DESIGN WORLD DECEMBER 2019

www.designworldonline.com

December 2019

inside:

2019

Leadership Winners Pages 3-16

LINEAR MOTION: How to size a rack-and-pinion

system for motion control

p. 74

MECHANICAL: How neutron scattering is

helping to create stronger bearings

p. 86

TEST &

MEASUREMENT:

Reducing error when using eddy current measuring techniques

p. 92

Using CFD

to model aircraft fuel systems page 80

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OFFSET SHAFTS. SOLVED. Offset Couplings from Zero-Max reduce space requirements for parallel offset shafts in large system applications. These specialized couplings provide machine designers with an important option for reducing overall machine size and footprint.

Compact in design, Schmidt Offset Couplings transmit constant angular velocity and torque in a wide range of parallel shaft misalignments. Handling high amounts of parallel offset up to 9 inches, they are available with torque capacities up to 459,000 in-lbs.

Schmidt Offset Couplings can be mounted to shaft hubs or directly to existing machine flanges. They are available for shaft displacements of 0.156 inches to 17.29 inches and torque capacities from 55 to 459,000 inch-pounds. Many design configurations are available including specials.

www.zero-max.com 800.533.1731

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2019

Leadership in Engineering

L ea d ership Winners Advanced Materials Digital Manufacturing

Here in our fourteenth annual issue

Electrical

on Leadership in Engineering, we announce the winners in the Leadership Awards Program that

Fastening & Joining

Fluid Power

we have been promoting throughout the year.

The Design World User Community has cast votes and

Industrial Automation

Mechanical

Mechatronics

we are pleased to celebrate the winners in this special section of

Motion Networks

“Leadership in Engineering.”

Software

Switches & Sensors

Test & Measurement

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2019

Leadership in Engineering

Advanced Materials

Congratulations!

CS Hyde Company

CS Hyde Company is a supplier of high performance materials used in most major industries, offering Pressure Sensitive Adhesive Tapes, films, Fabrics, Silicone, Rubber, Belting and Threads.

Capabilities include: Laminating Adhesives, Die Cutting Parts, Slitting,

Sheeting, and Print & Bar-Code Packaging.

Material can be provided in standard and custom sizes: 1-1/2, 3, and 6-in.

cores, and as large as 60 in. wide while maintaining tight tolerances.

Customers may also obtain die-cut pieces of material. CS Hyde Company

can cut custom shapes to a very tight tolerance. If you only need a few pieces of a complex shape, ask about the company’s rapid prototyping capabilities, which allow for small runs, with no tooling charges, and ultra-fast turnaround times.

In addition, the company can cold laminate an adhesive of your choice to a

variety of materials, and use the product line that 3M has to offer to ensure the best performance.

Whether it’s Teflon Tape, Silicone Foam, Kevlar thread, or Mylar film, CS Hyde

has what your company needs to keep running smoothly.

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www.cshyde.com

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2019

Leadership in Engineering

Digital Manufacturing

Congratulations!

Proto Labs

Protolabs is digital manufacturing source for custom prototypes and low-volume production parts. It’s a technology-enabled company that uses 3D printing, CNC machining, sheet metal fabrication, and injection molding to produce parts within days. The result is an unprecedented speed-to-market value for designers and engineers and an on-demand manufacturing resource throughout a product’s life cycle.

The rapid manufacturer provides a fast, easy and cost-effective way to obtain 1

to 10,000 parts within days. These quick delivery times are possible because it has automated the manual process of mold design and toolpath generation through the use of proprietary software.

Product developers can upload a 3D CAD model online at any time and receive an interactive quote with real-time pricing information and free design analysis within hours.

The manufacturability analysis helps eliminate problems, like sink or warp, so modifications can be made before any actual production begins.

Protolabs uses the latest additive manufacturing (aka 3D printing) technologies to

provide precision accuracy to plastic and metal part production — from small pieces with complex geometries to large, highly detailed patterns. The company’s CNC machining service uses three and five-axis milling along with turning with live tooling to machine up to 200 parts from more than 30 stocked plastic and metal materials. For those who need low-volume production, bridge tooling or on-demand parts throughout a product’s life cycle, rapid injection molding can manufacture up to 10,000 parts from hundreds of different engineering-grade plastic and liquid silicone rubber materials.

Protolabs’ quick-turn sheet metal fabrication is production parts. Protolabs also offers component assemblies, screen printing, and several finish options through its sheet metal service. www.protolabs.com

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suitable for both prototyping and low-volume

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2019

Leadership in Engineering

Electrical & Electronics

Congratulations!

LAPP

LAPP is a leading global supplier of cable and connection technology for factory automation. Its portfolio includes standard and custom industrial cables, connectors, cable entry systems and automation technologies that support the factories of the future. LAPP’s key markets include industrial machinery and plant engineering, as well as the food, energy and mobility sectors.

For more over 50 years, LAPP has been one of the world’s leading suppliers of cable and connection technology and is a recognized name in the industrial automation market. Its products range includes power and control cables, flexible data cables, industrial connectors, cable glands and accessories, as well as custom turnkey cable assembly and chain solutions. The company team designs each product to meet the demands of a variety of industrial applications, handling, automotive and robotics.

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including data communication, food and beverage, material

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2019

Leadership in Engineering

Fastening & Joining

Congratulations!

Master Bond

Master Bond is celebrating 40 years of formulating adhesives, sealants, coatings, and potting/encapsulation systems using advanced technology for challenging applications.

Master Bond’s line of epoxies, silicones, UV curable and LED curable

compounds can be customized to meet a myriad of property requirements including: • High/low temperature resistance • Electrical conductivity/insulation • Thermal conductivity • High/low viscosity • Flexibility and toughness • Chemical resistance • Optical clarity EP42HT-2LTE: Epoxy Has Ultra Low Coefficient of Thermal Expansion With a coefficient of thermal expansion of 9-12 x 10-6 in/in/°C, EP42HT-2LTE is a two-component epoxy for bonding, sealing, coating, and select casting applications. It has paste consistency with some flow that imparts outstanding dimensional stability and will bond well to a wide variety of substrates. EP42HT-2LTE is also noteworthy for its low linear and volumetric shrinkage.

EP90FR-V: Passes Vertical Burn Test

noteworthy applications include interior panels, door frame lining, and floor/ door assemblies. Because it is a superior electrical insulator, this epoxy is also a candidate for electronic potting and sealing applications.

Additionally, EP90FR-V is a non-halogenated system.

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system meeting FAR standard 14 CFR 25.853(a) for flame retardancy. The most

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Formulated for specialty aviation applications, EP90FR-V is a two-component

Fastening & Joining 2019 Leadership Winners PRESENTED BY

DESIGN WORLD

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2019

Leadership in Engineering

Fluid Power

Congratulations!

Brennan Industries, Inc. Brennan Industries is a global leader in manufacturing and supplying hydraulic fittings and instrumentation products. With an extensive inventory that includes more than 50,000 standard and special part styles and sizes, and distribution in the United States, Canada, Asia, and the United Kingdom, Brennan is committed to delivering the quality products you need.

Brennan controls their own manufacturing both domestically and

overseas, so if you need a custom solution, the engineering team can help with anything from altering a standard to developing a prototype.

This also means controlled quality; as an ISO 9001:2015, AS9100C and NADACAP, and ITAR certified company, Brennan adheres to the most stringent quality control practices, assuring exceptional products.

Brennan gives designers and engineers all the tools needed to make

the correct product selection. More than 10,000 CAD files are available for free download in a wide selection of formats. A pressure ratings tool, competitor cross reference, and online part catalog make it simple to find the product information you need. The website also features free informational whitepapers on a variety of industry topics designed to educate and inform.

Every Brennan fitting exceeds the S.A.E. standard for corrosion resistance.

Brennan’s standard trivalent plating performs at nearly double the SAE requirement. The zinc nickel plating solution offers five times greater protection. For the highest corrosion resistance available in a Performing at 23 times the standard, Brennan Black is fittings and adapters that provides more than 1,700 hours of unequaled rust protection.

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a proprietary coating, available on all steel hydraulic

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steel fitting today, the Brennan Black coating stands alone.

Fluid Power 2019 Leadership Winners PRESENTED BY

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2019

Leadership in Engineering

Industrial Automation

Congratulations!

AutomationDirect

A recognized name in the industrial automation market, AutomationDirect provides quality products with free in-house sales and technical support. The company provides customers with quick order and delivery through an online store and toll-free number.

With tens of thousands of part listings, new products include the

Productivity1000 PLC, the Do-more BRX PLC and the DURApulse GS4 AC drive. These products represent many years of design and development by AutomationDirect’s own engineering team as well as their strategic partners.

The company also offers motors, sensors, pushbuttons, enclosures, circuit protection and more.

Orders for in-stock items can be taken as late as 6 p.m. EST and be shipped for next-day delivery.

The company provides online tutorial videos through their web store at www.automationdirect.com as well as their YouTube channel. A Customer Forum provides peer support on technical and application questions.

AutomationDirect’s customer support team has been rated top-notch by its customers. For 15 years straight, the Tech Support team was voted by readers of Control Design magazine as best in service and support for various products. And, their own customer surveys consistently rank the company’s service as

www.automationdirect.com

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better than other suppliers.

Industrial Automation 2019 Leadership Winners PRESENTED BY

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2019

Leadership in Engineering

Mechanical

Congratulations!

Deublin

Since 1945, Deublin has grown from a small garage shop to the world’s largest manufacturer of rotary unions (rotating unions) — a mechanical device that allows transfer of pressurized fluid from a stationary source into rotating machinery for heating, cooling, or transfer of fluid power.

Deublin’s entree into the Rotating Union market was a design that

incorporated balanced mechanical seals. Innovative for its time, the design was immediately accepted by the industry and helped launch the growth of the company.

Rotating Union applications include Air Clutches, Gear Boxes, Machine Tool

Spindles, Textile Equipment, Rubber & Plastic Manufacturing Machinery, Steel Continuous Casting Machines, and Paper Machine Calender stacks. In 1989, the Deublin product line was expanded to include Steam Joints and Siphon Systems for Paper Machine Dryer Cans.

Rotary unions must accommodate a range of materials, viscosities, temperatures, pressures and speeds. That’s why the Deublin rotary union product line offers over 500 standard rotary unions, over 3,000 separate models, and more than 6,000 individual components to handle them.

With its world headquarters in Waukegan — a suburb of Chicago — Deublin spans the world with wholly owned subsidiaries in Austria, Brazil, Canada, China, Finland, France, Germany, Italy, Japan, Korea, Mexico, Poland, Singapore, Spain, Sweden and the United Kingdom. available through Authorized Distributors.

The company’s worldwide distribution network

allows OEM’s all over the world to specify Deublin rotary unions when purchasing equipment made in another country.

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In the rest of the world, Deublin products and services are

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2019

Leadership in Engineering

Mechatronics

Congratulations!

Yaskawa

One Source for All Motion. Yaskawa offers automation users Singular Control: the ability to program any type of motion device — from servo axes to robots — with the familiar function block programming that servos have used successfully for decades.

Operational Achievement: Generations of customers have learned to trust the

rock-solid consistency of Yaskawa supply and support, leading to satisfied end users and an end to unscheduled downtime.

Engineering Expertise: Yaskawa works as an extension of your engineering staff to provide the time, resources, and confidence to create elegant, reliable automation.

Motion & Drives Products: A range of rotary, linear, and direct drive servo motors are matched with digital SERVOPACKS and linked to single or multi-axis machine controllers, yielding a system with the best quality and reliability in the industry. Our AC inverter drives cover every application in the industrial plant, offering size and performance options from fractional HP to 16,000 HP. Robotics: With over 375,000 robots installed worldwide, Yaskawa has earned a reputation for robotic solutions that assure customer success. This line of industrial robots increase efficiency, provide consistent quality, and Robotic product portfolio ranges from 4-15 axis industrial machines, devices, and turnkey robotic systems.

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robots with load capacities of 2 to 800 kg to special

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boost productivity to deliver outstanding ROI. The Yaskawa

Mechatronics 2019 Leadership Winners PRESENTED BY

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2019

Leadership in Engineering

Motion Control

Congratulations!

maxon precision motors maxon precision motors focuses on comprehensive solutions optimized through a diversified product range and client consultation.

maxon motor manufactures small, high-quality brush and brushless DC motors

ranging in size from 4 to 90 mm. maxon’s rhombic wound ironless rotor motors provide high efficiency, low EMI emissions, fast acceleration, no preferred rotor position, torque constants, and long service life. The drive components are assembled and designed according to your individual needs. Our modular system includes planetary, spur, and special gearheads as well as encoders and control electronics.

With over 50 years of experience, high-tech innovations, and superior product quality, maxon is the reliable partner in drive technology. Individual, customized drive solutions are maxon’s greatest strength. maxon X drives Extremely powerful drives that are easily configured online — customers can fit the drives with specific mechanical and electrical components specific to their application needs. It is possible to customize the shaft lengths, winding types, ball bearings, and much more. When combined with maxon encoders and planetary gearheads, you form a high-precision, robust drive system suitable

be viewed immediately online and 3D CAD data for the configuration is available for downloading.

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strong drive system. In addition, detailed product data may

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for any application requiring a compact, powerful, quiet, and

Motion Control 2019 Leadership Winners PRESENTED BY

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2019

Leadership in Engineering

Networks

Congratulations!

Beckhoff Automation Beckhoff Automation is a global provider of open automation systems based on advanced PC Control technology. The “New Automation Technology” philosophy at Beckhoff represents universal and open automation solutions used in a wide spectrum of high-tech applications around the world. These applications range from control of machines and robots, to Internet of Things (IoT) systems, intelligent building automation and much more.

The comprehensive Beckhoff system architecture for machine and plant

automation promotes control hardware consolidation by advancing powerful PC-based control technology. This approach takes the best from automation technology (AT) and IT, making the most powerful tools available to engineering teams in one universal environment.

All the benefits from the early days of this effort remain from the integration of PLC, motion control and HMI, while adding other high-value functions for robotics, safety, high-end measurement, condition monitoring, and of course, cloud connectivity and IoT. Beckhoff has machine builders and manufacturers covered whether they need to gather and store process data in the cloud, integrate condition monitoring or implement track-and-trace functions in machinery. With TwinCAT IoT and TwinCAT Analytics software, machines directly benefit from Industrie 4.0 and IoT functionality. software packages share the same universal platform as

www.beckhoff.com

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all other machine programming tools from Beckhoff.

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Engineering efficiency is greatly increased because the

Networks 2019 Leadership Winners PRESENTED BY

DESIGN WORLD

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2019

Leadership in Engineering

Software

Congratulations!

COMSOL

COMSOL is a global provider of simulation software for product design and research to technical enterprises, research labs, and universities. Its COMSOL Multiphysics product is an integrated software environment for creating physics-based models and simulation applications. A particular strength is its ability to account for coupled or multiphysics phenomena. Add-on products expand the simulation platform for electromagnetics, structural, acoustics, fluid flow, heat transfer, and chemical applications. Interfacing tools enable the integration of COMSOL Multiphysics simulations with all major technical computing and CAD tools on the CAE market. Simulation experts rely on COMSOL Compiler and COMSOL Server to deploy applications to their design teams, manufacturing departments, test laboratories, and customers throughout the world.

Simulation specialists can turn their multiphysics models into simulation applications with the Application Builder tool available in COMSOL Multiphysics. This provides a new way for teams of engineers and scientists to bring the use of simulation to non-specialists.

With COMSOL Server simulation applications can be deployed and administrated via a web interface. With COMSOL Compiler simulation specialists can compile an application into a single executable file for unlimited use and distribution. Standalone executable applications provide freedom in distributing their work to their design teams, customers throughout the world. www.comsol.com

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manufacturing departments, test laboratories, and

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simulation specialists with an unprecedented level of

Software 2019 Leadership Winners PRESENTED BY

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2019

Leadership in Engineering

Switches & Sensors

Congratulations!

Carlo Gavazzi

Founded in 1931, CARLO GAVAZZI is a multinational electronics group active in the design, manufacture, and marketing of electronic and electrical components for industrial automation and building automation.

With several ISO9001 and ISO14001 certified manufacturing and R&D facilities

throughout Europe and Asia, and dozens of sales offices spanning the globe, you are assured that product support, service, and inventory are only a phone call, email, or mouse click away. CARLO GAVAZZI products are developed and manufactured in full compliance with the most important standard regulations, such as UL and CSA. Products include: SENSORS: Capacitive and Inductive Proximity Sensors, Photoelectric Sensors, Ultrasonic Sensors, Level Sensors, Magnetic Switches, Limit Switches, and Safety Interlocks.

SWITCHES: Solid State Relays, Solid State Contactors, Electromechanical Contactors, Definite Purpose Contactors, Overloads, Manual Motor Starters, Mini Circuit Breakers, Soft Starters, Electromechanical Relays, Push Buttons, and Pilot Lights.

CONTROLS: Current/Voltage/3-Phase Monitoring Relays, Switching Power Supplies, Timers, Digital Panel Meters, Energy Meters/Software, Current Transformers, PID

• Electrical and Electronics • Motion Control • Networks and Fieldbuses • Switches and Sensors • Test and Measurement

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Product Categories:

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Controllers, Fieldbuses, and Safety Modules.

Switches & Sensors 2019 Leadership Winners PRESENTED BY

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2019

Leadership in Engineering

Test & Measurement

Congratulations!

Cognex Corporation Cognex machine vision and barcode reading tools enable companies around the world to improve assembly verification, eliminate defects, automate production, and identify challenging barcodes reliably across a wide range of industries and applications.

Cognex Corporation designs, develops, manufactures, and

markets a range of products that incorporate sophisticated machine vision technology that gives them the ability to “see.�

Cognex products include barcode readers, machine vision sensors, and machine vision systems that are used in factories, warehouses, and distribution centers around the world to guide, gauge, inspect, identify, and assure the quality of items during the

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manufacturing and distribution process.

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CONFIGURED TO SAVE TIME

Discover 80 Sextillion mechanical part configurations Gain design flexibility to configure based on your exact specifications. MISUMI offers multidimensional configurations for millions of products, that is easy and saves you time.

Think beyond standard and consider configurability. The configurable component offers the best of both worlds as is combines the reliability, price and lead times of a stocked component with the design flexibilities of a custom component. Critical dimensions such as length and diameter can be selected to design specifications.

MISUMI.INFO/Configure

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Contents 12 • 2019

•

vol 14 no 12

•

designworldonline.com

A supplement of Design World December 2019

it’s a

material world 100 AM Engineers need a set of best practices...and change in mindset

68 _MOTION CONTROL

80 _3D CAD

Update on PACs

How to combine 1D and 3D thermal simulation for modeling aircraft fuel systems

Many of today’s automation systems blend motion control with robotics, vision systems, I/O, and HMIs on a single programmable automation controller. Some even connect with or serve as IoT gateways to allow communications between enterprise- level systems and the Cloud.

74 _LINEAR MOTION How to size a rack-and-pinion system for motion control

In a previous motion-sizing article, we reviewed how to properly specify a ballscrew-driven motion axis. Here we review how engineering teams can use a similar approach for sizing rack-and-pinion-based servomotor- driven axes on the same five-axis gantry. We’ll use manufacturer software to work through the application.

COVER_MPF 12-19_FINAL.indd 99

I N S I D E : Why M12 connectors are the right fit for the IIoT • The revolution in Ethernet connectors • Best of 2019

Inter

Cable & Connector Reference Guide

COVER_Interconnect_2019_Vs2.indd 115

86 _MECHANICAL

By studying the science behind bearings, materials, and products, specialists have developed proprietary surface coatings, heat treat processes, manufacturing methods, analytical modeling tools, and other patented techniques and technologies all aimed at one thing — engineering stronger bearings.

92 _TEST & MEASUREMENT Reducing error when using eddy current measuring techniques

Tips for reducing error with Eddy current measuring techniques include paying attention to circuit selection, placement, calibration and mounting.

12/6/19 7:30 AM

115-133

How neutron scattrering is helping to create stronger bearings

A supplement of Design World • December 2019

2019

Leveraging advanced 3D CAD-embedded CFD capabilities can add robustness and fidelity to a 1D system model.

12/2/19 3:24 PM

99-113

| Adobestock.com

92

104

110 Kennametal uses 3D printing to develop lightweight stator bore tool

ON THE COVER

The use of 3D-CAD embedded CFD with 1D CFD tools can quickly characterize complex components without the need of a specialist. | Adobestock.com

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

2019

BRONZE REGIONAL AWARD asbpe.org

18

December 2019 www.designworldonline.com

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DESIGN WORLD

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FEATURED MANUFACTURERS

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GRIPPERS. PINS. ROLLERS.

12.19

• contents departments 24 Insights 26

Teschler on Topic

28 Technology Forward 30 Green Engineering 35 Design For Industry 46 Design Notes 58 Internet of Things 64 CAE Solutions

134 Product World

136 Ad Index

LOCATE YOUR DEALER ONLINE!

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December 2019

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DESIGN WORLD

Follow the whole team on twitter @DesignWorld

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Allied spread 11-19.indd 22

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What do your users think of your products?

Any smart website designer or software company tests its products, not just for things like basic functionality, but for how the end user interacts with it. San Jose-based UserZoom recently published the results of a survey on user experience trends, and the results are fascinating. Survey respondents reported that the top trends impacting the user experience over the next five years will be Artificial Intelligence (80%), Voice Interfaces (64%), Automation (47%), and the Internet of Things (46%).

UserZoom’s study shows that user experience is slowly finding its place in industries beyond software, moving into fields as diverse as healthcare, transportation/automotive, biotech, banking, sports, education, and retail.

Gary Dostal, Manager – Mechanical Engineering, Komatsu Mining Corp. Group, told me that his company recently held customer review meetings for gathering feedback in areas including joystick controls and positioning, and seating options for cab design.

“We have local field service personnel that gather customer and operator input and relay that back to engineering and manufacturing,” he said. “Currently, we have two engineering field rotations at customer copper and oil sands sites. They serve as a direct interface with our customers to voice needs and to work with them on evaluating solutions.”

Dostal explained that they also gain input on new hardware during build of their first machines at the customer sites, along with close field follow to capture items for continuous improvement. Those items are recorded in Komatsu’s SalesForce cases and prioritized for action by the various business groups responsible.

Today, safety and ergonomics are major design focuses. In some countries, there are growing regulations for operator noise and vibration exposure as well as emission regulations that must be met to sell products in those locations.

“There certainly are competitive advantages to gaining early experience related results to make better design and business case decisions,” said Dostal. DW

Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com On Twitter @ DW—Editor

Te c h n i c a l S u p p o r t

(408) 460-1345

24 December 2019 www.designworldonline.com DESIGN WORLD

DW.Insights.12-19.Vs2.LL.indd 24

12/3/19 8:23 AM

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12/3/19 8:24 AM

Teschler on Topic When smart people make dumb decisions

Here’s an interesting task for you. Decide whether the following conclusion is true based only on the opening two premises: • All living things need water.

• Roses need water.

Therefore, roses are living things.

You made a mistake if you decided the conclusion was true. But don’t feel bad.

University of Toronto researcher Keith Stanovich, who originally composed this little test, says 70% of university students screw it up. The key is to realize that “all living things need water” isn’t the same as “all things that need water are living.” What makes the problem difficult to see is that the conclusion sounds sensible and jives with what you already know.

In fact, a significant number of people who score high on IQ tests don’t do well when navigating logical puzzles like this one. And an inability to reason through such exercises has larger implications about how people botch decisions pertaining to everyday problems.

This realization led Stanovich and his research group to develop what’s called the Comprehensive Assessment of Rational Thinking, a prototype test meant to gauge rational thought. It attempts to measure cognitive biases as well as probabilistic and statistical reasoning skills, including the ability to assess risk. The idea is that eventually, employers could use such tests to weed out potential employees who lack good decision-making skills.

Engineers stuck with managers having a reputation for illogical decisions might wish such a test was already in place. Bad managers are living proof that even people with sterling academic credentials and high IQs don’t necessarily take a rational approach to everyday problems.

A formal confirmation of this idea comes from researcher Wändi Bruine de Bruin who, while at Carnegie Mellon University, ran decision-making tests on people with a range of educational backgrounds and in diverse age groups. The tests measured qualities such as how well participants realized the limits of their own knowledge, recognized social norms, or were fooled by how problems were framed. Her group also asked participants about whether they experienced stressful events such as a suspension from school or losing their driver’s license.

It turned out that those who scored high on decision making were less likely to have these sorts of difficult life experiences, regardless of their educational backgrounds. Additional confirmation comes from writer David Robson who, in his book called The Intelligence Trap, chronicles a London School of Economics study which discovered that people with high IQs are just as likely as less intelligent citizens to face financial distresses like missing mortgage payments and high debt. These facts are particularly surprising, Robson says, given that more intelligent and better educated people tend to have more stable jobs with higher salaries. The implication is that financial problems are a consequence of their decision making rather than a lack of earning power.

The good thing about these findings is that they are becoming more widely known. So in a perfect world, more people will be promoted into management for their rational thinking styles rather than for reasons (such as who they know) that are less indicative of good decision making. DW

Leland Teschler • Executive Editor lteschler@wtwhmedia.com On Twitter @ DW_LeeTeschler

26

December 2019

Lee Teschler Column 12-19_V2_LT.indd 26

DESIGN WORLD

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Technology Forward The finish is just as important

as the build

For a technology meant to solve the problem of getting prototypes faster, 3D printing / additive manufacturing has taken an interesting journey. Introduced more than 30 years ago to engineers, it initially failed because it couldn’t prototype well enough.

Reintroduced about a decade ago, it was certainly better at prototyping.

So much so, that some saw the advantage of using this technology in a manufacturing context. There were a few challenges though: build speed, materials, and finishing.

The speed and materials challenges are being addressed in fascinating ways as vendors invent new approaches that build faster. Vendors are also using the pinpoint accuracy of additive manufacturing’s deposition capabilities to create materials that surpass natural materials.

Lately, some vendors are turning to the finishing challenge. This challenge has a few unique requirements, primarily that finishing must be automated to fit into a manufacturing scheme. Today’s manufacturing houses are using technology to innovate and improve production processes— something known as either digital manufacturing or Industry 4.0. But the finishing processes of additive manufacturing tend to be manual, laborious methods to remove excess powder, clean, blast and sand, and

machine, as well as examine for quality control. Such manual procedures are not in keeping with the concept of Industry 4.0. Noted Joseph Crabtree, CEO, Additive Manufacturing Technologies Ltd, “Beyond the fact that this is a juxtaposition of the modern with the archaic, the laborious nature of production means that up to 60% of the cost of an additively manufactured part is generated during the post processing stage of the process chain.

This is unsustainable.”

At some point, additive manufacturing will have to become a fully automated system to fit it with the automated manufacturing production environment.

Vendors are just beginning to develop systems that handle postprocessing in a more automatic way. Some of these methods include automatic powder reclamation, support materials that dissolve in water, and automatic polishing systems.

For example, PostProcess Technologies recently announced a new way to remove excess stereolithography (SL) resin as a part of its offering of automated and intelligent additive manufacturing post-print technologies. Building on its existing portfolio of SL resin removal technologies with an enhanced chemistry formulation, the PostProcess solution completely removes resin on 3D printed SL parts in 5 to 10 minutes.

In another example, Additive Manufacturing Technologies Ltd. Developed the proprietary Boundary Layer Automated Smoothing Technology (BLAST) for mass production applications. The BLAST is a physio-chemical performanceand aesthetics-enhancing process that can smooth a variety of thermoplastic polymers, and is a non-line-of-sight process that can smooth surfaces and complex internal cavities of polymer 3D printed parts.

These are good developments to help remove some of that cost at the post processing stage. More work, however, is needed. DW

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

28

December 2019 www.designworldonline.com

Tech.Forward.12-19_Vs2.LL.indd 28

DESIGN WORLD

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12/3/19 8:29 AM

Green Engineering Paul J. Heney

• VP, Editorial Director

Fluid power manufacturer receives environmental stewardship recognition

Emerson’s fluid control & pneumatics facility in Florham Park, N.J. was recently recognized by the New Jersey Department of Environmental Protection (NJDEP) for its leadership in Environmental Stewardship. The facility was highlighted for voluntary and proactive measures taken to improve the environment and foster sustainability. Besides being the headquarters for the fluid control & pneumatics businesses, the facility houses the global development center for the ASCO brand of fluid control solutions.

The recognition follows an inspection of the Emerson facility in Florham Park, where the company has taken significant steps to ensure a sustainable future. This includes management of wetlands, diversified arboreal investments and meadows development. The facility is designed to meet LEED Silver standards, using less water and energy, to reduce greenhouse gas emissions. Continued implementation of new micropractices has brought innovations, like biodegradable containers, and increased usage of dispensers to further reduce the environmental footprint.

“We are honored to be awarded by the NJDEP for our efforts in environmental stewardship,” said Manish Bhandari, group president for

30

fluid control & pneumatics at the facility. “Emerson recognizes that we have a role to play globally in using energy efficiently, reducing water use and minimizing greenhouse gas emissions. The State of New Jersey had partnered with us as we evaluated the Florham Park facility investment in 2015, and the partnership continues with state agencies and the Florham Park township.”

The Florham Park facility reflects the company’s overarching environmental goals to comply with regulations, minimize environmental impact, conserve energy, conduct regular training and periodically audit internal operations.

The Environmental Stewardship Initiative is a recognition program

December 2019 www.designworldonline.com

Green.Engineering.12-19_Vs2.LL.indd 30

developed by Compliance & Enforcement for use by all NJDEP programs that conduct compliance assurance inspections. The goal of this initiative is to encourage regulated entities to improve their environmental performance beyond the minimum requirements of existing rules and regulations.

The program is broad in scope and covers a diverse spectrum of environmental stewardship and sustainability-related practices.

The intent is to showcase the achievements of members of the regulated community and serve as an information resource to encourage others to follow. DW Emerson | emerson.com

DESIGN WORLD

12/3/19 8:31 AM

Power Review

Altra Motion Vol. 8 | No. 4 | 2019

The Power Brands in Power Transmission

Featured in this Edition...

Form-Flex® Now Available in TB Wood’s eCatalog Power Transmission Solutions for Seemless Tube Piercing Mills Twiflex T35 Top Drive Caliper Brake Warner Electric PK Spring-Applied Motor Brake Captive Design for Outdoor Power Equipment Stromag SHD Series Braking Systems for Luffing and Flat Top Tower Cranes BCMA Backstops and BSFI Caliper Brakes for Coal Mine Conveyor Systems

Form-Flex® Now Available in TB Wood’s eCatalog Follow Altra Motion on:

Creating A Premier Industrial Company Ameridrives Bauer Gear Motor Bibby Turboflex Boston Gear Delevan Delroyd Worm Gear Deltran

Altra Industrial_#1_12-19.indd 31

Formsprag Clutch Guardian Couplings Huco Jacobs Vehicle Systems Kilian Kollmorgen Lamiflex Couplings

Marland Clutch Matrix Nuttall Gear Portescap Stieber Stromag Svendborg Brakes

TB Wood’s Thomson Twiflex Warner Electric Wichita Clutch

For more information contact us at: info@altramotion.com or visit www.altramotion.com

Scan to download the interactive version of the Power Review

12/3/19 8:32 AM

Form-Flex Now Available in TB Wood’s eCatalog Now Available Form-Flex® Drawings & CAD. Dimensionally-accurate, to-scale models are offered in every possible configuration of Form-Flex AP, GP, A5 and G5 Series couplings. Easily select filters and compare products to meet specific requirements and applications. Request quotes, view related literature and product models. eCatalogs are also mobile device and tablet friendly.

View 3D Models

View dimensional drawings and product specifications

For more information, visit www.TBWoods.com and click on the eCatalog icon

Power Transmission Solutions for Seemless Tube Piercing Mills Altra Motion provides power transmission solutions for use in Seemless Tube Piercing Mill Plants. Altra brands supply a wide range of products used on all types of seemless tube piercing plant machinery including piercing mills, sizing/reducing mills, straightening mills, cooling beds and transport systems.

All Altra power transmission components, including universal joints, couplings, spindles, speed reducers, geared motors, clutches, brakes, and torque limiters are designed to provide years of dependable service in harsh mill conditions. Rugged Altra products can be found hard at work in seemless tube piercing mills across the US and around the world.

Altra Motion

Ameridrives Bauer Gear Motor Bibby Turboflex

For more information, download P-8479-C from www.AltraLiterature.com

A Global Footprint to Support Customers Around the World

Nuttall Gear

Altra Headquarters

Stromag

Altra Engineering & Service Centers Altra Manufacturing Facilities

Twiflex The Brands of Altra Motion Couplings Ameridrives www.ameridrives.com Bibby Turboflex www.bibbyturboflex.com Guardian Couplings www.guardiancouplings.com Huco www.huco.com Lamiflex Couplings www.lamiflexcouplings.com Stromag www.stromag.com TB Wood’s www.tbwoods.com Linear Systems Thomson www.thomsonlinear.com

Geared Cam Limit Switches Stromag www.stromag.com Engineered Bearing Assemblies

Wichita Clutch Heavy Duty Clutches & Brakes Twiflex www.twiflex.com Stromag www.stromag.com

Kilian www.kilianbearings.com

Svendborg Brakes www.svendborg-brakes.com

Electric Clutches & Brakes

Wichita Clutch www.wichitaclutch.com

Matrix www.matrix-international.com Stromag www.stromag.com Warner Electric www.warnerelectric.com

Engine Braking Systems

Power Transmission Solutions for Seemless Tube Piercing Mills

Jacobs Vehicle Systems www.jacobsvehiclesystems.com Precision Motors & Automation Kollmorgen www.kollmorgen.com Miniature Motors

Gearing & Specialty Components Bauer Gear Motor www.bauergears.com Boston Gear www.bostongear.com

Deltran www.thomsonlinear.com

Delevan www.delevan.com

Belted Drives TB Wood’s www.tbwoods.com

Nuttall Gear www.nuttallgear.com

Delroyd Worm Gear www.delroyd.com

Portescap www.portescap.com Overrunning Clutches Formsprag Clutch www.formsprag.com Marland Clutch www.marland.com Stieber www.stieberclutch.com

The websites offer the global metals industries convenient, 24-hour access to the Altra brands, products and applications critical to virtually every operation in metal mills and metal processing facilities.

www.AltraMetalProducers.com www.AltraMetalProcessing.com

Twiflex T35 Top Drive Caliper Brake The Twiflex T35 modular caliper brake is a hydraulic pressure-applied unit designed specifically for top drive applications. It features a split housing with a rear-mounting capability to provide a direct interchange with common brake platforms.

• Up to 2393 psi (165 bar) operating pressure produces a maximum 5845 lb (26 kN) nominal braking force

• Minimum disc diameter 10.2 in (260 mm)

• Compact, robust housing design is fully plated for optimum protection

• Pad retraction springs ensure running clearance in the ‘brake off’ state

• Mounting and port interface aligned with common caliper designs • Hardware cross-drilled as standard for wire-locking

• Standard disc thickness 0.5 in (12.7 mm)

• Design operating range between -4°F and 158°F (-20°C and +70°C) Altra Motion

I N T R O D U C I N G

T35 Top Drive Caliper Brake For Oil and Gas Applications

Twiflex T35 Caliper Brake

The Twiflex T35 modular caliper brake is a hydraulic pressure-applied unit designed specifically for top drive applications.

It features a split housing with a rear-mounting capability to provide a direct interchange with common brake platforms.

• Up to 2393 psi (165 bar) operating pressure produces a maximum 5845 lb (26 kN) nominal braking force • Compact, robust housing design is fully plated for optimum protection • Mounting and port interface aligned with common caliper designs • Hardware cross-drilled as standard for wire-locking • Minimum disc diameter 10.2 in (260 mm) • Standard disc thickness 0.5 in (12.7 mm) • Pad retraction springs ensure running clearance in the ‘brake off’ state • Design operating range between -4°F and 158°F (-20°C ALL PORT 1/8 NPT and +70°C) 140 BLEED PORT NPT TO 37 FLARE SPACE ADAPTOR

ALL PORT 1/8 NPT NPT TO 37 FLARE ADAPTOR

MIN DISC DIA 260mm 12.7 BRAKE DISC MIN DISC DIA 260mm

Altra Industrial_#2_12-19.indd 32

2 AIR GAP 2 AIR GAP

70

127 114

130 60 112

45 45 TO DISCTO EDHE DISC EDHE

127 114

60 112

2 X M16 HEX HEAD BOLT SCREW GRADE 10.9 Mv = 220Nm ± 15Nm 2 X M16 HEX HEAD BOLT SCREW GRADE 10.9 Mv = 220Nm ± 15Nm

130

1

92

2

1 3

92

2

5 4

3

50

10 5

4

4 HOLES SPACED AS SHOWN TAPPED 1/2”-13 UNC x 19 DEEP

10 14

12

14

12

50

150

4 HOLES SPACED AS SHOWN TAPPED 1/2”-13 UNC x 19 DEEP

www.twiflex.com

150

For more information, download P-8817-TF from www.AltraLiterature.com

12.7 BRAKE DISC

REQUIRED FOR PAD REMOVAL

140 SPACE REQUIRED FOR PAD REMOVAL

70

(INTERCHANGEABLE)

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Warner Electric PK Spring-Applied Motor Brake Captive Design for Outdoor Power Equipment The Pan-Cake Captive (PK Captive) range is a pre-assembled on/off dry failsafe electromagnetic brake. This failsafe brake is used for parking and emergency only. The brake uses a high coefficient of friction material and powerful coil to optimize torque in a low profile package. The coil can be linked with a pulse width modulation power supply to reduce power consumption and maintenance.

The benefits of this cost competitive range include one piece design for easy assembly, lower power consumption, and overall lower maintenance costs.

• High torque within a compact space envelope • Multi-step braking versions available • Low profile space saving design

• Hand release on request • IP65 as a standard, IP67 on request

Altra Motio n

I N T R O D U C I N G

• Non-sticking friction material under harsh conditions

PK Spring-Applie d Motor Brake Captive Design Electrically Released Brake for Outdoor Power Equipment

Outdoor Power Equipment Applications – ZTR Mowers – Riding Mowers – UTVs Warner Electric is a world design and manufacture leader in the of hydraulic, pneumatic and electromagnetic brakes and clutches.

Based on long-term relationships, most major mower OEMs now view the Warner Electric engineering team as an extension of their engineering departments. internal routinely ship prototype OEMs mowers to Warner’s Technology and Innovation Center so Warner engineers can develop a custom clutch/brake solution for the specific outdoor power equipment application and and perform all appropriate then define testing protocols in-house.

As a leader in the Turf & Garden market and an expert in the Electromagnetic braking technology, Warner becomes the ideal partner Electric Outdoor Power Equipment to solve your application.

Contact us today to discuss how our dedicated engineers can assist you.

For technical assistance call US: +1 800-825-9050 Europe: +33 (0)2 41 21 24 24

Parking and Stoppin g Standard Brake The Pan-Cake Captive (PK Captive) range is a pre-assembled on/off dry failsafe electromagnetic brake. This failsafe brake is used for parking and emergency only. The brake uses a high coefficient of friction material and powerful coil to optimize torque in a low profile package.

The coil can linked with a pulse width modulation power supply be power consumption to reduce and maintenance.

The benefits of this cost competitive range include design for easy assembly, one piece overall lower maintenance lower power consumption, and costs.

• High torque within a compact space envelope • Multi-step braking versions available • Low profile space saving design • Hand release on request • IP65 as a standard, IP67 on request • Non-sticking friction material under harsh conditions

For more information, download P-8806-WE from www.AltraLiterature.com

Stromag SHD Series Braking Systems for Luffing and Flat Top Tower Cranes FMGru, a leading tower crane manufacturer located in Italy, needed reliable emergency braking systems for several models of its flat top and hydraulic luffing cranes. The caliper brakes are mounted on the disc flange of the crane’s main hoist drums. Brakes are also utilized on flat top crane trolleys.

Stromag SHD Series brakes were chosen over competitive models based on superior performance characteristics and technical support. The Stromag team responded quickly to FMGru and collaborated with its engineers to ensure that optimal brake solutions were selected for each specific crane model application.

Stromag was also able to deliver complete braking systems, including Type CSH hydraulic power packs, to meet FMGru’s tight production schedule.

• Spring set, hydraulically released emergency brakes

Application Profile

• Compact design • Four models with dynamic braking forces from 11kN to 180kN

Product

SHD Series Braking Systems Luffing and Flat Top Tower Cranes

Application

Highlights

• Type CSH hydraulic power packs also supplied

FMGru, a leading tower crane emergency braking systems manufacturer located in Italy, needed reliable cranes. The caliper brakes for several models of its flat top and hydraulic luffing are mounted on the disc flange of the crane’s hoist drums. Brakes are also main are required to automatically utilized on flat top crane trolleys. The fail-safe brakes during operation or scheduledengage when power is cutoff to the hoist drive motor maintenance. Emergency suspended loads in place, reducing the risk of damage brakes are designed to hold from falling material.

Stromag SHD Series brakes performance characteristics were chosen over competitive models based on superior and technical support. quickly to FMGru and The Stromag team responded collaborated with its engineers to ensure solutions were selected that optimal brake for each specific crane model able to deliver complete braking systems, including application. Stromag was also to meet FMGru’s tight Type CSH hydraulic power production schedule. packs, Compact, SHD Series monospring caliper brakes space available on tower are ideal for use in the restricted crane designs. Four spring set, hydraulically brake models are available released SHD with dynamic braking options are available forces from 11kN to including lining wear 180kN. Various indicators and opening proving switches.

Type CSH hydraulic power packs are specifically Units comply with onshore designed for SHD Series brakes. and offshore tower and boom cranes requirements.

• Spring set, hydraulically released emergency brakes • Compact design • Four models with dynamic braking forces from 11kN to 180kN • Type CSH hydraulic power packs also supplied

Europe +49 (0) 2303 102 0

stromag.com

US 1-860-238-4783

For a complete list of our global sales offices visit:

altramotion.com/contac P-8800-SG

tus

10/19

For more information, download P-8800-SG from www.AltraLiterature.com

BCMA Backstops and BSFI Caliper Brakes for Coal Mine Conveyor Systems Robust braking and holdback solutions were required for use on a conveyor system at Sasol’s Impumelelo coal mine expansion project in South Africa. The conveyor OEM contacted Svendborg Brakes based on previous successful mine conveyor collaborations. While discussing the braking package specifications, it was determined that Marland Clutch, another Altra Industrial Motion company, could provide the conveyor system’s required backstops.

To meet the challenging application requirements, Svendborg supplied BSFI 360 DS Series dual-spring caliper brakes with 47,941 ft.lbs. (65,000 Nm) braking torque for use on the conveyor system’s midstation pulley. BSFI 325 models with 19,914 ft.lbs. (27,000 Nm) braking torque were utilized on the high-speed shafts of both the midstation and head drive gearboxes.

Marland provided various sized backstops for the conveyor system including, Model BC-45MAs with 45,000 ft.lbs. (61,012 Nm) holding torque for the tippler conveyors and BC-375MA models with 375,000 ft.lbs. (508,432 Nm) torque rating for use on the inclined conveyor. A model BC-90MA with 90,000 ft.lbs.

(122,024 Nm) torque rating was utilized on the bunker feed conveyor.

Application Profile

For more information, download P-8013-C from www.AltraLiterature.com Product

Application

Highlights

Svendborg Brakes BSFI 300 DS Series Brakes • Fail-safe, spring-applied, hydraulically-release d brakes • Two sets of spring packs allow for longer intervals between required brake adjustments Marland Clutch BCMA Backstops • Highest reliability • Self-lubricated, sealed oil chamber • 20-year, 24/7/365 typical service life • Full torque load testing available

BCMA Backstops and BSFI Caliper Brakes Coal Mine Conveyor System Robust braking and holdback solutions were required Impumelelo coal mine for use on a conveyor expansion project in South Africa. The multi-conveyor system at Sasol’s 26.9 km (16.7 mile) long overland conveyor, one of the longest single-flight system includes a country, that transports the coal from the mine to a distant storage bunker conveyors in the facility.

The conveyor OEM contacted Svendborg Brakes based collaborations. While on previous successful discussing the braking mine conveyor package specifications, Marland Clutch, another it was determined that Altra Industrial Motion company, could provide required backstops.

The OEM was aware of Marland’s industry-wide the conveyor system’s manufacturing rugged, reputation for designing reliable backstopping and clutch solutions.

To meet the challenging application requirements, dual-spring caliper brakes Svendborg supplied BSFI 360 DS Series with 47,941 ft.lbs. (65,000 system’s midstation Nm) braking torque pulley. BSFI 325 models with 19,914 ft.lbs. (27,000 for use on the conveyor utilized on the high-speed Nm) braking torque were shafts of both the midstation and head drive gearboxes.

Marland provided various sized backstops for the with 45,000 ft.lbs. (61,012 conveyor system including, Nm) holding torque for Model BC-45MAs with 375,000 ft.lbs. the tippler conveyors (508,432 and BC-375MA models with 90,000 ft.lbs. (122,024 Nm) torque rating for use on the inclined conveyor. A model BC-90MA Nm) torque rating was utilized on the bunker feed conveyor.

Similar brake and clutch powertrain components Shondoni mine expansion, were supplied for conveyors also located in South at the Sasol’s Africa.

Contact Svendborg

Brakes

US (Application Assistance)

1-303-285-1271

svendborg-brakes.com P-8013-C

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Contact Marland Clutch

US (Application Assistance)

1-800-216-3515 marland.com

Asia Pacific For a list of our AP sales offices: altramotion.com/conta ctus

12/3/19 8:33 AM

SMART MARLAND MONITORING SYSTEM You can now remotely monitor the condition of your Marland clutch from anywhere using your computer or cell phone. Up to the minute access to critical system operating conditions including Vibration, Temperature and Oil Level.

Performance Capabilities: • Monitor up to 6 devices from a single gateway • Set desired report intervals • Perform statistical analysis to identify maintenance and repair needs • Alarm notifications

Simple System Requirements: • Power supply (24Vdc, 120/240 VAC, 50/60 Hz) • Less than 200m line of site between gateway and devices • Access to local network or cellular signal

Reporting Capability: • Current measurements • Historic trending • Vibration analysis

Industrial Internet of Things

For more information call:

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or visit www.marland.com

Altra Industrial_#4_12-19.indd 34

12/3/19 8:33 AM

Design for Industry Food and beverage

Track system for industries with

strict cleaning requirements

F

Food and beverages and pharmaceuticals industries have some of the highest demands for easy to clean components. The IP69K-rated track is variant of the intelligent ACOPOStrak track system. The new version of the track can be pressure washed at temperatures up to 80°C. Not only is the new track protected against high-pressure cleaning, it is also completely protected against dust. With IP69K protection, the track system can be used in both dry and wet areas of complex installations.

The shuttles and segments of the new track variant are made of stainless steel, securely welded and resistant to corrosion. The stainless-steel housing enables the transport of corrosive products and operation of the ACOPOStrak in corrosive atmospheres such as salt spray. All of the track’s surfaces are chemically resistant, preventing particles or fluids from penetrating into the interior of the shuttle or segments. The shuttles’ magnet unit is completely protected against high-pressure cleaning.

DESIGN WORLD

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www.designworldonline.com

This version of the ACOPOStrak enables economical batch-size-one operation with the efficiency of mass production – even for industries with strict cleanability requirements.

ACOPOStrak can be expanded flexibly by adding track modules and processing stations. This makes machines scalable enough to adapt to changing production requirements at any time.

DW

B&R Industrial Automation www.br-automation.com/en

December 2019

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Design for Industry energy

I/O modules for mixed signal types

T

These EPIC I/O modules address the demands of specialty and lowcost applications, including dry contact monitoring, temperature control and mixed voltage. For system integrators and engineers, the I/O modules provide more options for bringing existing devices into groov EPIC, as well as meeting precise requirements for temperature control applications. They also include designs for mixed signal types, signal isolation, and channel density:

• GRV-IDCSW-12 (discrete input, 12 channels, dc contact switch status)

36

monitors the open/closed status of dry contact switches, and provides the necessary excitation voltage to power the circuit. This module is for monitoring distributed IT equipment, benchtop analyzers, motor run/ stop relays, or any device that offers only a dry contact for status.

Because there’s no need to install separate power supplies to drive the dry contacts—since wetting and monitoring are both provided—this module can save considerable time, money, space, and installation effort.

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• GRV-IVI-12 (analog voltage input,

12 channels, ±1.25 to ±160 V, channel-to-channel isolation): With 12 isolated channels, each configurable to one of eight ranges from ±1.25 to ±160 V, this module eliminates the need to segregate I/O signals over multiple modules, providing significant cost and space reduction for mixed voltage applications. The GRV-IVI-12 has 20bit resolution and is accurate to 0.1% of the configured range. It includes options for scaling, filtering, averaging, and more, speeding development time and distributing computation functions down to the I/O module.

DESIGN WORLD

12/3/19 8:37 AM

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

•

GRV-IRTD-8 (analog input, 8 channels, temperature/RTD or resistor) increases options for accuracy and I/O density in temperature applications. It provides 8 channels for 2-and 3-wire RTD inputs, with a maximum range of –200 °C to 850 °C. Users can take advantage of multiple fixed ranges or one or two auto-ranging methods to simplify configuration. GRV-RTD-8 can also be used for high resolution resistance measurements, with accuracy ranging from 4.2 Ohms at the 8K Ohm input range to 0.058 Ohms at the 10 Ohm range for 3-wire RTDs. PAC Project 10.2003 or the Opto 22 Library Package for CODESYS v1.0.2.0 are required for full support of these modules.

PRECISION NUTS & WASHERS

These modules also offer the following features: Two-position, hinged LED module cover that indicates module status and covers field terminations Touch-sensitive pad to trigger module information display on the groov EPIC processor Removable top-mounted connector with single, captive retention screw Spring-clamp field wiring terminals Hot swappable for installation and removal without turning off or stopping the system UL Hazardous Locations approved and ATEX compliant Wide operating temperature range of –20 to +70 °C Individually calibrated and factory tested twice—no statistical testing Guaranteed for life

• • • • • • • • •

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

ADAPTER SLEEVE ASSEMBLIES

Materials of: CARBON, ALLOY and HARDENED ALLOY STEELS Materials of: ALLUMINUM and CORROSION RESISTANT STEEL

Users can choose from almost 40 types of groov I/O modules to support their application requirements. DW

Opto 22 www.opto22.com

NUTS & WASHERS

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

W

HI

TT

ET

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IG

GI

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A

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.

WHAT DO YOU THINK? Connect and discuss this and other engineering design issues with thousands of professionals online

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.

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

DESIGN WORLD

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Electronic & Solenoid Valves for Fluid Control

Canfield Industries 12-19.indd 38

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Design for Industry Machine tool

For smaller, faster and more accurate linear motion

T

The Sigma Trac II combines an SGLF2 series linear motor with linear bearings, high resolution absolute optical scale, cable management, and optional bellows to create a turnkey linear stage. Leveraging Sigma-7 servo amplifiers, system designers and automation end users can design smaller, faster, more accurate linear motion systems for additive manufacturing, packaging, material handling, machining, and assembly applications.

Features include:

• Peak force output up to 540 N • Speeds up to 5 m/s • High reliability with 10 million double-stroke design life • Absolute encoder feedback with 9.765 nm resolution • Zero maintenance • Integrated cable management • Stroke lengths up to 1340 mm • Optional bellows and X-Y adapter kit This linear stage design will allow machine builders to create innovative mechanisms that are smaller and faster than before. When combined with

DESIGN WORLD

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Sigma-7 servo amplifiers, Sigma Trac II linear motor stages provide short settling time for greater repeatability in highly dynamic movements that are typical in packaging, assembly, and additive manufacturing applications. Sigma Trac II stages are available in 3 coil sizes and 13 base lengths, making it is easy to select the optimal linear servo motor stage for your application. DW

Drives & Motion Division of Yaskawa America, Inc www.yaskawa.com.

WHAT DO YOU THINK? Connect and discuss this and other engineering design issues with thousands of professionals online

December 2019

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

2D camera gives fast and detailed error analysis

T

Spontaneous errors in the manufacturing process can be a thing of the past with the EventCam. This industrial-grade 2D camera brings clarity when unexplained gripping, handling, and positioning problems arise or when unreproducible installation errors or machine downtimes occur.

The EventCam is for the detection and analysis of sporadic errors in industrial processes. It can be integrated into stationary and mobile applications, is network capable, and delivers single frames and video sequences in ultra-high image quality for detailed error analyses.

The optics, illumination, electronics, and ring memory of the camera are enclosed in a compact and rugged IP65 housing made from cast aluminum. The housing provides several mounting options that allow the camera to be installed in different positions, and these positions can be changed quickly and flexibly.

Configuring the camera is simple: the resolution, output format, and trigger signal can be set with a few clicks in the browser-based SOPASÂ Air software.

The EventCam is for fast and targeted error analysis. A connected automation system or sensor reports that an error has occurred in the process through the trigger input in the camera itself. The camera then begins storing single frames or video sequences.

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At the lowest SVGA resolution, the camera can record up to 240 seconds before and up to 100 seconds after an event; all can be stored in the internal ring memory. If full HD is required, it can record 25 seconds before and up to 15 after, if in 30 frames per second (FPS).

The video FPS can range from 13 to 65, depending on the resolution needed. In addition, EventCam can take photos of up to 15 FPS, taking 25 images before and 25 after in the highest resolution or 120 before and after in the lowest resolution.

In contrast to the time-consuming process of searching for an event in continuous video material, the EventCam enables a targeted root cause analysis to be performed in just a few seconds or minutes. It is not necessary, either, to first upload the images and film sequences from the memory card – they can be accessed over the network in real-time at 100 Mbit/s via FTP and the Ethernet TL Design World V1.pdf

1

6/17/19

interface on the camera.

The camera not only enables a fast and detailed retracing of events in running machines and plants, but is also useful when commissioning or optimizing them. The ability to quickly analyze errors in an unsupervised test run or a multi-hour/multi-day continuous test reduces the effort required to locate errors and therefore the time and costs associated with machine setup. The high mounting flexibility and simple configuration of the EventCam enables it to be used in a variety of machines, setup processes and tasks.

The EventCam is available in two variants. The version with a 0.4 m to 0.6 m working distance is primarily intended for stationary applications in machines, compact assembly, or pick-and-place robots. The camera with a 0.8 m to 6 m working distance

is designed for use in larger robots, handling gantries or machines. It also works well in safety applications in conjunction with safety laser scanner to take images of an area surrounding a machine. This enables users to see why downtime may have occurred and if, and why, someone tripped the safety scanner.

DW

SICK | www.sick.com

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Design for Industry Machine tool

Three-phase monitoring relays with a wider input voltage range

T

Three-Phase Monitoring Relays feature a wider input voltage range. The models, part of the DPB and DPC families, reduce the number of individual items that need to be stocked.

The DPB and DPC models have an upgraded switch mode power supply, which provides a wider input voltage range to cover different mains voltages, while reducing heat dissipation and improving reliability and stability. The DPB series has an input voltage range of 208 Vac to 480 Vac, while the DPC series has an input voltage range of 208 Vac to 690 Vac. All of the new models feature a frequency range of 50 Hz to 400 Hz. Key features of the DPB and DPC Three Phase Monitoring Relays include:

• Noise, harmonics, and transient filtering • Significant reduction in power consumption versus previous models • Wide input voltage and frequency range • Voltage ranges selectable by DIP switches • DIN Rail mounting • Plug-in option available for DPB series DW

Carlo Gavazzi | www.GavazziOnline.com

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Design for Industry Medical

Miniature voice coil motor is tiny but mighty

W

When you need a motor with a short stroke but with good power, consider a miniature voice coil motor. The miniature LVCM-019-022-02 linear voice coil motor, also called a linear dc motor, has a 1/2 in. (12.7 mm) stroke and a high forceto-size ratio. It produces 8.1 oz. (2.3 N) of continuous force and 25.7 oz. (7.1 N) of peak force in a compact 0.750 in. (19.1 mm) diameter x 0.875 in. (22.2 mm) housing.

This miniature high speed / high acceleration servo motor may be used in closed loop servo loop. Its zero cogging, clean, quiet, efficient, low inertia, high acceleration features make it suitable for applications such as: Pick-and-place, testing, laser steering, laser speckle reduction, mirror positioning, scanning, oscillation, switching, clamping, and haptic feedback in hand held medical, dental, or industrial applications.

The miniature LVCM-019-016-02 linear voice coil motor can be easily added to new or existing applications using the precision drilled and tapped 8-32 UNC-2B mounting holes in the coil and housing ends of the motor. DW Moticont | www.moticont.com

DESIGN WORLD

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December 2019

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Design for Industry Medical

Tiny sensor delivers images from smallest parts of anatomy

T

The OV6948 claims the Guinness World Record for “The Smallest Image Sensor Commercially Available” with its size of 0.575 mm x 0.575 mm. Derived from this ultra-small imager is the OVM6948 CameraCubeChip–a fully packaged, wafer-level camera module measuring 0.65 mm x 0.6 5mm, with a z-height of 1.158 mm.

These medical imagers address a market demand for decreased invasiveness and deeper anatomical access.

Additionally, these imagers address the many challenges posed by reusable medical imaging equipment, including cross-contamination risks and inefficiencies due to high maintenance costs.

“At Yole Développement (Yole), we expect disposable endoscope shipments to grow at a 35.9% CAGR over the next five years (1),” said Marjorie Villien, PhD., technology and market analyst, medical and industrial imaging. “This industry is driven by the recent recommendation from the US Food and Drug Administration (FDA) related to the cross-contamination issues due to improper cleaning of the endoscopes. In this context, all major endoscope OEMs are developing cost-effective, small-diameter disposable endoscopes with high image quality.”

Using wafer-level packaging technology, the OVM6948 is making the mass production of disposable medical imaging equipment possible. This complete module can be integrated into a catheter or endoscope with a diameter as small as 1.0 mm. With this camera’s small size and high 200x200, or 40 KPixel backside-illuminated resolution, high quality images can be captured from within the body’s narrowest blood vessels for neuro, ophthalmic, ENT, cardiac, spinal, urology, gynecology and arthroscopy procedures. Additionally, many space-constrained dental, veterinarian and industrial applications can also benefit from the OVM6948’s advanced design.

“Previously, procedures in the body’s smallest anatomy were performed either blind or using low quality images from fiberscopes, as existing cameras were too big and reusable endoscopes were not cost effective,” said Aaron Chiang, marketing director at OmniVision. “The OVM6948 wafer-level camera module offers a compact, high quality solution for disposable guidewires, catheters and endoscopes, which are experiencing growing demand because of their ability to reduce cross-contamination risks, downtime inefficiencies and costs associated with the repairs, preprocedural testing and sterilization of reusable endoscopes. In addition, these compact disposable medical devices can improve patient comfort and shorten recovery time.”

The OVM6948 is a “chip on tip” camera with backside illumination, which provides excellent image quality and better low-light performance to help reduce LED heat, along with improved sensitivity. It also allows for the use of superior lens technology over competing front-side illumination cameras in this class.

Additionally, this color analog camera with OmniBSI+ technology enables easy calibration in production and is reflowable with a 4-pin interface for simplified integration, which shortens time to market while reducing costs.

Other key features of this camera module include a wide 120-degree field of view and an extended focus range of 3 mm to 30 mm. Its image array is capable of capturing 200x200 resolution images and video at up to 30 frames per second, and its analog output that can transmit over 4 meters with minimal noise. The camera also offers low power consumption of 25 mW, generating less heat for better patient comfort and flexible procedure durations. DW

OmniVision | www.ovt.com

(1) Source: Solid-State Medical Imaging report, Yole Développement, 2017 & 2020 upcoming edition

December 2019 www.designworldonline.com 44

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5.55 [.22]

"A"

4.70 [.19]

0.50 [.02] 3.18 [.12]

Semiconductor

15.75 [.62]

Vacuum systems for

8.13 [.32] SNAP-IN BRACKET (V20 / V25)

3.18 [.13]

1.22 [.05]

25.20 [.99]

nanometer management of motion

22.00 [.87]

N

Ø21.80 [.86]

13.20 MAX [.52]

Nanometer management of motion is becoming more common across industry as technology solutions work to tighter and tighter tolerances. This trend is prevalent in numerous positioning sensitive industries, such as fiber optics, biomedical, micro machines, electronics, semiconductors, energy, optics, aerospace, and synchrotrons.

Nano-positioning applications are exacting and are further complicated when the management of motion is under vacuum, or when the requirement is for extended travel, finer repeatability, higher speed, greater uptime and — of course — lower cost. Drive mechanisms, bearings, feedback systems, motion controllers, and the kinematic structure all need to be designed to perfection to meet nanometer precision in atmospheric or vacuum environments.

Motion systems for nanometer precision have many critical components that must work well together for nanometer precision and when you place these components in a UHV chamber these components need to be carefully re-engineered to assure heat dissipation, outgassing, and precision motion.

For example, these vacuum systems use precision bearings. To consistently meet nanometer-level precision, the systems use crossed roller bearings.

Position feedback in a vacuum chamber must avoid outgassing. The vacuum systems use optical encoders that read either to a tape or glass scale, or when more precision is required read to a scale etched directly into a stainless steel of a ring (for rotary applications), or onto a nickel-plated invar spar (for linear applications).

For vacuum motion control applications, the vacuum system uses piezoelectric driven stages and linear and rotary servo motors. Ceramic servo motors are unique in their motion acting as a spiraling friction motor, which allows for unlimited travel without mechanical hysteresis while maintaining nanometer precision. Servo motors are more robust with higher forces and higher duty cycles but are currently limited to 10-7. These piezo motors stages are well suited for ultra-high vacuum environments (10-10 TORR) due to the material’s limited outgassing.

An extensive range of ultra-precise and repeatable motion control solutions (with exception of its air bearing systems) are vacuum compatible.

Linear, rotary, open center X-Y, hexapods, tripods and goniometer stages and systems are available in HV (10-7 TORR) or UHV (10-10 TORR) with ultra-low outgassing materials and components all carefully prepared and baked. DW

2.00 [.08]

CIT

AY

REL

25.75 [1.01]

M19x1.0 7.75 [.31]

4.65 [.18]

5.80 [.23]

2.75 X 0.50 TYP [.11 X .02]7.00 [.28]

(2X) Q0.40 [.02]

15.00 [.59]

(2X) 0.50 [.02] 2.54 [.10]

2.60 [.10]

5.08 [.20]

5.08 [.20]

2.54 [.10]

16.00 [.63] 20.20 [.80]

15.35 [.60]

23.70 [.93]

2X 4.75 [.19]

2.80 TYP. [.11]

11.00 TYP [.43]

7.80 [.31]

8.00 [.31]

0.80 TYP. [.03]

4.0 [.16]

0.80 TYP [.03]

2X [.25]

12.1 [.48]

Ø1.55 [.06]

15.1 [.60]

16.0 [.63]

Alio Industries | www.alioindustries.com

DESIGN WORLD

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L

Design Notes

Linear transport system assists

inspection of airbag components Edited by Mike Santora • Associate Editor

Gefasoft developed a system for the optical inspection of diffusors for airbags through 11 camera stations requiring varying inspection times. For this application, the company chose the eXtended Transport System (XTS) from Beckhoff Automation.

German automation systems supplier Gefasoft recently developed a system for the optical inspection of diffusors for airbags through 11 camera stations requiring varying inspection times. The company chose the eXtended Transport System (XTS) from Beckhoff Automation.

For complex component shapes, optical inspection systems typically require a series of cameras in serial or parallel stations to check all criteria. The Sova-VIS 16 system from Gefasoft Automatisierung und Software GmbH is no exception. Because they are safety-critical components of the car airbags, the cup-shaped, drawn sheet metal parts — produced in various versions with diameters of approximately 60 millimeters — must undergo inspection of their interior and exterior surfaces.

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While some inspection tasks require only a single picture, others require sophisticated lighting systems and multiple images. The interior wall of the diffusor is a critical surface that must be inspected for even the smallest imperfections with dimensions of only a few tens of micrometers. Line scan cameras are used before the part is trimmed to achieve the proper image resolution. The trimming process alone takes about 2 seconds, meaning the DESIGN WORLD

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RELIABLE MOTION SOLUTIONS. image acquisition times vary significantly between the individual stations.

If all camera stations were linked through a rigid conveyor system, such as a rotary indexing table, the station with the longest image acquisition time would determine the shortest cycle time of the entire system and limit the throughput rate accordingly. However, with the flexibility of the XTS, faster inspection stations can be served at a higher rate, while slower stations can be supplied with components simultaneously.

“With the Sova-VIS 16 system, the heterogeneous imaging times of the individual steps led us to look for a machine layout with a flexible, asynchronous transport system that would enable us to perform the job efficiently in a limited amount of space,”

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As safety-critical links between the airbag and the inflator or gas generator, diffusors must be inspected quickly and efficiently.

HIGHLY COMPACT SMARTMOTOR™ SERVO SOLUTIONS FOR AUTONOMOUS VEHICLES. • Fully integrated designs • Most compact, power-dense solution on the market • Complete servo system

explains Georg Schlaffer, marketing manager for Gefasoft. “Despite the presence of slower inspection stations, we were able to achieve an average cycle time of 1.9 seconds.”

Engineering Director Christian Schärtl explained that because of the demand for these parts, the end customer specified a cycle of less than 2 seconds.

Because two of the inspection steps take almost 4 seconds, these stations had to be duplicated and parallelized to meet this goal. “Other solutions with carriers

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Design Notes

and switches based on belts or chains would have required much more complex mechanics and would have been slower while taking up more space, said Schärtl.”

Because of the many camera inspection stations, the total length of the XTS line amounts to approximately 11 meters (36-ft) with 30 movers. Due to the mover’s weight, the line was equipped with a special guidance system made

by HepcoMotion. The mass of about 4 kilograms (8.8 lbs.) per mover was needed to accommodate the handling requirements with units for lifting and rotating — the diffusors must rotate precisely in front of the cameras and be able to move in two layers (“hat” and “cup”) so their top and bottom sides can be inspected.

The goal was to use a single inspection machine to fully automate the process, which ranged from picking up the parts from a pallet to stacking or sorting them with a robot. Distributing the inspection tasks over multiple independent machines was not an economical option for the end customer.

Besides the complex logistics between the machines and their increased space requirements, it would also have been too expensive to split up the feeding process of the diffusors from bulk containers.

After the surface of the components has been degreased, the diffusors are supplied to the inspection machine as bulkware in mesh pallets. A gripper

48

XTS movers with upper and lower mandrels (left and right images) pick up the diffusors in “hat “or “cup “orientation. Also visible is the sprocket used to rotate the parts in front of the line scan camera.

Positioned in “hat “and “cup “orientation, the diffusors pass through the inspection stations, some of which exist in duplicate versions.

takes the parts from a conveyor and passes them to the XTS. To ensure proper orientation for the workpiece holder of the XTS mover, the transfer station has a camera that detects the diffusor’s positional angle as well as its type. Each diffusor has a batch number embossed in its top, which is checked in the first camera station.

After detecting the batch ID, the system checks the interior of the diffusor, which requires it to be rotated in the mover from a “hat” to a “cup” position — with the opening pointing upward. To do this, the parts are picked up from the mover with a gripper, rotated 180°and

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placed back onto the mover. Meanwhile, the internal mandrel is withdrawn so that the part is centered and resting on its flange. To inspect the surface of the part’s interior it is then rotated in front of a line scan camera.

“What turned out to be a major challenge was the limited space because the camera and four lights had to fit inside the part, which only has an interior diameter of approximately 60 mm,” Schärtl explains.

“To resolve this, we had to design an integrated lighting and camera unit, which dips into the part while a servomotor docks from the outside to the rotatable mandrel in the mover. Also, a fast controller had to be developed for the lighting system. Moving the lighting unit into the component and rotating it takes a little more than 2 seconds. To achieve the line cycle time of 1.9 seconds,

Rod Ends and Spherical Bearings designed and manufactured to Aurora’s exacting standards for quality and durability.

With the eXtended Transport System, Gefasoft was able to optimize the quality inspection of cylindrical metal parts.

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Design Notes

we installed two of these inspection stations.”

The rotating stations are followed by a control station for material deviations and a station for inspecting the base of the diffusor. The last camera station of the first linear XTS section checks the flange for flaws. This configuration means that the first linear section holds six camera stations. With duplicate line scan and rotating stations, this brings the total to nine positions.

After the movers have passed through the 180°curve of the XTS, more camera stations, as well as a printing station for marking the diffusors, follow on the other side. The parts are flipped from “cup” to “hat” orientation before two parallel line scan camera stations check their exterior surface. This is followed by the inspection of the upper side of the flange, a camera-

To inspect the diffusor interior, parts are removed from the XTS mover and rotated 180°with a gripper to achieve the correct camera angle.

controlled inkjet printer for marking faulty components that is synchronized with the motion of the XTS movers, and a laser for marking the good parts. At the end of the second linear XTS section, a Stäubli TP80 robot picks up the parts from the mover for further processing. DW

Beckhoff www.beckhoff.com/XTS

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Design Notes

Additive manufacturing makes a

better pick and place device for food handling Edited by Mike Santora • Associate Editor Houdijk uses its 3D printers to make customized prototypes; it can take many iterations to achieve an optimized shape and finish to handle a specific product.

Food handling equipment specialist, Houdijk designs and assembles advanced handling systems for fully automated movement and loading of cookies, biscuits, and crackers. According to Gosling Putto, R&D Manager at Houdijk, “Product has to go from point A to point B — the less it is handled, the higher its quality will be.” However, customer requirements for variations in functionality can complicate applications.

For each handling system, the nature of the product itself needs to be taken into consideration; every cookie, biscuit, or cracker will have different dimensions and different characteristics (sticky, brittle, greasy, dry, etc.). Therefore, for each system, the engineers at Houdijk must test many separate and distinct functionalities. Putto explains how 3D printers enable this. “We use our 3D printers to make customized

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Houdijk 3D prints myriad brackets with various geometries. Before it invested in 3D printing, the company would have to cut and bend sheet metal to create parts, which was both labor-intensive and much more expensive.

prototypes. It can take many iterations to achieve an optimized shape and finish to handle a specific product.”

When it came to supplier selection, Houdijk invested in several FELIX 3D printing solutions — two Pro 3s and a Pro L (for larger parts). The two Pro 3s are for quickly producing small parts for faster iteration and optimizing a design. The machines are also robust and mobile enough for transport when traveling to a customer’s facility. When it comes to the Pro L, this is much more of an industrial machine and is used specifically to produce larger parts. It is also useful for that the Pro L is suitable for printing rubber-like materials.

“We use the printers to print vortex and venturi nozzles. So, if you blow compressed air through these components, you create a low air pressure spot that acts like a suction cup. This is the scientific principle we use to efficiently pick up and place the cookies and biscuits. We also 3D print myriad brackets with various geometries. Before we invested in 3D printing, we would have to cut and bend sheet metal to create these parts, which was extremely labor-intensive and much more expensive,” said Putto.

Houdijk is also looking to directly use 3D printing to manufacture support structures for mounting to other parts. If very tight fittings are not required and if the parts are not exposed to excess stress, the company has found that it can replace a large amount of turned and milled parts, which allows them to reduce costs and streamline their processes. They also produce sliding boards and dribble boards. The Pro L allows Houdijk to print large channels (around 300 mm long and 40 mm wide) on which cookies slide down from conveyor A to conveyor B while accommodating the height difference. They will also occasionally diverge and converge on these boards.

Running these printer systems has proven cost-effective for Houdijk in terms of material consumption, which compares very favorably with alternative FDM 3D printing systems, according to Putto. Houdijk has also found working with these printers postsale has provided the company with a working partner that offers reliable and fast feedback. DW

Felix Printers | www.felixprinters.com

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Design Notes

With thousands of insert options available, each one designed to meet certain application requirements, itâ&#x20AC;&#x2122;s not always as simple as specifying OD, ID, length, and thread count.

How to select metal inserts for molded plastics

Edited by Mike Santora â&#x20AC;˘ Associate Editor

Metal inserts are integral to the design and manufacturing of many molded plastic products.

Yet, because inserts are often viewed as commodity items, it is not uncommon for product designers to write up basic specs for an insert without confirming that it is the most suitable for the application. With the number of inserts required often reaching the millions, failure to source the proper insert can significantly increase costs, scrap rates, the risk of product failure, and result in excessive manufacturing downtime.

To solve this issue, many OEMs and plastic molders will team up with insert manufacturers that offer engineering expertise throughout the design and manufacturing process. This not only creates an extension of the OEMs own technical team but can assist in the discovery of non-standard insert designs that can overcome wear problems, improve performance or longevity, and provide significant cost savings in the long run.

For Carlton Tanner, he and an insert supplier are frequently forced to team up to assist an OEM that is having issues with the inserts they selected. Tanner is the senior manager with Blackland

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Design Notes

Tri-Star Industries helps injection molders and OEMs discovery non-standard insert

Precision Hardware — a Texas-based distributor of electronic and commercial hardware, rivets, and inserts.

“This is particularly the case when the OEM gives us an insert order for a new product and the specs are sketchy, which happens fairly often,” says Tanner.

Because there are thousands of insert options available, with each one designed to meet certain application requirements, it’s not always as simple as specifying OD, ID, length, and thread count.

Tanner emphasizes that even the most knowledgeable customers are wise to heed the advice of insert experts on their designs. He describes one such instance where an injection molder working for a major automaker had spec’d a threaded brass insert with diamond knurling for a new product they were set to produce.

“Fortunately, the OEM conducted an initial test with the insert, where it became evident that the design they selected was somewhat problematic for their production process,” Tanner explains. “Before they could place the million-plus part order, they needed a solution, fast.”

Fearing the issue could force production backups, cost run-ups, and missed deliveries for the OEM, Tanner took the issue to one of his primary insert suppliers, Tri-Star Industries. Tri-Star specializes in threaded inserts and compression limiters for plastics.

“What we found was that the knurled surface of the inserts was chipping slightly, both in transit and as the inserts were bulkloaded into the injection molding system (a standard operation),” says Tanner. “As a result, the accumulation of these small chips was gumming up the automated injection molding process, causing expensive unplanned downtime.”

The technical support team evaluated the specs from the injection molder and considered the end products various Many inserts have knurling, requirements before developing or the grooved pattern (often drawings for Tanner to review with diamond-shaped as seen here) the molder. Those included the idea to modify the knurling, or the on the outside, which helps keep grooved pattern (often diamondthem in place. Sometimes chipping shaped) on the outside of the insert, can be problematic in bulk loaded which helps keep its place. or automated productions.

Additionally, to prevent any minor chippings during shipment from entering the production, the technical support team suggested adding a layer of mesh to the bottom of the insert shipping container and an adhesive coating to the bottom of the container.

The mesh would function as a sieve, through which the chips can fall during transit; these errant chips will then stick to the adhesive surface on the bottom of the container.

In another instance, an OEM/plastics molder was sourcing inserts for use in commercial juice dispensing machine assemblies, the type often seen in cafeterias and restaurants.

“Because orange and grapefruit juices are highly acidic, the issue was that they would eventually cause a corrosion problem with a metal insert,” said Aaron Edelson, Tri-Star’s sales engineer.

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designs, like the one shown here, that can overcome wear problems, improve performance or longevity, and provide significant cost savings.

The beverage dispenser OEM had spec’d an insert that required an expensive, secondary plating operation that ensured a corrosion-resistant barrier was present.

In this case, Edelson recommended that the customer use a stainlesssteel insert instead. This would make it impervious to corrosion, and thereby protect the juices from any impurities that would result from corrosion.

The demand for stainless steel is increasing in many industries, from food & beverage, medical, and marine to integrated circuit manufacturers.

While it is important for an insert manufacturer’s technical support team to review each design, they should also have the ability to read, write, and modify CAD files and isometric drawings. Some manufacturers also include downloadable CAD information from their website for most standard catalog items. This allows engineers to visualize and validate their design concepts with the inserts they are considering using in their application.

Edelson adds that often an inquiry from him intending to confirm the specifications of an insert can lead a distributor or OEM/molder to a breakthrough in quality or service life.

“The teamwork among the engineering staff of the OEM customer and technical services/design staff of the insert manufacturer can create a type of synergy that results in superior product performance as well as cost and downtime savings,” Edelson says. DW

Tri-Star | www.tristar-inserts.com

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Internet of Things

EtherCAT G is now an addition to the EtherCAT standard

E

EtherCAT G was introduced by Beckhoff Automation in 2018 as an extension of the EtherCAT standard.

Beckhoff recently presented the gigabit technology addition to the ETG, and after thorough review, the organization’s Technical Committee accepted it. Right now, the ETG is working to add EtherCAT G to the corresponding technology specifications.

Dr. Guido Beckmann, Chairman of the ETG Technical Committee, explains why ETG welcomes the active integration of EtherCAT G into ETG: “With EtherCAT G, particularly data-hungry applications, such as machine vision and high-end measurement technology, can now be integrated. This extends the range of applications for EtherCAT technology.”

The 100 Mb/s EtherCAT technology remains a proven solution for the majority of applications. However, EtherCAT G offers additional user advantages, especially in applications where particularly large amounts of process data must be transported per device. This can include, for example machine vision, high-end measurement technology or complex motion applications that go beyond the scope of classic drive control. As an extension of standard EtherCAT technology, EtherCAT G is fully compatible; existing devices designed for 100 Mb/s can be seamlessly integrated into an EtherCAT G system, and EtherCAT G devices in a 100 Mb/s EtherCAT system behave like classic EtherCAT devices.

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The central element of EtherCAT G is the use of EtherCAT Branch Controllers, which essentially fulfil two main functions: On the one hand, they act as a kind of node for the integration of segments from 100 Mb/s devices; on the other hand, they enable parallel processing of the connected EtherCAT segments. This reduces the propagation delay in the system, which increases system performance many times over previous levels.

Typical for EtherCAT: The integration of EtherCAT G is simple, as the extension is fully compatible with the IEEE 802.3 Ethernet standard and no software adaptions in controllers are required for the standard mode. DW

The Technical Committee of the EtherCAT Technology Group www.ethercat.org/en

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Internet of Things

Software accelerates time-to-market of leading 5G, IoT and automotive electronics

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The PathWave Test 2020 software suite delivers an integrated experience for electronic manufacturers to accelerate time-to-market of their digital and wireless platforms and products. Developed on the PathWave software platform, the PathWave Test 2020 software suite enables 5G, IoT and automotive engineers and managers to streamline test data processing and analysis to speed product introductions and secure a competitive advantage in the market.

The software provides data sharing and management between platform software tools including test automation, advanced measurement, signal creation and generation, as well as data analytics. This integrated software platform allows application-tailored solutions to be developed and deployed to significantly accelerate electronic test workflows and product introductions.

At the core of the PathWave Test 2020 software suite is PathWave Desktop Edition, providing users with access to the platform for launching and managing applications in the design and test ecosystem.

PathWave Desktop Edition enables engineers to:

• Manage instrument discovery and installed design and test software • Share data with a common user experience across all design and test software • Accelerate development and deployment of solutions • Improve insights leveraging powerful new analytics and best-in-class measurement science DW

Keysight | www.keysight.com

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Internet of Things

An upgrade to managed Ethernet switches

A

Antaira Technologies announces a hardware update to the small port count managed Ethernet switches. The new hardware update will be known as “V2”. The affected switches are listed below: LMP-0501G-SFP(-T)-V2 LMP-0501-xx(-T)(-24)-V2 LMP-0600(-T)(-24)-V2 LMP-0601G-SFP(-T)(-24)-V2 LMP-0602-xx(-T)(-24)-V2 LMX-0500(-T)-V2 LMX-0501G-SFP(-T)-V2 LMX-0600(-T)-V2 LMX-0601G-SFP(-T)-V2 LMX-0602-xx(-T)-V2 These low-port-count managed switches are industrial-grade devices that are Ethernet ready to fulfill various markets’ edge-level networking applications in harsh and outdoor environments, such as manufacturing automation, security surveillance, power/utility, water wastewater treatment plants, oil/gas/mining, and transportation. These devices support Ethernet port connectivity, long distance data transmission, and have a superb reliability factor.

The version two (V2) hardware delivers more horsepower under the hood allowing a new operating system to be installed. With the new operating system comes a long list of features which brings these smaller switches up to the same feature set as the larger port count Antaira switches. Two of the most new and important key features are multi-ring Ethernet Ring Protection Switching (ERPS) and access control lists.

ERPS is an open standard used for creating redundant link rings. Ring technology helps prevent system outages by creating multiple paths allowing data to make it to its destination even when a link has failed. Using an open standard for the ring allows a customer to not be trapped by a customer’s proprietary protocol. Allowing a mixture of manufacturers’ products to be used in an application can also create the best solution.

Network security has become increasingly important and while no one feature can assure a secure network, layers of features provide the best security.

Access control lists make sure data can get to where it needs to go but all other traffic is blocked. Minimizing how data traffic flows on a network is an important step to securing any network. The new access control lists available with the new version two hardware will allow an administrator to control this traffic and begin to secure the network. DW

Antaira Technologies | www.antaira.com 60

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GPIO, one HDMI, and one USB 3.0. The UNO-420 enables connecting legacy equipment to new mesh networks.

Aimed at harsh industrial environments as well as in-cabinet installations with limited space, the UNO-420 terminal features a compact form factor (125 x 125 x 50 mm/4.92 x 4.92 x 1.97 in.) and supports a temperature range of -20 ~ 60 °C/-4 ~ 140 °F. To enable remote management of infrastructure, UNO420 supports diverse Wi-Fi, Bluetooth, 3G, 4G/LTE, and NB-IoT wireless modules that facilitate long-distance data transmissions, over-the-air (OTA) updates, and real-time communication. Considering the importance of cyber security amid the rise of the IoT, the UNO-420 terminal is also embedded with a Trusted Platform Module (TPM) 2.0 that provides security for cloud-based data operations. Furthermore, unlike standard data gateways, UNO-420 adopts a PoE-In design that allows the terminal to be powered via a LAN port, which reduces wiring and minimizes overall maintenance costs.

Designed to serve as a sensing data collector, the UNO420 is a compact data gateway that can be easily integrated with diverse equipment and machinery. The provision of comprehensive I/O interfaces, including three configurable COM, two LAN (one PoE-In), eight programmable GPIO, one HDMI, and one USB 3.0, allow raw data to be collected and transmitted directly to the cloud for subsequent visualization and analysis.

When combined with optional Wi-Fi, BT, 3G, 4G/LTE, and NB-IoT wireless modules that enable remote management, the UNO-420 provides a reliable, cost-efficient, and scalable terminal for infrastructure gateway applications.

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Internet of Things

with a power cable, the UNO-420 is designed with PoE-In support. This means a single Ethernet cable can be used for data transmissions and power delivery.

Ethernet cables are widely employed in existing infrastructures and considerably less expensive than fiber optic cables.

Accordingly, Advantech’s UNO-420 gateway with PoE-In support provides customers with an edge-to-cloud data sensing solution that requires minimal wiring and is cost-effective to install.

The UNO-420 data gateway is also equipped with WISE-PaaS/EdgeLink protocol-conversion software, which supports more than 200 industrial devices such as PLC, remote I/O, power meters via industrial protocols (e.g., Modbus, OPC-UA, and MQTT) to enable data collection from legacy devices. In addition to facilitating data integration, WISE-PaaS/EdgeLink allows user-defined data acquisition periods for each input interface, reducing the volume of data transmitted and stored on the cloud. This combined with the software’s plug-and-play functionality dramatically reduces programming and streamlines application development and deployment.

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pressure, and up to 72 psig during intermittent operation.

Key Features: • Intel Atom E3815 processor with 2 GB of DDR3L memory • Powered via PoE, single Ethernet cable for data transmissions and power delivery • Configurable RS-232/422/485 and 8 programmable GPIO • Supports dual wireless communication for Wi-Fi/BT/3G/4G/ GPS connectivity • Equipped with TPM 2.0 for enhanced cyber security • Edge-to-cloud connectivity with WISE-PaaS/Edgelink software • WISE-PaaS/Edgelink supports 200+ industrial device connectivity for data collection from legacy devices DW

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At 103 mm in length and 600 g in weight, the NPK 012 is 30% shorter and half the weight of other models. Although small, this swing piston pump offers incredible vacuum and pressure performance with low energy consumption, making it ideal for medical inhalation devices, sprayers, pick-and-place vacuum equipment, and more.

The vacuum version reaches 25.8 in. Hg, has a maximum flow rate of 13.5 L/min, and can deliver 15 psig continuously.

The pressure version delivers up to 36 psig of continuous positive

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CAE Solutions

Siemens expands SaaS offerings to Simcenter Amesim and Simcenter 3D

S

Simcenter 3D software and Simcenter Amesim software are available as a service. Through

a strategic collaboration between Siemens and Rescale, a leader in enterprise big computing, engineers can gain immediate, cost-effective software-as-a-service (SaaS) access to simulation tools. Particularly useful for small to medium-sized businesses, the SaaS framework offers tiered product bundles in which users can select the right level of capabilities they need, as well as monthly subscription-based billing and licensing and a pay-peruse computing infrastructure.

Large enterprises can also benefit from the availability of Simcenter on the Rescale cloud platform with multiple flexible licensing options available to solve specific business challenges. SaaS licensing can be used to add shortterm software licenses in times of peak usage or bring your own licensing (BYOL) can be used to let Simcenter customers leverage their existing investments when highperformance computing (HPC) capabilities are needed.

In addition to Simcenter Amesim and Simcenter 3D, Simcenter Nastran and Simcenter STAR-CCM+ can be accessed through the cloud so that companies of all sizes can create and simulate digital twins of their products, on-demand on an established HPC platform. DW

Siemens Digital Industries Software | www.sw.siemens.com 64

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CAE Solutions

Comsol Multiphysics update includes new sketching tool

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Comsol is set to release Comsol Multiphysics Version 5.5 in November 2019.

In this version, the Design Module offers a new sketching tool for easier creation and more versatile parametric control of geometry models, says Daniel Bertilsson, technology manager for mathematics and computer science at Comsol.

Comsol Multiphysics offers tools for engineering modeling, simulation, application, and deployment. It solves for multiple physical effects at the same time.

The company made the update announcement at its annual Comsol Conference held in October in Boston.

New and updated solvers speed a range of ultrasound technology becoming simulations. Two new add-on products, the increasingly important in a range of Porous Media Flow Module and the Metal applications from process engineering Processing Module, further expand on the and nondestructive testing to consumer product’s suite of multiphysics tools. electronics.

The new sketching tool makes it easier to Other new functionality—based on assign dimensions and constraints to planar the time-explicit discontinuous Galerkin drawings for 2D modeling and 3D work method—enables efficient multicore planes. computation of ultrasound propagation “We’ve carefully integrated the new in solids and fluids. This includes dimensions and constraints tool in the realistic materials featuring damping Model Builder so it becomes a natural part and anisotropy. The method also has of the Comsol Multiphysics workflow,” low-frequency applications, such as in Bertilsson says. “The new tools for seismology. The multiphysics capability dimensions and constraints can be used included in this new functionality can together with model parameters in Comsol seamlessly combine linear elastic wave to drive the simulation, whether for a propagation in a solid and its transition to single run, parametric sweep, or parametric a fluid, as an acoustic pressure wave, and optimization.” back again.

The new elastic wave functionality Acoustics simulations is available for users of the Structural Another update—new solver technology Mechanics Module, MEMS Module, and for acoustics simulations—is a nod to Acoustics Module. The fluid-structure

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EAGLE STAINLESS Tube & Fabrication, Inc.

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acoustics coupling is available in the Acoustics Module.

Extensive tubing inventory Eagle stocks stainless, copper, brass and aluminum in metric, hypodermic and fractional tubing in an extensive assortment of grades.

Porous media flow module This module gives users within industries such as food, pharmaceutical, and biomedical a range of transport analysis capabilities for porous media, trying, and transport in fractures. The flow modules cover linear and nonlinear flow in saturated and variably saturated media with special options for slow and fast porous media flows. The multisphycis simulation capabilities are extensive, with functionality that includes options for calculating effective thermal properties for multicomponent systems, poroelasticity, and transport of chemical species in solid, liquid, and gas phases.

Other highlights of this upgrade include: Import and export of the 3D printing and additive manufacturing formats PLY and 3MF. • Multiple spectral bands for radiation in participating media • Lumped thermal systems equivalent circuits • Combined full wave and ray optics simulations • Minimum-sized standalone application files with Comsol Compiler • Compressible Euler flow and nonisothermal large eddy simulations • Editing tools for repair of STL, PLY, and 3MR files

Cut-to-length tubing - Eagle can cut and de-burr any diameter in quantities from 1 piece to millions from lengths of .040” and longer with a standard tolerance of ±.005 on diameters of less than 1”. Closer tolerances are met quite often.

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Update on pacs

Many of todayâ&#x20AC;&#x2122;s automation systems blend motion control with robotics, vision systems, I/O, and HMIs on a single programmable automation controller. Some even connect with or serve as IoT gateways to allow communications between enterprise-level systems and the Cloud.

P

PLCs are still by far the most common choice for simpler setups of

standalone or single-axis motion. But such applications are seeing more inroads from motor drives sporting controller functions. These motor drives excel in machine designs that still need PLC functions with multiple interfaces â&#x20AC;&#x201D; including Ethernet communications and digital I/O, for example.

Because such motor drives can also incorporate motion controls delivering S-curve, camming, and freeform motion profiles, OEMs are more likely to pick them than programmable automation controllers (PACs) in otherwise-simple designs eliminating standalone PLCs. Contrast the needs of these motion designs with more complex setups. PLC modules for single-axis motion are managed by a main processor or primitive sub-processor in the motion module; they interface with a main processor over a PLC backplane. But any PLC modules for single-axis motion control with low encoder-frequency rates can limit performance. Other PLCs limit how fast the position register can update, which in turn limits machine throughput.

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SAFETY

PROCESS CONTROL

DCS MOTOR CONTROLS

CNC DIGITAL I/O

ANALOG I/O

DRIVES FEEDBACK MOTION and SEQUENTIAL CONTROL

HMIs ENTERPRISE and IIoT CONNECTIVITY

PROGRAMMABLE LOGIC CONTROLLER (PAC)

COLLISION DETECTION INTEGRATED VISION ROBOTICS

SCADA

PACs can operate in multiple domains simultaneously — including motion and sequential control, process control, logic, data management, and communications on a single platform. PACs are also used in Cartesian, SCARA, and six-axis robot applications needing coordinated motion across multiple axes as well as integration with other motion and data systems.

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PACs can handle higher bandwidth on the backplane ... and in complex motion applications can share motion data with multiple modules. That boosts performance.

High-bandwidth backplanes also makes for more powerful motion modules ... so depending on the processor core, a motion module here may be capable of complex axis-to-axis coordination advanced enough for advanced motion in machine-tool or robotic applications.

No matter the permutation, multi-axis machine controllers include hardware and software in a structure organized around the management of complex motion. Consider the task of tracing a circle with two linear axes. Such coordination necessitates fast axis-position updates and comparisons to predicted position — along with error correction to the speed command of each

axis-driving motor. This is a very demanding real-time task. The speed of the processor’s execution must be many times faster than the speed of the motor feedback.

Given the computing capabilities of today’s processors, PACs (and PCbased controllers) are primed to handle such multi-axis motion control. It’s true that each platform does this in its own way — and it’s common to have myriad independent motion axes in a machine with each operating independently off a start-signal input. But full multi-axis motion usually works to coordinate axes through mathematical definitions.

History lesson The earliest multi-axis motion control was computer numerical control (CNC) of the 1950s. These CNCs had computer

Differentiating PACs In a broad sense, a PAC is an industrial controller that combines the functionality of a PLC with the processing capability of a PC. The term programmable automation controller is generally accepted as having been coined by the ARC Advisory Group, which specified five characteristics that define a PAC: • Multi-domain functionality • A single, multi-discipline development platform • Flexible software tools that maximize process flow across machines or processes • An open, modular architecture • Compatibility with enterprise networks But with no industry-standard definition of a PAC, the distinction between PACs and PLCs is blurry.

Higher-end PLCs now incorporate some of the characteristics described above and are encroaching on what was once considered PAC territory. In fact, many PLCs now include standard programming languages, the ability to expand functionality through add-on modules, and connectivity to various bus systems. But PACs still differentiate themselves from PLCs by employing a more open architecture and modular design.

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hardware running programming languages for automating metal-parts manufacture.

The advent of the transistor and integrated circuit drastically reduced the size and cost of CNC hardware, but its command language and architecture persist to today.

In fact, multi-axis motion control since the 1950s has evolved as a unique class of controls to satisfy programmingenvironment requirements. The development has been complicated by how suppliers choose different processor platforms to go with their proprietary programming languages. User libraries arose to give users higher-level programming tools … but some are still vendor specific, complex, or time-consuming to use.

However, trends towards standardization continues to address such issues. PAC vendors now produce general-purpose control hardware that integrates into IT networks but is rugged enough for industrial settings — and modular like the PLC form factor. This necessitates relatively advanced controller hardware so the PAC can function in any control application. It also means that PACs are equally capable of managing large data-gathering networks, or running machine control logic, or doing both simultaneously. So when it comes to running multi-axis motion control, today’s computing power delivers.

I/O and connectivity Prompting more standardization on the software side is IEC 61131, which dictates the form of most ladder-logic programming today and (in recent versions) motion extensions for motion programming in the ladder environment. Depending on the motion job, the ladder approach may be fine … but it’s not usually multi-axis.

In addition, motion-controller inputs and outputs from homing and limit switches and encoders are high-level inputs that must be dedicated to a specific axis on which they’re setup to work. Sometimes PACs need add-on modules to execute special functions.

Remember that some PACs are architected much like PLCs, but the major difference (from an electronics

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PROGRAMMABLE AUTOMATION CONTROLLERS INTEGRATE MULTIPLE COMPONENTS MAIN CONTROL UNIT (PROCESSOR) KEYPAD and CONTROL LED STATUS INDICATORS MODULES

Programmable automation controllers (PACs) integrate multiple subcomponents.

All include a base unit with CPU and power supply; this base unit or complementary modules can also include analog, pulse, and other I/O; positioning, high-speed counter, motion, energy and power functions; and safety communications, controls, and relays.

POWER SUPPLY (on main unit or a module)

COMMUNICATIONS (on main unit or a module)

standpoint) is how PACs have a high-bandwidth backplane that 1) allows integration of various architectures and 2) allows additional processors to boost the functionality of the primary PAC. So software in the main PAC can manage intelligent peripherals, but it’s often useful add devices to the system architecture when an application needs control functions that exceed the main processor’s capabilities. A common add-on is remote I/O racks using standard offerings implemented with multi-megahertz Ethernet as the communications interface.

These setups often use an Ethernet gateway module in a local rack with the main controller … which in turn supports the Ethernet link to the remote I/O rack. Ethernet updates faster than older PLC backplanes ... though in a PAC with high bandwidth, data rates aren’t an issue.

Consider the special cases of testing and machine vision. Advanced test setups needing high-speed data acquisition often include timing and triggering functions on their PXI backplanes. Adding a PXI bridge module (or PCI or VME) to a PAC makes the technology available on other bus architectures in the PAC environment.

Most machine vision still uses standalone control because the processing burden and speed of vision demand it. But PAC suppliers continue to expand the repertoire of control capabilities by offering high-

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I/O MODULES

Programmable automation controllers compare most closely to what exactly?

According to some, today’s most demanding motion designs either incorporate a PAC or industrial PC (IPC) — and these are engineers’ two leading options for machine control right now.

Recall that until recently, industrial automation (including motion control) was extremely segmented.

So supervisory control and data acquisition (SCADA) systems were at the system top layer … separate from machine-level HMIs … in turn separate from PLCs on the machinery … with those oftentimes separate from devices reaching down to the motion control level — or at the end reaches of the machine executing other complex processes beyond the capabilities of a PLC. But now, many of today’s automation systems blend motion control with robotics, vision systems, I/O, and HMIs on a single PAC or IPC. Some even connect with or serve as IoT gateways to allow communications between enterprise-level systems and the Cloud.

Of course, solutions employing PLCs and simple motion controls remain suitable for myriad applications.

But where robust and flexible controls with an emphasis on the HMI are top priority, an IPC maybe most suitable ... and where wide-reaching operations need coordination of and communication with many axes, I/O, and systems, PACs excel.

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speed communications bridges to other subsystems. Machine-area networks with machine vision can be demanding — and yet the high-speed communications supported

by PACs are an industry-accepted solution.

Programming considerations Today’s PACs and the ways motion control has evolved over the last five years means there’s now more fluidity in what languages are used where. Controller hardware in the form of PACs is a vast departure from legacy systems with different devices performing different jobs — with a standalone motion controller segregated from the machine’s PLC set aside from its HMI. It used to be that all this hardware was associated with different processes and software. Now unifying hardware along with IEC 61131-3 has substantially changed the way industrial coders program — and even the ways industry conceptualizes discrete versus process control … as now they’re often run off one device with a flexibly selected mix of languages.

So it’s clear — no one IEC 61131-3 language leads for all uses. In fact, the best way to program with IEC 61131-3 languages is by using multiple languages together. That accommodates (among other things) the way every engineer has a different methodology for programming.

Sequential function chart (SFC): Recall that SFC is the highest-level code standard in IEC 61131. It is not technically a language but rather a means of partitioning code and visual display of the machine state or the mode in which a machine is currently running. States can be initialization states … or going from an initialization state to a standby state … or shifting from that state to an automatic or even manual mode … and so on.

SFC basically consists of diagrams showing how a machine should operate — serving as an operator layer that lets anyone approach and investigate sequential function charts and immediately understand how the machine is supposed to run — as well as processes associated with a part or material entering the machine … and what the end result will be and look like.

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Having these separate modes means engineers and operators can easily go into each and drill down to a “maintenance” layer.

Ladder logic: Many engineers fear that IEC 61131-3 aims to abolish ladder logic — though that’s simply not true. Many U.S. maintenance personnel have a long history with it. It’s a familiar and visual language that clearly displays sets of inputs, response actions in particular modes, and expected output. That’s a perfect maintenance layer because it clearly shows causal relationships — to let personnel troubleshoot and write code for the right aspect of the machine within that node causing problems.

The problem is that ladder limits other kinds of machine programming. Traditional designers program ladder logic in software such as C# and C++ as well as Python — visual languages that vastly complicate (or are incapable of) advanced mathematics, data processing, and cross-component communication drivers. For such operations, it would take a programmer an inordinate amount of time to click and drag and create coils.

Resulting programming would also be quite unwieldy — with rungs and rungs of visual code incredibly difficult to debug.

Function blocks: A better choice for more

involved processes is function blocks. The code lets programmers set an action and output action wrapped in a function block — because maintenance personnel don’t necessarily need to see developer back-end code. Programmers can put their structured text in that function block and that in turn can be locked down to into a library.

Such code can be compiled and even protected as part of the OEM’s intellectual property — IP in back-end structured text that end users can’t access.

Such layering of code with IEC 611313 and forethought about all the ways in which different personnel will interact with the design makes machine builds more robust. Asking who will ultimately read the code (and which language would be most helpful for them to interpret what the program is trying to do) also makes the design more accessible. Frameworks such www.designworldonline.com

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as Packaging Machine Language (PackML) and guidelines abound to make such layered code easier to write.

Blending control languages As mentioned, one key strength of programming with IEC 61131-3 is that it allows layering of code in multiple languages. That addresses the varied needs of all personnel types who will ultimately need to operate and access the machine and its code. It also lets engineers get away from using one language for everything. After all, some languages work better for processoriented tasks than discrete motion control, for example.

The IEC 61131-3 environment lets engineers blend even such disparate programming together. For example, there’s accommodation of PLCopen motioncontrol function blocks (with PLCopen being another industry standard to level the playing field for motion-control manufacturers) with motion functions such as MC_Power to power drives and MC_Jog to move motors.

One common approach is to create motion-control code in structured text (ST).

Staunch adherents to structured text feel ST excels in nearly every situation. However, a drawback can be less accessibility for technicians.

Another common approach is to create motion-control function blocks at the ladder level — especially where maintenance personnel may need to understand and track machine functions) or sequential function charts for higher-level perspectives on whole processes. DW

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for motion control Sixto Moralez Regional motion engineer Yaskawa America Inc.

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In a previous motion-sizing article, we reviewed how to specify a ballscrew-driven motion axis. Here we detail how engineers can use a similar approach for sizing rackand-pinion-based servomotor-driven axes on the same gantry. We’ll use manufacturer software to work through the application.

Rack-and-pinion mechanisms include a circular gear (the pinion) typically made of steel with equally spaced teeth. This pinion engages a linear gear (the rack) to convert rotational motion into translational motion. A servomotor directly drives the pinion to either cause the servomotor-pinion assembly (and attached loads) to travel along the rack or (less commonly) to cause the rack (and attached loads) to advance and retract.

So assume the Z axes (Z and Z prime) are ballscrew mechanisms sized with the approach we detailed in our last installment. (Visit linearmotiontips.com and search Sixto for this article.) Also assume our design’s axes X and Y (Y and Y prime) are rack-and-pinion mechanisms.

With such multi-axis systems, the easiest approach is to start the sizing at the smallest or most distal axes (in this case, our X axis) because these axes’ overall weight and any masses they bear will be part of the payload for the system’s larger upstream axes — here, Y and Y prime. So, let’s start with the X axis.

Payload is a 30-lb tool that must move side to side along the rack. The fastest speeds reach 20 feet per minute. Currently the system doesn’t have the torque needed for the move. Thus sizing is critical to ensure the servomotor will be able to move and control the load on the rack system.

Sizing software — including that which supports the design of rack-and-pinion axes — often makes specific component recommendations.

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M o t i o n First step: Entering data in sizing software

We use step-by-step approach to entering data into our motor and rive manufacturer software, about the Rack-and-pinion system to have the ability to select a servomotor. Let’s begin with the Pinion.

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Questions to ask are:

What is the diameter of the pinion?

Is the measurement in millimeters or inches? Assume our pinion is 3 inches in diameter. We will use this to determine the circumference of the pinion for distance travelled.

Who is the pinion manufacturer?

HDK? TSK Machinery & Engineering?

WITTENSTEIN? What is the thickness of the pinion? What is its width? Assume for our example our pinion is 1 in. wide.

What is the density of material? Pinions are often manufactured of steel, but some are made of aluminum. If unsure of the pinion’s material, some software includes a calculator to closely estimate material composition.

That factors into its inertia.

What is the pinion’s pitch-circle diameter (PCD)? Generally, pinion PCD is defined by its outer diameter.

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Calculating the move profile

The move profile of a rack-and-pinion axis is calculated in terms of linear distance. To get a safe move profile estimate, is always

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best to use stroke and acceleration values associated with a worst-case scenario. As previously stated, the maximum speed for our example 3D-printing application will be 20 feet per minute and the end user would like the axis to execute this speed within one minute.

Here, it’s easiest to enter anticipated move values in the software (in metric or U.S. standard units) to calculate the worst-case move profile. That’s because within design software, modifications to the acceleration ramps can be adjusted by Accel and Decel entries — as well as the type of units to use.

Design tip: Use pauses or dwells at the end of each move and a return move to start.

Servomotor and gear selection within software

To reiterate — choosing a servomotor for an application needn’t be tedious. Selection software accepts data about a given axis’ parameters to yield one or more servomotor options to satisfy the application.

In fact, some manufacturers’ design software integrates with digital catalogs to provide specific recommendations. That’s particularly useful for the final selection of

Rack-and-pinion systems often serve as the mechanical drives on stage-assembly base axes.

servomotors — as each series and model can have unique advantages and limitations.

For our rack-and-pinion axis, software will recommend low-inertia servomotors for small capacity applications.

Some software will also recommend the inclusion or omission of a gearbox — usually with industry-standard 3:1, 5:1, 10:1, 15:1, and 20:1 ratios. Where partnerships support it, final recommendations can take the form of fully integrated gearmotors. If ratios or gearbox types presented aren’t optimized to the design, particularly flexible software will allow the manual entry of third-party gearbox specifications. These values include the

gearbox ratio, inertia, and efficiency.

For example, adding a 3:1 gearbox to the servomotor for our application will actually let us choose a slightly smaller gearbox — a 200-Watt version instead a 400-W version — for an upfront motor cost that is 25% lower.

For example, Yaskawa’s Sigma-7 series servomotors are recommended by its SigmaSelect software to meet exacting automation and motion-control requirements. For the application example we present in this article, SigmaSelect identifies a Yaskawa low-inertia SGM7J servomotor as a suitable selection. This line includes motors that output 50 W to 1 kW.

LINEAR PITCH PINION

Shown here are some of the

PINION PITCH RADIUS

RACK PITCH LINE RACK PITCH DISTANCE

PINION PITCH CIRCLE

definitions relating to rack-and-pinion geometry.

RACK

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Addressing issues related to commutation alignment between AC PM servo motors and servo drive amplifiers — especially when motor and drive are from different manufacturers —

Load mass

External force +

–

Rack mass

Pinion pitch circle diameter Pinion inertia Direction of motion The mass of smaller axes (including payload, servomotor, and so on) borne by larger axes factor into the total calculated payload for the latter.

Yaskawa’s SigmaSelect software allows easy calculation of an axis’ motion profiles.

The mass of smaller axes (including payload, servomotor, and so on) borne by larger axes factor into the total calculated payload for the latter.

Reports from some software can summarize the basic design setup.

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This is a 3D printer gantry using a rack-and-pinion set.

More specifically, it identifies the SGM7J-04A 400-Watt servomotor (accepting three-phase 200 Vac input) as the best match for the parameters we’ve set. If the application requires more speed but not a lot of torque, Yaskawa SGM7J or SGM7A-series motors maybe more suitable. Conversely, if the application requires more torque and not a lot of speed, SGM7G-series motors may be best. Where an application has dimensional constraints, SGM7P-series may be necessary.

For a full list of servomotors fro this line, visit www.yaskawa.com/products/motion/ sigma-7-servo-products.

Regeneration, connectivity, reports

Advanced servo-design software will indicate if a regenerative resistor is needed and what capacity is needed. For more information on regeneration, visit motioncontroltips.com and search: Don’t forget these two things when selecting an amplifier.

Additional drive parameters to be entered include the power input and drive type — as well as any requirements for analog pulse control as well as EtherCAT or Mechatrolink-III connectivity, for example.

Look for servomotor selection software that can do the above and deliver full design reports to share with end users for machineperformance verification. DW

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Shown here are the values of a regeneration report.

Yaskawa America Inc. yaskawa.com/products/motion/sigma-7-servo-products

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How to

combine 1D and 3D

thermal simulation for

modeling aircraft fuel systems Leveraging advanced 3D CAD-embedded CFD capabilities can add robustness and fidelity to a 1D system model.

Mike Croegaert | Siemens Digital Industries Software

A common issue with modeling complex 1D systems is adding the required detail for complex components that cannot easily be represented through correlations or empirical data. To get the data for these types of components, engineers have two options: physical testing and 3D computational fluid dynamics (CFD) simulation and analysis. Physical testing can be costly and obtaining the data can be difficult for all possible operating scenarios. Whereas, 3D CFD can be time consuming and often requires an expert to get reliable results.

Fortunately, we now have the option to use advanced 3D CAD-embedded CFD solutions in conjunction with 1D CFD tools to quickly and accurately characterize complex components without the need for a specialist, while providing an added level of robustness to a complex system model.

The basic fuel system: solving pump limitations To illustrate the effectiveness of using this combination, a simple passenger aircraft fuel system example will be used. Figure 1 shows a 1D system model drawn on top of the basic fuel system schematic image. It

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Figure 1: Basic aircraft fuel system schematic. The three large blue sections represent the wing and the center fuel tanks, the white boxes represent pumps, and the fuel feed and transfer plumbing is represented in green. The refueling lines are represented in dark blue. Shut-off valves are depicted throughout the model as the circular symbols, indicating normally open or closed.

We now have the option to use advanced 3D CAD-embedded CFD solutions in conjunction with 1D CFD tools to quickly and accurately characterize complex components without the need for a specialist, while providing an added level of robustness to a complex system model.

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includes source components for the boundary conditions and extra loss components for items such as filters and couplings. The thin link lines represent a direct connection between adjacent components, but they are not pipes themselves.

Nodes sit in the middle of the links and serve as convenient points to enter elevation data and interrogate flow results of temperature and total pressure.

During normal operation, the fuel is drawn from the tanks with mechanical fuel pumps.

However, most mechanical pumps must be fully wetted to function properly. This means sometimes unusable fuel is left in the bottom of the tank. To extract the residual fuel, jet pumps can be added with the suction side connected to the lowest sump point on the inner wing tank. This pump feeds the collector cell by using the motive energy provided by a small amount of high-pressure fuel bled directly from the mechanical fuel pumps. For this example, the jet pumps are placed in the lowest portion of the tank.

In contrast to most other components, this jet pump does not come pre-supplied with performance data. That leaves the designer with two options to define performance. The first method is to enter detailed geometry for the pump and the 1D CFD tool can apply a built in empirical correlation for jet pump behavior.

The second option is a more rigorous databased approach. The pump requires a curve of flow ratio versus head ratio and a curve of motive flow rate versus pressure difference between

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the motive and suction arms. This data can come from many sources, including the vendor of the pump, physical testing, or 3D CFD characterization and analysis.

3D-1D characterization Sophisticated 3D CAD-embedded CFD programs have key technologies that facilitate 1D data generation. These tools can be used by the typical engineer as well as seasoned CFD analysts. They apply automated modified wall functions to capture boundary layer effects properly, regardless of the density of the mesh in the boundary layer. They also have an automated solver to determine the flow regime between laminar, turbulent, or transitional without intervention. The most advanced 3D CAD-embedded CFD software has a unique and automated mesher that is geometry aware. If the CAD geometry changes, the mesh changes automatically, updating as the problem solves, intelligently putting more mesh where it is needed.

Because these tools are completely CADembedded, the designer can run parametric studies, by not only varying flow conditions, but also changing the actual geometry over the course of a study, feeding data back to the 1D CFD software as seamlessly as possible.

Using an intuitive graphical interface, the designer inputs the key variables— choosing the units, the physics to consider DESIGN WORLD

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Figure 2: 3D CAD-embedded CFD adaptive mesh.

in the simulation (including heat transfer, gravity effects and rotation), the fluids to use in the simulation, and lastly, the initial conditions such as temperature, pressure, and initial velocity. The 3D software then calculates a computational domain surrounding the relevant fluid geometry.

The design engineer can resize the domain area or even slice the volume in half and do an axisymmetric simulation to save computational resources. The mesh (Figure 2), although highly automated, can be manually driven to add grid cells where needed and manually refined by selecting specific geometry, adding optional control planes, or even disabled bodies into the CAD model to serve as the mesh structure.

Once the model is prepared, the boundary conditions set, and goals determined, the simulation is ready to run launching the solver. The solver is the only aspect of 3D CAD-embedded CFD that does not operate directly in the CAD environment. Instead, a second window is launched to monitor the progress of the

solution. Custom-defined preview plots for parameters such as pressure, velocity, and even the mesh can be created. Goals can also be plotted to have a real-time monitor on current value and their trend toward convergence. Parametric studies can also be performed on multiple machines at once to improve performance.

Once complete, the results are loaded back into the CAD interface, the first example of a result is a cut plot that shows the contours of velocity with overlaid streamlines (Figure 3). The cut plane can be manually adjusted with a live preview. 3D CAD-embedded CFD can also generate three dimensional flow trajectories inside of the fluid region.

Typically, for characterizing a component using 1D CFD software, multiple simulations are needed to generate data over a range of flow conditions. Once the study is complete, the results can be saved to a file that acts as a raw record of the flow conditions at each boundary at each experiment point. Each point contains data for flow rate, pressure,

temperature, density, viscosity, enthalpy, and heat capacity. From this data, nondimensional curves can be created so that the software can extrapolate performance of the part over a range of fluids, temperature, and pressures.

After the curves are created, they can be imported into the 1D CFD tool either as an individual data curve or as a complete component. The software will parse the data and automatically determine what type of component to create. Once this step is done, the 1D CFD software adds the component to the catalog and automatically populates it with the data just generated.

Before using the component in the fuel system model, it will first be verified in a unit test. Unlike most components, components sourced from the 3D CADembedded CFD program require no further data to use because relevant data such as the curves are pre-applied. All that is required to run a unit test is to add boundary conditions and run an analysis, and the component should perform exactly as the software predicted during the characterization step. After the unit test has verified the component was created correctly, the jet pump can be added to the fuel system model (Figure 4), and the designer can run a series of analyses.

In this example, two transient simulation scenarios will be examined. In the first simulation, the jet pump has been included but blocked the motive flow, so the tanks will only feed into the collector cell via gravity. The connection between each

Figure 3: Sample results from 3D CADembedded CFD.

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Figure 4: Adding the characterized jet pump to the system model.

section of the tanks is through a series of holes in the ribs that separate each compartment. These holes span almost the entire height of the tank, but the bottom 2-in. of the tank is blocked by structure.

As shown in Figure 5a with the blue line, the outer tank is draining briefly into the inner tank marked in red. The outer tank stops flowing as the level of fuel drops below the holes in the rib.

Rendering the remaining 2-in. of fuel in that tank unusable. The inner tank in red, and the collector cell in green both drain together. The collector cell is drained via the mechanical fuel pumps, and the inner tank drains via gravity into the cell until it

too reaches about 2 in. of height and can no longer drain. The tank is exhausted of all usable fuel in about 125 seconds.

The second case shown in Figure5b has the jet pump enabled. Here, the jet pump is moving fuel from the inner tank to the collector cell at a rate of about 10 gal per minute. In this case, the inner tank drains much faster, but that fuel is being transferred to the collector cell to feed the pumps. Because the suction inlet to the jet pump can be placed at the lowest point in the tank, it can drain almost all of the fuel out of it before it stops providing flow. At this point, the fuel level in the collector cell starts to drop quickly until it is completely

Figure 5a: Scenario 1 – Jet pump inactive.

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exhausted. In this case, because more fuel is available, the tank does not drain for 320 seconds, a significant improvement.

Leveraging advanced 3D CAD-embedded CFD capabilities can add robustness and fidelity to a 1D system model. The 3D CFD solution does this by characterizing complex components within the CAD environment and then automatically importing the results into the 1D model. Here, a common issue with 1D system models of aircraft fuel systems was examined: how to add the required detail to the model for complex components that cannot easily be represented through correlations or empirical data. Siemens 3D CFD software, Simcenter FLOEFD, runs inside of several CAD packages including Siemens NX and Solid Edge, CATIA V5, PTC Creo, and a standalone version. This example also uses Siemens Flomaster 1D CFD software for the system simulation.

Until recently, designers had to choose between costly physical testing and timeconsuming 3D CFD that usually requires an expert to obtain reliable results. This approach that combines 3D CAD-embedded CFD and 1D CFD can be used to quickly and accurately characterize complex components without the need for a CFD analyst and provide an added level of robustness to complex models such as the aircraft fuel system. DW Siemens Digital Industries Software www.sw.siemens.com

Figure 5b: Scenario 2 – Jet pump active. www.designworldonline.com

December 2019

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M e c h a n i c a l

How neutron scattering is helping to create stronger bearings By studying the science behind bearings, materials, and products, specialists have developed proprietary surface coatings, heat-treat processes, manufacturing methods, analytical modeling tools, and other patented techniques and technologies all aimed at one thing â&#x20AC;&#x201D; engineering stronger bearings.

Edited by Mike Santora

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Vikram Bedekar and Rohit Voothaluru chose Oak Ridge National Laboratory for its applied expertise in advanced materials, supercomputing, neutrons, and nuclear science.

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When standard X-rays are not strong enough, it takes neutrons to see inside a material. ORNL is helping advance scientific discovery by accelerating ions to near light speed.

Recently, Timken researchers teamed up with the U.S. Department of Energy’s (DOE’s) Oak Ridge National Laboratory (ORNL) to gain a better understanding of how internal residual stresses (stresses that stay “locked-in” a material, resulting mainly from production processes) impact bearing performance. This research is now revealing insights into enhancing manufacturing methods to improve product quality and reliability.

Vikram Bedekar is a materials specialist with Timken and helped spearhead the residual stress testing initiative starting in 2015. At that time, a team of technologists, including Bedekar and Product Development Specialist Rohit Voothaluru, began considering neutron research to help solve a challenge that was occurring overseas.

This research venture was inspired by a challenge at a facility in Europe involving part distortion during heat treatment. The engineers needed to analyze the effects of the stresses that were generated during a new manufacturing process, but standard X-ray methods could only reach 200 microns below the bearing surface — a much deeper look was necessary. Neutrons can penetrate more than 20 millimeters deep, or in this case, all the way through the bearing.

As Voothaluru explains, X-ray analysis could not help the Timken team understand and estimate the stresses in the thickest parts of a bearing without cutting the bearing ring — a step that destroys the near-surface residual stresses.

Releasing near-surface residual stresses causes the stress state to rebalance when the bearing is cut, resulting in

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estimations that are different from the actual stress state inside the bearing.

“We used our modeling tools to recommend changes to the manufacturing process,” says Voothaluru. “Our computational models today can qualitatively estimate the trends in residual stress, but validating the models using a physicsbased approach is not possible using traditional techniques. There was a technical gap in the bearing industry, and no one had solved it.”

ORNL, located near Knoxville, Tennessee, is the DOE’s largest science and energy laboratory comprising nearly 5,000 staff members and thousands more visitors. Through basic and applied research, ORNL helps create solutions to problems in energy and security. Among other advanced capabilities, the lab operates two of the world’s leading neutron sources, which enable scientists and engineers to gain new insights into materials and biological systems.

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Discoveries fueled by neutron research have already helped scientists unlock countless innovations such as stronger glass for mobile devices, drugs that more effectively treat diseases, more reliable aircraft and rocket engines, improved armor for the military, and batteries that charge faster and last longer.

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Combine those improvements with Tormach’s PathPilot CNC Controller (which brings all premium features standard — not hidden behind a massive paywall), MX machines are the highest performing and most cost-effective machining solutions of their size on the market today.

Led by Bedekar and Voothaluru, the research team applied and was accepted for research at Oak Ridge’s Neutron Residual Stress Mapping facility. Using the lab’s High Flux Isotope Reactor (HFIR), which offers the fastest neutron capability in the world, the team hoped to define the entire gamut of residual stresses experienced in the manufacturing stages of bearing components.

“The faster a neutron travels, the higher the penetration,” says Bedekar. “Neutrons don’t carry an electrical charge, which allows them to pass through material without affecting it or being affected by it.

In that way, they can reveal information DESIGN WORLD

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about the structure and properties of a material.”

Over five days, the researchers used ORNL’s neutron scattering capabilities to discover how residual stresses evolve during manufacturing.

The lab’s specialized instruments allowed entire bearing component sections to be examined front to back and top to bottom without destroying the parts.

Neutron scattering is an important technique in advancing materials research because neutrons (having no electric charge) can travel inside materials without damaging them. Once inside, the neutrons reveal the material’s internal structure at the atomic scale, creating new possibilities for future technologies.

Researchers and engineers in many industries use neutron scattering to address scientific challenges. Discoveries fueled by neutron research have already helped scientists unlock countless innovations such as stronger glass for mobile devices, drugs that more effectively treat diseases, more reliable aircraft and rocket engines, improved armor for the military, and batteries that charge faster and last longer.

At ORNL, the researchers were able to map out differing internal stresses resulting from each step in the bearing manufacturing process and generated significant data showing

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how a bearing’s stress state changes with each iteration. The team intends to use this residual stress map to improve computational models for improved internal stress predictions and optimized manufacturing processes.

“Now we have a baseline we can use to predict manufacturing stress distortions for any product produced in a subtractive machining process,” says Voothaluru. “We came to Oak Ridge to develop a quantitative model that is based on actual physics and having achieved that, we aim to validate and take our model to the next level. We were most intrigued when we first observed the differences in the residual stresses in the thicker vs. thinner sections of the bearing and their effects on distortion.”

“Eventually, we believe we can tailor the processing or tailor the residual stress to the desired performance of the bearing,” adds Bedekar. “We have already used the data produced at ORNL to create computer models that will more accurately predict residual stresses for bearings in the future, which opens the door to improving other manufacturing processes for power transmission products like gears and couplings.”

In time, Timken hopes to return to ORNL to expand on its initial findings and test more parts made with heat-treatment modifications.

“At Timken R&D, we want to push the limits of scientific knowledge by using the capabilities of the entire world, not just what’s in our own facilities,” Bedekar says.

“It takes state-of-the-art labs like Oak Ridge to uncover knowledge that hasn’t been explored before and each day we spend there is very exciting.

“Importantly, the work we are doing has the potential to influence innovation across the broader spectrum of industry by benefiting other manufacturing processes where heat-treat and machining techniques produce residual stresses that can impact product quality and reliability.” DW Timken | timken.com

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Reducing error

when using eddy current

measuring techniques

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Tips for reducing error with Eddy current measuring techniques include paying attention to circuit selection, placement, calibration and mounting.

Kevin Conlin Business Development Manager Kaman Precision Products

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Inductive eddy current technology is an extremely versatile non-contact method for measuring an objectâ&#x20AC;&#x2122;s position, distance, or vibration.

Unaffected by environmental contaminants or target finish characteristics, these sensors can operate in a vacuum or in fluids, so they work well for dirty applications, like those with oil or dust present. To get the most out of eddy current sensors, follow these tips for reducing errors that can affect a measurementâ&#x20AC;&#x2122;s accuracy.

Eddy current measurement basics Inductive eddy current sensors operate by generating a high frequency electromagnetic field about a sensor coil, which induces eddy currents in a target material. Eddy current sensors require a conductive target (usually some sort of metal), and sensor performance is affected by target material conductivity.

Nonconductive material between the sensor and the target is not detected. Also, the sensors do not require a ground connection to the measuring system, and the measuring distance is typically 30 to 50% of sensor diameter.

Inductive eddy current sensors have a large spot size compared to other technologies. They also have a higher frequency response; an advantage when

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Target EM Field Eddy Current

Sensor

Opposing EM Field measuring fast moving objects. This can make them a better choice than contact technologies like linear variable displacement transducers (LVDTs), which can interfere with the dynamics of the object being measured. Touching something that is moving to make a measurement adds mass, slowing down the system so it is not being measured at the actual speed.

Eddy current performance is affected by temperature changes, but can ignore contamination that would foul up laser triangulation/ LED, ultrasonic, or capacitive measurement technologies.

Sources of error with eddy current measurement techniques Care must be taken to avoid common error sources associated with eddy current sensors.

If not, users may not get a good measurement, may get more error than can be tolerated for the application, or they may not be able to get any measurement at all.

The main sources of error include: • Selecting the wrong circuit type • Presence of another metallic object near the target • Temperature variations or environ mental conditions that affect measure ment accuracy • Multiple sensors mounted in too close a proximity • Incorrect mounting Tips for reducing errors Select the right circuit Eddy currents can be interpreted and processed into useful information in signal conditioning

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AC Current

The diagram shows the basic operating principle of eddy current measuring, with the sensor’s high frequency electromagnetic field inducing eddy currents in a target material which generates an opposing electromagnetic field.

electronic circuits. Three common circuit types include: • Colpitts circuit – single channel analog position measuring systems • Balanced bridge circuit – single ended and differential analog linear position measuring systems • Phase circuit – single/multiple channel analog high-precision position systems To select the right circuit, begin by looking at the measurement – what kind are you taking? Is it single or differential? Look at the target – is it magnetic or non-magnetic?

Knowing this information will go a long way to setting users on the path to reducing error.

For example, when the Colpitts circuit is used as a position measuring device, the sensor coil becomes the inductor in the oscillator circuit. When the sensor coil interacts with a conductive target, the oscillator frequency and amplitude vary in proportion to the target position. This variation is processed into an analog signal proportional to displacement.

Typically, Colpitts circuits are recommended for low cost, general purpose measurements where linearity is not required. They can be a good choice for fuel injector testing, valve lift measurements, shaft or cylinder run out and vibration, and machining and grinding.

With a balanced bridge circuit, the target movement causes an impedance change in the sensor coil. This change of impedance in the coil is measured by the demodulator

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Signal Conditioning Electronics

circuit, linearized by a logarithmic amplifier, and then amplified in the final amplifier stage.

In the single-ended configuration, the systems are a good choice for both ferrous and non-ferrous targets, including general purpose linear position measurement, laboratory, research, development, and testing, metrology, and factory process control.

Differential bridge systems are frequently the best choice for fast steering mirror (FSM) position applications, pointing and tracking in night vision and laser systems, control systems for active vibration monitoring and control systems, and photolithography stage positioning and control.

If a phase circuit is used, the effects of eddy currents are not only amplitude related, but also phase related. This circuit is based on phase detection using pulse width modulation (PWM) techniques.

Typical recommended applications include stage positioning in atomic force microscopy (AFM), Z-axis positioning in photolithography equipment, laser optics positioning, precision grinding, and semiconductor wafer transport mechanisms.

Adjust for the presence of another metallic object near the target Measuring one metallic object when another metallic object is too close by is a major source of error. This may depend upon the material, the size of the target, and the measurement range. For example, DESIGN WORLD

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Kaman’s DIT-5200 is a high-precision eddy current, balanced bridge measuring system offering sub-nanometer resolution in single, dual, and three-channel configurations.

it may be especially difficult to measure if the target is conductive but small and thin and difficult to get close to. The potential for error will also depend upon how much material is required to interact with the eddy current field.

For example, in a racing engine research and development application, a Kaman customer wanted to ensure they were getting the correct engine stroke and were developing a system to test how various conditions would affect the stroke.

They were trying to measure a piston moving, but there was another piston in close proximity and the measurement was “seeing” both pistons.

In this case, Kaman recommended mounting one sensor behind the piston and one in front of it. Each sensor was used to measure half the stroke. The end user was able to get closer to the piston with a smaller sensor that did not “see” the other piston.

Adjust and calibrate for the temperature and conditions Be sure to calibrate the system in the environment in which it will be operating.

Calibrating in one environment and then placing it in another may induce errors.

High and low temperatures have the potential to change the measurement. A measurement at room temperature may change when taken at 500°F or at 1,000°F. To adjust for this, if measuring across a wide temperature range, users should perform calibrations to show what error may exist at different temperatures.

For example, one recent customer was taking several measurements of blades inside a large gas turbine. The system is optimized for the key measurement, which is taken at 800 to 900°F, but also takes measurements at room temperature as the turbine is beginning operations.

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The measurement could be accurate at one or the other of these points – but not both.

For this system, Kaman developed a sensor that was accurate at the higher temperature, and then used mathematical calculations to develop curves providing information on the error to be expected at the room temperature measurement.

Environmental conditions are also an issue in cases where there are multiple moving pieces and the system is trying to read only one. If the sensors pick up another moving metal object, one may be able to place another piece of metal in between to shield it. The fixed object absorbs the signal but one can still see the moving target. In short, the fixed piece simply becomes part of the environmental conditions and one can calibrate around it.

For applications that measure on a rotating target like a shaft, the surface velocity of the shaft can also affect the measurement. As it spins faster, it may look like a smaller target. Again, mathematical calculations can be developed to account for the size of the target, the material it is made of, and how fast it is moving to ensure that a proper measurement can be made using an eddy current sensor.

Avoid multiple sensors Two or more sensors mounted in close proximity to each other may result in their electromagnetic fields intermixing, which may cause interference and reduce measurement accuracy. This interference is in the form of “cross talk,” resulting in beat notes whose frequency will be the difference between the frequencies of the oscillator in each unit.

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Pay attention to mounting The quality of any measurement depends on the mounting fixture. The amount of conductive material in or near the mounting fixture will have an impact on system performance. Mounting the sensor in a material that absorbs too much of the field results in measurement errors. For example, mounting an eddy current sensor inside a large steel block and recessing the sensor would absorb the field so it would be hard to measure.

A sensor is “side-loaded” when its field interacts with conductive material other than the target. Shielded sensors reduce this effect. For optimum performance, keep conductive material out of this field if possible. Perform in-situ calibrations if conductive material other than the target will be in the sensor’s field.

To eliminate the possibility of error, make sure the sensor is mounted so it is aimed as squarely at the target as possible.

It should not be recessed and there should be nothing in its way to absorb the signal. If possible, mount the sensor inside a plastic block.

In addition, the target and sensor should be parallel to each other. Some non-parallelism can exist without inducing significant error. A non-parallelism of up to 3 degrees will increase nonlinearity less than 0.5% of full scale. Non-parallelism of 10 degrees will increase non-linearity approximately 4% of full scale.

Allow for a certain amount of error One final tip is to accommodate room for error. If one is looking for a measurement at half-inch, try to ensure the measurement can be made at three quarters of an inch, so there will be room to work within. Account for temperature errors by performing measurements with systems ahead of time to understand the shifts that may take place at higher temperatures, and be able to adjust for errors that may occur at different temperatures. The goal should be to reduce errors to as low as possible. DW

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A supplement of Design World December 2019

itâ&#x20AC;&#x2122;s a

material world 100 AM Engineers need a set of best practices...and change in mindset

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110 Kennametal uses 3D printing to develop lightweight stator bore tool

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A d d i t i v e

T e c h n o l o g y

AM Engineers need a

set of best practices...and a change in mindset Technology advances alone are not enough to drive additive manufacturing into production workflows. But simple building blocks, such as best best practices, management acceptance, and software to streamline production, can make the process of integrating additive into industrial manufacturing more seamless and direct.

Brian Crotty • Manager Marketing & PR at 3YOURMIND Anna Schröder • Junior Marketing & PR at 3YOURMIND

The benefits of additive manufacturing have been validated by the leap into serial AM by almost every global manufacturer. But to bring additive into wider adoption, there are still several steps that have nothing to do with the intelligence of a single engineer. Instead, it will be a result of the entire industry building structures, best practices and a shared mindset that allows companies to pull the maximum value from this new technology.

Maximizing value using additive manufacturing A strong additive manufacturing business case typically saves a company 20 to 80% on production costs or reduces lead time to one or two weeks.

A struggle for almost every engineer is how to determine which parts in their inventory are a good fit for additive. As Deloitte mentioned in their report “Challenges of Additive Manufacturing”: “Even though current engineering graduates may have learned about the technology, it is unusual to find potential recruits who understand the holistic capabilities of the technology. Additive Manufacturing is not a technology for specialist technicians like welding, for example, but rather a field for generalists able to combine such different

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disciplines as mechanical, fluid and material engineering.”

When we speak of maximizing AM value, it’s clear that cross-disciplinary thinking and an understanding of technical and economic influences are key ways to ‘find the gold’ in a company’s inventory. The increasing use of 3D printing for tooling, jigs, spare parts and production line innovations at companies like Heineken and Ford are great examples. But Design for Additive Manufacturing projects can also simplify assemblies or optimize component structures. These ‘backstage’ applications are opportunities to respond to real world logistic challenges and technical problems in near to real-time.

These backstage applications offer an immediate, profitable part. Helping to find that part are software programs such as CAD software that simulates and DESIGN WORLD

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analyzes a part and PLM production programs that gather data for various methods, while other tools such as the AM Part Identifier, from 3Yourmind, review economic and technical specifications to score the suitability of parts for additive manufacturing. Companies like Additive Minds (EOS) and Additive Manufacturing Solutions (AMS) who analyze part information to select AMsuitable parts have also found success by balancing technical and economic criteria.

Only in the last several years has additive manufacturing been used at scale. Thus, the principles of DfAM (Design for Additive Manufacturing) and the process steps are being validated for the first time.

Tips on balancing technical and economic criteria: Step 1: Train engineers to use data •‘Knowledge is power, but data are gold.’ Every industry on the path to digitalization needs to keep this saying as a mantra. Industrial manufacturing already uses some of the most advanced digital systems in the world for stock level management, logistics, predicting supply and demand, and aiding the

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Additive Technology humans on their production floor. But because of the scale of production, the huge cost of downtime, the complexity of production steps and increasing demands on product design, there’s little time left for integrating new systems - particularly ones that require fundamentally readjusting production workflows like additive manufacturing.

Only in the last several years has additive manufacturing been used at scale. That means that the principles of DfAM (Design for Additive Manufacturing) and the process steps are being validated for the first time. But companies don’t need to work in the dark - as long as they act like programmers by building in methods to anticipate and test production data ahead of time. Huge advances in the accuracy of simulation and PLM software can predict the results of AM production and post-processing, for example. Just as important is accepting there will be numerous challenges in an industry technically still in its infancy. Analyzing production data will be the best way to make the required solutions visible.

Manufacturing is complex, and it stands to make much faster gains by

placing experienced engineers (who know the “O-tone” of production machines) alongside young engineers (who are digital natives to manage the data streams). Such a team will create a new treasure chest of intellectual property for overcoming technical issues associated with AM. As stated in the Wohlers’ report, at this stage the biggest challenges can only be overcome by trial and error.

We expect universities will continue to adjust their curriculum so mechanical engineering courses understand principles like dynamic design and data analysis for production evaluation. But also that business management and workflow engineering degrees will increase in prominence to control and optimize the input of data into these systems.

Step 2: A mindset of patience and • endurance It’s clear additive manufacturing workflows have a different set of requirements than traditional manufacturing - they require an even higher level of data management and

distribution. Companies are currently solving this challenge by placing AM production in parallel to their current production. But what’s needed is a change management program to more closely integrate the two production systems.

Software will be a key driver in this change because it bridges the ‘knowledge gap’, commonly cited as the biggest inhibitor to scaling AM. Software helps to standardize data transfer between ERP, MES, AM production and design software. It will be able to translate information from older manufacturing techniques to additive.

For example, the tolerance ranges for surfaces at the contact points - a key metric for quality assurance - becomes the maximize size and location of support structures in the AM processing stream. These systems and these data take time to build in a new organization, and it is important that the expectations are set correctly at the outset of the transition.

Over time, the software will become an assistant that guides the AM production process. Assistants always

Additive manufacturing workflows have a different set of requirements than traditional manufacturing and require a high level of data management and distribution. Software will be a key driver because it bridges the ‘knowledge gap’, commonly cited as the biggest inhibitor to scaling AM. Software helps to standardize data transfer between ERP, MES, AM production and design software.

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need a training period to be worked into a company though. Smart algorithms and machine learning are helping to speed up the process, but at the end of the day there is no substitute for knowledge accrued from time spent on the production floor. And that transition to seamless production looks more like a marathon than a sprint.

Step 3: Software to enable AM • production execution Many companies have already proven that additive manufacturing can be integrated into serial production. In 2018, companies like Ford, Airbus and Adidas were putting 3D printed parts into serial production.

They have crossed the initial barriers of dedication, training, experimentation and problem solving. Outside of this relatively small innovation group that established the production workflows, however, there are still bottlenecks to overcome - production access, management and tracking.

There is a general resistance to change which will shift naturally in the coming years as financial and technical benefits become visible. The sharing of knowledge in public forums like AMUG (Additive Manufacturing Users Group), America Makes in the US, and Additive Manufacturing Forum and Mobility Goes Additive in Europe will be instrumental

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in facilitating this change in mindset.

These institutions bring successful applications into the spotlight and provide information about bestpractices that can be extended into production.

Software will provide another important key to increasing production, as it’s only with a structured data system that the production parameters and customer requirements will be delivered to the right places on the value chain. Tracking using software will allow for the necessary quality assurance to integrate seamlessly into the complete process chain. For the craftspeople and technical engineers that understand the importance of steady, monitored processes, this level of detail and tracking is the only way to scale execution over the long term.

the most value out of AM technology, and it becomes even more complicated when coordinating with production engineers and employees who need to put AM parts into products that are used every day. When that knowledge comes together, the resulting use cases become game-changers for manufacturing.

The past several years have proven that technology advances alone are not enough to drive additive manufacturing into existing production workflows. But if simple building blocks are put in place-using data to define best practices, a change in mindset at management level, and software structures to streamline production--the pathway to integrating additive into industrial manufacturing will be a far more seamless and direct process. n

Long-term solutions to scale additive manufacturing Since 2014, 3D printing machine investment for production has grown by another 50% to 2.9B, according to Deloitte research. But the majority of AM machines are running under capacity. The main hurdle is to connect the knowledge of the business, innovation and purchasing departments. Each holds a different piece of information on how to get

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A d d i t i v e

T e c h n o l o g y

It’s a

material world

Additive manufacturing’s success in any industry relies on the availability of materials; both standard and innovative hybrid materials.

Leslie Langnau • Senior Contributing Editor

Additive machines continue to increase their building speeds. Additive vendors continue to develop new ways to make parts layer-by-layer. But the main news story this year is about materials. Additive vendors offered a number of new materials to meet designers’ needs. Here’s a look at some of the recent introductions.

Figure 4 Production Black 10 3D Systems unveiled an advanced photopolymer that displays thermoplastic behavior. Developed for the company’s Figure 4 3D printing system, the Figure 4 Production Black 10 (PRO-BLS 10) can be used to produce end-use plastic parts without tooling. This application will speed part production.

Figure 4 PRO-BLK 10 works with a simple isopropyl alcohol (IPA) wash and does not require a secondary thermal post-cure process. In customer testing of a variety of parts, the Figure 4 system and the material delivered a part in hand on average up to 4X faster (including print and cure time), compared to customers’ existing 3D production systems.

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Noted Chris Nicoll, prototype lab manager at D&K Engineering, a product design and contract manufacturer based in San Diego, CA, “One thing we’re excited about with Figure 4 PROBLK 10 is the capability to produce complex, fine details on parts without tooling. We created several threaded parts in the same print with a variety of dimensions and each one is perfect.

With the enhanced speed, we’ll also be able to take on more projects, which will help us grow our business.”

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The Diran material is a nylon-based material for the Stratasys F370 printer. This FDM thermoplastic offers extreme toughness and low friction, with resistance to hydrocarbon-based chemicals and a smooth surface for low sliding resistance.

In addition to 3D Systems’ Figure 4 PRO-BLK 10, the company also announced four additional Figure 4 materials: • Figure 4 EGGSHELL-AMB 10: A process-optimized material for the production of sacrificial tooling for casting true silicone components.

• Figure 4 HI TEMP 300-AMB: Ultra-high temperature (300 Celsius) rigid plastic for production applications such as high temperature component testing and stators and motor enclosures.

• Figure 4 FLEX-BLK 20: Durable, flexible, high impact, fatigue resistant material with long term environmental stability for functional assemblies and prototypes such as automotive styling parts, consumer goods and electronic components, snap-fit assemblies, containers and enclosures.

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Additive Technology

• Figure 4 RUBBER-BLK 10: Hightear strength, malleable, material for prototyping hard, rubber-like parts such as grips, handles and couplings.

RPU 130 from Carbon Carbon introduced a new resin--RPU 130. RPU 130 fills the need for a tough, rigid, and high temperature additive manufacturing material suitable for rigorous applications in industries such as automotive. This material is also partially derived from plants, addressing the growing demand for more sustainable, high-performance materials.

Rigid polyurethane is Carbon’s most versatile rigid material family.

RPU 130 was developed to address the need for superior impact resistance and dimensional stability at elevated temperatures that additive materials don’t address. In addition to automotive, RPU 130 fits a range of industrial and consumer product applications such as air ducts and brake caliper covers for vehicles, sunglasses, tool housings, and device enclosures. It combines some of the best characteristics of Carbon’s RPU 70, FPU 50, and EPX 82 resins into a single, tough, heat and impact resistant

material, similar to ABS, unfilled nylon, or polypropylene.

Said Dr. Joseph DeSimone, CoFounder and CEO of Carbon, “Although some of these properties have been available before in additive, RPU 130 is the first to combine them all into a single manufacturing material suitable for the most demanding conditions.”

It is the latest dual-cure engineering resin exclusively for Carbon’s Digital Light Synthesis technology.

Producing RPU 130 required innovations in not only material science, but also software and hardware. In addition to the new dual-cure resin, Carbon is offering a new heated C5 Cassette required for use with the material, a new dispensing solution, and tuning through software to ensure great end-use products.

RPU 130 was made with environmentally sustainable raw materials. Carbon partnered with DuPont Tate & Lyle Bio Products to use Susterra propanediol, a 100% bio-based building block that delivers high performance across a variety of polymers, coatings, and ink applications. Compared with conventional petroleum-based alternatives, Susterra propanediol produces 48% less greenhouse gas emissions and uses 46% less nonrenewable energy from cradleto-gate. Nearly 30% of RPU 130 is composed of this plant-based material.

H13 Desktop Metal introduced the H13 tool steel for its Studio System. Characterized by its stability in heat treatment, exceptional hot hardness, and abrasion resistance, H13 is a tool steel for hot work applications. High toughness and hardness also make it suitable for cold work tooling applications.

H13 tool steel enable designers and engineers to print mold inserts, extrusion dies, forging dies, and sheet metal tooling, including stamping, embossing, bending, and countersinking. Examples of its application follow:

• Injection mold cores are used for the molding of mouthpieces for asthma inhalers. H13 is suitable for such mold cores due to its hot hardness and abrasion resistance. During the injection molding process, the cooling of a mold like this can traditionally account for up to 95% of the mold’s entire cycle time.

By 3D printing the mold with the Studio System instead, the part can incorporate a conformal cooling channel that closely follows the molding surfaces profile, increasing the cooling rate of the mold.

Such a feature dramatically reduces the mold’s cycle time, which may allow more parts to be molded every hour.

Furthermore, 3D printing the mold to near net shape will reduce the wear on EDM tooling required to finish the mold, reducing both lead time and costs.

• The complex geometry of an extrusion die often makes it a difficult part to machine. This limits the ability of manufacturers to iterate on the extrusion die design, due in part to the high lead

RPU 130 is a tough, rigid, and high temperature additive manufacturing material suitable for rigorous applications, such as those in automotive. This material is partially derived from plants, addressing the growing demand for more sustainable, highperformance materials.

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Injection mold cores are used for the molding of mouthpieces for asthma inhalers. H13 is suitable for such mold cores due to its hot hardness and abrasion resistance. By 3D printing the mold, the part can incorporate a conformal cooling channel that closely follows the molding surfaces profile, increasing the cooling rate of the mold. Such a feature dramatically reduces the mold’s cycle time.

time and cost of machining. At the same time, the part must withstand the extreme temperatures and pressures required to successfully push molten materials through the extrusion die. 3D printing in H13 tool steel enables design teams to quickly and easily produce dies featuring complex extrusion profiles previously unattainable via machining.

• Creating a mold for a zinc zipper for clothing is another application. Such a mold often has a number of fine details, such as a logo, textures, and subtle draft angles that are critical to the part’s molding success. The Studio System 3D printer has a high-resolution nozzle so that users can achieve the fine details required for this part.

Inconel 625 Markforged introduced Inconel 625 this year for its Metal X system. The easy-toprint material is resistant to corrosion and high temperatures, and is used for applications that are exposed to harsh environments seen in the chemical processing, offshore, and aerospace industries.

“Inconel is traditionally a difficult and expensive material to work with.

Engineers would often have to wait for a contract supplier, invest significantly in mold creation, or purchase a powder-based process that requires intensive facility build-outs and highly

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trained technicians,” said Jon Reilly, VP of Product at Markforged. “Now manufacturing Inconel is fast, safe, and affordable.”

Inconel 625’s corrosion-resistant properties make it a suitable choice for applications exposed to extreme environments, and printing it with the Metal X system provides the following benefits: • Rapid, affordable production – Compared to outsourcing, 3D printing Inconel reduces the lead time of producing a part to just a few days and at an affordable price point.

• 3D Print in-house – users can safely print Inconel 625 in-house without the need for rooms or equipment to handle hazardous powders or for a highly trained staff to operate.

Anatomy materials When Stratasys Ltd. Introduced the J750 Digital Anatomy 3D printer for the medical industry, it also introduced new materials to take advantage of the printer’s ability to replicate the feel, responsiveness, and biomechanics of human anatomy.

The new materials are TissueMatrix, GelMatrix, and BoneMatrix, used for cardiac, vascular, and orthopedic 3D printing applications. A Blood Vessel Cleaning Station that removes support material from inside 3D-printed blood www.makepartsfast.com

vessels was also released.

In addition, Stratasys introduced several new durable, temperature and chemical resistant FDM thermoplastics for production-grade, custom 3D-printed tooling and parts. These materials accommodate high temperatures and challenging requirements common on the production floor. These materials include: Antero 840CN03 for the Stratasys Fortus F900 3D printer, and Diran 410MF07 and ABS-ESD7 for the Stratasys F370 3D printer.

Each of these thermoplastics is suited to handle the requirements of manufacturing applications in industries such as automotive and aerospace to engineer 3D printed jigs and fixtures, tooling, prototypes and production parts.

Developed for the F900 3D printer, Antero 840CN03 is the second PEKKbased polymer offered by Stratasys in its portfolio of proprietary Antero high performance polymers. It leverages the Kepstan PEKK technology from Arkema.

The Antero material is formulated to create custom tooling and parts with consistent electrostatic discharge (ESD) performance, and fits printing high temperature- and chemical-resistant parts with ultra-low outgassing and excellent wear properties.

Suited for aerospace and industrial applications, the Antero material with December 2019

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Creating a mold for a zinc zipper for clothing requires a number of fine details, such as a logo, textures, and subtle draft angles critical to the part’s molding success. H13 Tool Steel handles such requirements.

ESD properties can create strong yet lightweight parts used in frames, panels and components. (The material is also a part of Stratasys Direct Manufacturing, the company’s contract manufacturing division.)

“Manufacturing spacecraft poses intense material challenges in the development of parts that exhibit the right attributes,” said Brian Kaplun, Senior Manager for Advanced Manufacturing, Lockheed Martin Space. “One of those challenges is getting the right ESD or electrostatic dissipative properties, among other physical and mechanical characteristics. Stratasys Antero ESD fits our needs for outgassing and electrostatic dissipative properties in a strong but lightweight additive manufacturing material.”

The Diran material is built for durable tooling applications. It is a nylon-

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based material for the Stratasys F370 printer. This FDM thermoplastic offers extreme toughness and low friction, with resistance to hydrocarbon-based chemicals and a smooth surface for low sliding resistance. Diran’s toughness withstands the rough handling of tools common in a manufacturing setting.

The ABS-ESD7 thermoplastic, previously only available on the Stratasys Fortus printers, is built for static-sensitive applications to prevent discharge or attraction to other materials like powders, dust and fine particles.

Extending factory floor materials to the Stratasys F370 3D printer, users can capitalize on prototyping and production requirements for low cost and highly customizable parts. Delivering an affordable, ESD-safe material on a platform dedicated to ease-of-use, repeatability and part accuracy, ABS-

ESD7 suits manufacturing tooling applications.

High temperature nylon Essentium Inc., announced its new portfolio of advanced high-temperature (HT) nylon materials for additive manufacturing. The materials deliver high heat, chemical and fatigue resistance as well as high strength for industrial applications while being as easy to print as Polylactic Acid (PLA) thermoplastics at low print temperatures.

The HT nylon range of materials is an alternative to niche HT materials that require high-temperature extruders.

Combining nylon with carbon fiber, the materials are more than four times stronger than high-performance Acrylonitrile Butadiene Styrene (ABS) and have a heat deflection temperature of 200°C, allowing manufacturers to print

tough and impact resistant parts to withstand the rigors of the factory floor.

The materials open more capabilities for additive manufacturing users such as for producing high-performance machine parts, tools and jigs and fixtures in aerospace, automotive and electronic manufacturing sectors. n 3D Systems | www.3dsystems.com Carbon | www.carbon3d.com Desktop Metal | www.desktopmetal.com Markforged | https://markforged.com.

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The machine tool industry is seeking lighter weight tooling machining components. Some OEMs are turning to 3D printing to deliver on that request. One OEM is Kennametal. It recently reported that it developed a 3D printed stator bore tool specifically to meet growing customer demand for lighter weight tooling used to machine components for hybrid and electric vehicles.

E-mobility components are typically machined on smaller, low horsepower CNC machining centers that require lighter weight tooling.

Kennametal´s 3D printed stator bore tool weighs half that of the conventionally manufactured version, while still meeting accuracy, roundness, and surface finish requirements for aluminum motor body boring.

“The main bore that houses the stator of an electric motor measures approximately 250 mm in diameter (9.84 in.) and approximately 400 mm (15.74 in.) in length, with a smaller bearing bore at the bottom,” said Harald Bruetting, Manager, Program Engineering. “When manufactured using conventional means, a reamer for this type of application would weigh more than 25 kilograms (55 lb), far too heavy for the existing machine tool or for an operator working with the tool.”

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Weight reduction through additive layer manufacturing. The total weight of this 3D-printed stator bore is 10.7 kg, down from 25 kilograms (55 lb). 3D printing was able to cut the weight in half, and meet surface quality, roundness, and accuracy requirements.

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The same stator bore design, but even lighter. Instead of using a 3D printed metal tube, a tool version with a carbon fiber tube was used, reducing the weight even further to 9.5 kg.

Bruetting and Kennametal´s Solution Engineering Group turned to the company´s in-house additive manufacturing capabilities to 3D-print a strong but lightweight indexable tool, equipped with proven Kennametal technologies including fine adjustable RIQ reaming inserts for high precision finishing and a KM4X adaptor for maximum rigidity. The tool also features internal 3D printed cooling channels that help maximize productivity and tool life.

“By using metal powder bed 3D-printing together with finite element analysis software, we were able to design and build a tool that brought the moment of inertia very close to the spindle face, increasing its rigidity while meeting the customer´s weight restrictions,” said Werner Penkert, Manager, Future Solutions.

Two versions of the tool were built, one with a carbon-fiber tube, the other using a 3D-printed metal tube. The results were impressive. The tool with the 3D printed tube weighed in at 10.7 kg (23.6 lb) and the carbon fiber version at 9.5 kg (20.9 lb), less than half of their conventional counterparts. n Kennametal | www.kennametal.com

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Check out the latest MC² on integrated motors INTEGRATED MOTORS FOR DISTRIBUTED CONTROL

CONTROLS

POWER SUPPLIES

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Recall that traditional servo systems necessitate the wiring together of a separate motor, encoder, amplifier, and controller. In contrast, integrated motors are sometimes classified as plug-and-play motion components — as they can usually be setup out of the box with less engineering effort.

In short, integrated motor-drive systems combine a motor and a drive at the very least, with some integrated-motor variations also including other components such as controllers and encoders.

In this latest installment of the MC² series, you’ll find some resources on integrated motors to differentiate the most common variations of these motion-control mainstays, using the motors to satisfy requirements for loading, stroke, speed, accuracy, and design life.

Also check out our library on networking and connectivity considerations for integrated motors and market-specific topics including 3D printing, conveying, robotics, and textile manufacture.

Educational installment brought to you by:

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I N S I D E : Why M12 connectors are the right fit for the IIoT • The revolution in Ethernet connectors • Best of 2019

Inter

A supplement of Design World • December 2019

2019

Cable & Connector Reference Guide

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As sensors, data, and real-time decision-making transform manufacturing, M12 connectors deliver the speed, reliability, and ruggedness that smart factories demand.

Joe Amato Director of Business Development binder USA

Global tech analysts predict that more than 20 billion devices will be connected by 2020, and that the Industrial Internet of Things (IIoT) will be a $200 billion market by 2021. In the simplest terms, the IIoT is realtime data connection, driven by processing and transmitting data at faster speeds, on progressively smarter and smaller machines. input like temperature, vibration, The ultimate value of the IIoT, however, goes beyond data or sound frequencies. This data is collection and transmission. It encompasses the complete transmitted back to a central location visibility and control of virtually all electromechanical factors or cloud where decision makers can in the manufacturing process, empowering companies access it. This process requires reliable to move beyond descriptive and diagnostic analysis to high-speed connections, often in predictive intelligence and preventive action. Quantifiable environments that include dust, noise, benefits include the ability to identify disruptions, such as temperature changes, and vibration; product or process variance, and circumvent or redesign in the food and beverage industry, it to avoid these issues. Plant operators can discover unused capacity, reduce maintenance costs and downtime, improve also includes the challenge of frequent washdowns. safety, and maximize overall equipment effectiveness (OEE).

Connectors act as the vital link A comprehensive view of the manufacturing process between the cables carrying data or assembly line is accomplished by placing networked and the devices that record and sensors on physical equipment to collect data. These communicate information. The demand sensors perform condition monitoring, analyzing constant

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for faster data transmissions that can accommodate visuals has driven the development of connectors able to support the gigabit data requirements for the latest sensors. To add to the complexity, machines are getting smaller, putting pressure on component makers to deliver greater speed, power, and capacity in an ever-shrinking footprint.

The ABCs of M12 connectors: coding, pins and locking systems Introduced in 1985, the M12 connector has built a decades-long track record as one of the most reliable connectors for industrial applications. Once used primarily by automobile manufacturers, the M12 has become the industry standard in factory automation, autonomous robotics, communication, measurement and control, and many other applications.

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Coding On the plant floor, personnel need to be able to disconnect existing connectors for maintenance and install new connectors on newly-laid cables quickly, especially where connections must remain dust- or water-tight. M12 connectors are easily installable and clearly coded to reduce the chance of accidental mis-mating.

Figure 1. Sensors perform condition monitoring efficiently, analyzing and reporting data to support human decision-making.

For signal and data transmission: A-coded for sensors, dc power B-coded for PROFIBUS D-coded for 100Mbit Ethernet and Profinet X-coded for 10Gbit Ethernet (See Figure 2.)

M12 coding for power supplies: â&#x20AC;˘ S-Coded and K-Coded connectors are designed for ac power supplies

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Figure 2. As applications require higher-speed connections, X-coded connectors will likely replace D-coded connectors. (Pictured: binder M12 X-coded female connectors)

up to 630 V/16 A. Ideal power connector for applications including: ac motor and drives, motor control switches, and frequency inverters.

• T-Coded and L-Coded connectors are designed for dc power supplies up to 63 Vdc/16 A. (See Figure 3.) Ideal power connector for low-voltage applications including: dc motor and drives, fieldbus Ethernet components, network devices, and LED lighting fixtures.

Pins M12 connectors are available with 3, 4, 5, 8, or 12 pins. The ideal pin count depends on the application. For example, most sensors and power applications use 3 or 4 pins, where Profinet and Ethernet use 4- and 8-pin counts. (See Figure 4 for examples.)

Locking systems There are three basic types of locking systems on an M12 connector: • Push-pull: Locks easily and securely, with an audible click indicating that the proper connection has been established.

• Threaded coupling: A threaded nut on the plug is mated with a corresponding set of threads on the receptacle.

• Bayonet: An interconnect mating design that uses pins on the receptacle and ramps on the plug for quick-connect and disconnect coupling.

FACT: HELUKABEL supplies pre-assembled data cables for Industrial Ethernet systems. With molded M12, RJ45 and the new ix Industrial connectors, customers can piece together any possible combination of cables and connectors to design a product built exactly for their needs.

Additional M12 features and options The connector choice for a specific application can be further customized by selecting options such as those below: • Gender: male, female, male/female • Termination styles: crimp, screw, clamp, or IDT (Insulation Displacement Termination) • Housing material: plastic, metal, or stainless steel • Contact plating material: Au (gold), Sn (tin), CuSnZn (optalloy) • Degree of protection: IP67, IP68, or IP69K • Cable length • Cable jacket: PUR or PVC • Panel mounted or field-attachable • Rated voltage • Rated current

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Three reasons M12 connectors are the smart choice for Industry 4.0.

Though M12 connectors were available decades before the IIoT was even a concept, they have become the preferred connector for industrial Ethernet. For data transmission, they are used on the device side — pulling data from devices and transmitting it to the application where data is aggregated to provide useful information to the user. They are also used to transmit high levels of power supplies for extended time periods in applications such as ac motors and drives, motor control switches, and low-voltage applications like fieldbus Ethernet components and network devices.

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Figure 3. M12-L, a DC power supply Profinet compliant connector and field wireable cable from binder.

1 Unrivaled ruggedness Compared to the RJ45, the other most commonly used industrial connector, M12 connectors offer superior performance in harsh conditions due to: • Circular design that shields contacts from contaminants such as dust, moisture, and foreign objects, while also protecting against impact, vibration, UV exposure, and temperature changes • Minimum IP67-rated ingress protection against dust and water • Additional options with IP68 and IP69K ratings for demanding washdown environments (See Figure 5.)

Mating cycle ratings are another important consideration for machine builders. Ratings are determined by the material used for contacts and plating, as well as the thickness of the plating. Cheaper connectors, made for example with tin plating and copper alloy contacts, will not perform as well as those made with corrosion-resistant materials such as thick gold plating and beryllium copper contacts, which are typically rated for >100 mating cycles.

2 EMI shielding Hard-wired connections offer some intrinsic advantages over wireless connections, primarily the security of physical connections and the avoidance

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M12 A-coded connectors from binder are IP69K-rated, as well as Ecolab and FDA certified, making them ideal for harsh washdown applications in the food/beverage and chemical industries.

of wireless interference. This is especially important because the new IIoT-enabled factory is often filled with electromagnetic interference (EMI), also called radio frequency interference (RFI). Unseen and unheard by people, this electronic noise pollution frequently interferes with highprecision sensors already taxed by physical noise and vibrations of a busy factory floor.

The increasing pervasiveness of EMI places an additional burden on manufacturers to design equipment that both generates as little EMI as possible, and ensures that their equipment has reasonable resistance against EMI so that operation isn’t affected when it is a factor.

To satisfy these requirements, manufacturers must use connectors and connecting cables with sufficient shielding properties. Good shielding is achieved when the following conditions are met: • Cable shield is terminated to conductive (metal) housings • Cable shield is carefully secured to the connector to provide 360° shielding • Mated connector has a good galvanic connection between the metal receptacle housing and the metal panel surface

3 Compact size The Industry 4.0 trend towards miniaturization requires more compact components and connectivity solutions, even as power and data transmission needs grow. Increasingly-smaller devices and sensors are transmitting more data, which requires more connection points, which means that Positionable, lockable, field wireable connectors have to deliver the same connectors, capable of transmitting (or more) power density in a smaller impressive amounts of data and power, footprint. ensure that the M12 will continue to be Originally designed to reduce the an essential component of Industry 4.0 size of the 7⁄8 in. connector, which and beyond. DW was standard at the time for sensors, the M12 connector has an outside Binder USA | binder-usa.com diameter locking thread of just 12 mm.

Its small footprint makes it well suited Sources: for applications with little free space Bain & Company. Beyond Proofs of Concept: such as automation control systems, Scaling the Industrial IoT. Web. Jan. 30, 2019. telemetry modules, compact LED Columbus, Lewis. 2018 Roundup of Internet of lighting fixtures, and value actuators.

Things Forecasts and Market Estimates.

Forbes. Web. Dec. 13, 2018.

Today’s factories create significant EMI challenges.

Advanced sensors exist alongside miles of old cabling, wireless phones, and network devices.

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M12 technology continues to evolve Machine designers and OEMs are incorporating M12 connectors into new machines, as well as updating existing infrastructure. With backwards compatibility, replacing older and less robust technology like RJ45 connectors is relatively simple and cost effective.

Manufacturers of M12 connectors continue to innovate, adding new features to meet the quickly-changing needs of the robotics, automation, food and beverage, alternative energy, and cellular communication industries.

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Deloitte Digital/WIRED Brand Lab. Industrial IoT: How Connected Things Are Changing Manufacturing. Web. Accessed May 20, 2019.

Electronics Sourcing Online. Smart sourcing for industrial IoT. Web. June 15, 2018.

Fenical, Gary. The Basic Principles of Shielding.

In Compliance. Web. Mar. 1, 2014.

Schweiz, Laura. Ethernet Connectors Evolve to Meet New Demands. Machine Design.

Web. Mar. 14, 2016.

Thomas. Measuring EMI Shielding Effectiveness.

Thomasnet.com. Web. Accessed May 18, 2019.

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The revolution in

Ethernet connectors?

The new ix Industrial interface opens new opportunities, including for cable manufacturers.

Contributed by: Horst Messerer Product manager HELUKABEL

Hardly any other connector is as widely used as the RJ45 (also known as the western plug). It has been around since the 1970s, and in the decades that followed, technologically superior variations were developed for use in industrial applications.

It’s hard to imagine the industrial world today without them, not just for their convincing price to performance ratio, but because they are almost synonymous with Ethernet connections. However, this could change as the ix Industrial interface has recently emerged as a promising alternative with a significantly smaller design and more robust construction (Figure 1). It is opening up new opportunities in device manufacturing and offers benefits to end users.

RJ connectors were introduced in the 1970s by Bell Laboratories in the USA and standardized a few years later by the FCC (Federal Communications Commission). One of the best-known versions is the RJ45 connector — used for telecommunications and data transmission in offices for decades — that connects PCs to wall outlets with patch cables ranging from Category 5 to Category 7. Over the years, more technologically advanced, industry-approved RJ45 connectors have been developed. These are compatible with larger cables and wires, can be assembled without crimping tools, and are shielded to meet industry EMC requirements. A popular example is the RJ45 connector used in Siemens DRIVECLiQ systems, which has two integrated power contacts that allow data and power transmission over a single cable; up to eight data cables (four pairs) and two power cables can be connected to it.

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A barrier to miniaturization While the features listed above are adequate for the RJ45, it does pose significant drawbacks. First, the connector is not robust enough for many applications; industrial versions only have one locking hook, which unlike the plastic office version, is made of metal and thus provides at least some durability.

A far more serious drawback, however, is the size of the plugs and sockets.

As miniaturization advances, devices get smaller and smaller, as do the circuit boards upon where the sockets are mounted. As a result, the connector’s dimensions of 7 to 11 mm become comparatively large and the product designer must ensure sufficient space is allocated. The limits of miniaturization, especially for compact mobile devices, displays, small programmable controllers, cameras, and sensors, are then defined

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by the size of the RJ45 connector.

It’s easy to understand why a smaller Ethernet connector would be desirable.

Robust and 70% less space required A modern alternative that could replace the RJ45 industrial version has recently emerged: the ix Industrial interface with 10 contacts, Cat 6A classification, and data transmission rates of up to 10 Gbit. It is compliant with IEC/PAS 61076-3-124 and due to multiple advantages could potentially supersede the standard industrial RJ45 in its implementation as a robust, miniaturized Ethernet interface.

Some advantages of the ix Industrial interface include a more compact mating surface and high mechanical robustness. Designed with industrial settings in mind, it has two sturdy locking mechanisms with metal hooks

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Figure 1: The new industrial Category 6A: ix Industrial connectors from HIROSE with Ethernet cables from HELUKABEL. | All images courtesy of HELUKABEL

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HIGH QUALITY CONNECTORS & CABLES

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Figure 2: With the new ix Industrial connector, a packing density 5-times larger than a conventional RJ45 can be achieved.

Innovative Cutting-edge Interconnect Solutions

to ensure resistance to vibrations and contact durability. It is suitable for ambient temperatures from –40° to 85°C (–40° to 185°F) and shielding provides EMC robustness.

The space-saving aspect of the ix female connector is truly impressive: it only requires 30% of the space of a RJ45 female connector (Figure 2), thus allowing circuit board size to decrease even further, which is key to device miniaturization. At the same time, efficiency and sustainability also improve, as smaller housings require fewer raw materials. A smaller fan with lower power consumption is also more likely to suffice, given less air is needed to circulate in the housing. Therefore, the ix Industrial interface makes sense from an economic and ecological point of view. Furthermore, it could be

a far more reliable alternative to USB connectors on inspection cameras.

New Ethernet interface assembly solutions New connector technology often requires cable manufacturers to adapt existing products or develop new cable technologies. Given its early stage, cable manufacturers are optimistic about the opportunities offered by this new Industrial Ethernet interface and their ability to provide plug-and-play assembly solutions with ix Industrial connectors to device manufacturers (Figure 3). The industry focus is currently automation technology, video and camera technology, visualization in mechanical engineering (e.g. detection, quality assurance, etc.), and companies that manufacture measurement Figure 3: Two data connectors in two sizes: RJ45 with 8 pins and ix Industrial

• Industrial • Medical • T&M • Robotics • Autonomous Vehicles

®

®

The Original Push-Pull Connector

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with 8 plus 2 pins.

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Plug & use technology platform for wearable IoT applications Modular connections for flexible use Signal & power with 360° mating freedom

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Figure 4: The ix Industrial connector is supplied in various codings for reliable connection.

systems, all whom require patch cables to transmit power and data. Additionally, cables with “mixed” connections, i.e. ix coding at one end and RJ45 coding at the other, need to be offered as the market adopts this new technology.

The ix connectors are currently available with A-coding for standard Ethernet (4 or 8 pins, plus two power cables rated at 3 A for 50 or 60 Vdc), or B-coding for application-specific installation; both versions are straight (Figure 4). Two 90°-angle plug versions as well as a field-wireable plug with C-coding for standard Ethernet will be launched in 2020. The significant space-savings compared to their RJ45 counterparts open additional miniaturization opportunities to device manufacturers, especially since horizontal, vertical, or upright versions of the corresponding housing are also available (Figure 3). Durability, compactness, high data transmission rates, and a double locking mechanism clearly speak for the new ix Industrial interface. Now the wait begins to see how the market responds. DW The Helukabel Group | helukabel.com

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Cham pions M12 Power S & T Code

M12 Ethernet D & X Code

M12 Stainless Steel

B & D Code Crimp

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Best of 2019 Interconnect manufacturers continue to innovate, with new connector designs with key features like miniaturization, modularity, ease of use, and high speeds and bandwidth. Read on to see some of the more unique designs released in 2019 from a handful of manufacturers. For more product developments, visit connnectortips.com.

Low-profile wire-to-board connector

Hybrid push-lock connector

Hirose Electric Co. Ltd. hirose.com

ODU odu-usa.com

DF51 series wire-to-board connector enables OEMs to reduce the size of end devices.

Part of the SignalBee connector family, the 2.0-mm pitch connector has a user-friendly positive lock that provides a clear tactile click and secures a reliable connection.

The dual side-lock design prevents socket lift due to vibration or cable wrenching.

This crimp connector is available in many variations including straight, right angle, in-line connection, and single or dual row. It has a rated voltage of 250 Vac/dc and an operating temperature of –40° to 105° C.

All-in-one hybrid ODU-MAC Push-Lock connector solution is part of the ODU-MAC Blue-Line portfolio, which is a modular, easyto-use manual mating connector system for everyday mating cycles. Its modular design allows it to combine many individual connectors into one. With the growing trend for miniaturization, the ODU-MAC Push-Lock can be custom-fitted with up to 70 signal contacts and power, coax, air, fluid and data rates. The ODU-MAC also offers easy onehanded operation, up to 5,000 mating cycles, push-pull design for secure connections and space savings, and IP67 rating.

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Small and lightweight mixedlayout connectors Harwin harwin.com Gecko-SL series mixed-layout connectors enable significant space and weight reductions in electronic hardware. The respective power and data current ratings are 10 and 2.8 A max per contact. Initial release comprises female and male cable connectors, plus female vertical and male right-angle PCB connector options. They are fitted with sturdy, stainless steel screw-lok fixings (in conventional and reversed formats), to ensure ongoing interconnect integrity. They have 20 G vibration and 100 G shock resilience and operate in temperatures from –65° to 150°C. Low outgassing properties are also exhibited.

Nine new connector styles for wearables Fischer Connectors fischerconnectors.com Nine new products in the Fischer Freedom allow for easier design of SWaP (Size, Weight and Power) requirements, cable management optimization, electronic network integration and wearable technology. New LP360 products include: Size 14 (7 signal and power contacts): cabled receptacle and panel plug; active devices: USB 2.0 adaptor, LED, Rugged Flash Drive.

Size 08 (4 signal and power contacts) in plastic (high-end composite based on PEEK) with cabled plug and panel receptacle; in metal with panel receptacle and panel plug. Key features include no key code and nonmagnetic quick-release locking for easy 360° mating, membrane-sealed contacts for easy cleaning, and low-profile design and ergonomics for fixed or wearable ecosystems and cable-free devices.

Snap-in IP67 twin distributor Binder USA binder-usa.com Snap-in IP67 twin distributor for 720 series of miniature circular connectors is a single male connector into two female connectors. It features 3 and 5 gold-plated contacts rated up to 7 A at 250 V (5 A at 125 V). The twin distributor is also a compact robust splitter, for splitting off a connection with two protected paths. It has an IP67 rating; medical-grade versions are also available.

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High-powe, tool-free, pluggable connector

Double-sided board-to-board connectors

WAGO wago.com

Phoenix Contact phoenixcontact.com

WAGO’s Multi-Connection System grows with the expansion of the MCS MAXI 832 series. This addition extends its wide range of wire-to-board and wire-towire pluggable solutions at the high-power end of the range up to 66 A/600 V and up to 4 AWG conductors.

The MCS MAXI 832 series is the world’s first tool-free pluggable connector, making wiring by hand easier. It provides Push-in Cage Clamp termination with intuitive orange lever actuation. It is 100% protected against mismating, offers a wider conductor range and higher current carrying capacity.

With Finepitch board-to-board connectors, PCB designers can customize individual PCB orientations with different stack heights and numbers of positions. Two compact pitch sizes are available — 0.8 mm with EMC shielding and 1.27 mm for unshielded applications. Unique double contact system features hermaphroditic contacts, consisting of both of male and female elements. This enables vibration-proof connection in a very confined space. The high-contact count design saves space for high-speed signal and data transmission. Both the FP 0.8 and FP 1.27 series are available in 12 to 80 positions and can handle currents up to 1.4 A and voltages up to 500 Vac.

High-speed cabled receptacles and assemblies TE Connectivity Ltd. te.com TE Connectivity continues to extend its Sliver line of connectors and cable assemblies for SFF-TA-1002 with new cabled receptacles and cable assemblies that consolidate signal and power into one cost-effective solution. Sliver cabled receptacles for SFFTA-1002 enable card edge and cabled applications supporting riser card, cable, SSD drive and custom design connectivity. They support high speeds through PCIe Gen 5 with a roadmap to 112G. The dense 0.6-mm pitch of the connectors also supports next-generation silicon PCIe lane counts where current products in the market begin to max out.

The cable assembly solution connects chip-to-chip, card-tocard or card-to-chip.

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High-bandwidth interconnects Samtec samtec.com Edge Rate high-speed, high-bandwidth interconnects save space on PCBs, and are designed for high-cycle, rugged applications. Unlike some connectors that may have micro burrs on the mating edge of the contact, the mating surface of the Edge Rate contact is the smooth, milled side. This reduces wear tracks on the contact, increasing durability and cycle life of the contact system. Contact wipe on the 0.8 and 0.5 mm pitch products is 1.5 mm for a reliable connection. Additionally, the contact geometry is designed, simulated, and optimized for 50 and 100 ohm systems given the contract pitch and appropriate grounding schematics.

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•

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Endoscopy Camera

Molding Materials Include: • Silicone Rubber • PVC • Polyurethane • TPE • Polyester • Santoprene

Product Categories: • Video Cables • Patient Monitoring Cables • Sensor Probe Cables • RF Generator Cables • Robotic Surgery System Cables • Aesthetic Surgery Cables • Single Use Cables

•

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bayinfo@baycable.com

ISO 9001:2015; ISO 13485:2016 WWW.BAYCABLE.COM

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2.00-mm wire-to-board connector Molex molex.com Micro-Latch 2.00-mm wire-toboard connector system is designed for compact applications needing a high-temperature design. It offers better terminal retention, enhanced ruggedness, and exceptional mating capability. Key features include 2 to 15 single-row plug-in circuits, with both vertical and horizontal configurations; through-hole terminals; a 2.00 mmpitch low-profile connector; RoHS compliance and high-temperature capabilities; crimp terminals and cables widely available in the market; a fastener with terminal lance; a friction lock; and polarizing features — like the removal of one side housing wall — to help avoid mis-mating.

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Minimal insertion length contact Mill-Max mill-max.com New minimal insertion length contact expands the company’s range of receptacles designed to work with shorter mating leads. Receptacles are fitted with beryllium copper contact clip characterized by an early engagement contact point, dual entry capability, low contact resistance and high current carrying capacity. They accept lead diameters from 0.037 – 0.043 in. (0.94 – 1.09 mm) with a minimum mating lead length of 0.058 in. (1.47 mm) for top entry insertion, a 30% reduction in required lead length from current receptacle offerings.

USB 2.0 Type B connectors Stewart Connector, a Bel group company belfuse.com USB 2.0 Type-B connectors comply to Universal Serial Bus Standards. These connectors are designed in a vertical and horizontal configuration and able to support data speeds up to 480 Mbps for USB 2.0 applications. A frog leg shield pin design increases reliability during soldering process and later in the products life cycle. They are plated with 30 micro-inches of gold on each contact to withstand a peak current of 1.5 A per contact.

They are also molded in LCP plastic which allows for extended operating temperatures from –55° to 85°C.

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Single-pair Ethernet push-pull connector

SMA right-angle quick-connect adapter

LEMO lemo.com

Amphenol RF amphenolrf.com

New 1000 Base T1-Single Pair Ethernet (SPE) Push-Pull connector, based on transmission standards (IEEE 802.3.

1000Base-T1) is designed to operate over a single twisted-pair copper cable supporting an effective data rate of 1 Gbit/sec in each direction simultaneously. It is available in the B series and also in a watertight version — the T series. The connectors are initially designed for automotive and industrial data transfer.

The role of SPE is also to gain space and weight (with a more simple cable) and can be used in other markets such as machine, robotics and rail technology.

Expanded SMA quick-connect adapter line includes a right angle jack to plug configuration. This precision machined 50 ohm adapter allows for quick and easy mating with all existing threaded SMA jack and plug connectors. It easily converts any standard SMA plug test cable into a quick-connect cable without compromising the electrical integrity of the assembly. Push-turn thread on, pull off style of coupling used by this SMA adapter does not require any tooling for mating or unmating. This right angle adapter offers excellent electrical performance through 20 GHz and is constructed with a gold plated, brass body.

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Product World Spring actuated brakes Miki Pulley mikipulley-us.com These BXW Spring Actuated Electromagnetic Brakes provide dynamic braking when the power is disengaged and excellent performance in long-term holding applications.

BXW brakes use internal compression springs to provide power-off, fail-safe braking. The primary moving part in this brake

design is the armature plate. When actuated, the brake compression springs push the armature plate into the friction disc when the power is disengaged. This feature provides fail-safe braking and allows the brake to maintain position over long periods.

Additional features: quiet operation, high holding torque, space-saving, long service life, stable, reliable braking power, and

manual release mechanisms.

BXW Brake specifications are depending on model: • Brake torque: 0.88 ft/lb to 0.369 ft/lb (0.12 to 5.2Nm) • Brake outer diameter: 1.457 to 2.953-in. (37 to 75mm) • Ambient Temperature: 14 ~ 104° F; (-10 ° ~ 40 ° C)

Photoelectric sensors AutomationDirect automationdirect.com 4mm (smooth) and 5mm (M5 threaded) round photoelectric sensors are now available in a broader range of sensing distances in both diffuse and through-beam sensing configurations. These DC-powered metal sensors provide high accuracy in minimal mounting space and are suitable for use in a variety of short or long-distance sensing applications.

Diffuse photoelectric sensors that detect

object presence with reflected light from the target are available in detection distance ranges up to 120mm. With available detection distances up to 600mm, through-beam photoelectric sensors detect object presence when the target obstructs light traveling from the emitter to the receiver. Emitters and receivers are sold separately. These photoelectric sensors are IEC IP67 rated and cULus and CE approved.

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

Standard motors with safe encoder mount B&R br-automation.com B&R is now equipping all standard motors with a safe encoder mount. They can now be used for safety applications without restrictions. A special safety motor is no longer necessary. The delivery times and prices of the standard motors remain the same. Safety applications can be implemented in less time and at a lower cost.

Safety applications used to require the use of special

motors with a safe encoder mount. Now, a positive-locking element ensures that the encoder and motor shaft cannot slip unnoticed. This makes it possible to implement safety functions such as Safe Positioning and Safe Homing, for which safe position feedback is required.

Offset couplings

Integrated motor/actuator

Zero-Max zero-max.com

Curtiss-Wright curtisswright.com

These Schmidt Offset Couplings provide machine

The Exlar GTX100 is the second frame size in the integrated motor/

designers with a proven method to ensure machines

actuator series. Incorporating the inverted roller screw technology,

operate with constant phase accuracy and constant speed

the GTX100’s high power density and compact form factor make it

throughout the rotation and cycle of the machine.

a suitable replacement for hydraulic cylinders.

Where precise performance of system components

The GTX Series actuators offer the power, precision, and

is required, and reduced machine size is important, these

programmability of a servo system while minimizing the maintenance

Offset Couplings provide a solution. They are available

difficulties and mess of hydraulics. With continuous force ratings up

in sizes with a large range of parallel misalignment

to 15,392 N (3,460 lbf), speeds up to 953 mm/sec (37.5 in/sec),

capacity, with shaft displacements of 0.156 to 17.29-in.,

and standard stroke lengths from 150 mm (5.9-in.) to

and torque capacities from 55 to 459,000 inch-pounds.

300 mm (11.8-in.), the GTX100 can be applied across a

Providing length and space savings, they eliminate radial

range of factory

vibration from one end of the offset coupling to the other

automation applications.

end. Most important, the Schmidt Offset Coupling allows for dynamic misalignment changes with no performance loss.

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Ad Index Allied Electronics ................Cover,22,23 AllMotion ................................................ 24 Altech Corporation ................................1 Altra Industrial Motion Corp. ............... ..................................................31,32,33,34 Anchor Fluid Power ...........................43 Aurora Bearing Company ...............49 Automation24, Inc. .............................29 AutomationDirect ..............................IFC Bird Precision ........................................61 Canfield Industries, Inc .....................38 CGI Inc. ...................................................65 Chieftek Precision ..............................26 CIT Relay & Switch .............................45 Del-tron ..................................................76 Digi-key ...................................................19 Eagle Stainless Tube ........................67 Encoder Products Company ..........50 FAULHABER MICROMO .................. IBC Fixtureworks .........................................20 Keller America ......................................55 Keystone Electronics Corp. ....... 27,91

it ’s a

material world

104

110 Kennametal uses 3D printing to develop lightweight stator bore tool

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I N S I D E : Why M12 connectors are the right fit for the IIoT • The revolution in Ethernet connectors • Best of 2019

Inter

KNF Neuberger ...................................62 Master Bond ........................................49 Memory Protection Devices ........... 57 Misumi USA Inc .................................... 17 Moog Animatics ..................................47 NB Corporation .................................... 51 Newark, An Avnet Company ......... 98 OKW .......................................................... 21 Oriental Motor .....................................83 Phoenix Contact .................................. 71 Pyramid Incorporated ........................61 Rotor Clip ...............................................53 Schneider Electric Motion USA .....95 Smalley Steel Ring .............................25 Smart Products USA ........................ BC The Lee Company .............................97 Tormach ................................................ 89 TRACO POWER North America .....63 Trim-Lok ..................................................41 Whittet-Higgins ................................... 37 Zero-Max, Inc. ........................................ 2

Make Parts Fast Supplement

A supplement of Design World December 2019

100 AM Engineers need a set of best practices...and change in mindset

SALES

A supplement of Design World • December 2019

2019

Cable & Connector Reference Guide

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jbrownlee@wtwhmedia.com 224.760.1055

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Publisher Mike Emich

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Mike Francesconi

Managing Director

mfrancesconi@wtwhmedia.com Scott McCafferty smccafferty@wtwhmedia.com 630.488.9029 310.279.3844 @SMMcCafferty David Geltman dgeltman@wtwhmedia.com EVP 516.510.6514 Marshall Matheson @wtwh_david mmatheson@wtwhmedia.com 805.895.3609 Neel Gleason @mmatheson ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

3D Platform .........................................108,109 CS Hyde Company ..................................... 111 HP 3D Printing ............................................ 112 Xcentric Mold & Engineering ................. 113

Interconnect Supplement Bay Associates Wire Technologies, Inc. ................................ 131 binder USA ................................................. 127 Canfield Connector .................................126 Fischer Connectors ................................. 125 HELUKABEL USA ...................................... 119 I-PEX Connectors ......................................118 LEMO USA, Inc. ......................................... 124

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