy construction, medical and others.

Eckhart believes that the tooling industry is ripe for change with the introduction of additive manufacturing technology to help redesign factory tools.

“We believe that with additive manufacturing, there is a real opportunity to reinvent how industrial tools are designed, manufactured, and ultimately used by customers,” says Eckhart President and CEO, Andy Storm.

“Our intent is to completely replace existing metal tools with 3D printed equivalents.”

Eckhart has chosen to work with Stratasys, a global leader in applied additive technology solutions, in an exclusive three-year collaboration agreement to advance the adoption of 3D printing for factory tooling in North America.

Based on the unique ability of additive manufacturing to help drive innovation for next generation factory tooling, Eckhart sees three main ways the additive processes can help the tooling industry: • Light weighting and ergonomics: The lighter and more organically shaped a tool is, the easier it is to operate and move around the assembly environment. Additive manufacturing is unique in its ability to produce organically shaped, light parts while still being strong.

Stratasys’ carbon-fiber-reinforced nylon (FDM Nylon 12CF) has a strength-to-weight ratio that enables it to replace metal in many applications.

• Line-of-sight improvement: Additive manufacturing can be used to design voids in a tool.

Traditionally made tools often have extra material that doesn’t provide

a value. By reducing the unneeded material, line-of-sight is improved.

By cutting material out you can see more of the assembly operation.

• Simplified build structure and simplified bill of materials: Additive manufacturing can be used to reduce the part count of an assembly. By redesigning an assembly of many parts into a single part and 3D printing it, designers reduce part count and simplify both the build structure and the bill of materials for manufacture.

As part of the partnership with Stratasys, the Eckart lab in Warren, MI, includes Stratasys’ Fortus 450mc, F370, and Fortus 250mc 3D Printers. Eckhart also uses a range of Stratasys materials, including the carbon-fiber-reinforced (FDM Nylon 12 CF).

In addition to accelerating the adoption of 3D printing, the partnership will leverage both companies’ expertise in adjacent markets to promote the adoption of Industry 4.0 and the use of micro sensors in 3D printed tools to begin integrating advanced diagnostics that will enable the smart factories of the future. DW

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

8

April 2018 www.designworldonline.com

Leslie Column 4-18_Vs2.LL.indd 8

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Green Engineering Paul J. Heney

• Editorial Director

Five ways jobsites are getting greener

The search for engineering efficiency can go beyond designing greener equipment in more environmentally friendly manufacturing plants. There are plenty of improvements that can be made on the jobsite when working with off-highway equipment in the construction and related industries. The Association of Equipment Manufacturers (AEM) recently announced some green trends in this area, courtesy of Todd Imming of The Korte Co.

1 The art of prefabrication. Building things elsewhere prior to their installation on a project site isn’t necessarily new, but it’s come a long way and is gaining in popularity as pressure ratchets up on project budgets and timelines. This is happening most on structures designed to contain repetitive elements. Think hospitals, hotels, jails, nursing homes—anything institutional. The technique has a few big advantages:

DESIGN WORLD

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April 2018

11

3/27/18 3:09 PM

Green Engineering The search for engineering efficiency can go beyond designing greener equipment in more environmentally friendly manufacturing plants.

• Building elements in a factory before on-site assembly keeps more of the job out of the elements that could potentially delay construction.

• With external conditions well controlled, fewer workers are needed to build prefabricated parts compared to what would be needed on site.

• It’s safer to build these components prior to assembly, as workers aren’t needed in dangerous positions or conditions.

• Fewer workers are needed on site, too, because assembly is much easier than building piece by piece from the bottom up.

• Expect to see more projects use prefabrication techniques—especially those on strict deadlines with tight budgets.

2 Improvement in Building Information Modeling (BIM). BIM has also been around a few years, but the technology improved to the point where contractors and owners are finding it extremely useful. In fact, BIM is required as a cost- and time-saving element of all government-funded structures in the United Kingdom. It’s against the law there not to use BIM. BIM software allows designers to produce 3D mockups of a planned structure that also incorporate cost and time information. Variables—such as construction methods or different materials—can be manipulated in the software to compare the costs over time of differing techniques or materials used.

3

Virtual/augmented reality.

No longer just for video gaming, construction companies have begun using VR/AR technology to enhance worker safety training. Workers can visualize what they are learning

12

instead of just reading it in a booklet. That reinforces how serious construction site hazards can be—and has made work sites safer.

Firms also use apps that tie VR/ AR technology to their BIM software.

Contractors and owners can do virtual walkthroughs of a structure long before it is complete. Owners can make more informed design decisions earlier in the construction process, saving time and cutting costs.

4 Fly ash bricks. If you’ve driven past a coal-fired power plant, you’re likely to see two kinds of piles: Heaping mounds of coal ready to burn, and heaping mounds of waste ash from fuel already used. Waste ash is typically stored in “ash ponds” that do nothing but sit, posing serious risks to groundwater. That was the case in India, where the rapid expansion of coal-fired plants prompted concerned locals to wonder whether there was a way to use the mountains of coal ash quickly rising across the country.

Fly ash bricks are lighter and stronger than traditional bricks or cinder blocks. They’re also cheaper to make. It’s helped mitigate the fly ash problems in India while also making it cheaper to build dwellings for a rapidly increasing population.

The idea is catching on in the U.S., too, as firms are capitalizing on the chance to produce better-quality building materials while lessening the environmental impact of ash ponds.

5

AEM | Aem.org The Korte Co. | korteco.com

WHAT DO YOU THINK?

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

Solar roads and materials. Pilot programs underway throughout the world show that roads made of extra-tough solar panels can work.

The technology is expensive and is not yet perfected, but the potential benefits of dual-use materials such as

April 2018 www.designworldonline.com

Green Engineering 4-18 Vs3.LL.indd 12

solar roads has proved too attractive to abandon. The maturation of technology that allows electric vehicles to charge up while in contact with solar roads sweetens the pot.

And it isn’t just about rights of way. Roof-mounted solar panels are great, but if an entire structure can also generate electricity, it’s that much more clean, free energy pumped into the grid. Solar-capable building materials may put the enterprising fly ash brick makers out of business, but they may also help end our reliance on fossil fuels for power generation. DW

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Dunkermotoren 1-18.indd 13

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Contents 4 • 2018

•

vol 13 no 4

•

designworldonline.com

April 2018

72

Design equipment faster, smarter, and under budget with TiPS from leading suppliers. | istockphoto.com

Aerospace COVER_FINAL2__4-18.indd 95

| istockphoto.com

54 _MOTION CONTROL

72 _3D CAD

How to design gearmotors for extreme ambient conditions

CFD helps sports fans keep cool

Following some straightforward advice on gearmotor design will help ensure your gearmotor works in the most extreme environments.

3/27/18 1:26 PM

95-112

www.bearingtips.com

A Supplement to Design World - April 2018

Fans who watch the Atlanta Falcons play at their new home stadium keep their cool even when their team is struggling thanks to CFD analyses.

Design equipment faster, smarter, and under budget with TiPS from leading suppliers. | istockphoto.com

60 _LINEAR MOTION Robot-transfer unit and other linear-transfer system considerations

As robotics applications proliferate, robot integrators have begun to apply more 7th-axis tracks — also called robot-transfer units or RTUs — as well as linear tool-tray transfer systems.

66 _FLUID POWER Tubing versus hose in mobile machinery

80 _MACHINE INTERFACE

Bearing Tips 4-18_Cover_FINAL.indd 113

Specialized HMI software can reduce the workload to create and maintain graphic user interfaces.

86 _MATERIALS Polymer materials keep offshore risers safely afloat

Polymer-based solutions for fire protection and buoyancy help progressive riser technology push the limits.

Although you may prefer one over the other, it’s likely that mobile machinery uses both hydraulic hose and tubing, as both offer unique advantages.

ON THE COVER Although mobile machinery often has a combination of hydraulic hose and tube, hose is preferred where there is bending, rotation and other movement between two components. | istockphoto.com

A | S | B | P|E

A | S | B | P|E

American Society of Business Publication Editors

American Society of Business Publication Editors

Fostering B2B editorial excellence

2017 Regional

April 2018 www.designworldonline.com

CONTENTS 4-18_Vs4 MG.LL.indd 14

Fostering B2B editorial excellence

2017 Regional

PR INT

DESIGN

Revenue of over $3 million

Revenue of over $3 million

Award Winner

14

3/27/18 1:29 PM

113-119

HMI screen design gets faster and clearer

Award Winner

DESIGN WORLD

4/2/18 8:45 AM

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departments 04 Insights 06 Teschler on Topic 08 Technology Forward 11 Green Engineering 20 Design For Industry 30 Design Notes

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April 2018

DESIGN WORLD

4/2/18 8:52 AM

DESIGN WORLD

Follow the whole team on twitter @DesignWorld

DESIGN & PRODUCTION SERVICES

EDITORIAL

VP, 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 Production Associate Tracy Powers tpowers@wtwhmedia.com

Your worldwide source for high performance Tapes, Films, Fabrics, and Silicone

DIGITAL MARKETING

Digital Marketing Director Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia

Engineering Plastic Films

Webinar Manager Lisa Rosen lrosen@wtwhmedia.com Digital Marketing Coordinator Aly Ryan aryan@wtwhmedia.com @wtwh_aly Leadlift Onboarding Specialist Mike Ulanski mulanski@wtwhmedia.com @wtwh_mike

DIGITAL MEDIA/WEB/ DEVELOPMENT

Events Manager Jen Kolasky jkolasky@wtwhmedia.com @wtwh_jen

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

Events Marketing Specialist Christina Lograsso clograsso@wtwhmedia.com @wtwh_christina

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

Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com

Videographer Manager John Hansel jhansel@wtwhmedia.com @wtwh_jhansel Videographer Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh Videographer Derek Little dlittle@wtwhmedia.com @wtwh_derek

Customer Service Representative Stephanie Hulett shulett@wtwhmedia.com Digital Production Manager Reggie Hall rhall@wtwhmedia.com

FINANCE

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

2011 - 2017

WTWH Media, LLC 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103 Ph: 888.543.2447 | FAX: 888.543.2447

800-461-4161 sales@cshyde.com www.cshyde.com

Medical Design & OUTSOURCING

Staff page 4-18_Vs1.indd 17

www.designworldonline.com

April 2018

Slitting Die-Cutting Die-less Knife Cutting Adhesive Lamination Automated Sheeting Belting

Sold by Lineal Foot Available with adhesive No minimum orders

2014 Winner

DESIGN WORLD

Teflon™ PTFE Ultem® PEI Kapton®- HN, FN, XC Cirlex® PEEK™ DuPont® Mylar PET TPX® & Many More

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4/2/18 8:56 AM

FREAK © Allied Electronics & Automation, 2018

Allied Electronics 2-18 - spread_DW.indd 18

3/27/18 1:48 PM

Automation & Control Freak?

Same here.

We carry more automation & control brand names than any other distributor in North America.

It’s true – we checked.

Get your A&C fill at Allied Electronics 2-18 - spread_DW.indd 19

alliedelec.com

1.800.433.5700 3/27/18 1:48 PM

Design for Industry Harsh Environments

H

Miniature data recorder handles harsh

environments

Harsh, wet and dusty environments can pose serious reliability challenges for data collection.

The SLICE IP68 data acquisition system is designed to measure physical signals in challenging test environments.

With a footprint of 60 x 60 mm, this system can embed in most test articles with size and mass constraints. The rugged enclosure features special sealed layers and IP68-rated connectors, and meets

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DESIGN WORLD

4/2/18 8:58 AM

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

MIL-STD-810G for temperature, altitude, shock and vibration. This durability allows testing in non-pressurized environments with inclement weather or with quick altitude changes that result in condensation on the instrumentation.

SLICE has onboard signal conditioning and supports a variety of external sensors including bridge and IEPE transducers for gathering repeatable measurements like acceleration, displacement, strain, pressure, temperature, voltage and more. Data direct-writes to 16 GB internal flash memory.

The unit is self-contained with the microprocessor, flash memory, control circuits and a sensor interface with excitation, variable gain and 16-bit ADCs. The modular system is configurable based on required features and channel count, including variable sampling rates up to 500k sps/channel. The 3-channel sensor input layers stack up to 24 channels, which can be daisy-chained for higher channel counts. DW

BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

PRECISION NUTS & WASHERS

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

ADAPTER SLEEVE ASSEMBLIES

Materials of: CARBON, ALLOY and HARDENED ALLOY STEELS

DTS | www.dtsweb.com

Materials of: ALLUMINUM and CORROSION RESISTANT STEEL NUTS & WASHERS

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

WHAT DO YOU THINK?

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other engineering design issues with thousands of professionals online

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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April 2018

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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

4/2/18 8:58 AM

Design for Industry O f f- h i g h w a y Consistent manure injection system operation is ensured using specially designed Overhung Load Adaptors from Zero-Max. They provide a stable mounting platform ensuring bearing support on the distribution manifold between the hydraulic motor and the impeller/blender.

Adapters protect farm

equipment from contamination

O

Operating over plowed fields, manure injection equipment requires consistent performance for accurate injection. These systems offer many benefits over dry fertilizer application systems, which is why manure injection systems have grown in use. They inject nutrients directly into the soil at the precise depth and time of root formation. Manure injection enhances crop growth while reducing fertilizer run-off.

But contamination protection for the hydraulic motor shaft seal and bearing support in manure injection equipment is necessary. The short cultivating season doesn’t allow for equipment breakdown and servicing. One solution is overhung load adaptors.

Overhung Load Adaptors (OHLA) provide a stable mounting platform and bearing support between the hydraulic motor and the impeller / blender used on the distribution manifold. OHLA’s cover and protect the hydraulic motor’s shaft seal from outside grit and contamination.

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DESIGN WORLD

4/2/18 9:00 AM

When color is a value...

• Enhance operator safety

Use colors to clearly designate which elements to handle

• Identify machine functions or sections – simplify operation

Overhung load adaptor gives bearings a stable platform for the manifold between the hydraulic motor and impeller/blender.

• Create strong aesthetics

Colors tie to equipment elements, reinforcing perception of design quality and product value

Various designs are available to meet new and unusual overhung load system requirements. These designs include custom inverted bearings and multiple lubrication ports that increase the OHLA’s load capacity and bearing life.

Designed for either face or foot mounting, standard overhung load adaptors are available in more than 50 standard models. SAE mounts available include A, B, C, D, E, and F mounts with 2 or 4 bolt mounting flanges. Plus, there are many shaft variations including splined, threaded, tapered and extended output shafts. Special input bores and housing modifications are also available.

Manufactured to ISO 9001:2008 quality standards, all custom Overhung Load Adaptor designs include a detailed CAD approval drawing submitted prior to manufacture.

Overhung Load Adaptors are used in underwater and high heat applications plus many other types of difficult and hostile environmental conditions. They are widely used in applications such as workboats, recycling systems, forestry shredders, road paving, industrial conveyor drives, and many others where hydraulic systems require stability and shaft seal protection. DW

Available in six colors: orange, grey, yellow, blue, red, black. Colors are controlled to maintain consistency during production and over component lifecycle. *Trademark applied for

Request Catalog 077AM

Elesa USA Corporation www.elesa.com Toll-Free 800-374-7686

Elesa. More than 30,000 SKUs. A unique partner.

Zero-Max | www.zero-max.com

DESIGN WORLD

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April 2018

Since 1941

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4/2/18 9:00 AM

Design for Industry Medical

PCs for the medical market

T

The medical industry is working to upgrade computing systems from older technologies, especially as the market trends toward a digital and cloud-based environment with custom apps to enable more immediate and network-wide system of record-keeping.

Siemens Digital Factory (DF) offers a portfolio of seamlessly integrated hardware, software and technology based services to support manufacturing companies. Siemens plans to offer its IPC technology for this market segment.

Complementing the PC product offerings, rugged handheld units with Windows 7 or 10 compatibility will be offered for technician ease-of-use and connectivity to cloud-based systems.

A scalable portfolio of products, based on Intel CPU technology, will provide a full spectrum of configurations to suit most applications currently in the medical equipment market.

Single- and multi-touch panel PCs will be offered in 7-in. to 22 in. displays in the Nanobox/ Nanopanel and Microbox/Micropanel designs. DW

Siemens Corp. | www.siemens.com

April 2018 www.designworldonline.com 24

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DESIGN WORLD

4/2/18 9:02 AM

M I C R O H Y D R AU L I C S. M I C R O H Y D R AU L I C S.

MACRO CAPABILITIES. CAPABILITIES. REDUCING THE SIZE AND WEIGHT REDUCING THE SIZE AND WEIGHT

OF F L U ID C O NT R O L .

OF F L U ID C O NT R O L .

Designing hydraulic systems to perform flawlessly under less-than-ideal Designing hydraulic systems to factor perform flawlessly under conditions is hard enough.

But in the need to keepless-than-ideal components conditions is hard enough.

Butand factor in thegot need to keep components as small and light as possible, you’ve a real challenge. as small andyou’ve light asgot possible, and you’ve real challenge.

Fortunately, a real solution.

Thegot LeeaCompany.

Fortunately, you’ve got a real solution. The Lee Company.

For more than 65 years, we’ve been engineering stateFor more than 65 years, we’ve been engineering stateof-the-art microhydraulic components with diameters of-the-art components with as small asmicrohydraulic 0.10 in. and weighing as little as diameters 0.1g, but as small as 0.10 in. and weighing littlepsi. as 0.1g, but able to withstand pressures up to as 8,000 able to withstand pressures up to 8,000 psi.

And because everyone of our designs originates And everyone of our originates out ofbecause an application need, anddesigns is scrutinized with out of an application need, and is scrutinized 100% testing and inspection, we’re found in with 100% testing and inspection, we’re found in just about every mission-critical fluid control just about you every mission-critical fluid control challenge could imagine – from challenge you could – from miles above the earthimagine in satellite miles abovesystems, the earthtoinmiles satellite positioning below positioning to miles below in downholesystems, drilling. Plus many in downhole in drilling.

Plus many applications between. applications in between.

If you require precise fluid control, and If you require precise uid control, and absolute reliability, go flwith the experts. absoluteThe reliability, go with the experts.

Contact Lee Company.

Contact The Lee Company.

Innovation in Miniature Innovation in Miniature

The Lee Company The Lee Company

2 Pettipaug Rd, Westbrook CT 06498-0424 860-399-6281 | Fax: 860-399-2270 | 1-800-LEE PLUG | www.TheLeeCo.com 2 Pettipaug Rd, Westbrook CT 06498-0424 860-399-6281 | Fax: 860-399-2270 W E S T B R O O K • L O N D O N • P A R I S •| F1-800-LEE R A N K F U PLUG R T • M| I www.TheLeeCo.com LAN•STOCKHOLM WESTBROOK•LONDON•PARIS•FRANKFURT•MILAN•STOCKHOLM

See us at OTC, Booth #2109 and AUVSI XPONENTIAL, Booth #1703 Lee_MacroCapab_DWorld_6-17.indd 1

5/12/17 10:14 AM

The Lee Company 4-18.indd 25 1 Lee_MacroCapab_DWorld_6-17.indd

4/2/18 10:14 8:19 AM 5/12/17

Design for Industry Medical

3D force sensing technology eliminates false touches

C

Combining technologies can lead to interesting developments. Such was the case for Peratech, a developer in 3D force-sensing technologies. The engineers took an active-matrix 3D force touch sensor and integrated it with a flexible OLCD, for a new type of flexible HMI.

The flexible display incorporates multi-point force-touch sensing of arbitrary size, from wearable devices to large displays. The surface of the sensing display is flexible, allowing it to curve and conform to the shape of the end application, such as a wristband, dashboard or other work surface.

“This is a significant technological milestone for us,” said Jon Stark, Peratech CEO. “No other flexible active-matrix 3D touch sensor with integrated display is available on the market today.

Our collaboration with Merck and FlexEnable has created a new enabling solution for humanmachine interfaces to address existing demand.”

April 2018 www.designworldonline.com 26

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DESIGN WORLD

4/2/18 9:03 AM

One advantage is that Peratech’s QTC technology can eliminate false touches, opening the door to previously unsuccessful force-touch applications.

These false touches, commonly associated with capacitive touch sensing, have limited the adoption of touch for safety critical uses including medical, industrial and automotive applications.

The integrated solution is based on FlexEnable’s low-temperature organic thin-film transistor (OTFT) fabrication expertise using Merck lisicon OTFT material technology together with Merck licristal liquid crystal materials. All of the circuitry that drives the organic LCD is integrated alongside the 3D touch sensing elements, making display and force touch a single component in terms of design and system integration.

TL Design Worls ad copy.pdf

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1/25/18

The result is a high-resolution forcesensing display. The force sensor provides a raw spatial resolution of 25 ppi using 100 by 64 active-matrix sensing elements for the 3D touch sensor. The elements, or sensels, detect both location of touch points and the amount of force applied to each sensel in the contact area, making the theoretical interpolated resolution greater than 10,000 ppi with standard ICs typically used in consumer, automotive, and industrial electronics. DW

Peratech | www.peratech.com

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LOCAL: 714-562-0500 FAX: 714-562-0600

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April 2018

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4/2/18 9:03 AM

Design for Industry Medical

Easier to clean conveyors

S

Sanitary Flange Line Vac air operated conveyors move materials through

systems that require frequent or mandatory cleaning. The ISO 2852 compatible sanitary flanges limit areas where bacteria can grow and help prevent contamination. Made from type 316 stainless steel to provide maximum hygiene and corrosion resistance, these Line Vacs are available in 1-1/2 in., 2 in., 2-1/2 in. and 3 in. flange sizes.

Flanged Line Vacs convert flanged piping systems into a powerful conveyor for product, parts, scrap, trim and other bulk materials. Their larger size makes them perfect for conveying bigger parts and large volumes of material over long distances.

Sanitary Flange Line Vac Conveyors eject a small amount of compressed air to produce a vacuum on one end with high output flows on the other. Response is instantaneous and regulating the compressed air pressure provides infinite control of the conveying rate.

Applications include material conveying, part transfer, fiber tensioning, scrap trim removal and filling operations.

April 2018 www.designworldonline.com 28

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These Line Vacs are CE compliant and meet OSHA pressure requirements.

Additional families of Line Vac are available to fit hose, tube or threaded pipe. Many smaller sizes are available down to 3/8 in. hose or 3/8 NPT threads and large hose or pipe sizes up to 5 in. Many other materials are available including aluminum, type 303 and type 316 stainless steel. A Heavy Duty Line Vac is available in hardened alloy for abrasion resistance and maximum conveying power. DW

Exair Corp | www.exair.com/sflv.htm

DESIGN WORLD

4/2/18 9:05 AM

Design for Industry Food & Beverage

Smart plug-and-play

flowmeter measures flow and temperature of conductive liquids

To track fluid flow in beverage and other applications, vendors are introducing a number of “smart” products. One is the Picomag electromagnetic flowmeter, which is an in-line transmitter for measuring temperature and flow of conductive liquids in pipe sizes ranging from ½ in. to 2 in., such as drinking and industrial water. It measures flow up to 198 gal/minute with ±0.5% full-scale accuracy and ±0.2% repeatability, and temperatures from 14 to 158°F (-10 to 70°C) with ±4.5°F accuracy.

The Picomag combines a sensor and transmitter in the same housing, with a 1.4-in.

TFT color display showing flow, totalizer and temperature readings, as well as warning and alarm messages.

Outputs include 4-20 mA, pulse, switch, and 2-10 V. IO-Link connectivity provides flexible integration into automation systems. The Bluetooth wireless interface directly accesses process and diagnostics data, and enables the user to configure the measuring device on the fly. The device can be operated and configured on Android and iOS devices through a free SmartBlue App. The IO-Link interface allows installation into fieldbus and other existing infrastructures. The IO-Link Master allows data access from the control room, and automatically transfers configuration parameters after a device replacement.

The flowmeter can be used on process skids where space is often limited, or in difficult to reach locations. Picomag can be installed into any pipe up to 2-in. (50 mm) diameter, even in confined spaces. Various process connection adapters are available, including NPT-thread, R-thread, internal thread, Tri-Clamp or Victaulic, and it is available in models that accept ½-, ¾-, 1- or 2-in. connections.

The stainless steel Picomag flowmeter has high shock and vibration resistance, IP65/67 protection and a PEEK measuring tube. It fulfills EMC requirements according to IEC/EN 61326. It also conforms to the requirements of the EU and ACMA directives, and has a cULus listing. DW

Endress + Hauser | www.us.endress.com

DESIGN WORLD

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www.designworldonline.com

April 2018

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4/2/18 9:07 AM

Design Notes Using ideal cushioning technology from Aventics, medium-duty aluminum cylinders are often specified in high-speed/high-load applications, lasting longer and improving production throughput. At the same time, the user benefits from reduced maintenance and cost of replacement parts.

Increase cylinder life by eliminating

end-cap slamming

Nathan Irvine • Product Specialist, Drives & Sensors • Aventics Corp.

For high-speed equipment in applications such as timber processing, heavy-duty steel pneumatic cylinders were often specified because of cycle speeds and harsh operating conditions. However, using cushioning technology from Aventics, medium-duty aluminum cylinders are often specified in high-speed/high-load applications, lasting longer and improving production throughput. At the same time, the user benefits from reduced maintenance and cost of replacement parts. (It should be noted that in many applications, only pneumatic cylinders with excellent mechanical cushioning adjustment and impact bumpers can truly achieve ideal cushioning.)

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Design Notes 4-18_Vs3.LL.indd 30

DESIGN WORLD

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Ideal cushioning is a method of decelerating the pneumatic

piston as it reaches the end of its stroke inside the cylinder. As a result, the end-of-stroke bounce, or end-cap slamming, is eliminated, which is often a main culprit of cylinder wear, longer cycle time and noise. The piston velocity reaches its maximum along the way, and is exactly zero by the time it reaches the end

WHEEL OF FORTUNE We love to see YOU win! rutronik24.com/18143

cap. By reducing the piston velocity to zero speed at precisely the end of travel, the cylinder incurs less stress. Vibration in the machine is also reduced and the total cycle time is improved, sometimes boosting machine speed by as much as 30%.

For ideal cushioning to work properly, the piston velocity must

be adjusted correctly during commissioning. Since the velocity of the piston in a cylinder may be difficult to detect by eye, technicians often used an electronic velocity time meter (VTM) that was attached to the outside of the cylinder tube. The VTM allowed the true velocity of the piston to be determined quickly and easily, even for all sequences in a cylinder cycle. The cushioning adjustment was then completed using a simple screwdriver, where the free outlet flow was adjusted so the piston stopped right at the end cap with zero speed. Cylinder pistons could then be adjusted one at a time with the first one used as a standard to conform to a maximum speed for a given pressure and cylinder load.

Tool for cushioning adjustment Adding to its range of engineering and assembly tools, Aventics

Electronics

introduced a Cushioning Adjustment Tool (CAT) to improve on the VTM concept and help installers set up cushioning parameters using an LED display and visualization with an optional smartphone app that clearly shows which way the cushioning needs to be adjusted. The smartphone app also displays the piston

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Ideal cushioning is a method of decelerating the load as the piston reaches the end of its stroke inside the cylinder. As a result, the end-of-stroke bounce or end-cap slamming is eliminated, which is a main culprit of cylinder wear, speed and noise.

Semiconductors

Displays & Boards

Passive Components

Storage Technologies

Electromechanical Components

Wireless Technologies

For more information about RUTRONIK: sales-na@rutronik.com | www.rutronik.com

Committed to excellence

DESIGN WORLD

Design Notes 4-18_Vs3.LL.indd 31

 

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Consult | Components | Logistics | Quality

4/4/18 12:30 PM

Design Notes speed just before cushioning begins, plus the cushioning characteristics as a plot of piston position versus time. This allows users to fully benefit from the characteristics of the cylinders in the system.

The diagnostic tool attaches easily to

the cylinder. The CAT detects if and how the cushioning setting must be changed by evaluating the position and speed

Aventics introduced a Cushion-

of the piston using magnetic sensors.

ing Adjustment Tool (CAT) to help installers set up ideal cushioning parameters using an LED display and advanced visualization in an optional smartphone app that clearly shows which way the cushioning needs to be adjusted.

The device only measures 2.2 by 3.3 in. and can be removed once everything has been set correctly. An integrated battery that can be recharged via a micro USB connection supplies the power.

The associated app is compatible with

Tame the Harshest Environments Extreme Heat +200°C

Vibration Damping

316 Stainless Steel Simplicity Bearing

SimplicityÂŽ Plain Bearing Inch Series

Welding

Design Notes 4-18_Vs3.LL.indd 32

4/2/18 9:42 AM

Android smartphones using a Bluetooth connection, with

LED display showing red, yellow and green, or from your

In the past, you often needed experience, a special touch and a lot of patience to correctly adjust the cushioning for pneumatic cylinders. Now you simply adjust the

smart phone. In the past, you often needed experience, a

cushioning according to the LED.

the iOS application coming soon.

After the sensor is attached to the cylinder and

switched on, all functions can be read from the three-color

special touch and a lot of patience to correctly adjust the cushioning for pneumatic cylinders. Now you simply adjust the cushioning according to the LED cues. Dialing in the cylinder cushioning is still handled the same way using a basic screwdriver, but the new Cushioning Adjustment Tool makes the adjustment easier, faster and more precise for trouble-free operation, quiet running, and high cycle frequencies in pneumatic systems. DW

Aventics | www.aventics.com/us/IdealCushioning

with the Toughest Linear Solutions Dust

Extreme Cold -240°C

Simplicity Plain Bearing Metric Series

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Metal Debris 6402 Rockton Road, Roscoe, Illinois 61073, USA • 1-800-962-8979

pbclinear.com

Design Notes 4-18_Vs3.LL.indd 33

4/4/18 12:44 PM

Design Notes Edited by: Mike Santora • Associate Editor

HMI keeps syringe filling machine sharp

An OEM that builds machines for the healthcare industry needed to create a syringe filling system. The requirements included using no I/O motors, and the ability to work with multiple devices including a Universal Robots’ UR-3 with Lexium motors, Stratix 2000 Ethernet Switches, and Schneider Electric sensors.

Syringes needed to be filled in a precise and consistent manner. The full application also needed to be managed via Ethernet in order to compliment the customer’s current process and keep errors to a minimum.

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These devices from multiple manufacturers were already part of the customer’s application, so it was imperative that the solution could communicate with them while providing a reliable assembly application.

Syringes needed to be filled in a precise and consistent manner. The full application also needed to be managed through Ethernet to compliment the customer’s current process and keep errors to a minimum.

Managing robots through an Ethernet switch for real-time control, although not a new concept, is not extremely common in the industrial robotic industry. This method allows for a more secure system of process management cutting concerns like data collision and out-of-order delivery.

Working through Airline Hydraulics, an automation product distributor, the OEM was able to mount all the robot motors in place with the Pro-face GP4000M 22 mm modular HMI programed with the HMI Development software, GP-Pro EX. The HMI with software acted as the “brains” of the solution bringing the UR-3 and the filler with Lexium motors together. This modular HMI starts and stops the robot and

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The HMI with software acts as the “brains” of the solution bringing the UR-3 and the filler with Lexium motors together.

manages the entire filling operation. The finished machine has no I/O motors, and the home sensors go directly to the motor, everything else is done through Ethernet.

With the Pro-face HMI’s connectivity options, it was able to communicate with multiple devices from multiple manufacturers. This allowed the robot to consistently execute the program, completing the filling station with efficiency and accuracy. The entire solution can be managed by Ethernet,

Equal to the Toughest Tasks The Position Sensor with Patented Pressure Equalization

allowing the customer to keep the filling station in a controlled LAN environment.

GP-Pro EX HMI Development software is simple to program and maintain, allowing the filling station process to be consistent and accurate. Meeting these requirements allows the customer to avoid inconsistent product issues.

The robot filling application can be used for multiple assembly line solutions, including can, bottle, or pill case filling, and other intricate operations resulting in a specific amount of product being placed in a unique container. DW

Schneider Electric | www.schneider-electric.us

Novotechnik’s new LWX Series of heavy-duty sealed position transducers is engineered for extreme operating environments where high temperatures, vibration, high-pressure equipment wash downs, grease, and other contaminants are present. The patented pressure equalization technology prevents buildup or the “pump effect” that can degrade operation in repetitive mechanical, vehicle, automation and robotic applications.

Key specs include: • Stroke lengths from 75 to 750mm • Sealed to IP-67

• Linearity 0.05% • Resolution better than 0.01mm • All metal corrosion resistant housing

For complete LWX information, visit www.novotechnik.com/lwx Novotechnik U.S., Inc. 155 Northboro Road • Southborough, MA 01772

DESIGN WORLD

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Design Notes

Reach advantage: surgical

microscope gets an upgrade Bryan Signaigo • Design Engineer • Seiler Instrument and Manufacturing

When medical professionals began requesting an overhaul of When the microscope is in use, the arms must be long enough to allow reaching the surgical site. Additional length beyond the surgical site enhances maneuverability and prevents the arms from locking up while extended.

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surgical microscope design, Seiler Instrument saw an opportunity.

Users needed better maneuverability, longer reach, better cable management, and brighter illumination for surgical microscopes.

Seiler’s answer was its next-generation microscope, the Alpha Air. To handle maneuverability and reach, engineers redesigned the support arms. The support system allows the practitioner to move the surgical microscope into a comfortable position for viewing the area of interest. With limited space, users often prefer wall or ceiling-mounted structures over a mobile floor stand unit.

When the microscope is in use, the arms must be long enough to allow reaching the surgical site. Additional length beyond the surgical site enhances maneuverability and prevents the arms from locking up while extended.

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During the redesign, the length of both arms was increased more than 12 inches, increasing torque applied to the pantographic arm. Some of the total desired reach was split between the two arms. This design choice was twofold: It helped meet the reach requirement and kept the storage position as compact as possible. These same arms are used in all systems, maintaining low cost due to the economy of scale.

The engineering team was still cautious about overextending arm length though. With longer support arms, the mobile stand is more unstable and could tip. Thus, to prevent tipping, the mass of the base was increased. This increased mass makes the system heavier and less mobile but, with reach being the priority, engineers accepted tradeoff. This counterbalance system required an updated design to accommodate the increased torque requirements.

When the microscope is not in use, the arms fold into a storage position that needed to be as compact as possible.

The Pantographic Arm contains a counterbalanced gas piston system, making arm movements easy and smooth.

The power supply housing also doubles as a support arm.

The engineering team also improved maneuverability by redesigning one of the tensioning mechanisms. Each user has a different expectation of how much force is needed to position the system. The previous tensioning mechanism was too coarse of an adjustment and not sensitive enough to allow a larger range of tension between loose and locked.

Redesigning the lightsource created better cable management, brighter illumination, and improved aesthetics.

The Alpha Air replaces two generations of the Evolution XR6.

The first generation of the XR6 incorporated a 50W Metal Halide light source with a backup 100W Halogen in the event of bulb failure. That solution also required using an expensive and fragile fiber optic light guide. The next generation XR6 eliminated bulb replacement and the need for the light guide by implementing a new LED lightsource design. Now, the Alpha Air uses improved LED technology. Two power output options were integrated into the microscope to allow powering camera accessories. These output options eliminate the need for an additional power cable for each of the accessories. Finally, the overall microscope appearance was improved by redesigning the power supply housing. Ergonomics, magnification, and illumination are all critical for a physician to perform their work as effectively and efficiently as possible. DW

Seiler Instrument | www.seilerinst.com

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Internet of Things

Plug-and-play IoT upgrade reduces capital expenditure by 50%

E

EcoStruxure is Schneider Electric’s IoT-enabled, open and interoperable system architecture and platform. The EcoStruxure architecture enables scalable design and operation of connected systems with cybersecurity built in at every layer; across connected products, edge control and apps, analytics, and services.

EcoStruxure is Schneider Electric’s IoT-enabled, open and interoperable system architecture and platform. It enables scalable design and operation of connected systems with cybersecurity built in at every layer.

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Schneider Electric experts helped upgrade Dow Corning’s existing Foxboro I/A Series control system to the EcoStruxure Foxboro DCS in phases, ensuring continuous, transparent operations.

Recently, Schneider Electric helped Dow Corning upgrade its distributed control systems in its Carrollton, Kentucky, plant. The upgrade involved the existing Foxboro I/A Series control system.

This upgrade should reduce capital expenditure by 50%.

“We worked closely with Schneider Electric to develop a strong action plan that enabled us to modernize our distributed control system and take better advantage of new, valuefocused technology solutions,” said Chris Wolfschlag, project manager, Dow Corning. “This was a difficult project because we only had one week to perform the upgrade, but by working as a team with Schneider Electric, we were able to complete the project sooner than anticipated. Bringing the system back online faster gave us two full days of extra production, which positively impacted our bottom-line performance.”

Working in tandem, Schneider Electric experts helped upgrade Dow Corning’s existing Foxboro I/A Series control system to the EcoStruxure Foxboro DCS in phases, ensuring continuous, transparent operations. The team retained much of the DCS infrastructure, including its human-machine interface, field wiring and documentation, which prevented any need for a complete system shutdown or any halt to production. This plugand-play approach helped Dow Corning reduce its capital expenditure by approximately 50%, as well as complete the upgrade in less than a week.

“Modernizing to the EcoStruxure Foxboro DCS helps us improve how we

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control the efficiency, reliability and safety of our operations, in real time,” said Wolfschlag. “Because it gives us better visibility into the financial and business performance of our operations, we are better able to evaluate how our decisions and actions impact our overall operational profitability.”

Dow Corning upgraded with an eye toward speeding project execution and reducing engineering, operating and inventory costs. Additionally, through the project management, cabinet design, factory acceptance testing, start-up and additional modernization services Schneider Electric is providing, Dow Corning expects productivity to increase as well.

“As the speed of business increases, many industrial assets are pushed closer to their thresholds of reliability and safety, decreasing throughput and negatively affecting operational profitability,” said Hany Fouda, vice president, Process Automation offer management, Schneider Electric.

“Schneider Electric’s IIoT systems and solutions change all that. By helping Dow Corning preserve existing infrastructure while modernizing to the EcoStruxure Foxboro DCS, we believe they are now even better able to control and avoid potential risks to the safety, efficiency, reliability and profitability of their operations.” DW

Schneider Electric | www.schneider-electric.us

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Internet of Things

Industrial Ethernet plug-n-play connectors

T

These molded M12 and RJ45 pre-assembled data cables for Industrial Ethernet systems let users

modularly assemble any possible combination of cables and connectors to “design” a product built exactly for their needs.

In combination with high-speed data cables with transmission rates of up to 10 GBit/s, the molded M12 and RJ45 connectors offer a fast and reliable connection within control cabinets, machinery and in-the-field operations. The cable/ connector combinations are directly related to the customer’s intended application use – static, occasional movement, or continuous-flex.

The molded M12 connectors come in D- and X-coded versions, both male and female, for use with Category 5 and 6A cables, which cover higher data transmission rates of up to

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10 GBit/s. Due to their metal casing, both the connector and socket are robust and resistant to dirt and moisture when connected, in accordance with IP-67 certification.

The sturdy design of the RJ45 connector makes it suitable for industrial applications. It supports data rates up to 10 GBit/s and has a maximum bandwidth of 500 MHz. The connector is available in a linear or angled version.

Both the molded RJ45 and M12 plug-and-play versions are UL/CSA approved. DW

HELUKABEL USA, Inc. | www.helukabel.com/us DESIGN WORLD

4/2/18 9:58 AM

TOMPKINS LIVE SWIVELS Reduce the stress on both you and your equipment with Tompkins Live Swivels. Live Swivels prolong the life of hose by reducing the effects of torque, twisting, kinking, and bending stress. These fittings are available in Zinc Plated Steel, 316 Stainless Steel and Brass in a variety of sizes and configurations to help you, and your equipment, remain stress-free. www.tompkinsind.com

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Internet of Things

Miniature, right-angle board-to-board battery connectors

D

T

Developed in response to market demand for miniaturization, the 9155-700 Series board-to-board battery

connectors are compact, mechanically stable, high-integrity connections for use in medical, industrial, and commercial applications subject to high shock and vibration.

These 2-mm-pitch, right angle board-to-board battery connectors, are rated for 125 Vac, up to 2 A, and 5,000-cycle durability. They provide miniaturized, mechanically stable, high-integrity connections in harsh environment applications subject to shock and vibration, including: handheld and portable devices that require dock or cradle charging, patient monitoring devices and other portable medical electronics, industrial programming modules, point of sale (POS) terminals, and a broad range of IoT devices. The connectors have a compact design with a 4 mm connector height, a stable contact point 2.1 mm above the PCB, robust and reliable gold-plated beryllium copper (BeCu) contacts, two SMT anchor brackets, and optional plastic locating bosses.

Made of high-temperature nylon plastic compatible with

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RoHS soldering, 9155-700 Series connectors are rated for operating temperatures spanning -40°C to +125°C. Two-, three-, and four-way versions are rated for 2 A, and five- and six-way versions are rated for 1.5 A. The series also features a design that retains the contact nose within the insulator to prevent damage in both the static position and during mating deflection, and is offered with either 0.4 μm or 0.8 μm selective gold plating with pure tin tails to suit less demanding applications, as well as extreme environment applications, which can benefit from the increased durability and wear resistance enabled by heavier gold plating. DW

AVX Corp. | www.avx.com

April 2018 www.designworldonline.com

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News

Diode arrays protect CAN networks from transient damage

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The AEC-Q101-qualified TVS Diode Arrays protect automotive Controller Area Network (CAN) lines from damage due to electrostatic discharges (ESDs), electrical fast transients (EFTs), and other overvoltage transients.

AQ24CANFD Series TVS Diode Arrays can absorb repetitive ESD strikes above the maximum level specified in industry standards without performance degradation and can safely withstand 3 A surges at low clamping voltage. Like a growing number of devices designed for use in automotive electronics, the AQ24CANFD Series is PPAP-capable.

Automotive applications for AQ24CANFD Series TVS Diode Arrays include protecting: Drive-by-wire (CAN BUS) lines.

Engine control modules.

Anti-lock brakes.

Air bag and other safety circuits.

Electronic control units.

Body control units.

ADAS control units.

Power train control units.

• • • • • • • •

They are also suitable for factory automation and lightning control (DALI) applications.

AQ24CANFD Series TVS Diode Arrays offer these benefits: ESD (21 kV) and surge (3 A) protection in excess of industry standards.

Low dynamic resistance (0.5Ω RDYN) for a 10% reduction in clamping voltage when compared to similar market solutions.

Low capacitance (11.5 pF typ.) helps preserve signal integrity and minimize data loss. DW

• • •

Littelfuse | Littelfuse.com

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Internet of Things News Report finds OPC UA standard well positioned for IoT applications

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The ARC Advisory Group recently reported on the role the OPC data connectivity standards play in control automation and in future IIoT, and in Industrie4.0 based solutions.

Key report findings confirmed that with an estimated global install base of more than 45 million units, OPC is the de facto standard for open data connectivity and that OPC UA is well positioned to serve as the next data connectivity foundation for control automation applications in traditional industrial settings and new ones like building automation, transportation, and others. Key contributing factors to the success of OPC UA included the scalability, performance, and robustness of the technology and the large community of end-users, vendors, and other standards bodies actively working with the OPC Foundation to best use OPC UA in their applications.

cycloidal reduction gears

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Did you mean: DieQua Corporation?

Commenting on the popularity of the OPC UA standard, Thomas Burke, OPC Foundation president, said, “OPC UA has something to offer everyone from end-users and product vendors to other standards bodies. After people look at what is really out there as far as a single standard that has the scalability, performance, and flexibility to meet the challenges of modern data connectivity and interoperability and has the reputation and a large enough adoption base needed to make it a safe investment - they come to realize OPC UA is the real deal.” DW

ARC | www.arcweb.com

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CAE Solutions

Go from concept to manufacturing in one design system

C

Creo 5.0 3D computer-aided design (CAD) software helps users go from concept to manufacturing in one design environment. The software introduces five new capabilities for product design and offers new productivity enhancements.

With Creo 5.0, concepts can be transformed into smart, connected products, bridging the physical and digital worlds with augmented reality (AR) capabilities in every seat. The software introduces capabilities in the areas of topology optimization, additive and subtractive manufacturing, computational fluid dynamics, and CAM. Topology optimization: Creo Topology Optimization Extension automatically creates optimized designs based on a defined set of objectives and constraints, unfettered by existing designs and thought processes. This helps users save time and accelerate innovation by enabling creation of optimized and efficient parts.

Additive and subtractive manufacturing: Creo enables users to design, optimize, print check, and additively manufacture parts without the need for multiple pieces of software. By streamlining the process and reducing the need to recreate models, more time can be spent focused on the design. Creo 5.0 introduces the Creo Additive Manufacturing Plus Extension for Materialise, which extends these capabilities to metal parts, allowing customers to print production-grade parts directly from Creo. Additionally, the extension allows users to connect to the Materialise online library of print drivers and profiles.

The Creo Mold Machining extension provides dedicated highspeed machining capabilities for molds, dies, electrodes, and

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prototype machining. Creo 5.0 supports 3-axis and 3+2 positioning machining.

Creo Flow Analysis: The Creo Flow Analysis extension is a computational fluid dynamics (CFD) solution, which allows designers, engineers, and analysts to simulate fluid flow issues directly within Creo. The seamless workflow between CAD and CFD allows users to integrate analysis early and often to understand product function and performance.

Creo 5.0 also includes key productivity improvements, such as an improved user interface, geometry creation with sketch regions, and volume helical sweeps. Other enhancements include improvements to surfacing, sheet metal design, and the application of draft features involving rounds. Users can also design in Creo while maintaining perspective display mode.

The Creo Collaboration Extension for Autodesk Inventor enables organizations to consolidate onto a single CAD system, enabling them to reduce the cost and effort associated with maintaining multiple systems and integrations, and enabling better data reuse and resource sharing. Creo 5.0 supports bi-directional exchange of both parts and assemblies with Autodesk Inventor. DW

PTC www.ptc.com/en/products/cad/creo/whats-new

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4/2/18 10:10 AM

Your Custom Gearbox Solutions are CGI Standard Products.

Advanced Products for Robotics and Automation CGI Motion standard products are designed with customization in mind. We understand most off-the-shelf products or a complete in-house design may not fit your application, so our standard products are designed for functional flexibility. Our team of experts will work with you on selecting the optimal base product and craft a unique solution to help differentiate your product or application. So when you think customization, think standard CGI gearbox assemblies. Connect with us today to explore what CGI Motion can do for you.

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4/2/18 8:24 AM

CAE Solutions

Collaboration

works to improve CAD simulation

SimScale GmbH, a provider of the full-cloud engineering simulation platform, announced a collaboration with Siemens PLM Software and Tech Soft 3D to optimize the simulation workflow through better CAD model handling. SimScale will bring the benefits of Siemens’ Parasolid software and HOOPS Exchange to a browser-based CAE. The latest release of SimScale will integrate Parasolid and HOOPS Exchange for a more convenient and seamless simulation workflow, while at the same time increasing simulation result accuracy—both in FEA and CFD. Parasolid is a 3D geometric modeling component for

MEDICAL MOLDED CABLE ASSEMBLIES

computer-aided design, manufacturing and engineering analysis (CAD/CAM/CAE) solutions, while HOOPS Exchange is a CAD translation software development kit (SDK). DW

SimScale | www.simscale.com Tech Soft 3D | www.techsoft3d.com

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Upgraded PCB

design software In version 4.0 of PCB Artist, the free design software offers features and functions found in paid PCB design packages. PCB Artist includes advanced layout capabilities, a library of more than 500,000 components, and free technical support.

New features include: • Enhanced Powerplane Thermal Controls for full control of connection parameters to plane layers.

• Spiral Wizard to simplify the creation of inductive coils.

• Automatic Component Rename feature for easy organization and modification of reference designators.

• Native Eagle Import of Schematic (.sch), PCB (.brd), and Library (.lbr) files.

DW

IMPACT CAN DESTROY AN OBJECT OR A SINGLE ELEMENT OF THAT OBJECT

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CAE Solutions

Design, build and commission automation systems

E

Engineers can more quickly design, build

and commission automation systems using the enhanced Rockwell Software Studio 5000 integrated development environment. The latest software release includes a new user interface with a common, modern look across all Studio 5000 applications, and includes updates to help engineers improve productivity from design to deployment.

The Studio 5000 Logix Designer application includes updates to several programming languages and a modern structured text editor to help optimize design time. The text editor has been updated with new features, such as collapsible code segments and inline value monitoring, for more productive programming and editing.

The modified structured text editor improves ease of use for programmers at different skill levels. Power users currently using structured text programming and new engineers who are unfamiliar with it will both be comfortable using the modern editor.

The new Logix tag-based alarm function allows engineers to easily add alarms to structures and manage them in a single environment, which helps save time by avoiding the need for programming. The update also includes new drive safety instructions in accordance with IEC 61800-5-2, and motion instructions for expanded kinematic support. In addition, the modern user interface includes multimonitor support and tabbed views to help improve usability and reduce design time.

The Studio 5000 Logix Designer application also includes support for the Allen-Bradley GuardLogix 5580 and Compact GuardLogix 5380 controllers. This provides high-performance options for users as they design safety systems and can help reduce overall machine costs.

The Studio 5000 View Designer application now includes data logging and trending for easier troubleshooting. And it gives engineers access to emulation capabilities for virtual commissioning and testing applications to help reduce system development time and risk.

The Studio 5000 Architect application supports system wide capabilities that can reduce design

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complexity and time. For example, the updated version has adopted the open data-exchange interface, AutomationML (Automation Markup Language), for expanded connectivity and robust data sharing between the Studio 5000 software and other engineering tools such as EPLAN Electric P8.

A new Studio 5000 Application Code Manager lite edition is available for download as a single-user edition for machine and equipment builders who operate on a smaller scale. At no added cost, this version will contain bulk-programming and library-management capabilities, with a standard version available as an annual subscription.

In addition, to help jumpstart development, Rockwell Automation now provides a Machine Builder Library and Process Object Library for Studio 5000 Application Code Manager. Both libraries can be downloaded from the Product Compatibility Download Center (PCDC) for no additional cost.

The Studio 5000 Logix Emulate application now has an updated interface for connectivity to operator training systems like Cape Software VP Link and MYNAH Mimic, along with an improved user interface. DW

Rockwell Automation Inc. | Rockwellautomation.com

April 2018 www.designworldonline.com

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4/2/18 10:15 AM

Unlimited advantages... ...replace metal bearings with plastic

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Sensor Notes

How does sensor technology benefit from IO-Link?

T

Safety-rated

inductive sensor

Balluff released a complete family of inductive safety sensors.

To better understand a

These devices can be easily and

machine’s performance, many sensor manufacturers are turning to IO-Link.

inexpensively connected directly to the Balluff “Safety Over IO-Link”

Providing sensor information to a programmable logic controller (PLC), power management software and enterprise resource planning (ERP) systems, IO-Link is the first standard IO technology worldwide Baumer’s O300 miniature (IEC 61131-9) for communicating laser sensors with sensors and actuators. With IO-Link, the industry can get more information from even the simplest products. While IO-Link has existed for several years, it surpassed 1 million links in 2012.

SICK describes the relationship between IO-Link and sensors this way: “Sensors and actuators become active process participants in an end-to-end automation network. As senders, they independently report errors and statuses to the control. As receivers, on the other hand, they receive signals – and process them. The result: cost and process optimization throughout the entire supply chain – across all industries.”

Here’s a look at some of the newest IO-Link enabled sensors on the market.

Miniature laser sensors Baumer’s O300 miniature laser sensors with IO-Link reliably detect very small objects and gaps in assembly, pharmaceutical and process automation. With their IO-Link integration, O300 laser sensors are Industry 4.0-ready. IO-Link allows the quick and easy configuration of sensors for all applications using standard network components. In addition, additional data, e.g. for predictive maintenance processes, are available for evaluation.

Due to a laser beam that focuses to within 0.1 mm and a high repeat accuracy of 0.1 mm, objects can be positioned with high precision and followup processes controlled exactly. With a response time of less than 0.1 msec, the sensor detects even closely spaced objects, thus allowing fast processes and high throughput rates. A big advantage is the exact alignment of the laser beam to the mounting holes by design (qTarget). qTarget ensures guaranteed detection with pinpoint accuracy over the entire series.

The no-wear teach-in method (qTeach) allows easy, user-friendly commissioning of the sensor. The weak point of pushbuttons and potentiometers is eliminated with the tamper-resistant qTeach teach-in method, thus offering maximum reliability and system availability. DW

module, allowing integrators to implement a complete safety + automation sensing and network solution.

These sensors detect the approach of metallic targets without direct contact, and do not require a special mating actuator. This means that safety signals for position and endof-travel can be generated, or metallic workpiece carriers can be sensed directly.

They are also suitable as pulse transmitters for counting tasks and speed sensing. They are available in industry standard form factors including M12, M18, M30 and Q40.

The product family includes both PLd/ SIL CL 2 and PLe/SIL CL 3 devices.

The M12 plug connector means that the inductive safety sensors can be connected to any desired safety processor, including safety relays, programmable logic modules or safety controllers. And connection to the Balluff “Safety Over IO-Link” module is “plug-and-play.” DW

Balluff Inc. | balluff.com

Baumer | baumer.com

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4/4/18 1:06 PM

What is LVIT technology?

L

LVITs—Linear Variable Inductive Transducers—are contactless position sensing devices that use eddy currents developed by an inductor in the surface of a conductive movable element to vary the resonant frequency of an L-C tank circuit. The most common form of an LVIT uses a small diameter inductive probe surrounded by a conductive tube called a spoiler that is mechanically coupled to the moving object. Typical LVITs have full ranges from fractions of an inch to 30 in. or more. Modern electronics using microprocessors and small component

Extreme Duty LV-45 Series

size makes outstanding performance possible, achieving linearity errors of less than ±0.1% and temperature coefficients of 50 ppm/°F, along with either analog or digital outputs.

LVITs are found in a wide variety of different applications that require position information or feedback. Typical LVIT applications include mobile hydraulic cylinders, subsea hardware, civil engineering testing and factory automation.

Being contactless, the basic measurement mechanism of an LVIT does not wear out over time. LVITs also do not have the higher installed cost associated with other contactless technologies.

They were created by Alliance Sensors; below is one of its newest designs.

Industrial Duty LR-27 Series

Automation Duty LR-19 Series

LVIT replaces linear potentiometers H. G. Schaevitz LLC Alliance Sensors Group has expanded its sensor product offering by adding a line of LR-19 series inductive linear position sensors using LVIT Technology; contactless devices designed for factory automation and a variety of industrial or commercial applications. With their compact design and high stroke-to-length ratio, LR-19 sensors are suitable for both industrial testing laboratories and OEM applications.

LR-19 Features: • Contactless operation prevents wearout from dither or cycling • Six ranges from 25 to 200 mm (1 to 8 in.)

• 19 mm (0.75 in.) diameter anodized aluminum housing sealed to IP-67 • Radial cable exit version comes with swivel rod eye ends • Axial termination versions with either M-12 connector or cable Operating from a variety of DC voltages, the LR-19 series offer a choice of four analog outputs and all include ASG’s proprietary SenSet field recalibration feature.

The LR series also includes two larger body versions, the LR-27 and LRL-27, for those applications needing a heavier duty unit and a spring-loaded version called the LRS-18. DW

H. G. Schaevitz LLC Alliance Sensors Group | alliancesensors.com

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M o t i o n

C o n t r o l

How to design gearmotors

for extreme ambient conditions

Gabriel Venzin | President | ABM Drives, Inc.

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Following some straightforward advice on gearmotor design will help ensure your gearmotor works in the most extreme environments.

Designing a gearmotor application is tough enough in more or less “normal” conditions, normal here meaning something like room temperature and stable or typical humidity and altitude. Throw that application into an extreme environment and the design gets more complicated. But it doesn’t have to be. For anyone designing a gearmotor application in extreme ambient conditions, there are some guidelines that when adhered to will help ensure that the design succeeds.

First, the basics A gearmotor is a combination of a gear reducer and an electric motor. The two most important factors at the gearmotor output shaft are its rpm and torque. A right angle, straight or parallel shaft gearbox can be combined with a permanent magnet ac, ac induction, or brushless dc motor.

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M o t i o n

C o n t r o l

other unique conditions that may be relevant to the design. In the following sections we’ll cover temperature, altitude and humidity and the way these factors influence gearmotor selection.

Temperature What happens to the gearmotor when the temperature drops to -40° C?

Gearmotor systems for demanding applications, such as dockside crane hoists, trolley and bridge drives, need to be engineered for many years of severe duty cycles that demand minimum maintenance.

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The gearmotor applications discussed here are not exposed to high-pressure water spray, such as in freezers, unheated facilities or enclosures. They’re used in applications such as forklifts and electric vehicles, lifting technology, construction equipment, packaging machinery, as well as dockside crane hoists, and trolley and bridge drives, among others.

The goal is to have the gearmotor operate for decades of exposure to extreme ambient conditions with low maintenance because they may not be easily accessible. There’s not much mechanically different in a gearmotor for extreme temperatures and altitudes; mainly it’s lubrication, duty cycles, heating or cooling considerations and construction materials selection. So these tips can be used to upgrade existing systems as well.

The typical types of gearmotors we’re talking about include hoist drive gearmotors, which lift loads between 3.2 and 40 metric tons. They are powered by a 2.5 to 38 kW asynchronous cylindrical-rotor motor with 3-stage parallel shaft gearboxes for lifting speeds of 4 to 8 m/min at drum diameters of 140 to 405 mm and 4/1 reeving. Typical pole-switching motors (8/2-pole) are used.

Variable speeds are programmed with inverters for acceleration and deceleration ramps with extremely slow start and braking which minimizes load swings.

A good start is to review data on past extreme temperature conditions in which the application will be operating and any

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From -40° C (-40° F) to +60° C (+140° F) a meter of ductile iron expands 0.123 mm. That’s the temperature range we’ll be covering here.

Altitude is the other extreme we’ll be covering. For an internal combustion engine, the general rule of thumb is a 3 to 4% power loss for each 1,000 feet above sea level. So a 300 hp car at 10,000 feet would lose 30 to 40 hp. Less density means less compression.

Less actual matter in the atmosphere (oxygen, nitrogen, and argon mostly) is being drawn into the cylinders, and therefore compression is less. For a gearmotor, that means less atmosphere to dissipate heat.

How to compensate for temperature extremes? (A standard temperature range is -20° to +40° C.)

A common extreme temperature swing is when a forklift moves from a -30° C freezer to a +40° C dock door. For both extremely cold (-40° C) to very hot conditions (+60° C) you’ll need to address the following.

Gearbox oil – Synthetic lubricants are used when mineral oils have reached their performance limit for frequent starts and stops, high loads, system shocks, low or high-temperature service, extended oil service interval requirements and reduced internal friction besides reduced operating temperatures. They also operate at higher temperatures without losing viscosity, forming residues and offering resistance to foaming. Petroleum products begin to degrade at or below +100° C, whereas synthetic hydrocarbon lubricants function well to +125° C. Synthetics offer extreme low-temperature advantages as well. They also have lower vapor pressures than petroleum products, an important factor in ensuring that the lubricant doesn’t break down. The chemical homogeneity DESIGN WORLD

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of synthetic lubricants results in greater load carrying capacity, higher viscosity indexes, better lubricity, greater efficiency and extended serviceability than their petroleum-based counterparts.

Shaft seals – If the gearmotor remains

at low temperatures for extended periods of time, upgrade motor shaft seals to NBR (elastomeric) material or use highgrade grease for shaft seal lubrication.

Elastomeric materials are composed of a polymer, filler, processing aid, protectants, and curing agents. Many times standard oil seals are made of Nitrile or rubber and are rated for temperatures up to +125° C. If ambient or oil temperatures rise above this level, you will have to use higher performance materials.

Motor cooling fan – These should be made of aluminum, GGG (nodular iron) or special plastic material.

For proper function and use in temperatures from -20° to -40° C Housings – Switch end shield material from GG (grey cast iron) to GGG (nodular iron). Nodular ductile iron possesses high strength, ductility and resistance to shock.

Annealed nodular ductile iron can be bent, twisted or deformed without fracturing. Its strength, toughness and ductility duplicate many grades of steel but have low-cost casting procedures similar to gray cast iron.

Ordinary gray cast iron has a random flake graphite pattern. Nodular ductile iron has a few hundredths of a percent of magnesium or cerium in its formula causing the graphite to form in small spheroid “nodules” rather than flakes. They cause fewer discontinuities in the structure of the metal for a stronger, more “ductile” iron. You can also use aluminum if allowable stress is not exceeded.

Rotor shaft – Switch material from 1045

steel to alloy steel, e.g., 42CrMo4 or similar.

1045 is a low hardenability carbon steel with a typical medium tensile strength range of 570 to 700 Mpa or Brinell hardness range of 170 to 210. It’s characterized by fairly good strength and impact properties. 42CrMo4 Alloy Steel is chromium-molybdenum steel with high strength and hardenability. It has high fatigue strength and good lowtemperature impact toughness.

Motor heating – This could be a heater jacket, motor heating bands or the winding could be powered to maintain a certain temperature (this is also used to prevent moisture build-up in high humidity environments). External heating jackets, covers or housings are often installed by crane builders because they also need to protect the gearbox and other components.

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Junction Boxes – Switch from plastic to aluminum Fan Shroud – Switch from plastic to sheet metal version Brake Design – Completely enclosed instead of open design De-rating Torque – It might even be necessary to de-rate the

maximum acceptable gearbox torque or use a larger gearbox.

For proper function and use in temperatures from +40° to +60° C

Note that temperatures above this must be reviewed on a case by case basis and cannot be covered by simply changing certain components.

If the gearmotor is mounted inside an enclosure near combustion engines or other systems that generate heat or are exposed to direct sunlight, it will require internal motor components that have higher temperature ratings. High ambient temperatures can also negatively impact motor torque and direct sunlight will degrade sealing components.

Junction Box – Switch from plastic to aluminum Fan Shroud – Switch from plastic to sheet metal version

Altitude For proper function and use at high altitudes Heat dissipation on the surface of motors and gear units decreases with altitude. The thermal performance is reduced due to thinner air. Typically rated installation altitude is a maximum of 1,000 m above sea level. For higher altitudes, you should consider the following.

Verify the actual duty cycle of your application and ask yourself is a continuous duty motor really needed here? If it turns out that the application requires the same duty cycle as the rating of a motor at 1,000 m above sea level you can install a larger motor or add forced-air cooling to compensate reduced cooling capacity provided by the thinner air. In many cases, it makes sense to discuss possible options with the motor OEM.

Wind turbine pitch drives are engineered for decades of continuous duty cycle that demand minimum maintenance and must satisfy the toughest requirements for reliability and durability.

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A word about duty cycles Duty cycles do not only impact the motor performance rating, e.g., a continuous duty cycle S1 motor will provide a higher output if it’s used at an S3 intermittent duty cycle, but also especially for gearboxes used in extraordinary applications where torque peaks and system shocks are possible. For such situations, it’s critical to carefully determine what duty cycle and what peaks/shocks per a specific time period are experienced so the engineering team of the motor/gearbox OEM can select and recommend a suitable drive system. So even if the application does not have a high rated torque and duty cycle requirement, other operational factors could result in the need for a much larger and stronger geared motor to be required to assure a satisfactory service life. And as a final word, always inform the motor OEM if your application is being used in extreme

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ambient conditions – this can be a game changer.

More information about recommended service lives for different applications have been published by the American Gear Manufacturers Association (AGMA.) These duty cycle recommendations have been determined from the experience of many gearmotor manufacturers. AGMA standard 6009 lists many applications by a service class (I (1 to 1.39), II (1.40 to 1.99), III (2 and above)) with class I being the simplest applications and class III being the hardest. Typically the total duty cycle for an application will take into account ambient temperature, cyclic duration, mass acceleration, operating time, and cycles per hour.

How to determine duty cycle First, you need to establish a target life. Not the calendar time, but the operating time. You need to know the duty cycle of the application during operation, and the number of hours the machine operates during the day.

As an example; a gearmotor drives a conveyor in short bursts, 2 minutes at a time, with 2 minutes off before repeating, over and over, during two 10-hour shifts, five days a week. You need it to operate trouble-free for at least five years or 13,000 hours.

Service life is 25,000 hours nominal with a 1.0 service factor, based on an AGMA standard. 25,000 hours is a nominal figure, so 50% won’t last that long. Use L10 life ratings, which means that 10% of the gearboxes operated at that load are expected to fail before the L10 life, and 90% are expected to last longer. So a gearbox with a nominal life of 25,000 hours would have an L10 life of 5,000 hours. According to AGMA guidelines, a conveyor not uniformly fed and operated more than 10 hours a day should have a 1.50 service factor. A similar calculation will need to be done for the motor.

Humidity The most common system used to classify a product’s intrusion and water resistant compatibility is the IP rating, which is published by the International Electrotechnical Commission (IEC). (IP DESIGN WORLD

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stands for International Protection, but is sometimes referred to as Ingress Protection.)

Today, ac induction and permanent magnet ac motors typically meet protection classes IP54 or 55 and with certain steps can even satisfy IP65 or 67 demands. So the IP ratings do not properly provide protection for high humidity environments and other steps are necessary to protect the gearmotor. To prevent corrosion, protect all bare metal surfaces.

Also, motor laminations should be painted.

Use a continuous low voltage and current power supply to your winding to prevent condensation when the motor is not in use.

For brakes, all wear surfaces must be stainless steel and sometimes a completely enclosed outdoor brake is the best solution.

Feedback and improvement Life Cycle Cost analysis is a management tool that can help companies minimize waste and maximize energy efficiency for many types of systems. A complete understanding of everything that makes up the total cost of a system throughout its lifespan provides an opportunity to reduce energy, operational and maintenance costs.

Analyze each element of the life cycle and determine a realistic value for use in computing the total life cost, including purchase price; installation and commissioning cost (including training); energy costs; operation costs; maintenance and repair costs; downtime costs; environmental costs (disposal of contaminant liquids and contaminated used parts, such as seals); and decommissioning/disposal costs (including restoration of the local environment and auxiliary services.)

In addition to supporting a design decision, the LCC analysis can be used to reflect changes in scope, schedule or application.

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Robot-transfer unit and other linear-transfer system considerations

As robotics applications proliferate, robot integrators have begun to apply more 7th-axis tracks — also called robot-transfer units or RTUs — as well as

R

linear tool-tray transfer systems.

Robots excel in repetitive assembly and process operations that include welding, trimming, routing, drilling, fastening, composite layup, coating, and painting.

Traditional installations mount the robot arm to a fixed station which in effect limits its reach. In contrast, facilities that use RTUs or linear tool-tray transfer systems extend the reach (and usefulness) of robots.

Recall that RTUs are long tracks in facilities that carry robots through work cells and between work stations.

Another advantage of 7th-axis robotic tracks is that plant engineers can install multiple robot arms on a given RTU to boost plant flexibility and productivity.

A similar concept, linear tool-tray transfer systems extend the work reach of robots much like that of 7th-axis

systems. However, instead of carrying the SCARA or other robot along a line, linear tool-tray transfer systems move workpieces and work fixtures past a servicing robot that remains stationary. Such setups are increasingly practical as robotic arms have become less expensive and more flexible.

Key to both RTUs and tool-tray transfer systems is that the designs are heavy-duty. That’s why some manufacturers use high-precision helical rack-andpinion sets to handle the high dynamic loads of SCARA positioning and large workpieces common in automotive applications, for example — even while holding accuracy to within tight tolerances.

Here, usually a support carriage complements

Benedict Talan | President | LazerArc of Motion Index Drives

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Aerotech’s PRO series industrial linear motor and ballscrew positioning stages come in multiple versions. Noncontact linear encoders enable minimum incremental motion to 5 nm and sub-mm repeatability.

Optional HALAR factory calibration improves positioning accuracy to ±0.75 µm. Travel is 50 to 1,500 mm for standard models to 2 m/sec.

The performance of RTUs depends largely on the proper sizing and selection of the linear guides to bear the payload being transported.

the rack-and-pinion drive. Where both the rack-and-pinion set and ruggedized slides are modular, they mount end-to-end to get unlimited travel lengths.

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Accuracy and load ratings of RTUs and tool-tray transfer systems Choosing an appropriate 7th-axis robotic slide or transfer system includes careful determination of required accuracy or

repeatability. Overall accuracy depends in part on the gearing integrated into the linear system’s drive — whether an RTU or a tooling transfer. Maintaining accuracy over long strokes further increases design

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Look for RTU and lineartransfer builders that supply the motion design with an application-appropriate motor type, controls, and physical subsystems (including cable management). For the latter, engineered features can protect both the cables and carriers from fatigue-related failure — especially where robots need heavy-gauge cable and power supplies to perform tasks such as welding.

costs, even by many thousands of dollars for an average setup. But a typical rack-andpinion system with accuracy to 0.036 mm per meter (to give one example) can exhibit 0.240 mm more positioning error over a 15-meter length than a setup with accuracy of 0.02 mm or better per meter.

Accuracy of RTUs and transfer systems ultimately depends on: • (As mentioned) backlash in the axis’ gear reducer — typically from less than 1 arc minute to more than 18 arc minutes, and the backlash between the rack and pinion in the drive system • The amount of preload and installation alignment of the rack-pinion system • The motor encoder’s counts per revolution — as well as proper commissioning of the servo or ac motor controlling drive parameters • The system’s linear guides.

In fact, linear guides (and their specification to maintain accuracy and support the payload) are key to RRU and transfer-system design. Some suppliers offer integration of linear-bearing guides in versions with parallelism from 9 µm to more than 30 µm over 3,000 mm for a given guide size.

Other guide-related parameters include the overall weight to be transported; the speed with which the load must move (often expressed in m/sec); the moving mass’ center of gravity; presence and degree of any tilting moment; and overall duty cycle and expected life and environment. Proper sizing of the RTU or transfer-system guides depends on accurate estimations of these factors.

All with all motion components, differences exist between manufacturers’ linear bearings; some of these affect the performance and maintenance requirements of RTUs and linear-transfer systems. So here are some questions to ask during the specification process:

LazerArc 7th-axis systems (as all linear tool-traytransfer systems) allow effective use of space, which is especially useful for large assembly tasks. In fact, some tool-tray transfer systems include gear reducers that directly output motion to the pinion that engages the rack (to boost accuracy and performance thanks to a lower component count).

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• What are the linear bearings’ runout specification? Can sections of rail be changed out independently?

• Are any of the linear-guide options self lubricating? Does the manufacturer offer protective bellows where the RTU or linear-transfer system operates in environments where painting or coating is taking place?

Some RTUs and transfer systems include linear bearings that are ground in a way that allows change-out of individual sections — and not entire spans of bearings that some manufacturers insist are ground as matching pairs. The latter can be expensive and time-consuming ... so look for RTUs and linear transfer systems that incorporate quality bearing assemblies that allow partial track change-outs if damaged (to shorten MTTR).

Of course, uses for RTUs and linear transfer systems abound — and include material handling, welding, inspection, and painting, to name a few disparate application examples. The robotic functions on an installation ultimately determine what types of safety or specialty features the RTU or transfer system will need — whether in the form of engineered cable carriers (on dynamic material-handling axes) or explosion-proof motors and full bellows (for painting applications). Where automating a specialty setup, partner with manufacturers’ sales engineers that work to understand end processes and suggest features specific to the application. Also look for integrators DESIGN WORLD

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I2C pressure transmitters

Keller’s I 2C pressure transmitters are purpose-built for integration into low-power system designs dependent on reliable pressure measurements. These fully compensated digital instruments are available in pressure ranges up to 15,000 PSI with various pressure and electrical connections, and are available in vented, sealed, and absolute -reference versions for maximum versatility. For more information, contact Keller America toll-free 877-253-5537 or email sales@kelleramerica.com.

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This custom LazerArc tool-tray transfer system includes oversized linear-bearing guideways for high load capacity. It also includes a precision rack that’s hardened and ground with a surface finish to 4.58:1 (and a DIN 6 gear-rack rating) to deliver ±0.0003in./ft accuracy.

supply custom RTUs and transfer systems to deliver on accuracy while keeping costs down — with application-specific lengths, transfer speeds, payload ratings, and safety factors — though the latter should be at least 2:1.

More on selecting linear tool-tray transfer systems As the motion of production lines becomes increasingly precise and repeatable, there’s been a rise in automation to replace large-

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scale manual handling and assembly tasks — especially with the use of linear tool-tray transfer systems. Some transfer systems have load capacities exceeding 100,000 lb ... and some are suitable alternatives to rotary index tables. Plus like RTUs, linear tool-tray transfer systems often integrate with robotic controls to effectively communicate (and coordinate tasks) with collaborating robots.

When choosing a linear tool-tray transfer system for an installation, engineers begin by collecting information about the sizes

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and shapes and weights of workpieces to be handled, current operations, the allotted time for assembly or other processes, and available plant-floor real estate. But there are other design parameters relating to the linear tool-tray transfer itself.

First of all, are the design’s variable frequency drives (VFD) mounted in a control panel or controlled directly via a PLC? VFDs boost motor-output efficiency and transfer-system performance. What motors does the potential tool-tray transfer

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use — servomotors or ac induction motors?

Designs with servomotors and motion systems compatible with robotics can network into larger controls for advanced connectivity and IoT functionality. That’s especially true of systems that incorporate precision sensor and switch feedback. Yet another question to ask: Can the linear tool-tray transfer system integrate with tooling fixtures, welding robots, and other machinery controlled with PLC logic?

Note only some linear tool-tray transfer systems have the accuracy to support the assembly of complicated workpieces. Those that do include precision guide rails and rack-andpinion systems plus closed-loop motor controls and programmability, and fast indexing speeds.

Transfer units from some manufacturers also include tubular steel and machine-welded construction for ruggedness … and the ability to accommodate customer trays and fixtures.

Accommodating tooling trays in turn quickens transfer times.

Other tool-tray transfer features to appeal to end users include surface coatings for eliminating the need for external lubrication; internally mounted cable-management trays; and hard stops in case of overtravel. DW LazerArc by Motion Index Drives | www.lazerarc.com

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Tubing versus hose

in mobile machinery

Although you may prefer one over the other, it’s likely that mobile machinery uses both hydraulic hose and tubing, as both offer unique advantages.

Josh Cosford | Contributing Editor

In this world, there are as many preferences as choices.

Dark meat versus white meat. Baths versus showers. Wagons versus SUVs. Every one of these choices is personal, and every one is inconsequential. You don’t care that Bob likes white meat and drives a Volvo station wagon. It’s his choice; it doesn’t matter in the grand scheme of things. Unless he’s racing his wagon, there’s no practical advantage to his preference.

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Regardless of which you prefer, it’s more common than anything to see mobile machinery include both hydraulic hose and tubing, as both offer unique advantages.

Some choices in fluid power are inconsequential, such as which of the top brands of D03 valves to use, or what color to paint your power unit (machine grey for the win!). Some choices do matter, and there are practical advantages and disadvantages. Picking a piston pump over a vane pump brings vastly different pumping characteristics to your system since the strengths and weaknesses of each are diametrically opposed. But what about the age-old battle between tube and hose … is there a clear winner, or is the choice inconsequential?

There is a level of comfort to either tube or hose, and it depends on your past usage and preference. If you came from a shop using primarily hose assemblies, you probably enjoy the ease and speed of a hose assembly, which can be cut and crimped in minutes. If you worked at a machinery OEM, I’m sure you’ve cut your teeth making tube sections to hard pipe a cylinder or motor, and you prefer the clean, permanent appearance of tubing.

However, there are some cases when it makes sense to choose one over the other, or where there is no choice but one. Often, you can plumb an entire system with only tube or only hose, and everything will work just fine. Just fine and optimal are two different things, of course, and what is optimal depends on the application.

Hose has come a long way Hydraulic hose has come a long way and was once only used when it was absolutely necessary. It was necessary to choose hose when you had two

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Most mobile machines use tube along the boom or arm, where bending is not required. They resist motion and provide a streamlined, clean look.

moving components of machinery requiring a conduit for hydraulic fluid to travel. If you had a pivoting arm, boom or bucket, you needed a flexible joint to send flow to the cylinders or motors on the other end.

Pipe and tube are obviously rigid and would buckle, break or burst if you attempted to treat them like bendy straws. And herein lies the advantage of hoses—they’re flexible.

Progress has occurred, and hydraulic hose is vastly superior to olden days, especially in pressure capacity. Hose assemblies are available in pressure capacities matching any tube or pipe, and their flexibility has advantages beyond just a joint between two moving components, although that remains their primary advantage.

For some machine designers, hydraulic hose is the only option to plumb an entire system. From a design perspective, it offers a couple advantages over tubing. Because it is flexible and ductile, hose can absorb vibration inherent in any hydraulic machine.

Machines plumbed with hose rather than tube appear to operate more smoothly and with less vibration.

The same properties of hose that allow it to absorb vibration allow it to absorb spikes in pressure. If you’ve been around machinery

plumbed with hose, you’ll have noticed how it comes to attention and stiffens when pressure rises or spikes. Although hose can’t eliminate the pressure spike, it can reduce the damaging effects it has on seals, valves and other components, especially those not meant for high pressure, such as return line filters.

Of course, where there is vibration, there is also sound. Pumps, especially, produce vibration harmonics that can be annoying and grinding to sensitive ears, especially over extended periods. Often times, the sound resulting from a particular power unit or system can’t be predicted until it is fired up.

Chasing down the exact source of vibrating tube, fitting, plate or mount can be like finding Waldo.

The long-life benefits of tubing If you think I’m being unfair to tubing, think again. If you work in a plant or shop with old hydraulic machines, take a pause and go out to inspect that machinery. Take note of the age of the hard plumbing on that machine; chances are it’s the same plumbing that existed when the machine was first commissioned, even if it’s older than I am.

Tubing, when done well, is extremely reliable and maintenance free. The only

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time it is changed is typically when a modification or upgrade is done to the machine. Tubing resists motion or vibration—although it can transmit it, it doesn’t cause it to shake or move the assembly itself. The inherent flexibility of hose allows it to chafe, rub and scratch against other surfaces if it’s not well supported. Many failures occur at those points of contact on a hydraulic hose, but tubes simply resist motion altogether.

Tube assemblies can be more work up front, but look cleaner and have other advantages. They can still be manufactured to be removed and replaced if the attached components require servicing because they’re made with semi-flexible bends at strategic points. You rarely see a straight shot of tube, but rather an L or S shape to provide some flexibility so the assembly

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Mobile machinery often uses a combination of hydraulic hose and tube, which both offer unique advantages.

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can be pulled and replaced between two fixed locations.

Tube assemblies also provide longlasting, leak-free service, especially with newer O-ring face fittings used. Although older assemblies with JIC type flare have been in operation for decades, if a tube does leak, it will nearly always be between the seat and face of a JIC connection.

At this point, I haven’t even mentioned the cost of either option. Tubing has natural high-pressure capacity, and dollar-for-dollar is actually less expensive to manufacture and sell than hose. Tubing can be purchased for pennies per foot, but any high-quality hose with reasonable pressure rating is rather expensive, and the cost rises exponentially with size. A 1-in. ID hose rated for 4,000 psi can be hundreds of dollars, but even including labor, a tube can be made for a fraction of the cost.

I should mention, however, tubes are more labor intensive, and require special machinery. You need expensive bending and flaring equipment, and the investment in that can run five digits. Hose crimping equipment can also be expensive, but you can get by with field-attachable hose requiring only two wrenches. Even a handpump operated crimper can be had for a few hundred dollars if you wish to go that route.

Regardless of which you prefer, it’s more common than anything to see mobile machinery include both hydraulic hose and tubing, as both offer unique advantages.

Where there is movement, rotating and lifting, hose will likely be the choice but along the machine’s boom or arm, tube is the often the best choice. DW

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CFD helps sports fans

keep cool

Fans who watch the Atlanta Falcons play at their new home stadium keep their cool even when their team is

| istockphoto.com (Marilyn Nieves)

struggling thanks to CFD analyses.

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Jean Thilmany | Senior Editor

April 2018 www.designworldonline.com

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When the $1.5 billion Mercedes Benz

Stadium opened in August 2017, the new home of the Atlanta Falcons wowed football fans with its impressive architecture. While the structure was designed with building information modeling (BIM) rather than CAD software, CFD and BIM offer downstream designers important information for their analyses.

While BIM files and CAD files serve separate industries, they both include performance characteristics, specifications, and connections important to those studying the files. And they both include information needed for downstream analysis.

In fact, the stadium’s HVAC designers began with BIM models of pertinent areas of the stadium in the same way fluids analysts import CAD models of a computer fan or a turbine blade into fluids analysis software to study airflow throughout a system.

Southland engineers used Autodesk Revit BIM software to capture the geometries of the HVAC model they want to analyze in the CFD software, said Chris Skoug, principal engineer at Southland Engineering. The engineering firm was contracted by stadium’s the design-build mechanical contractor, Atlanta Stadium Partners (ASP).

After spending one year building the model within the CFD software—Fluent, from ANSYS--they ran a number of analyses with the same program to help engineers redesign and validate the stadium’s ductwork system, Skoug said.

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Engineers spent a year building the model within ANSYS’ Fluent CFD software, examining a number of analyses to help engineers redesign and validate the stadium’s ductwork system. Fluent is the same program relied upon by mechanical engineers, and HVAC engineers used it in much the same way mechanical engineers do—to study airflow and heat distribution.

In order to validate the performance of the HVAC system in the ring duct configuration, Southland performed a CFD analysis of the system using ANSYS Fluent for CFD simulation.

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Fluent is the same program relied upon by mechanical engineers. And HVAC engineers used it in much the same way mechanical engineers do—to study airflow and heat distribution.

Southland’s efforts led to savings of about 500 tons of ductwork and $8 million in labor and materials, Skoug adds.

Bringing in analysis Designing the stadium’s HVAC system was a challenge due to the bowl-like venue’s volume--more than 70 million cubic feet-and the number of potential spectators--up to 75,000, with seating reaching about 160 feet above the field across multiple tiers and concourse levels, Skoug said.

That’s a lot of fans to keep comfortable at great height.

Another challenge: the venue would be used for multiple purposes including truck pulls, concerts, and Atlanta United FC soccer games. Designers were told to

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anticipate an event held about every third day. The stadium uses a blackout curtain that can be pulled across the upper part of the stadium when those seats aren’t needed, Skoug said.

“So it made sense not to waste the energy cooling that area during those events.”

The original HVAC design concept called for sending down cool air from ductwork attached to the trusses that cross the ceiling. Those beams extend from the 19 columns that allow for the bowl-like design of the stadium, said Drew Thomas, senior design engineer at Southland Industries, of which Southland Engineering is a part.

The support structure also allows for the retractable roof, comprised of eight flowerpetal-shaped panels that open in the same manner as the aperture of a camera.

“It was thought the ductwork could follow those trusses; that they’d provide natural, hanging support,” Thomas said. “But doing it that way flooded the whole volume with a lot of air and used unnecessary energy.”

At that point in the design Atlanta Stadium Partners called in Southland Engineering to propose alternate HVAC concepts to its original design.

The team proposed a ring of 80-inch ductwork that would surround the seating area and feed cool air into the upper bowl of the stands. Another 80-inch ductwork ring would run adjacent to the first to cool DESIGN WORLD

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the lower level. The two rings would share the same support structure and the blackout curtain could be drawn between them.

The two rings ensure the upper area needn’t be cooled when the curtain was drawn and seats in the top rows weren’t occupied.

The system would include 12 air handlers, each supporting 100,000 cubic feet of airflow per minute to result in total airflow at 1.2 million CFM. Aggressive design In order to validate the performance of the HVAC system in the ring duct configuration, Southland performed a CFD analysis of the system using ANSYS Fluent for CFD simulation. But analysts weren’t looking just to verify that their circular aircooling system would work, said Abdullah Karimi, CFD team leader at Southland Industries.

“The uniqueness of the stadium resulted in concept considerations that CFD could help with,” Karimi said. “We used CFD as a tool to be more aggressive with our design. So even during validation we use it to iterate. We use analysis results to optimize and modify our design.”

Before they could simulate and run the analyses, of course, analysts had to model the stadium in three dimensions with BIM software, using Autodesk Revit. True to form for a project of this scope and size, modeling was not without multiple steps, with analysts using a more expanded version of their usual model-to-CFD method.

Using the Revit model as reference, engineers kept the main geometrical attributes of the ductwork and the stadium itself. This simplified—but didn’t oversimplify—the CFD-model geometry.

Creating the CFD model based upon the BIM software took nearly a year, Karimi said, due to the stadium’s complex design, the unique ring of ductwork, and the interaction between stadium and cooling system. The analysts individually modeled each of the HVAC system’s 750 inlets that brought supply air into the system and the 240 diffusers within the ductwork that blew out cool air.

The CFD software ran on a computer equivalent of approximately 100 typical desktops.

CFD analysis inputs included the heat load from external and internal lighting. A 160,000-square-foot sheet of translucent Ethylene tetrafluoroethylene film illuminates the eastern side of the stadium to bring in outside light and to offer a view of the Atlanta skyline. The ETFE material is durable, translucent, and much lighter and needs less structural support than glass.

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These images of the CFD analysis show how the stadium would be cooled based on the chosen HVAC design.

The light transmitted through the film “did funky things to the load and airflow pattern in that area and the seating area adjacent to it,” Karimi added.

Internal sources of heat and light include the spectators and the stadium lighting itself, with one unique addition: the video screen or “halo board”--a 63,000-sqarefoot, 3,200-lineal-foot video screen

that wraps around the top of the dome.

One stadium column is wrapped in an LED screen on three sides as well.

The final Fluent CFD model included more than 90 million areas. Analysts computed the interactions between the areas on different model runs to determine airflow patterns and temperature distributions, Karimi said.

The model, when eventually ready to run, was made up of a mesh of close to a huge

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While the structure was designed with building information modeling (BIM) rather than CAD software, CFD and BIM offer downstream designers important information for their analyses.

100-million tetrahedral cells.

“Usually the CFD strategy is to keep the mesh size small in order to solve faster with the software,” Karimi said. “With a mesh so large, the team developed a hybrid meshing strategy.”

That strategy called for analysts to use separate model runs to analyze heat and light forces acting upon the stadium rather than analyze for all those factors at once, or even in combination. They used the same model to solve for one phenomenon after another.

“Because of the complexity of the problem, there were multiple physical phenomenon involved,” Karimi said. “For instance, we ran a radiation model to look at heat load from multiple sources. The halo screen around the center of stadium was a huge load. The solar radiation was different depending on the time of day.

“We made the whole model, then went one by one to solve for phenomena—first solving without radiation, then with radiation. Then we solved for solar radiation for certain days of the year. Then buoyancy,” Karimi added. “We did this one at a time. If we did find any hot spots or anomalies we tried to take care of that before moving on to the next model.”

The CFD software results didn’t take into account shifting solar load, differences in seat occupancy, changing ambient temperature, or pre-cooling HVAC strategies implemented by the building automation system.

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Because the engineers couldn’t model every spectator—with individual body size, body heat, and all other variables— the analysts came up with a unique way to model heat from the crowd.

The design conditions called for spectators to feel as though they were in 75 degree Fahrenheit air temperatures.

As Karimi put it: “It’s really hard to analyze the surface area of 75,000 people and to find the cooling result right at their surface.

“To simplify, we cut a plane about one foot above the seating level and assumed that was the temperature we were striving to meet,” he says.

The visualization helped engineers find the optimal airflow-outlet angle for each blower located on the ductwork.

“The graphical results of the CFD simulation helped us get a good visual of the airflow patterns within the building, which guided our design,” Karimi said.

“We’d see hot spots or abnormal airflow patterns and then do iterative simulation.”

Another issue was that the air ducts were to be located well above seating area, he said. The roof itself is 340 feet above the playing field. For reference, the Statue of Liberty could stand upright, torch upheld, below the stadium’s roof.

The HVAC plan called for air cooled to 53 degrees Fahrenheit to be dispersed from the system in order to cool the air temperature to 75 degrees Fahrenheit for all stadium seating.

“But air that cold will drop straight down; we needed to throw it down at angles and then it will be swept out toward the field,” Karimi said.

Based on the CFD model runs, the engineers were able to optimize the angle at which each of the diffusers located on the ductwork dispersed air into the stadium. The diffusers are about 18-by-36 inches, with 240 of them located around the ductwork. Most blow out air at about 5,000 cubic feet per minute, though CFM numbers eventually varied as engineers optimized the angles at which air was dispersed from the outlets, Karimi said.

“Ideally you want the angle the same the entire way around, but we had some

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The final Fluent CFD model included more than 90 million areas. unusual areas within the stadium with different loads and airflow patterns, so the diffusion couldn’t be identical,” he said.

“The two circles of ductwork run parallel to each other, but the openings that come out of them blow air at a couple of different angles, some straight down and some angle out.”

The CFD analysis allowed engineers to optimize the angle at which each outlet dispersed air.

The analysts did find that, as they expected, a stratified thermal layer of air gathered above the upper bowl seating area.

The layer is due to the natural convention of the load within the space, as well solar load on the roof.

Southland suggested stadium operators release this buildup of load after a large event by opening the venue’s shoulder relief louvers.

“This was contemplated by the design team and provisions made for control of these relief louvers,” Skoug said.

Not only are fans now kept cool during stadium events, Southland’s analyses and design saved about 500 tons of ductwork and $8 million in labor and materials over the original HVAC design.

So while Southland can’t assure Falcon fans a win, engineers and analysts can assure spectators won’t feel the heat while rooting for their favorite team. DW ANSYS | www.ansys.com

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HMI screen design gets faster and clearer Edited by Mike Santora | Associate Editor

In the 1980s, creating a graphical

interface for machine and equipment required a programmable display unit or HMI, together with primitive programming software. Before the advent of software created exclusively for HMI screen design, developing an HMI required programming expertise and advanced computer knowledge. HMI development and maintenance was time-consuming and expensive (we can call this stage HMI Design 1.0). The introduction of specialized HMI design software reduced the workload to create and maintain screens for the HMI.

HMI Design 2.0 In HMI Design 2.0, there were two parts to the HMI design software. First, a graphical component for drawing the screen display, and second, an operational component for programming screen operations.

The operational component required the setup of special commands called screen tags. Configuring these screen tags still required some expertise, and there was plenty of room for improvement in both design and operation.

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Recently, with the introduction of a range of new HMI design methods and concepts, HMI design time has been reduced by doing away with unnecessary steps and re-using previously created resources.

Fig. 2

HMI Design 3.0 In the 1990s, the Windows operating system opened the door to many possibilities.

As industry embraced Windows software applications, HMI design began to integrate the graphical and operational components so that you could change the properties or attributes of a graphical part to program your operations. While expertise in HMI design, such as tag settings, became unnecessary and creating screens became much simpler, elements such as placing parts and changing attributes remained static for many years and time requirements for HMI design did not reduce significantly.

HMI Design 4.0 Recently, with the introduction of a range of new HMI design methods and concepts, HMI design time has been reduced by doing away with unnecessary steps and re-using previously created resources. In HMI Design 4.0, the design process is simplified, operators are more efficient, and operations are more productive.

The current state of screen design When we analyze how much time is spent on HMI screen design, statistics show that the number of screens (base screens) on a large HMI usually exceeds 500. And the number of parts per screen often exceeds 100. Considering the time and effort it takes to create even a single part, you can

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see how time-consuming it can be to design HMI screens. Over 70% of HMI designers use scripts. But surveys show that the development and maintenance of scripts are a heavy burden for screen designers. User interface innovations such as smartphones have had a significant influence on industrial HMI design, and users now demand screens that are clearer and easier to use.

Layouts To create screens in conventional HMI design software, you draw parts on pages known as “base screens,� which have a resolution that matches the HMI. When drawing these parts, you specify the X and Y coordinates and its width and height as attributes for the part. These attributes behave like absolute values against the screen resolution. If you want to use the same screen data on another HMI unit with a different screen resolution, you need to adjust the position of every single part. Additionally, if you re-use a portion of the screen elsewhere, you cannot change the relative position of parts on the original screen from the other page, which limits the freedom to create a good layout.

(See Fig. 1) In HMI Design 4.0, layout screens now offer a new method of screen design, different from the base screen with no dependence on HMI resolution.

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Fig. 3 Example themes in Microsoft Windows

The following is an example of the grid layout. The grid layout has rows and columns like a table. When you draw a part on the screen, drop the part into a cell and the part sizes automatically to fit into the cell area. (See Fig. 2) The size of rows and columns on the grid is relative to the resolution of the screen. If the screen resolution changes, the size of rows and columns adjusts accordingly. As a result, it can retain the location of parts relative to the original layout.

In addition to using a grid layout for an entire screen, you can also apply the grid layout to a portion of a screen with a layout frame. This configuration allows reusing content that you can resize. Compared to drawing parts on base screens, grid layout screens do not require fine adjustments to locations of parts, making commands such as Align Left and Distribute Evenly unnecessary. This function reduces the time required to draw parts on the screen.

A simple screen layout with rows and columns can limit the placement of parts.

However, with HMI Design 4.0, you can increase screen complexity by combining cells and drawing further grids in one or more cells. This feature considerably

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increases the degree of freedom offered by layouts. Using the grid layout can substantially reduce the time and effort required to draw parts on the screen and increase the freedom of screen layout. With increased screen re-use, you can realize a reduction in overall HMI design time.

Templates Instead of being required to design a screen from scratch, HMI Design 4.0 introduces the concept of templates, with preset features and appearances.

You can significantly reduce the time and effort of HMI design by using theme templates to give you the look and feel you want, color set templates to define the color tone, and navigation templates for screen changes. And, because you can change templates even after the HMI design is complete, you can make fine adjustments without disrupting the entire design. (See Fig. 3) Using theme and color set templates, not only can you design screens faster and with less effort, but also create unified screens instantly with pre-designed, userfriendly, screen options delivered as part of the software package. For example, without

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the use of color sets and themes, deciding all Stop switches will be red might result in a different shade of red on every screen. Color sets can prevent this from happening.

With the use of themes, you can also change the default values of part attributes and then register that attribute for use in other parts. For example, to set the font size for titles in parts to 20 points, which is larger than normal, you can edit the size of a part’s text font to 20 and save it as the default font size for titles. After that, changing the font size of parts is no longer required.

The number of screens and screen navigation operations may seem simple for a small to mid-sized HMI, but the setup for screen change operations is quite complex. For example, change screen switch requires you to specify the destination screen number. Whenever there is a change in screen configuration or a change in the destination screen number, you need to review and edit the settings for all change screen switches. This factor increases time spent on maintenance.

HMI Design 4.0 eliminates this issue with navigation templates.

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Navigation templates automatically configure screen changes. The design of change screen menus is set up in a template, and screen numbers for screen changes are configured automatically, based on the screen structure. You can replace the navigation template to change the appearance of the menu; however, the screen structure does not change, eliminating the need to review all of the screen settings.

Improving the reusability of screen data and reducing the time required for HMI screen design through the use of templates are two key elements of HMI Design 4.0.

It has been 40 years since the introduction of the first HMI, and for a long time there were no real innovations in the way screens were designed. Today, automation users demand more from their HMI, and the user interface is more

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important than ever as it has been directly linked to production efficiency. Some aspects of HMI screen design — such as PLC communication settings and scripts used in HMI processes — still require much time and effort. But the innovative capabilities of HMI Design 4.0 are now making HMI design much more efficient and cost-effective.

At Pro-face (by Schneider Electric), our commitment to innovation at every level starts on the shop floor with best-in-class devices like the GP and SP Series HMIs. By empowering operators with smart devices that are easier to use, thanks to user-friendly displays created with our BLUE screen design software, our end-to-end offers deliver a better total customer experience. DW Schneider Electric | www.schneider-electric.us

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Polymer materials keep offshore risers safely afloat

Polymer-based solutions for fire protection and buoyancy help progressive riser technology push the limits.

Collin Gaskill, Product Development Engineer | Patrick Waal, Head of Sales | Trelleborg Offshore

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The oil and gas industry is renowned for

continuously pushing the limits. The exploration of offshore oil and gas continues to move into deeper waters and the

demands for drilling operations to perform faster and more

effectively to provide higher cost savings and safe well

completions have grown. Adding to this challenge is the

requirement to extract more oil and gas than ever before, and

exploit even harsher reservoir environments in new locations

around the world. With these challenges in mind, we look at

why next-generation corrosion-free, polymer-based solutions

can be the vital element to ensuring the protection of people, structures and equipment on offshore risers from surface to seafloor.

Exceeding expectations Although technology has advanced to better address the everchanging needs of the offshore environment, customers still require superior, cost-effective solutions with an increased focus on onboard safety and extended service life; increasing to up to 40 years from 20 years.

For both of these focus areas, choosing the most appropriate material is imperative and not surprisingly, polymer materials are becoming a more popular choice within the offshore industry. Polymer-based materials such as rubber and polyurethane are naturally flexible and very durable.

Compared to alternative materials, such as steel, ceramic wool or fiberglass, polymer-based materials can withstand greater temperature extremes, weather conditions, and vessel movements while offering an exceptionally high durability. It is a diverse group of materials that can perform at every level to damp, seal and protect, and most of all has an extremely long lifespan.

Safety for challenging environments It is no surprise that onboard safety is a key priority for offshore riser platforms but this is becoming progressively difficult in increasingly challenging environments as installations move further offshore.

Advanced fire protection systems are critical to ensuring onboard safety, whether it is the platform’s surface protection, an onboard deluge system or coating for the pipes and flanges for example. The performance of these systems is Buoyancy units can be fitted along the length of the riser to reduce the weight of riser joints in water.

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Installation of Elastopipe fire deluge system.

essential for the safety of personnel, asset protection and preventing fire escalation.

So, in the offshore oil and gas sector where the risk of uncontrolled, rapid fire spread is greater than most, firestop solutions need to provide full assurance to the onboard team that they will not fail to protect against fire. If damage is caused, costly shutdowns and repairs would be required and in the worst-case scenario, the platform may fail altogether.

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The harsh offshore weather environment causes metal products and components to be susceptible to rust and corrosion, which is detrimental to the performance and function of the platform. Additionally, ceramic wool and similar materials used for fire protection will become less effective when wet. These less than optimal solutions simply are not an option when protecting people, structures, and equipment.

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Throughout the fire exposure period, it is key that any fire protection specified for use on an offshore facility provides the required fire protection and integrity; protecting areas between modules and decks to prevent the spread of flames and hot fumes. The critical temperature on the surface of a component is project specific information, with typical values of 392° to 752°F. Similarly, in accordance with the Health and Safety Executive (HSE), the generation of smoke and non-toxic fumes must remain low. Additionally, the dampening, noise reducing, flexible nature of rubberbased materials protects equipment from vibration, collisions, explosions and earthquakes.

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Topside applications Laydown decks—The platform laydown deck areas are susceptible to regular impact and abrasion due to containers being loaded onto the platform, as well as to the harsh offshore elements. Before fire protection is considered, the deck should be protected against chemical and mechanical conditions and ensure that it is resistant to fatigue.

A flexible decking material capable of withstanding these conditions is an ideal solution. Rubber provides the corrosion protection in addition to environmental and impact protection, while maintaining the required fire protection rating.

Surface tiling should feature insulation to isolate fire temperatures from areas below and should also ensure a non-slip surface for worker safety. The flexibility of a rubber-based tile means that it can take up movement in any direction, reducing the likelihood of cracking. Similarly, as tiles are regularly exposed to the sun, it ensures UV and ozone protection, so that surface is not damaged over time.

Flanges—Considered as one of the weakest areas of any platform or refinery, fire protection for nuts and bolts used in flanges should be considered. Typical fire protection covers the complete flange with a housing, not allowing for easy inspection of the units. By using a molded rubber-based material on just the flange nuts, the stud bolts are protected from elongating and the flange from breaking the seal during a fire. Installation is simplified with lowering

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Fire deluge systems—With a large number of aging platforms and rigs currently in operation and the threat of critical failure looming, the onboard deluge system is one application in particular where benefits from flexible fire protection will help reduce fire risks and potential downtime or closure.

By choosing a flexible, rubber-based material, these deluge systems are noncorroding and can withstand jet fires with a heat flux of 390kW/m² at temperatures above 2552°F.

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Extending service life though corrosion protection One of the most effective methods of extending the service life of a riser is to protect it from corrosion, particularly in the highly corrosive splash zone region. The splash zone is the area immediately above and below the water’s surface and is a major corrosion concern for offshore installations.

As the water level rises and falls the metal surfaces of the riser are alternately becoming wet and dry, which causes the metal to corrode when the saline water is exposed to oxygen.

External surfaces exposed in the splash zone should be protected with special corrosion protection systems. Rubber-based coating on risers as a form of corrosion protection is an extremely popular solution and is widely recognized in the offshore industry as the most effective method of riser corrosion protection particularly in the highly corrosive splash zone region.

When selecting a corrosion coating for a riser, manufacturers should ensure that the supplier they select can fully customize the coating material to meet the specific project needs. Most rubber-based solutions can incorporate a range of protective qualities such as anti-fouling to inhibit marine growth. Additionally, rubber-based corrosion protection solutions are resistant to abrasion, chemicals, wear, blast, impact, jet fire, ozone, UV, and salt water.

An important feature of any riser corrosion coating is the fact that the coating is chemically bonded to the metal surface or substrate permanently and will not crack

©2018 U.S. Tsubaki Power Transmission, LLC All Rights Reserved.

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Distributed Buoyancy Modules are used to reduce the top tension loads by providing uplift to sections of the riser.

or disbond. As a material specifically engineered to protect against sea and weather conditions, rubber corrosion coatings will guard against corrosion for the lifetime of the riser.

In addition to the splash zone, rubberbased riser corrosion protection can be applied as a rubber lining for any exposed steel components located on a riser.

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Riser protection surface to seafloor The drill riser provides a conduit for the drill string and drilling fluids from the ocean floor to the rig. A drilling riser typically has a large diameter, low-pressure main tube with external auxiliary lines that include highpressure choke and kill lines for circulating fluid. All of these lines need to be protected during handling, storage, deployment, www.designworldonline.com

retrieval, and drilling operations.

Some of the most trusted protection systems for bare riser joints include polymer-based protection covers. These protection covers are manufactured from polyurethane or polypropylene and are specifically designed to protect the drilling riser from impact damage when running or retrieving through the drill floor and moon pool area or during handling operations in the riser storage bay.

Drilling risers—which can reach lengths of 10,000 ft or more and weigh millions of pounds—must be kept in tension to ensure safe operation of the equipment.

By decreasing the requirement on vessel tensioning systems to a more manageable level, discrete buoyancy units can be fitted along the length of the riser to reduce the weight of riser joints in water. These buoyancy units are made out of a polymerbased foam that not only lowers the weight of the riser string to a manageable amount April 2018

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M a t e r i a l s

but also protects the riser and auxiliary lines from impact and abrasion subsea.

Taking protection to the next level, a newly designed and tested helically grooved buoyancy option is available on the market that not only optimizes uplift, but also effectively eliminates riser motions and higher levels of drag in onerous offshore current environments compared to traditional riser buoyancy. The new multifunctional solution integrates the technology to suppress vortex-induced vibrations (VIV) and reduce drag into riser buoyancy equipment during manufacturing, essentially eliminating the requirement of ancillary suppression equipment, alleviating complicated and time intensive riser running and retrieval procedures.

Similarly, buoyancy technology is used to offset tension loads on deep-water umbilicals and risers for floating production systems. Distributed Buoyancy Modules are used to reduce the top tension loads by providing uplift to sections of the riser to generate pre-defined configurations that allow the vessel a full range of surface movement without putting undue stress on subsea lines.

These configurations include “Lazy Wave,” “Steep Wave,” “Lazy-S,” “Steep-S,” and “Pliant Wave.”

Evolving riser technology for the future As complicated exploration and production activities target more challenging reservoirs, an evolution of current riser technology will be required to ensure continued safe and costeffective operations. Advanced engineering

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analysis and simulation design tools provide the ability to effectively develop new riser equipment technologies considering the real world environmental and operational challenges they will be required to perform under.

Computational Fluid Dynamics (CFD) analysis studies provide the means for exploring optimized equipment designs with consideration of minimizing hydrodynamic loading. Riser technology can be successfully designed to be multifunctional, suppressing VIV and reducing drag simultaneously while performing its primary protection and buoyancy roles. Local and global Finite Element Analysis (FEA) allows for equipment to be designed smarter, minimizing required size and material while

Rubber-based coating on a riser in the highly corrosive splash zone.

optimizing loading paths, performance and design lives. Employing these advanced engineering tools will help advance riser technology moving into the future to expand and extend the capabilities of the industry.

Conclusion While deep-water drilling and production has been revolutionized by increasingly advanced technology in recent years, making high performance and dependable solutions has never been more important.

This is because the requirement for equipment to operate safely and effectively while providing peace of mind is becoming more challenging in these demanding and dangerous environments.

By installing effective and reliable polymer riser protection systems, the safety of hydrocarbons transportation installations will be increased. In the harsh offshore oil and gas industry, operators need the assurance of a material that delivers proven performance, without fail. It is the responsibility of the manufacturer to ensure that they can provide high performance and reliable solutions, now more than ever. Similarly, operators should look to work with manufacturers who can provide the most advanced solutions to guarantee performance and importantly, safety. DW Trelleborg Offshore trelleborg.com/en/offshore

DESIGN WORLD

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Aerospace/Defense

High

temperatures and uncertain conditions pose design challenge for batteries

Michele Windsor • global marketing manager • Accutronics

Picture the scenario; you’ve been roped into a rock climbing challenge, but you haven’t been provided with any protective clothing. While there is a possibility of scaling the cliff-face safely, the knowledge that you are unable to withstand an unprotected drop would be enough to deter most people. There is a similar concern with electronic devices in harsh environments, where the components must be designed specifically for the conditions.

Whether it is security camera systems designed for the high temperatures of oil refineries or military communications equipment for use in rugged terrain, design engineers must ensure that the components used in their equipment are durable. This

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Aerospace/Defense means understanding the precise conditions their application will be used in and specifying accordingly.

For example, design engineers that are given a brief to develop a handheld military radio for use by soldiers in the field must consider where those troops will be deployed. While the product enclosure and components must be rugged in any case, the components must also fully perform in a wide temperature range if the radio will be used in hot and humid conflict zones.

Design engineers must pay particular attention to this when selecting a battery for their device. In countries such as Afghanistan, for example, the average maximum

Fortunately, there are a number of off-the-shelf professional batteries capable of safely withstanding the operating temperature, such as the -20° to 60° C range offered by Ultralife Corp.’s batteries. These also offer high energy density, a long cycle life and a stable discharge rate.

Yet, temperature is not the only consideration for battery selection.

Factors such as lifecycle and durability must also be considered, especially for remote applications. It is important that device OEMs consult battery OEMs such as Accutronics to determine what will best suit their applications. It is advisable

“While newer technologies are allowing businesses to augment human performance in previously difficult environments, the true benefits lie in an effectively designed and specified device.” temperature is 38° C (100° F) during summer.

Batteries themselves can heat slightly during discharge, so design engineers must specify a battery with a maximum operating temperature of at least 50° C (122° F).

Otherwise, the radio may function effectively during training exercises but fall short when it is needed most.

However, there cannot be a one-sizefits-all approach to battery selection in such a scenario. The rise of counterfeit electronics in recent years has driven a surge in fake batteries, which do not offer the same safety and performance features as professional military batteries. As such, these batteries can generate excess heat during discharge that, combined with no guarantee of reliability, increases the likelihood of failure.

that design engineers use bespoke batteries for extreme environments.

While newer technologies are allowing businesses to augment human performance in previously difficult environments, the true benefits lie in an effectively designed and specified device. With the right components and power supplies in place, OEMs can reap the performance benefits. AD Accutronics | accutronics.co.uk

WHAT DO YOU THINK?

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Aerospace/Defense

High-temperature, harsh -environment tantalum capacitor technologies

Solid-tantalum capacitors have evolved with better design, construction, and testing methods to handle emerging requirements for harsh, high-temperature applications that put a premium on reliability.

Chris Reynolds • AVX Corp.

Wet tantalum capacitors are a proven, mature technology. They’ve long been employed in demanding, high-temperature applications because they have a variety of useful qualities. These include a non-solid electrolyte capable of controlled self-healing, high bulk capacitance at highvoltages (e.g., up to 5,600 µF at 125 Vdc), high volumetric efficiency, excellent stability, good high-temperature performance, high-reliability and a long lifetime. In recent years, this technology has been further developed to handle harsh 200° C industrial applications.

AVX TWA-X Series 230°C high-temperature, axial-leaded wet tantalum electrolytic capacitors.

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Aerospace/Defense

IS

AVX THH 230°C Hermetic Series high-temperature SMD tantalum chip capacitors.

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However, the trend in consumer, communications, and medical markets has long been toward digital applications with low operating voltages (e.g., 6 –25 V) that could be handled by surface-mount capacitors.

So, solid-tantalum chip capacitors up to 220 µF and rated to 200° C have come to be preferred over hermetically-sealed, axial-leaded wet tantalum capacitors. The reasons: Solid-tantalum chip capacitors are smaller, cost less, and deliver the lowESR and high-frequency response necessary for high-speed digital applications.

Additionally, in recent years, solid-

tantalum capacitors with hermetic, surface-mount device (SMD) packaging became available. This packaging allows the internal element of a solid tantalum chip capacitor to operate in an inert gas. This environment helps resist moisture ingress and enables operation at temperatures up to 230° C with higher capacitance and voltage ranges (up to 330 µF and 63 Vdc). Hermetically sealed, high-temperature, solidtantalum SMD capacitors also stand up to harsh mechanical shock and vibration. They are available with a range of termination finishes designed for compatibility with hightemperature PCB and hybrid circuit assembly, high-melting-point (HMP) solder, epoxy, and wire bonding processes.

Tantalum capacitors are one of just a few capacitor technologies that can operate reliably at temperatures above 175° C.

Basic capacitors consist of a pair of conductive or semi-conductive plates separated by an insulating dielectric. The dielectric stores charge when voltage is applied, effectively blocking dc and enabling the transmission of any ac signal.

Capacitance vs. temperature for the AVX THJ Series tantalum capacitors vs. the OxiCap NOS Series niobium oxide ceramic capacitors, which are manufactured using the same process as tantalum capacitors and exhibit electrical parameters similar to general, low-ESR tantalum capacitors.

Eagle Stainless

Tube & Fabrication, Inc. Franklin, Massachusetts

Phone (800) 528-8650

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Voltage derating vs. temperature for the AVX THJ Series tantalum capacitors vs. the OxiCap NOS Series niobium oxide ceramic capacitors.

Tantalum capacitors are a subset of electrolytic capacitors. These are polar devices in which one plate is maintained at a positive potential and the other at a negative potential.

Solid tantalum capacitors have a tantalum positive plate with an insulating film of tantalum pentoxide, which acts as the dielectric, on the surface. A negative plate (i.e., a counter electrode or cathode) is made of manganese dioxide or a conductive polymer. In wet tantalum capacitors, the negative plate is a high-surfacearea tantalum cathode that includes an acid electrolyte.

The top two tantalum technologies for high-temperature applications are solid tantalum capacitors with a manganese dioxide cathode in a molded SMD or hermetic ceramic package, and wet tantalum capacitors with a hermetic metal can construction and an axial lead. The cathode type has the greatest impact on a capacitor’s frequency qualities and determines the applications to which it is best suited. For example, solid tantalum exhibits a better frequency response for filtering applications, and wet tantalum exhibits higher bulk dc capacitance and higher voltage ratings.

Tantalum capacitor performance Tantalum capacitors are known for their reliability, ruggedness, high volumetric efficiency, and parametric stability. Standard tantalum chip capacitors are rated for operating temperatures spanning -55 to 125° C. This range easily handles most consumer and in-cabin automotive

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electronics.

Enhanced, professional-series tantalum chip capacitors can be made to comply with AEC-Q200 automotive industry specifications and to withstand continuous operation at temperatures up to 175°C with a base reliability of 0.5% per 1,000 hours.

Advanced, high-temperature, molded tantalum-chip capacitors capable of operating continuously at up to 200° C are also available. Beyond this are two recently introduced series: an extension to existing high-temperature axial-leaded wet electrolytics and a hermetically sealed SMD version. Both can operate as high as 230° C.

A look at the temperature coefficients of tantalum capacitors reveals they gain in capacitance value at higher temperatures. Wet tantalum capacitors can realize even higher capacitance at high temperatures. The capacitance tolerance limit at the 25° C specification for solid, hermetically sealed, high-temperature tantalum capacitors is ±20%, while wet electrolytic capacitors are made with tolerance bounds of ±10% and ±20%.

Tantalum and niobium-oxide ceramic capacitor technologies also have different temperature limits for capacitance. Solid, hermetically sealed tantalum chip capacitors exhibit narrow capacitance over their operating range, dropping up to 20% at -55° C, rising by 20% at 85° C, and holding to a maximum 30% increase from 150° to 230° C. Wet tantalum capacitors display a much wider variation over their operating temperature range. The level of

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Aerospace/Defense Leakage current vs. temperature for solid tantalum capacitors.

variation depends on their size and capacitance/voltage (CV) rating.

The capacitance of wet tantalum capacitors can drop by 20% to 85% at -55° C and rise from 12% to 80% at 125° C.

In addition, tantalum capacitors exhibit an applied voltage vs. temperature relationship. At high temperatures, the voltage ratings specified at ambient temperatures must be derated to avoid diminished reliability. The category voltage—the maximum voltage at which the part can operate up to 230° C—for solid, hermetically sealed, high-temperature capacitors is high for solid tantalum

technology: 50% of its rated voltage.

This property can be advantageous at high temperatures. The higher reliability resulting from operating at a reduced voltage can more than compensate for the lower reliability resulting from operating at high temperature.

Tantalum capacitor direct current leakage (DCL) also depends on temperature, rising by a factor of 10 between 25 and 85° C. DCL arises from parallel resistance paths in the dielectric and results in the slow discharge of the capacitor. In tantalum capacitors, leakage current rises linearly with temperature, which

increases energy loss. The DCL specification limit for 125° C operation for solid, hermetically sealed, hightemperature tantalum capacitors is 12.5 times the initial limit.

For about 50 years, wet tantalum capacitors packaged in a hermetically sealed, (typically) tantalum metal housing have been available in high-temperature designs suitable for operating up to 200° C with a category voltage equaling 60% of the rated voltage at room temperature (0.6Vr). More recently, material advances in powder, silver, molding resin, and other materials have also allowed solid tantalum chip capacitors in molded bodies to build up a track record in 200°C applications.

It has been challenging to boost the operating temperature for tantalum chip capacitors beyond 200° C because this temperature exceeds the glass transient temperature of the epoxy materials used in the capacitor body construction. Design engineers finally devised a reliable, SMD

AVX TWD 125°C High-Temperature Maximum Capacitance (HTMC) Series axialleaded, hermetically sealed wet tantalum electrolytic capacitors in a standard T4 case.

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Aerospace/Defense capacitor rated for 230° C by housing solid tantalum capacitor elements in hermetically sealed ceramic packages.

These high-temperature SMD tantalum capacitors enclose the capacitor element in a hermetically sealed ceramic housing filled with inert nitrogen gas to create an inner atmosphere that inhibits the oxidation of the solid tantalum electrolyte. This design has performed well during both high-temperature operating life testing (2,000 hours at 230° C and 0.5 Vr and 10,000 hours at 200° C and 0.5 Vr) and moisture resistance testing (1,000 hours at 85°C and 85%RH, Vr).

Solid, hermetically sealed tantalum chip capacitors are also rugged, satisfying mechanical shock and vibration specifications of 100g shock and 20g vibration.

Available ceramic housing sizes include CTC-21D (“9”) and “I” cases with L-shaped or flexible J-lead terminations for applications subject to extreme shock and vibration or undertab (facedown) terminations for applications in which minimal footprints take precedence. The smallest case size measures 11(±0.2) x6(±0.2)x2.5 mm (LxWxH), while the largest measures 12.10×12.5×6.5 mm (LxWxH).

The capacitor elements in these packages provide high capacitance ratings (up to 100 µF) over a wide voltage range (16–63 Vdc). Their capacitance is stable over the range of rated operating temperatures (-55 to 230° C). In that the capacitance of tantalum capacitors actually rises with temperature, these capacitors can lead to significant size reductions and lower component counts in a variety of critical, high-temperature, highreliability electronic systems.

New axial-leaded, hermetically sealed wet tantalum electrolytic capacitors are also capable of 230°C maximum operating temperatures.

They are currently available in the standard T4 case size, measuring 26.97-mm long and 10.31 mm in

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diameter with an insulating sleeve. This series represents the largest standard case size for axial-leaded wet tantalum capacitors and provides high CV ratings up to 330 µF/125 V.

There are numerous emerging, short-lifetime applications that demand high energy density after a period of latency (e.g., a remote trigger). Such applications require that capacitors rest in a charged state for many months prior to activation.

These situations may be able to use parts rated at 125° C, even if the environment periodically exceeds this temperature. In this regard, a new capacitor technology targets low-frequency pulse applications.

The capacitors have high CV ratings (up to 50 mF/6 V) that overlap with supercapacitor technology but can operate continually at 125° C and exhibit extended lifetimes of up to 10,000 hours.

Termination material options Tantalum capacitors are available with a variety of termination and metallization materials. Hightemperature capacitor designs incorporate metals with melting points that are well above the temperature rating of the capacitor, such as tin (Sn), palladium/silver (PdAg), and gold (Au).

With regard to mounting, many solders used in commercial systems have low liquidus points that prevent their use at high temperatures.

These applications require highmelting-point (HMP) solder and/ or high-temperature epoxies with a liquidus phase around 265° C. Above the liquidus phase temperatures, the solder enters a phase of plasticity that can degrade PCB mounting. As such, it is important that the HMP solder material functions well above the operational temperature. Ditto for high-temperature epoxy used for mounting as well as mechanical reliability via its elastic properties.

Molded SMD, hermetic SMD, and axial-leaded, hermetically sealed wet

www.designworldonline.com

tantalum capacitors all have different capacitance and voltage range capabilities. Each are better suited to certain applications than others. When their performance capabilities overlap, the cathode type, which also greatly affects frequency performance, will help determine the best applications for each technology.

In downhole electronics, hightemperature is usually classified as 150° C and above. Temperatures of 150° to 175° C were long considered the maximum typical for drilling operations, but the need to drill deeper has significantly boosted this range in recent years. As such, the components employed in today’s wells must withstand extreme temperatures often exceeding 200° C at pressures greater than 25 kpsi. These components must also handle both continuous vibration up to 20 g and extreme shock spanning 100–2,000 g.

The aerospace and defense markets also increasingly demand extreme-temperature passive components. For instance, avionics continue to incorporate more sophisticated electronics that continuously provide power, diagnostics, and communications at temperatures exceeding those of traditional automotive underhood applications. Unmanned aerial vehicles increasingly work in environments too dangerous for manned flight. These critical systems demand the utmost reliability where components must be capable of withstanding temperatures exceeding the current military and aerospace standard of -55 to 125° C.

Designers now have a range of reliable, high-temperature capacitor solutions to choose from, and can more easily and effectively match the unique performance characteristics of their individual applications to the appropriate capacitor technology to achieve better performance than ever before. AD AVX Corp. | avx.com

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Aerospace/Defense

High-voltage connectors

meet the demands of mission critical satellite communications

The US Air Force and a major defense contractor tapped Caton Connector Corp. of Kingston, Mass., to supply high-voltage connectors and cable assemblies for an exceptionally demanding mission-critical application: the Milstar Satellite Communications System.

The mission of Milstar, according to the Air Force, is to provide “the President, Secretary of Defense, and the U.S. armed forces with assured, survivable satellite communications (SATCOM) with low probability of interception and detection. Designed to overcome enemy jamming and nuclear effects, Milstar is the most robust and reliable SATCOM system currently employed by the Department of Defense (DoD).”

Caton was charged with designing and manufacturing high-voltage power-supply cables for various aspects

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of Milstar. They faced significant challenges and a daunting quality assurance and testing process. One of the most challenging aspects of the program was testing for the vacuum of space. The cables were required to withstand continuous use at 50,000 ft at temperatures of -55° C.

“We overcame multiple challenges during the design phase,” said Keith Rooney, Caton’s Milstar project lead. “Designing the cables was straightforward. However, the customer’s voltage requirement kept being raised after the design was completed. This increased demand on manufacturing time and tolerances,” said Rooney. “We managed to keep the design DESIGN WORLD

4/2/18 11:34 AM

and testing program unchanged while meeting the increased voltage requirement. Caton employed its patented no-corona high-voltage connector technology that it developed in the 1980s in order to meet demanding military applications.”

While the design of the Milstar connectors and cables was simple, the manufacturing process required extraordinary attention to detail. “Tight tolerances mean that parts were methodically made. There was no rushing these parts. Every piece took as much time as necessary to ensure quality and pass testing,” explained Rooney. Each connector lead needed to be tested to

“The mission of Milstar, according to the Air Force, is to provide “the President, Secretary of Defense, and the U.S. armed forces with assured, survivable satellite communications (SATCOM) with low probability of interception and detection.”

ground and to each other. This need further increased the difficulty of testing.

Caton’s high-voltage in-house testing facility was custom designed to handle most any high-voltage testing requirement. The lab is so fully equipped that other manufacturers and universities occasionally lease it to conduct their own tests. Testing Milstar, however, put the lab through its paces. Rooney described the challenges of testing this satellite component:

“Testing at simulated 50,000 ft altitude while at -55° C is extremely difficult. The temperature alone is at the hairy edge for brittleness of silicone.

Due to material shrinkage at that temperature, any slight misalignment or the connector not being fully mated could cause the cable assembly to fail at the interface. At that altitude, a void or air gap is expanded, and the voltage required to bridge that gap becomes sufficiently less, making this test extremely difficult.”

After successful validation, Caton’s high-voltage connectors and cables were used to power Milstar and are actively enabling its mission from orbit. AD Caton Connector | caton.com

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Aerospace/Defense

ITT Enidine

announces new

flight-critical components

ITT Enidine has added high capacity laminated (HCL) elastomeric bearings and Frahm dampers to its extensive rotorcraft solutions portfolio.

“With an extensive engineering, manufacturing and testing facility and services list, Enidine offers a flexible, personalized approach to meeting the demanding application requirements of rotorcraft design,” said David Snowberger, Rotorcraft Business Development Manager, ITT Enidine. “From custom elastomers, to rate controls, and energy absorption devices, we specialize in serving as an extension of the customer’s engineering and manufacturing teams. With this team-based approach, our ability to design, develop, test and produce products all within one facility allows us to bring the highest quality

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engineered components to market on time and under budget.”

Enidine’s HCL elastomeric bearings are flightcritical components that give rotorcraft designers precise, engineered control over stiffness and damping, reducing in-flight vibration and allowing flexibility in the blades and rotor assembly. Critical to aircraft performance, the innovative HCL bearings are designed to support high loads and blade motion without lubrication. The HCL bearings decrease rotorcraft maintenance costs by reducing bearing replacement intervals with a design that is resistant to dust, debris and fluids. They eliminate unplanned bearing maintenance with a visual inspection that indicates when the HCL bearing is approaching endof-life, and they reduce in-flight vibration which improves the reliability of other aircraft systems.

Enidine’s Frahm dampers are dynamically tuned vibration absorbers, used on rotorcraft airframes and rotors to reduce vibration and increase comfort for pilots and passengers. The highly engineered Frahm dampers are precisely tuned to resonate at the same frequency as the rotorcraft components, absorbing and counteracting undesirable vibration throughout the aircraft. The Frahm dampers are featured on a major manufacturer’s new commercial helicopter, which recently began delivery and flight service.

The company’s highly engineered rotorcraft solutions increase aircraft performance, fuel efficiency and longevity of flight-critical components, protect cabin interiors from noise and vibration and improve the safety and comfort of passengers and crews. The company’s full rotorcraft application portfolio includes: • Multi-modulus HCL, journal and spherical bearings • Frahm dampers • Pylon isolation systems • Engine, APU and ECU isolators, and • Cabin noise attenuation systems.

ITT Enidine | www.enidine-aviation.com

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Eagle Stainless Tube & Fabrication Inc. Eagle Stainless Tube & Fabrication Inc. is the leading supplier of ultra high precision, cut-to-length, stainless steel tubing, nickel alloys, and alluminum for medical, electronic, semiconductor industrial, and aerospace applications.

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The Lee Company Miniature Latching Solenoid Valve for Power Sensitive Applications The Lee Company’s new Latching Solenoid Valve is the ideal solution for power sensitive applications. By incorporating permanent magnets into the coil design, this miniature solenoid valve offers a dramatic reduction in overall power consumption, particularly when operating with extended “ON” periods. Unlike traditional designs that require continuous voltage to energize the valve from its natural state, this latching solenoid requires only a momentary pulse of less than a Joule to switch to and remain in state.

Available in both 2-way and 3-way configurations, this 2 position latching solenoid valve features Lee’s unique and patented MultiSeal™ technology which radically simplifies port layout, offers significant space savings, reduces machining costs and provides superior reliability over traditional sealing methods.

The Lee Company 2 Pettipaug Road P.O. Box 424 Westbrook, CT 06498 inquiry@theleeco.com www.theleeco.com Tel: 860-399-6281 Fax: 860-399-2270

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Master Bond Inc. Epoxy Meets Airbus Specifications for Flame Retardancy Master Bond EP93FRHT non-halogenated epoxy was developed for aircraft applications where stringent requirements for flame retardancy, smoke emission, and toxicity levels must be met.

This material has passed rigorous Airbus requirements including the following tests: • vertical ignition • optical density of smoke generated by solid materials • toxic gas analysis All three tests passed with flying colors, well under the permissible acceptable criteria.

Master Bond EP93FRHT is a two component epoxy that can be used as an adhesive, sealant and potting system. It is ideal for use in aircraft interior applications. To learn more about this specialty product, contact us today.

MASTER BOND INC. 154 Hobart Street Hackensack, NJ 07601-3922 main@masterbond.com Tel: +1-201-343-8983 Fax: +1-201-343-2132

maxon precision motors Flat motors for compact designs Helicopters are masters of the skies and can land without a runway, but they hit their limits when faced with steep or uneven terrain. A group of engineering students in Zurich are working on a project that involves testing an adaptive landing system for helicopters. The system comprises of four individually controlled legs, which independently adjust to the surface below – without intervention from the pilot. The idea behind this is to facilitate safe landing at any time.

On each landing leg, a maxon brushless EC flat motor is used to drive a ball screw gear. There is only a limited length available in the power train and the flat motors were the ideal choice because of their compact size, excellent performance and high torque.

Learn more about the maxon solutions and visit www.maxonmotorusa.com

maxon precision motors, inc.

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Renishaw REVO® SFP2 a CMM measurement revolution The REVO® SFP2 makes surface finish inspection an integral part of your CMM measurement procedure.

Powered by 5-axis measurement technology, the SFP2’s automated surface finish inspection offers significant time savings, reduced part handling and greater return on CMM investment.

Renishaw, Inc. 1001 Wesemann Drive West Dundee, IL 60118 www.renishaw.com Tel: 847-286-9953

Stock Drive Products/Sterling Instrument Comprehensive Mechanical Solutions for Critical Motion Control Applications Aerospace and defense components require high accuracy and tight tolerance machining. Established in 1950, SDP/SI’s combination of design, manufacturing and assembly capabilities allow us to meet the critical tolerances and functionality needs that the defense and aerospace markets demand. Our expertise includes custom design and assembly of gearboxes, planetary gearheads, differentials, and more. Custom material and plating options are available.

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A Supplement to Design World - April 2018

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B e a r i n g s

Bearing Tips:

Electric current protection and more

Edited by Mike Santora | Associate Editor

Electrically insulated rolling bearings feature electrical insulation that is built into the bearing, providing reliable protection against current passage and electrical corrosion. Typical applications are electric motors, generators and other electrical machines. The Austrian manufacturer NKE Austria GmbH offers electrically insulated rolling bearings in several versions. In this article, Klaus Grissenberger, Application Engineer with NKE, explains the causes of the passage of electrical current through rolling bearings, damage symptoms and countermeasures, properties and production processes of electrically insulated bearings.

A difference in electrical potential between the outer and inner ring of a rolling bearing can lead to a damaging electric current that permanently damages the bearing’s raceways and impairs its running characteristics.

A current flow results in electrical discharge in the contact zone between the rolling elements and the inner or outer ring. This interference, in turn, causes local melting of the surfaces. The result: pitting, material transfer and local microstructural damage through thermal stress. At least a thin layer of the eroded surface is re-hardened, making it extremely hard and prone to cracking. This process is called electrical corrosion and often affects bearings in electromechanical applications, such as generators and electric motors, but also machines that are powered by electric motors, such as pumps and gearboxes. Additionally, the electric discharge renders the lubricant useless. The base oil and additives contained in the lubricant

NKE SQ77E deep groove ball bearing with insulation on the inner ring.

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Schaeffler offers an option of an angle measuring system integrated into the bearing for all rotary table bearings.

oxidize, resulting in the characteristic black color of the lubricant. Premature aging permanently impairs the lubricant’s ability to form a separating layer between the metal surfaces. The bearing’s damaged functional surfaces and the loss of lubrication action result in a rapid loss of the bearing’s functionality.

Possible causes of undesirable passage of electrical current through rolling bearings The main reasons for current discharge are known. Asymmetries in the magnetic flux of an electrical machine give rise to a low-frequency voltage between the shaft and the housing, which results in a flow of current through the rolling bearings. Such a passage of current can also result from the use of unshielded asymmetrical electric cables if the earth connection of the machine is ineffective.

Another cause is the use of frequency

converters: The operating principle of many frequency converters is based on pulse width modulation (PWM) and generates high-frequency common mode voltage, which also results in a passage of current through the rolling bearings.

Lastly, electrostatic charging of the shaft and housing followed by discharge through the rolling bearings is also a possible cause.

the housing or on the shaft. However, this entails additional design measures of the surrounding parts. A simple, economical solution in this case is to use electrically insulated rolling bearings.

Damage symptoms and possible countermeasures

Electrically insulated bearings – properties and application

Electrically insulated bearings from NKE, designated with the suffix SQ77, are provided with an oxide ceramic insulation layer. An overview of the design variants of the insulation layer is given in the table. Electrically insulated rolling bearings from NKE offer the same outer dimensions and technical characteristics as the corresponding uninsulated types.

The most important advantages of these bearings are higher operating reliability, which is assured by optimal Overview of the design variants of electrically insulated NKE rolling bearings: protection against electrical corrosion.

Electrically insulated bearings are less NKE suffixes SQ77 SQ77C SQ77E SQ77H expensive than, for example, applying (standard) insulation to housings or shafts. They Insulation on outer ring inner ring Breakdown voltage > 1000 V > 2000 V > 1000 V > 2000 V are interchangeable with conventional Bearing types Deep groove ball bearings, cylindrical roller bearings (further types please bearings because they have the same enquire) dimensions and technical characteristics.

Bearing sizes Outer diameter D Narrow or single-row bearings They also offer a reduced risk of 90 ≤ D ≤ 500 Bore diameter d damage and longer operating life than (for up to D = 1000 mm 75 ≤ d ≤ 150 conventional bearings when used in please enquire) Boundary ratio bore diameter d to electrical machines. When users handle width B electrically insulated bearings properly, d > 3∙B there is no risk of damage to the coating.

Wide or double-row bearings The main range of electrically Bore diameter d insulated bearings consists of cylindrical 150 < d ≤ 315 roller bearings and deep groove ball Width range bearings, but all other bearing types can 20 < B < 315

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Typical signs of electrical corrosion include grey, tarnished tracks in the raceways and on the rolling element surfaces. Melt craters (Figures 1a and 1b) or fluting is also discernible, mainly on the raceway surfaces. Damage due to current discharge usually manifests itself in increased running noise.

To prevent damage of this kind, it is advisable to insulate the bearing seat in

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B e a r i n g s

also be electrically isolated. Application areas include traction motors in railway vehicles, electric motors and generators, particularly in conjunction with fastswitching frequency converters.

Production process and operating principle of electrically insulated rolling bearings For electrically insulated bearings, the insulating layer is applied to the outer ring (SQ77 or SQ77C – Fig. 2a) or the inner ring (SQ77E or SQ77H – Fig. 2b) by plasmaspraying, a thin-film technology. During plasma- spraying, an electric arc is created between two electrodes with a suitable gas supply. The plasma jet serves as a carrier medium for applying the aluminum oxide powder (Al2O3) either to the outer or inner ring at high velocity. To obtain optimum protection, the oxide layer also covers the side faces of the sprayed rings.

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(Fig. 1a) (Fig. 1b)

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Current passage has led to a formation of craters/flutes on the inner ring raceway (Fig. 1a) and the lateral surface of the rolling elements (Fig. 1b) of a cylindrical roller bearing.

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In the next process step, the layer is then sealed to prevent any penetration by moisture.

The physical effect of the insulation layer depends on the frequency of the voltage that causes the harmful currents in the bearings. In the case of dc voltage, the insulated bearing has Ohmic resistance. The higher this resistance is, the lower the electrical current. The resistance value of the insulated bearings is greater than 50 MΩ, thus limiting the electrical current to a level that cannot cause damage to the bearing.

In the case of ac voltage, the capacitive nature of the insulated bearing is advantageous. The bearing then behaves in approximately the same way as a parallel circuit consisting of a resistor and a capacitor with a frequency-dependent resistance, called impedance. The impedance determines the magnitude of the alternating current that flows through the bearing for given values of voltage and frequency. Here too, the impedance should be as high as possible to reduce the current to a level that is incapable of damaging the bearing.

To achieve high impedance values, the resistance of the insulating layer must be high, and its capacitance must be low.

Engineers can create this situation by making the insulating layer as thick as possible and by reducing the overall insulation surface area. When transferred to the bearings, this means that this layer should be applied to the bore of the inner ring. However, the coating is usually applied to the outer diameter for reasons of cost and due to the constraints of the manufacturing process. In most cases, this still results in more than adequate protection against damage from electrical corrosion. Another property of the coating is its dielectric strength. Depending on their version, the bearings from NKE have a dielectric strength of at least 1000 V or 2000 V.

For electrically insulated bearings from NKE, the insulating layer is applied to the outer ring (SQ77 or SQ77C – Fig. 2a) or the inner ring (SQ77E or SQ77H – Fig. 2b) by plasma-spraying, a thin-film technology.

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Torque motors and rotary axis bearings No other type of electric drive exists in which the motor and bearing support have so much influence on each other as in driven high-precision rotary tables and rotary axes: The three sources of heat, the rotor, the stator and the bearing, are all very close to each other due to the very compact design. The design measures taken for heat transfer and heat dissipation

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A difference in electrical potential between the outer and inner ring of a rolling bearing can lead to an electric current that permanently damages the bearing’s raceways and impairs its running characteristics. must be tailored to each application to ensure optimum functionality. The rigidity of the bearing support and the machining forces also directly influence the air gap between the stator and the rotor. Because of these close functional dependencies between the motor and the bearing, the components of rotary tables and rotary axes always have to be developed as a system.

To keep the development outlay for customer-specific designs at a manageable level, Schaeffler has three series of standard torque motors from INA – Drives & Mechatronics AG & Co. KG (IDAM) and three series of INA rotary table bearings and rotary axis bearings readily available. The torque motors and bearings can be combined as desired, enabling the user to apply the right solution for any machining process – whether it’s combined soft turning and milling, plane milling, gear grinding, grinding and hard turning, spindle applications, positioning tables, or pivot axes for ultra-precise machining.

Rotary table bearings With its two series of axial-radial cylindrical roller bearings and a series of double row axial angular contact ball bearing, each Schaeffler rotary table bearing series has its own particular strengths.

As part of a complete redesign, Schaeffler was once again able to increase the performance spectrum of its X-life YRTC rotary axis bearings regarding tilting rigidity and speed. The new YRTC bearings have low and uniform frictional torques and therefore even high limiting speeds. Additionally, they also have

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strong axial and radial runout accuracies.

This combination of characteristics means that the X-life YRTC bearings are particularly suitable for use in plane milling machines as well as in highly loaded positioning and pivot axes and extremely high precision machining.

Overall, the X-life YRTC rotary table bearings can guarantee the machine tool industry’s international competitiveness in many areas, including combined milling and turning with extended operating duration, higher speeds and high cutting capacity.

Low friction bearings The raceway geometry of the YRTS axial-radial bearings allows them to achieve levels of bearing friction which is lower than those previously achieved in preloaded roller bearings. When combined with the high rigidity, this means the YRTS bearings are wellsuited for use at high speeds. A further advantage is the integrated measuring system, which is also available as an option for all rotary table bearings.

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High-speed bearings ZKLDF axial angular contact ball bearings are particularly low friction bearing units for use at high speeds, for high axial and radial loads, and high tilting rigidity requirements.

When combined with RKI torque motors, ZKLDF...B bearings provide a significant increase in rotary table limiting speeds. Applications of choice for these bearings are bearing supports that have a long operating duration in rotary tables with a main spindle function (e.g., for combined milling and

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turning operations), bearing supports in milling, grinding, and honing heads, and in measuring and testing equipment.

The range of bearing supports, drives and angle measuring systems available from Schaeffler means the company can supply all the main components for rotary axes and driven rotary tables.

The portfolio of products which can be combined in many different ways allows manufacturers to offer rotary tables and rotary axes with their own USPs at a low development cost. DW

DESIGN WORLD

4/4/18 3:27 PM

BEARINGS BEARINGS

GGB Bearing Technology Make Bearing Selection a Priority Early in the Design Process Have you ever considered your bearing component in the beginning of your design process?

Although bearing selection is often an afterthought in the product development process, considering bearing needs as early as possible can yield significant cost efficiencies, performance enhancements and other improvements in the final product.

Advantages of early collaboration • Reduce production costs • Avoid Delays in Manufacturing • Improve design • Improve overall system efficiency • Improve functionality • Avoid overspend • Increase customer satisfaction • Improve overall size & weight Many design engineers may not realize that the bearings often determine other components, including the housing, shaft and support structures.

Working with GGB early, allows us to review your assembly to determine the best solution possible!

Removing press fit bearings can be difficult and dangerous. Cutting or using a chisel and hammer can damage the shaft. Quality Bearings & Components offers a comprehensive line of safe and cost-effective tools for mounting and dismounting of bearings and transmission parts.

QBC/BETEX HSP self-centering pullers with integrated pump and cylinder are designed for ease of use and safety. The pullers can be operated by one person, in any position, even upside down. The arms slide inwards simultaneously, the harder the force, the tighter the grip. The jaws are made of high-quality steel, ensuring long life.

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Product World Entry-level touch panels with 10.1-in. displays Beckhoff beckhoff.com CP6x00 Control Panels and Panel PCs with 10.1in. widescreen displays are an expanded line of entry-level panels. First launched with 7-in. displays, this line has been expanded by three new cabinetmounted devices, each with a 10.1-in. widescreen display. PC-based control technology in the costsensitive, lower to middle performance range and can now be scaled even more precisely in line with individual application requirements.

The new widescreen variants have a Thin Film Transistor (TFT) touch display with a resolution

of 1024 x 600 WSVGA, which paves the way for comprehensive operator interface and visualization options. Added to this is superior display quality with 16.7 million available colors on the 10.1-in. diagonal screen. The latest additions to the entry-level class include two fanless Panel PCs and a purely passive Control Panel. These devices permit the cost-effective implementation of control and visualization tasks for small and medium-sized machines, production systems and buildings.

Left-hand shaft worm gearboxes AutomationDirect www.automationdirect.com The IronHorse worm gearbox line now includes left hand shaft models in four frame sizes, and six gear ratios from 5:1 to 60:1. IronHorse cast iron worm gearboxes (worm gear speed reducers) are mechanical power transmission drive components that can drive a load at a reduced fixed ratio of the motor speed.

Constructed of cast iron one-piece housings, the worm

gearboxes feature a C-flange input. Designed to change drive direction by 90° and to increase torque output, worm gearboxes are used when space is at a premium, such as for conveyors, or to simplify mechanical design. IronHorse gearboxes are mountable in any direction, except motor pointing up.

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To ensure high-level performance with this expanded I/O count,

basic instructions can be executed in 21 nanoseconds and program memory is 800 kB (100K steps). These capabilities are combined with extensive data memory, more than double the capacity of a typical micro PLC. These features allow the FC6A Plus to handle large programs with complex control requirements such as PID, flow totalization and recipes.

Two models are available, each with 24 Vdc input power. The 16 I/O

model has 8 inputs, and 8 relay or transistor outputs. The 32 I/O model has 16 inputs, and 16 transistor outputs. Each model also includes an integral 0-10 Vdc analog input with 12-bit resolution. Each model can accommodate up to three plug-in discrete, analog, serial communication or Bluetooth cartridges. Each discrete cartridge has 4 discrete I/O points, either 4 inputs or 4 outputs. Each analog cartridge has 2 analog I/O points, either 2 inputs or 2 outputs.

Keyless shaft-hub locking devices Miki Pulley mikipulley-us.com Posi-Lock bushings provide a solid connection between shaft and mounted devices. They provide system designers with a keyless option for locking into position gears, pulleys, sprockets and other components in a mechanical system. Posi-Lock bushings have socket-head cap screws that tighten quickly and easily. When tightened, these screws allow the inner and outer hub of the Posi-Lock to move along shaft contact surfaces. The movement between the inner and outer wedge of the Posi-Lock creates a tight, friction connection between hub, shaft and the Posi-Lock.

Providing excellent axial and radial runout, Posi-Locks have a maximum allowable torque of 553.17 ft-lbs (750 Nm) and maximum axial stress of 26,552.24 ft-lbs (36,000 Nm).

Three different models are available designed for various applications. Sizes available handle a hole size range from 0.236 to 1.654-in. (6mm-42mm).

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

Gel encapsulant with removability and optical clarity Master Bond masterbond.com

Precision Components

MasterSil 170 Gel is a two-component system with strong flowability for potting and encapsulation applications. It possesses a low mixed viscosity of 1,000 cps, has a long working life after mixing (2-4 hours for 100 g batch), a low exotherm upon cure and is easy to dispense.

This solvent free silicone product does not require exposure to air for cross-linking. It has a convenient one to one mix ratio by weight and

MDTX - Secauc us, NJ Design & Man ufacturing - Bo ston, M Design2Part Santa Clara, CA A

• Intricate components as thin as .0005" • Eliminates cost of hard tooling • Eliminates burring and stress problems • Short lead times • In-house forming, laminating and plating • Prototype through production Download Capabilities Brochure

will cure at 75°F or more quickly at elevated temperatures.

See us at:

Photo Etched Parts

This versatile composition is resistant

Flex & Rigid-Flex Circuits

to water, is able to withstand severe thermal cycling without cracking and has extremely low shrinkage upon cure. This soft, pliable and compliant silicone system is repairable and its hardness penetration is 65 mm. MasterSil 170 Gel is available for use in ½ pint, pint, quart, gallon and 5 gallon kit containers. Shelf life in original, unopened containers at 75°F is 6 months.

• Medical, Aerospace and Telecom markets • Adhesiveless construction • Selective plating of gold and tin • SMT and through hole component assembly • Package sizes down to 0201 and .4mm pitch • Microvia sizes down to .001" diameter Download Flex Circuit Design Guide

EMI/RFI Shielding • Global supplier standard and custom products • Commercial and military markets • Over 100 finger stock gasket profiles • Shielded vents and filters • Conductive foam and elastomer gaskets • Board level shielding Download Shielding Catalog

www.tech-etch.com

DESIGN WORLD

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TECH-ETCH, INC., 45 Aldrin Road, Plymouth, MA 02360 TEL 508-747-0300 • FAX 508-746-9639 • sales@tech-etch.com

ISO 9001 AS9100D

REGISTERED

4/3/18 10:19 AM

Product World Flaring standoffs for compact electronic assemblies PennEngineering pemnet.com MicroPEM MSOFS flaring standoffs have suitable miniature fastener solutions to attach and/or space components in compact electronic assemblies. They install permanently in thin panels of any hardness and material, including stainless steel, other metals, plastics, and printed circuit boards. The flaring feature adds value by allowing for installation into multiple panels.

Additionally, these standoffs have been engineered

with a minimal footprint enabling reduced centerline-toedge designs, especially suiting attachment applications where available space for fasteners may be limited. Their extremely small and reusable threads reliably accept mating hardware to complete final component attachment.

MSOFS flaring standoffs are manufactured from 300 Series stainless steel and offered

in thread sizes #0-80, #2-56, and M1 to M2. They will install in thin panels (thicknesses from .008 to .012-in. and 0.2 to 0.3 mm) using a punch flaring tool and a recessed anvil.

Wire-actuated encoder as integrated position sensor SIKO siko.global.com The SGH25 wire-actuated encoder has a measurement range up to 2.5 m and long service life. The variety of interfaces meets the highest requirements, even in applications that are critical for safety. With this performance profile, the wire-based position sensor is suitable for applications in mobile machines such as dumper trucks, excavators and agricultural machinery, where it measures the position of hydraulic and telescopic cylinders and communicates it to the machine control system via integrated communication protocols.

In comparison to the SGH10 basic model with a measurement range of up to 1 m, the SGH25 has an extended measurement range up to 2.5 m, while its big brother, the SGH50, covers large measurement ranges up to 5m. The SGH series can be integrated directly into hydraulic cylinders. A newly developed plastic provides a strong design and extends the fluid temperature range from 85°C previously to 105°C now.

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DESIGN WORLD

4/4/18 3:40 PM

S U M M I T

&

S H O W C A S E

The Robotics Summit & Showcase is a multifaceted educational forum and showcase dedicated to addressing the technical issues involved with the design, development, manufacture and delivery of commercial robotics and intelligent systems products and services. l The Conference Program of keynotes and general sessions are specifically designed to impart to technical professionals the information they need to successfully develop the next generation of commercial robotics systems

l The Showcase provides attendees with hands on access to the latest design and development solutions for producing robotics and intelligent systems products and services.

mAY 23-24, 2018

THE WESTIN BOSTON WATERFRONT BOSTO N , M A

Re g iste r on l i n e at rob oti c s s u m m i t . com EXHIBIT AND SPONSORSHIP OPPORTUNITIES For more information, contact Mike Emich 508.446.1823, memich@wtwhmedia.com, PRESENT ED BY:

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4/2/18 8:17 AM

Ad Index

SALES

Aggressive Hydraulics ............................... 92

Keller America Inc ......................................... 63

Aignep USA .................................................... 37

LiveWorx .......................................................... 121

Allied Electronics &

Madison Co. .................................................... 57

Automation ...............................Cover,18,19

Maple Systems ............................................. 45

Allied Moulded Products, Inc. .................. 76

Micromo ........................................................... 85

AllMotion .............................................................4

NBK America LLC ..........................................68

Altech Corporation .........................................2

Novotechnik ................................................... 35

Aurora Bearing Company ......................... 37

NTE Electronics, Inc. ................................... 122

AutomationDirect .......................... Gatefold,1

OEM Controls ................................................. 43

Bay Associates Wire

Tom Lazar

Mike Caruso

mcaruso@wtwhmedia.com 469.855.7344

Garrett Cona

gcona@wtwhmedia.com 213.219.5663 @wtwh_gcona

Jessica East

OKW USA ......................................................... 29

jeast@wtwhmedia.com 330.319.1253 @wtwh_MsMedia

Technologies Corp. ................................48

PAVE Technology .......................................... 91

Bergquist/Henkel .........................................123

PBC Linear ................................................ 32,33

Michael Ference

Beta Layout ....................................................89

PHD Inc. ........................................................... 65

Bimba ...................................................................5

R+W America .................................................. 75

Bird Precision ................................................. 43

Rutronik ............................................................ 31

Bodine Electric Company ........................... 71

Smalley Steel Ring ..........................................9

Bosch Rexroth ..............................................IBC

Smart Products USA, Inc. ........................... 10

CC-Link Partner Association ..................... 81

Sorbothane ....................................................49

CGI Motion ...................................................... 47

Spartan Scientific .........................................49

Cicoil .....................................................................7

Specialty Graphic Imaging

Clippard ............................................................BC

Association ............................................... 78

CS Hyde Company ........................................ 17

Sunstone Circuits ........................................ 83

Del-tron ............................................................ 59

Tech-Etch, Inc. ..............................................125

DieQua .......................................................44,70

Tensility International Corporation ........88

Digi-Key Electronics ...................................... 15

The Lee Company ....................................... 25

Dunkermotoren .............................................. 13

Tompkins Industries, Inc. ............................ 41

Elesa USA Corporation .............................. 23

Trim Lok ............................................................ 27

Fabco-Air, Inc. ................................................. 16

US Tsubaki ......................................................90

Fluid Metering, Inc. ......................................64

USA Fastener ................................................94

Fotofab ............................................................ 77

Whittet-Higgins .............................................. 21

igus ..................................................................... 51

Zero-Max, Inc. ...................................................3

mference@wtwhmedia.com 408.769.1188 @mrference

Michelle Flando

mflando@wtwhmedia.com 440.670.4772 @mflando

Mike Francesconi

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

mfrancesconi@wtwhmedia.com Scott McCafferty 630.488.9029 smccafferty@wtwhmedia.com 310.279.3844 David Geltman @SMMcCafferty dgeltman@wtwhmedia.com 516.510.6514 EVP @wtwh_david

Marshall Matheson

Neel Gleason

ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

Interpower .......................................................69

Aerospace & Defense Tips Supplement Eagle Stainless Tube .............................. 102,103 Master Bond ........................................................97

April 2018

maxon precision motors ................................. 99 Renishaw ............................................................. 107

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Design equipment faster, smarter, and under budget with TiPS from leading suppliers. | istockphoto.com

SDP/SI-Stock Drive Product...........................109

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The Lee Company ............................................ 101

Bearing Tips Supplement

www.bearingtips.com

A Supplement to Design World - April 2018

GGB Bearing Technology ............................... 116 Design equipment faster, smarter, and under budget with TiPS from leading suppliers.

Quality Bearings & Components ................. 117

| istockphoto.com

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Follow the whole team on twitter @DesignWorld

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DESIGN WORLD

4/4/18 4:31 PM

Maximized productivity.

Minimum space. cabinet-free

The future of industrial automation is cabinet-free

Cabinet-free technology?

IndraDrive Mi The future of industrial automation is cabinet-free. Bosch Rexroth is moving drive technology from the cabinet onto the machine to save valuable space on the shop floor and streamline production. The cabinet-free drive system, IndraDrive Mi, eliminates drive electronics from the cabinet and lets you mount a more compact controls enclosure directly to the machine â&#x20AC;&#x201C; reducing machine footprint and energy consumption for cabinet cooling while maximizing flexibility.

By the numbers: IndraDrive Mi cabinet-free technology provides its users with 100% reduced cabinet control space and 90% reduced wiring effort, making IndraDrive Mi the fast and flexible solution for your production.

Order the free Advancing Factory Automation Kit: www.boschrexroth-us.com/factoryautokit For expert advice call 1-800-REXROTH (739-7684) or email us at info@boschrexroth-us.com

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