Design World February 2016

www.designworldonline.com February 2016

INSIDE: LINEAR MOTION: Selecting linear actuators for valve automation PAGE 62

SENSORS: Key standards to know when specifying sensors PAGE 82

Two

creative

motion solutions for demanding applications

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3D CAD: If you draw it, can you print it?

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Insights The hands-on engineer returns There’s a classic stereotype about engineers that many of them started as tinkerers, tearing apart dusty old radio sets, fixing equipment on the farm, or helping an older relative rebuild a classic car in the family garage. But I’m beginning to wonder if, in another generation or so, the stereotype will be that most engineers got their start in the Maker community.

We’ve seen an interesting convergence over the past few years—a growing awareness of the need to get kids interested in STEM careers, the explosion of 3D printing technology, and hands-on programs like Dean Kamen’s FIRST robotics competition. The Maker movement seems to be at the intersection of a lot of this. Even the government has taken notice—last June, the White House hosted its first ever Maker Faire to highlight the importance of this trend.

At the Maker Faire, more than 150 U.S. colleges and universities committed to support Maker education. A recent report by these “MakeSchools” found that: • The experience is being driven by a spirit of creativity and kids’ excitement in doing something concrete.

• Schools are putting money into incorporating Making into their curricula, as well as creating spaces on campus specifically for this activity. (See my recent Insights column on CWRU’s Sears think[box].)

• Making is a cross-disciplinary educational activity and it’s often being used to solve real-world problems.

• The Maker movement can also teach students about entrepreneurship—a needed skill in a country that is creating fewer and fewer new companies each year.

For a long time, I’ve heard older engineers fret about the next generation of college graduates. They’re too dependent on everything from handheld calculators to the Internet. Next it was mobile phones and even FEA software. The argument was that they won’t know how to get their hands dirty. They’ll be overly reliant on computers to do their thinking for them. It’s a compelling argument—and I’ll admit, the worry was starting to creep into my mind, too.

But, as the saying goes, the pendulum is swinging back, and we may have a far different future ahead.

What an interesting turnabout it would be if the engineers of the next few decades turn out to be more hands-on, more intuitive and more cross-disciplinary than the previous generation of designers. I can’t wait to watch these kids innovate. DW

What’s your take on the Maker movement?

Comment on Paul’s blog on Pneumatic Tips, www.pneumatictips.com/blog

4

Insights 2-16_Vs2.LL.MD.indd 4

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Te s c h l e r o n To p i c

Recipe for a bad boss: Too smart, too gritty There is an apocryphal tale about intellect that took place in the 1920s.

That’s when a psychologist by the name of Lewis Terman identified and began tracking 1,500 children he considered to be geniuses based on IQ tests. Terman figured a number of them would make big contributions to society. Many of them did, in fact, graduate from college years ahead of their peers and wound up in professional occupations.

But as a group, they never lived up to Terman’s expectations. Some couldn’t hold jobs, and they had a much higher-thanaverage suicide rate. None of them went on to win a Nobel prize, though two kids who Terman surveyed and excluded eventually mounted the stage in Stockholm.

The lesson, or course, was that basic intelligence can’t really predict success.

Fast forward to modern times, and this lesson-learned seems to have been lost, at least until recently. That’s one conclusion from looking at how executive recruiters and head hunters have been hiring executives and managers.

Take for example Russell Reynolds Associates, a search firm that recruits at the CEO level. There, the emphasis has long been on recruiting candidates with high intelligence, according to Dean Stamoulis, a principal at the firm.

But the sands of top management recruiting have shifted, quite possibly as aftermath from hiring smart people who turned out to be cruddy managers. High IQ is now out, replaced by something Stamoulis calls results intelligence. He loosely defines this quality as being similar to grit: The ability to get beat up and bounce back when faced with difficulties without blaming or rationalizing away mistakes.

Among management recruiters, it has become stylish to search for job candidates with grit-like qualities. The trend may have started with a 2013 TED Talk by research psychologist Angela Duckworth. While teaching seventhgrade math, she noticed her best students weren’t necessarily the smartest, but rather those who worked hard and maintained their focus. The mental leap made by hiring managers seems to be that grit is just as important for managers as for seventh graders.

Now, however, there is a grit backlash. It

may be that grittiness, like intelligence, is a poor predictor of management success. The problem is that bosses who are too passionate about their goals can burn out the people who work for them.

And they may not know when to quit though it’s obvious to others involved that the goal is unachievable.

Someone who has seen the problem first hand is Mary Herrmann, managing director of executive coaching at BPI Group. Herrmann estimates about 35% of the firm’s coaching assignments involve bosses with grittiness issues—either too little or too much. Those who are too passionate about their goals are often new to the job, Herrmann said, and want to see quick wins. So they may not listen too well to subordinates, particularly when there is unwelcome news.

Another failing of the too-passionate boss: Moving too fast before sufficient facts are in. But sometimes the difficulty is simply cultural. “A lot of successful managers think what worked in one place will work as well in another,” she said. “And sometimes the ‘too passionate’ label gets put on executives who are brought in as change agents when the reality is the organization isn’t ready for it.”

Herrmann has advice for professionals finding themselves suffering burn-out from an overly gritty manager: “I’m a big believer in direct feedback. A leader needs to hear feedback about this, and an evolved leader will ask for it.”

Maybe so. But here’s my own advice for individuals bringing this kind of message to their boss: Be ready to duck. DW

Le la n d Te sc h le r - Exec u t i ve Edi to r ltesc h ler@wtwh m edi a .co m

On Twitter @ DW—LeeTeschler 6

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February 2016

2/5/16 11:57 AM

Š 2016 Helical Products Company | www.heli-cal.com

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Te c h n o lo gy Fo r wa rd

How to set up 3D printing for failure in 3 steps All too frequently, hype and inaccurate claims still replace facts about 3D printing (3DP) and Additive Manufacturing (AM) systems capabilities. You could easily make the case that hype is to blame for 3DSystems recent decision to shut down its Cube business.

Many still claim (or hope) that 3DP/ AM systems will become mass production machines, producing hundreds of thousands of parts and objects with the efficiency of traditional manufacturing equipment, like CNCs. The implication is that 3DP/AM will replace CNCs. But just what is meant by mass production? What number comes to mind?

One to three hundred parts an hour? OK, 3DP/AM can do that, depending on the part size, complexity and 3D printing technology used.

How about 1,000 parts an hour?

Depending on the part size, part complexity and the 3DP/AM technology, it could happen.

What about 500,000 parts per minute? Not yet. That’s still CNC, injectionmolding territory.

Ignorance sets up impossible-tofulfill expectations. And if you don’t meet customer expectations, they stop buying. It has happened before in the 3DP/AM industry.

So, here’s how to set up 3DP/AM for failure: 1. Insist on 3DP/AM doing what it is not designed to do.

If you are making very small, simple geometry parts, say ½ × ½ × ½ in., you can produce about 50 or so on a typical 3D printer build table (19 × 19 × 19 in.) in an hour, maybe less, depending on the 3DP/AM technology you use.

CNC machines can mass produce several thousand parts in under a minute.

It’s no comparison. Even if HP succeeds in delivering its Multi-Jet fusion system with its supposedly faster build capabilities, it won’t be as fast as a CNC. 2. Insist that 3DP/AM will supersede a trillion dollar machine tool industry.

According to various reports, the global machine tool industry is worth about a trillion dollars. In 2014, China reported an export value of $11.63B in machine tool sales. China reported an import value of $17.78B in machine tools. Japan reported imports of $5.16B, and Germany of $4.29B. Those figures are just a few of the countries buying and selling machine tools.

Various market research firms claim that the number of 3D printers sold globally in 2014 is around 158,000. Sales are expected to grow from $1.6B in 2014

to $4.8B by 2018. 3DP/AM has a bit of a way to go before it becomes a trillion dollar industry.

3. Fail to educate yourself about 3DP/AM strengths and weaknesses.

3DP/AM vendors may eventually figure out a way to speed up part build. They may develop material with faster flow rates through a nozzle, or test the limits of mechanics to move axes faster with repeatable accuracy and minimal vibration, or fuse powder together with even more lasers without overheating the build chamber or vaporizing the powder.

It can happen. But not this year. Probably not next year. Or the year after that even.

For years, manufacturing has been looking for a tool that will produce custom one-off or small production runs inexpensively. It’s here—the 3D printer/ additive manufacturing machine. 3DP/AM fills the gap that has long existed between mass and custom production. DW

Le sli e La n gn a u - M a n ag i n g Edi to r lla n g n a u r@wtwh m edi a .co m

On Twitter @ DW—3Dprinting

8

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February 2016

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l Contributors Spotlight

RYAN KLEMETSON

Two positioning components speed OEM product development

Target Markets Manager Tolomatic

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ROBERT GLOECKNER

Selecting linear actuators for valve automation

Advanced Engineering Group MICROMO

Ryan has worked on multiple custom

Robert Gloeckner is an R&D Engineer with the Advanced Engineering Group at MICROMO. Robert was born and raised in Dresden, Germany, and he attended the Dresden University of Technology. His specialties are mechatronics, robotics and electrical drives, and he built his engineering experience with various companies in Sweden, Germany, California and Oregon before joining MICROMO. Outside of his career, Robert’s passions include technology, photography, tennis and surfing.

actuator design projects in a variety of industries, including oil and gas, medical, commercial, and industrial printing applications. Prior to joining Tolomatic, Ryan spent five years in the mobile hydraulics industry. He obtained an AAS degree in Manufacturing Engineering from Alexandria Technical College.

While Ryan looks forward to the continued integration of technology into

54

our everyday lives, he also likes to think about what life would be like in the past, particularly the mid to late 1800s. “[It was] a very interesting time as the U.S. experienced its industrial revolution. Some of the early ingenuity, which helped us evolve into a more modern society, truly offered individuals the chance to become whatever they wanted to be and for some, made a significant impact on the rest of the world.”

TED TOMITA Global Product Marketing Manager

Key standards to know when specifying sensors Ted has more than 25 years of sensor technology

Honeywell Sensing & Productivity Solutions

experience with previous positions in sales, business development and strategic marketing. He earned his B.S. in Electrical Engineering from the University of

82

Illinois at Chicago and MBA in Marketing from the Illinois Institute of Technology.

PAVEN PATEL

BARRY SIROKA

General Manager Epoxyset

Business Development Manager Epoxyset

7 tips to get the best adhesive

7 tips to get the best adhesive

Paven Patel graduated Boston University with a degree in Chemistry

adhesives and specialty polymers industry in marketing and technical support with W.R Grace (Emerson & Cumming) before becoming VP of Tra-Con/National Starch. After a successful 11 years at Tra-Con/National Starch, Barry became head of Business Development of Polymers at The Fiber Optics Center where he expanded product offerings into new diverse markets and brought on and managed suppliers, including writing product specifications for new offerings. Barry began at Epoxyset in June of 2015 bringing over 35 years of experience. His extensive career lends him to give this advice: “Learn everything you can and network throughout every industry. You can learn from everybody.” And his predictions for what the future holds? “It’s going to get warmer and hotter and there will be new innovations that we can’t even imagine yet. 20 years ago I couldn’t even tell you some of the things that we have now.”

Barry Siroka began his career in the

72

and Biochemistry and began working for Epoxyset in 2010 upon graduation.

With a strong understanding of needs of customers and the market, he has implemented a stronger web presence and has begun developing a global network to build the Epoxyset brand internationally. His efforts over the least three years have benefited Epoxyset in increased sales, wider target audience, and increased brand recognition. Paven plans on continuing to work for Epoxyset helping its growth and also intends to pursue an MBA.

Contributor Page 2-16_vs4.MD.LL.indd 11

February 2016

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DESIGN WORLD

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The Mechatronic Solution for 21st Century Automation Follow the whole team on twitter @DesignWorld EDITORIAL

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Co nten t s |

|

February 2016 • vol 11 no 2

designworldonline.com

F E AT U R E S CONTROL 54 MOTION Two positioning components

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speed OEM product development

3D CAD If you draw it, can you print it?

3D printing delivers a number of benefits to manufacturing. But to truly take advantage, engineers need updated, intuitive, easy-to-learn CAD tools.

Innovative components help OEMs revolutionize their designs.

MOTION 62 LINEAR Selecting linear actuators for

82

valve automation

SENSORS Key standards to know when specifying sensors Everything from an excavator to a thermostat is getting smarter and the demand for more intelligent and connected systems is driving more demand for sensors in nearly every industry. A report by market research firm BCC Research anticipates the sensor market will grow by more than 10% by 2020.

A comparison of conventional and emerging technologies for valve actuation and automation in process industry applications reveals more options than ever for designers.

& JOINING 72 FASTENING 7 tips to get the best adhesive

The process of evaluating and choosing an adhesive is easier when you consider a few key parameters.

ON THE COVER Zero-backlash actuators and integrated gearhead encoders give designers multiple options for demanding applications.

2015

2015

2015 O N LIN E

Photo courtesy of MICROMO revenue over $3 million

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DESIGN WORLD

CONTENTS FEBRUARY 2016_first page_Vs4.LL.indd 14

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Con te n ts

2.2 01 6 D E PA R T M E N T S

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04 Insights 06 Teschler on Topic 08 Technology Forward

11 Contributors

18 Green Engineering 20 Engineering Exchange 22 Design For Industry 32 Design Notes 42 CAE Solutions 48 Internet of Things 88 Product World

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92 Ad Index

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Contents FEBRUARY_second page_Vs1.indd 16

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SAB North America 2-16.indd 17

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» Gree n E n g i n e e ri n g

Minimizing production losses in the food and beverage industry n Jean-Pierre Berlan • Director of Processing • Tetra Pak U.S. and Canada

Food and beverage companies have the power to make a difference in reducing waste, which occurs throughout the entire supply chain.

Doing so not only affects a company’s bottom line (reduced waste equals lower costs), but benefits the planet through the conservation of natural resources and reduced levels of greenhouse gases. Waste can happen anywhere on the value chain, and producers can take action to reduce it or even eliminate it in their parts of the process.

By looking at their processing and packaging operations, both of which offer opportunities to pare waste, food and beverage producers can start addressing this issue. Here are some ways to take action.

The processing side Inefficient lines, formulation changes and maintenance can cause product losses in large-scale food manufacturing plants. Plant managers can cut waste by employing strategies to prevent product loss and maximize production efficiencies.

They should start with the easiest issue first: inefficient plant designs.

In the U.S. dairy industry, milk losses can average 2 to 3% from the time the raw milk enters the factory to when the finished product is packaged and shipped. Although this may sound insignificant, it adds up to approximately 1.4 billion pounds of milk per year in the U.S., and that number more than doubles if it includes cheese production.

These losses happen for various reasons. In one case, when large-scale equipment is used to process food,

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the machines must be cleaned for food safety. During those cleanings, milk is lost. A typical plant processing 500,000 gallons can lose 3%, or 15,000 gallons, a day. One solution is employing equipment designed to run much longer between cleanings, maximizing efficiency and minimizing product loss.

Inefficient equipment design results in further losses, as well as the diverse range of products consumers currently demand, which challenges plants to produce a broad number of SKUs. On a daily basis, producing products that require many different ingredients and format changes incurs multiple line changes, which leads to production stops and starts and additional cleaning cycles. Inevitably, this leads to more losses.

Processing plants should be designed in the most efficient way possible, which means they should be compact and have equipment that can fulfill more than one function. Tetra Pak has developed a number of technologies aimed at making liquid food processing plants more efficient and compact.

These include the OneStep technology that significantly cuts processing time—and the loss associated with it—by giving processors the ability to change fat contents more quickly.

Water consumption is another area where food and beverage manufacturers can reduce waste. For example, processing a gallon of milk takes 2 to 3 lb of water, and inefficient plant design can send that figure higher. This is water used primarily to clean and rinse the equipment, which can be reduced by installing equipment that requires fewer cleanings and offers other efficiencies. For the

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U.S. dairy industry, which produces about 23 billion gallons of milk per year, it’s easy to see that it is critical to diminish losses to conserve water.

The packaging side Packaging also plays an important role in preventing food and beverage waste. For starters, the choice of package affects environmental impact, shelf life, and resource consumption during transportation and storage. Consider milk in aseptic cartons. It remains safe to drink for up to six months after packaging without refrigeration until opening. Chilled milk lasts only about two weeks and requires electricity during transport, retail display and home storage.

Containers that protect product without refrigeration reduce waste along the chain by averting energy consumption needed for chilled transport and

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storage. Further, storing goods in ambient condition reduces spoilage risk, said Antonio Rendina, Tetra Pak’s aseptic performance management director.

Producers also must consider packaging that strikes a balance between protecting product to ensure its sale and consumption, rather than waste, and using an economical amount of material to produce the container.

Reducing packaging weight also uses fewer resources in transportation and leaves less material at the end of the package’s lifecycle.

Ergonomic packaging design can also help producers reduce waste that occurs after a product leaves the store. For example, by considering how people open and close packages during the design phase, companies

can avoid waste by making packages easier to open and more efficient in closure and storage to keep unused portions intact. Testing packages’ usability among various age groups, ranging from young children to seniors, is key, said Rendina. If they can handle the packages capably, they are less likely to fumble, drop, spill and waste product.

Taking a holistic view of packaging and processing elements throughout the food and beverage manufacturing value chain—and enacting changes where possible—helps prevent waste, which ultimately benefits businesses, the environment and society. DW

Tetra Pak tetrapak.com/us

3/6/2015 11:34:56 AM 2/5/16 12:35 PM

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Innovative trends in robotics, Part 3 The topic I wanted to talk about is Soft Robotics and if you haven’t heard about Soft Robotics, you can think of it as a new approach that fits in with a lot of other segments and branches of overall robotics taxonomy where you can get, for example, industrial robots.

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military/aerospace

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» Design for Industry

material handling

Gearmotors enhance material handling energy efficiency Energy efficiency is an ever growing concern and a focus point in the manufacturing and material handling portions of the supply chain industry, not only to reduce cost and time, but also to help protect the environment.

Gearmotors, electric motors, speed reducers and ac vector drives play key roles in improving the energy efficiency of material handling operations. For example, NORD Gear has a two-stage bevel series— the SK92.1 and SK93.1—with gear efficiencies up to 97%. These helical bevel gearmotors can deliver 30% energy savings. Typical right angle worm reducers range in efficiency from 40 to 90% depending on size, ratio and output speed.

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February 2016

The two-stage bevel drives are available in a range of ratios. Features include UNICASETM, a quiet, leak-free housing design, along with wearfree infinite life gearing.

Installation, for replacement or other need, involves using the company’s worm replacement footplate and universal shaft. The footplate, which drops into all standard worm mounting footprints, is available with either threaded or through holes and an optional extended design.

DW

NORD Drivesystems nord.com www.designworldonline.com

2/5/16 1:46 PM

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» Design for Industry

medical

Capacitive sensors measure low forces

Consumer electronics, medical devices and other applications are spurring the development of sensors to measure a range of parameters. One of the latest is a capacitive-based miniature force sensor that can accurately, and with high repeatability, measure forces as low as 1 g.

This sensor lets you measure applied force at discreet points, even at low levels. It is suitable for a number of applications, including medical devices, electronics robotics and others.

Although capacitive sensors have largely supplanted resistive for touch screens, until recently, resistive sensors were the main option available for measuring force.

Resistive sensors are often limited in sensitivity at low levels of pressure. Capacitive sensors, on the other hand, have two electrodes separated by a compressible dielectric structure. When pressure is applied, the gap decreases and capacitance rises. Consequently, capacitive sensors are less susceptible to wear or failure even if subjected to multiple repeat loads.

Capacitive sensors are typically stable in terms of repeatability and durability, and can measure low levels of pressure accurately.

Thus, developers of wearable technology and products are evaluating capacitive sensors for these applications.

“By integrating capacitive tactile sensors in the testing and development of wearables, manufacturers could capture and quantify the amount of pressure experienced by customers at specific spots to optimize fit and function,” said Jae Son, founder of Pressure Profile Systems (PPS). “Comfort, after all, plays a large role in determining whether someone will like a product or not.”

There are also many applications in medical equipment design.

According to Son, such applications include an advanced catheter 24

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February 2016

system that provides clinicians with more useful and detailed data to aid in diagnosis of esophageal problems, and a screening clinical breast exam called SureTouch that detects breast lumps and, essentially, quantifies the sense of touch. One manufacturer wanted to use a miniature force sensor to control the amount of force used when injecting insulin using a syringe. Capacitive miniature force sensors are being evaluated for this application.

The technology is also well suited for monitoring blood pressure and could be used to create an alternative to pressure cuffs or embedded into future fitness and smartwatches that currently only measure heart rate.

Even within the realm of capacitive sensors, there are different methods to detect a person’s data. In the most familiar use, capacitive touch screens in smartphones use a layer of capacitive material to hold an electrical charge. Touching the screen changes the amount of charge at a specific point of contact.

Capacitive sensors from PPS use two built-in electrodes separated by a compressible gap, eliminating the need to use the electrical charge delivered by the human finger. Thus, the sensors can be activated by someone wearing a glove, for example medical or laboratory personnel, or any object that can apply force.

The miniature force sensor is available in two sizes, each with three force options, and comes with a small microcontroller that performs the capacitance conversion. For more sophisticated applications, up to 128 single-element sensors can be daisy-cained together with a single interface. DW

Pressure Profile Systems singletact.com

www.designworldonline.com

2/5/16 1:46 PM

medical

» Design for Industry

3

0

Small sensor with six degrees of freedom

When Size and Performance Matters Medical-Industrial

When it comes to measuring high rates of shock and angular velocity for crash, blast and impact testing, the 6DX PRO may fit the need. These sensors come in a shock-hardened enclosure that’s as small as the diameter of a penny. Weighing only 12 g, they terminate to a single triaxial connector.

The six degrees-of-freedom sensor includes three accelerometers (±2,000 or 20,000 g) and three angular rate sensors (±300, 1500, 8K, 18K or 50K deg/sec) in a rugged enclosure that is less than 3⁄4 in3 (19 x 19 x 14.5 mm). Focused on human injury assessment testing, the sensor is shock rated up to 20,000 g and is IP67 rated.

Testing applications include: helmet testing, automotive safety, airplane seats, parachutes, amusement rides and blast testing. The 6DX PRO is delivered calibrated with pigtail or adapter cables to support a variety of termination options. It’s repairable if damaged and meets NHTSA, FAA, ISO 6487 and SAE J211 data acquisition requirements. DW

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2/5/16 1:49 PM

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» Design for Industry

medical

Sterilizable brushless dc-slotted mini motors for surgical power hand tools It’s always best to use components designed for specific industries or applications. This line of motors was designed for surgical powered hand tools—arthroscopic shavers, ENT microdebriders and large bone drills. Plus, they withstand up to 1,000 cycles of autoclaving.

Arthroscopic shaver brushless dc mini motors drive powered surgical hand tools used in minimally invasive joint surgery; surgical procedures that are responsible for repairing joints such as hip, knee, and shoulder joints. Noload speed of the arthroscopic shaver motors ranges from 4,000 to 7,000 rpm, while maximum continuous torque is 117 to 119 mNm.

Large, bone-drill brushless dc mini motors consist of a cannulated gearbox and motor to allow for in-line pin

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and k-wire driving and provide high torque at operating speed. These battery-powered systems meet extreme torque demands without stall during joint replacement surgeries such as those of the knee, hip, and shoulder. The large bone-drill motor offers a no-load speed of 950 rpm with maximum continuous torque of 818 mNm.

Ear, nose, and throat (ENT) brushless dc mini motors have the high speed and high torque required by powered surgical hand tools used in minimally invasive surgical procedures of the ear, nose and throat as well as arthroscopic surgeries of small joints. With no-load speeds of 11,800 rpm and a maximum continuous torque of 39 mNm, these motors perform precise cutting of tissue and clean burring of bone. For highspeed drilling in spine, cranial, maxiofacial,

and otologic (ear) surgery, a spine drill will provide 90,500 rpm of no-load speed and 9.2 mNm maximum continuous torque. DW

Portescap portescap.com

WHAT DO YOU THINK?

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

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off-highway

» Design for Industry

Angle sensor for extreme environments Here’s a sensor that can handle the harsh or extreme environments off-highway equipment experiences. The RSX7900 series of angle sensors provides up to IP69K ingress protection, extremely long life of more than 100 million movements and ISO13849 PL-d safety compliance in a noncontacting design.

The sensor is available in six standard measuring ranges with angles from 0 to 60° to 0 to 360° with unrestricted rotation. Resolution is 12-bit across a 4 to 20 mA output with linearity to ±1% at ≥ 90°. Repeatability is 0.2° and update rate is 5 kHz.

Single and dual redundant versions are available and the life specification is valid even under high shock and vibration conditions up to 50 and 20 g respectively. The RSX-7900 series is available with a CANopen interface.

The sensors offer anodized aluminum housing with a stainless-steel shaft for enhanced corrosion protection with salt and spray resistance. Axial and radial shaft loading is

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up to 300 N thanks to a double-row, angular contact ball bearing design. The 70-mm diameter sensor has a nominal length of only 35 mm and is available with a wide choice of shaft styles for maximum installation flexibility.

The RSX-7900 series angle sensors operate from 9 to 34 Vdc supply for 12 and 24 V off-highway vehicle and construction equipment applications. DW

Novotechnik novotechnik.com

WHAT DO YOU THINK?

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

www.designworldonline.com

2/5/16 1:54 PM

safety

6 POWER TRANSMISSION

0

RETAINING DEVICES & maintenance & assembly tools

Online change for safe automation now possible The function “non-persistent online change� now means that individual changes in user programs can be transferred to the control system. This function is available in Release 13 of the automation system PSS 4000 for safety applications.

User programs and software blocks of a control system are often only put through final testing during commissioning, when they undergo multiple modifications. The “non-persistent online change� function allows individual changes to be fed into one or more control systems of the automation system PSS 4000 without it being necessary to compile and load the entire program, which saves time during commissioning.

The changes are fed in without stopping the control system— the new program becomes active on the head modules with the next clock cycle after downloading. The changes apply for a maximum of 12 hours or until the control system is restarted, so they are not permanent (non-persistent). If the changes are not accepted, the control system re‑establishes the status of the last complete download.

As well as simplifying and accelerating commissioning, the function improves the handling of safety in hectic commissioning processes. DW

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2/5/16 12:41 12/21/15 10:05 PM AM

semiconductor

Âť Design for Industry

7

0

Reliably attach printed circuit boards

These ReelFast surface mount fasteners have a variety of attachment options for printed circuit board applications. Depending on type, the fasteners can be specified to mount, stack, or space boards; attach components to boards; create rightangle attachment points on boards; or enable repeated access without requiring loose screws.

All types are supplied on tape and reel compatible with existing SMT automated installation equipment and install permanently where designed in the same manner and at the same time as other surface mount components prior to the automated reflow solder process. Where necessary, a polyimide patch affixed to the end of the fasteners allows for vacuum pickup.

These fasteners reduce board damage and scrap due to improper secondary installation operations by offline equipment.

The line includes Type SMTSO steel nuts and spacers/standoffs and Type SMTSOB brass versions with or without threads for board mounting, stacking, or spacing applications; Type SMTRA fasteners introducing re-usable threads at right angles to boards for mounting board to chassis, chassis to board, or component to board; Type SMTPFLSM all-metal, spring-loaded captive panel screws; and Type PSHP captive panel screws with color plastic caps for subsequent access to assemblies without the use of loose screws or the risk of compromising thread integrity over time.

They are available in a range of unified or metric thread sizes and lengths. DW

DFI 2-16_Vs3.LL.MD.indd 31

Gain time, find the optimal solution.

For optimized process flows, trust in our broad sensor portfolio for the F&B industry and packaging machines.

PennEngineering pemnet.com February 2016

Push the process.

DESIGN WORLD

 

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Learn more at www.baumer.com/food-beverage

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2/5/16 2:04 PM 14.04.15 09:48

» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

Custom coil auger helps save dough Newcomb Spring recently supplied large, custom coil auger components to a national food distributor.

Working on-site at the distributor’s facility, Newcomb analyzed dough-mixing machinery and previous auger components, created drawings and customized their manufacturing process for the new parts.

Previous parts in the customer’s dough mixing machinery often failed, did not fit properly and required maintenance. The mixing augers are vitally important to the dough preparation process—when they broke, not only did dough production stop, but total output was affected.

“The old replacement augers just didn’t fit right,” said Donald Jacobson III, technical salesperson, Newcomb Spring. “OEM replacements were not available, so the customer had to make do with what they could buy through distributors.”

The design team travelled to the customer’s facility during a scheduled maintenance day, when all relevant equipment was shut down for cleaning.

“Us going on-site, seeing the machinery and working with the customer’s maintenance and production personnel provided us with a unique insight into how these parts needed to work,” said Jacobson. “Our ability to plan this on a maintenance day also saved the distributor a lot of money.”

The engineering team created plans for the new parts based on the dimensions of the previous augers and the auger’s position when mounted in the mixing machinery. The application and operating conditions of the parts were factored as well, which helped the team alter the design and recommend materials.

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Design Notes 2-16_Vs5.LL.MD.indd 32

In a traditional order process, engineers would receive specifications and a CAD file. The company would then custom manufacture the order to meet requirements. While the company often provides design assistance, in this project, staff were involved from the initial design phase. They were presented with a problem part, then collaborated to identify the needed specifications.

“It was a really interesting challenge—much more than just reverse engineering the old parts, since the old parts didn’t work properly,” said Jacobson.

“We worked with the distributor and reviewed their production processes to the design of these augers, which are really just giant compression springs.”

The new components have significantly reduced downtime and unscheduled maintenance. Order specifications for these parts are now stored in the engineering team’s archives, and the customer is able to easily obtain new replacement augers when they are needed. DW

Newcomb Spring newcombspring.com

February 2016

2/5/16 1:38 PM

Mixing augers

are vitally impo rtant to the dough preparat ion process—whe n they break, dough productio n stops and tota l ou tput is affected. The en gineering team created plans for the new parts based on the di mensions of the previous au gers and their po sition when mounted in the mixing machine ry.

Design Notes 2-16_Vs5.LL.MD.indd 33

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Developing & Manufacturing Custom Products

CONSUMER PRODUCTS

» De sign Note s

Edited by: Mike Santora • Associate Editor

SPRINGS, WIRE FORMS, MACHINED COMPONENTS, & ASSEMBLIES

Two-part stage aligns fibers in photonics

Springs & Component Systems for Consumer & Professional Products Used for Lawn Maintenance & Housing Construction Development & Rapid Prototyping from Design Phase to Production Brake Bands, Throttle Rods, Idler Pulley & Guard Return Springs, Pneumatic Manifolds, & Belt Hooks Value-Added Brush Box Motor Assemblies ISO 9001:2008 • Made in the USA

Learn more at: www.mw-ind.com (847) 349-5780

Computer-controlled fiber aligners help boost throughput in photonics-packaging applications. Before the telecom boom at the end of the millennium, fiber alignment in the manufacture of photonics products was a tedious manual task. Here’s a summary of the first designs to automate the job and what’s possible with today’s technology.

Analog gradient search: The analog-phase demodulation hill-climbing technique worked (and in some cases, still works) for clean, quasi-Gaussian couplings already near optimal alignment. But it locks in on local maxima and flat spots in multimode couplings and imperfect devices with misalignment.

Instrumentation based on this principle was popular, though bulky and with too little travel for fully automated fiber alignment.

Digital alignment algorithms: The first digitalgradient search technique in the 1990s aligned fiber-optic devices with the motorized linear

Empowering Innovation.

Engineering Value.® Design Notes 2-16_Vs5.LL.MD.indd 34

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stages of the day—slow and low-resolution devices with limited synchronization compared to today’s piezoelectric nanopositioners. But these setups were flexible, and their massive motorized positioners worked for the emerging industrial era of photonics.

Note that analog gradient search and digital alignment algorithms didn’t address angular alignment, and new photonic devices made angular alignment a mainstream concern. First, planar waveguides became key to switching and modulating in photonic networks. Second, angular alignment needed automation, as optical switches based on steering of collimated beams necessitated throughput-optimized gimbaling alignment of collimators and other optical elements. Third, confocal optical trains (COTs) in new photonics need relatively precise angular alignment.

These needs, in addition to unabated alignment requirements for high-throughput transverse alignment, drove the introduction of the F-206 hexapod 6-axis fiber alignment system. This instrument combined six actuators with a stictionless kinematic

www.designworldonline.com

2/8/16 1:47 PM

Developing & Manufacturing Custom Products

VALVE MARKET

By integ rating s ix degrees of freed om, F-2 facilitate 06 s comple x alignm like this e n 10-DOF waveguid ts MUX/DE e MUX pa ckaging.

flexure coupling. This component integrated a fast photodetector and a flexible assortment of digital algorithms for autonomous fiber alignment automation in up to six degrees of freedom.

A key advantage of the hexapod parallel kinematic approach is the ability to cast the rotational pivot point anywhere in space.

Conventional stage-stacks are limited to rotating about the fixed mechanical centerpoint of their rotation stages and goniometers. This is defined by their bearings and fixturing structures and cannot readily be moved around. With the hexapod, process engineers could place the rotation point about an optical sweet spot with a single software command. Examples include: • for multichannel waveguide alignments, the rotation can be about the first optical channel • in collimator-collimator alignments, the rotation can be centered on either collimator’s face • for COT alignment, the alignment can pivot about its focal point, which might be buried inside a package and only blindly accessible by tweezers.

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Design Notes 2-16_Vs5.LL.MD.indd 35

SPRINGS & MACHINED COMPONENTS

New hexapod options, new fiber-optic alignment power Recent advances in hexapod design and controls have now enabled a host of robust, high-load, long-travel hexapods to be deployed for high-throughput industrial alignment applications. Building on previous high stiffness designs and triangulated geometries, these systems offer travel ranges of several centimeters while accommodating loads of many kilograms. These designs are suitable for use in any mounting orientation and offer up to 50% higher acceleration than previously possible. In addition to integrating optical metrology with the hexapods’ six degrees of freedom plus two additional linear or rotary axes of motion, their new controllers integrate data recorders for correlation of optical power with position. 100-x-100-m scans can be achieved in as little as 650 msec with these speedy mechanisms.

Interfacing options have also expanded and improved, with standard TCP/IP and USB ports offering high-speed communications and compatibility with factory automation

February 2016

DESIGN WORLD

35

Springs for Control, High Pressure, Safety Relief, Poppet, & Actuators Sizes from .010” to 2” Bar Diameter Comply with 1° Squareness & Squareness Under Load Requirements for Critical Valves Experience with Various Spring Materials Including Steel, HighCorrosion/High-Temperature Alloys, & Low Cost Coating Solutions Comprehensive Testing & SPC Analysis on Final Reports ISO 9001:2008 • Made in the USA

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» D e s ig n N o tes

architectures. New, optional remote-control pad/ displays offer hands-off manual operation.

Modular piezofiber alignment engine for transverse alignment and tracking As the telecom boom crested in the early 2000s, a manufacturer asked the design team at Physik Instrumente to create a cost-effective fiber-alignment platform for coarse-to-fine transverse alignment. The company wanted a simple stack of stages with the NanoCube XYZ nanopositioning stage (for 100 µm of travel in three orthogonal axes with 2-nm resolution).

Three motorized stages would allow many millimeters of coarse positioning to accommodate different devices in the company’s production. The system was software-based (to leverage new fast

&

The HIGHS

analog I/O interfaces), modular, opensource and based on LabVIEW. Two main challenges were that the machine had to handle fiberthrough-tube designs (which complicate the search for first-light) and irregular coupling crosssections, which can impede gradient searches. In the end, PI engineers built a machine with a two-step sequence. First, a compact double-spiral scan uses a motorized long-travel stage for first-light capture

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February 2016

Linear Slides and Cam Roller Linear Guide Rail System Components

J.W. Winco, Inc. offers high quality, heavy duty linear slides and telescopic linear slides, along with cam roller linear guide rail systems components, suitable for every application. Explore our full line at www.jwwinco.com or contact us with your requirements.

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and rough optimization. Then a fast raster scan (previously impossible without modern piezoelectric positioners and advanced controls), combined with synchronous data acquisition to compile the transverse coupling cross-section and identify the global maximum. This approach would literally align virtually anything in a flash.

The raster-scan approach is insensitive to local maxima. The global maximum can always be observed and selected. This option had been unavailable a decade earlier due to the limitations of the motion devices of that day.

Since piezo devices are so fast, why not collect data to localize the global maximum directly rather than inferring the vector to it from the limited data older architectures could provide?

Recently this architecture, called CyberAligner, has enjoyed many advances, including an upgrade to updated versions of LabVIEW and leveraging I/O capabilities provided by today’s multifunction analog/ digital hardware. DW

Complete Motion Solutions Pneumatic, Electric & Hydraulic Actuators

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for silicon photonics chip manufacturing and inspection: The system integrat es several hardware componen ts and software for automa ting assembly and align ment, such as pick-and-place rob otics, machine vision or pre cision positioning devices .

PHD offers an extensive line of pneumatic actuators that are known for long life and high quality. Over our 55 years of innovation, we have extended our product offerings to include built-to-need components, price alternative components, electric actuators, specialty workholding clamps, and motion control robots.

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

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phdinc.com/dw216 • 1-800-624-8511

February 2016

Design Notes 2-16_Vs5.LL.MD.indd 37

DESIGN WORLD

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2/8/16 9:56 AM

Âť D e s i g n N o tes

Edited by: Mike Santora • Associate Editor

Machine tool probes help forge wheel and car chassis The automotive industry is fiercely competitive.

Produc tion tim es for c are rela ar chas tively sh sis ort, and kept wit c a n be hin 20 t o 25 min machin utes. Th e tool p e robe sys the ope t ems pro rator w v it ide h turnkey for realtime po solution sitionin s measure g and ment a nd in-p control rocess measure ment.

Tier-one car manufacturers are constantly looking for breakthroughs in areas such as performance, safety and design, all of which place ever stricter requirements on the processing of metal components. SuperAlloy Industrial (SAI) is a supplier of lightweight forged metal products. The forged wheel and car chassis components SAI produce are used by several car manufacturers.

SAI uses Renishaw machine tool probe systems, including the OLP40, RMP60, OMP60 and the NC4.

SAI came to Renishaw because it needed to enhance product quality and reduce the amount of rework and corrections during processing to achieve high-quality levels.

The production of aluminium forged wheel rims The forged wheel production process is complex, particularly for low-volume, high-diversity production. Strict standards are applied to workpiece setting, reference measurements and key dimension detection during metal processing, as the precision requirements for machining wheel mounting surfaces exceed the requirements of even the aerospace

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Design Notes 2-16_Vs5.LL.MD.indd 38

February 2016

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2/8/16 1:56 PM

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» D e s i g n N o tes To increase pr oduction precis ion and reduce scra p, SAI equipped th e lathes with Reni shaw OLP40 to uch probes, which us e optical signal transmission an d are adapted fo r turning processe s.

industry. SAI currently has 600 CNC machine tools working on wheel rim production, including 150 Victor Taichung lathes and 450 YCM milling machines. So how does SAI ensure that the precision and stability of 600 machine tools remains consistent?

To increase production precision and reduce scrap, SAI equipped the lathes with Renishaw OLP40 touch probes, which use optical signal transmission and are adapted for turning processes. The CNC milling machines were equipped with RMP60 machine tool probes, which use wireless radio transmission to measure workpiece position and reference height, as well as providing in-line key dimension detection, thereby increasing production performance.

Y. C. Kao, senior manager of SAI‘s Wheel Production Dept., said: “The automated workpiece setup, enabled by Renishaw machine tool probes, allows us to ensure that the cutting 40

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February 2016

dimensions remain stable and consistent when we are producing wheel rims, as well as reducing human error. For example, the air valve hole cutting thickness Process Capability Index (CPK) rose from 0.71-1.13 to 1.35-1.43 when using Renishaw machine tool probes.”

3D appearance modelling for forged wheel Wheel styling design has moved from flatter surfaces toward more 3D effects in recent years, causing wheel rims to become even larger, and placing increasingly stringent demands on processing precision. Until 2011, SAI‘s acceptable tolerances for wheel rim production (with the flatter designs used at the time) were 0.05 to 0.10 mm. However, the tighter tolerance requirements of the current 3D designs has gradually increased cutting times and processing; wheel rim appearance processing takes as long as 180

www.designworldonline.com

2/8/16 9:57 AM

Your Global Automation Partner

to 240 minutes, with the result that any rework imposes considerable pressures in terms of both production time and cost.

OLP40 probes carry out in-process measurement control to achieve tolerance of less than 0.02 mm, and can replace human measurements and updates to workpiece coordinates. This greatly improves cutting and efficiency for surface precision processing after coating. Even more importantly, it reduces rework by 80%, as before the introduction of inline measurement systems wheel production generally had to be processed twice to achieve the necessary precision.

Production times for car chassis are relatively short, and can generally be kept within 20 to 25 minutes. The machine tool probe systems provide the operator with turnkey solutions for real-time positioning and measurement and in-process control measurement.

The company now has 10 CMMs fitted with Renishaw probes. For machine tool performance checks, SAI has also fitted its machining centers with QC20-W telescopic ballbar measuring instruments for the most comprehensive diagnostic testing and verification functions. DW

Precision processing for car chassis

Renishaw renishaw.com/mtp

The safety and stability of lighter vehicles moving at high speed is closely connected to the manufacturing of the car chassis. The higher the precision of chassis produced with aluminium alloys, the safer and more stable the car is when travelling at speeds as high as 200 km/h.

SAI now has 38 Tongtai high-end, five-axis CNC machine tools, all of which are equipped with OMP60 optical machine tool probes and NC4 non-contact laser tool setters.

Unlike wheel rim production, chassis production tends to involve high volume and lower diversity, but nevertheless still requires high-precision metal cutting and processing.

OMP60 optical machine tool touch probes use modulated optical transmission to provide 360° signal transmission. The probe simplifies measurement and calibration processes, thereby achieving high-precision measurement for workpieces with complex profiles. The NC4 uses laser technology to perform high-speed, high-precision measurement of cutting tools as small as 0.2 mm, and to perform tool breakage detection on cutting tools as small as 0.1 mm.

Its non-contact method avoids the potential for causing wear or damage of cutting tools.

www.designworldonline.com

Design Notes 2-16_Vs5.LL.MD.indd 41

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February 2016

DESIGN WORLD

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2/8/16 9:57 AM

»»

» CA E Solu t i o n s

Cloud-native CAD will disrupt the PLM platform paradigm Bruce Jenkins • President • Ora Research

Onshape is different from older-generation engineering software. It is based on immutable microversions, which makes for a solid foundation for other collaboration tools, such as the Follow Mode shown here, as well as tools being developed for the future.

An illuminating blog post by Onshape engineering team member Ilya Baran revealed some fundamentals of how the new cloud-native CAD system works: “We are careful to distinguish several types of data: the User Interface (UI) state—for example, selection, camera view, current tab; the Part Studio definition—for example, feature list, part names and colors, import data; [and] Regeneration results—the “b-rep” (bodies, faces, edges and so on), triangles for display, regen errors.”

How do these data types differ? “The UI state generally doesn’t persist (except for things like named views),” Baran wrote. “The regeneration results are cached, but they can always be rebuilt from the definition. The Part Studio definition is what we store in the database, and that is where collaborative editing happens.”

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Then Baran explained something that begins to suggest why we believe Onshape is not only a breakthrough in CAD, but also poised to disrupt the established paradigm for PLM platforms. “For a given Part Studio, at each point in time, the definition is stored as an eternal, immutable object that we internally call a microversion,” he wrote. “Whenever the user changes the Part Studio definition (for example, edits an extrude length, renames a part, or drags a sketch), we do not change an existing microversion, but create a new one to represent this new definition. The new microversion stores a reference to the previous (parent) microversion and the actual definition change.

In this way, we store the entire evolution of the Document; this is accessible to the user as the Document history, allowing the user to reliably view and restore any prior state of an Onshape Document.”

2/5/16 1:30 PM

Your Global Automation Partner

» CAE S olutions

Next, Baran revealed how Onshape is fundamentally different from older-generation engineering software. “Basing Onshape on immutable microversions also makes for a great foundation for other collaboration tools: those we already have, such as the Follow Mode or the Compare tool, as well as those we are developing for the future,” he said. “It also has benefits beyond just collaboration abilities: Because old microversions are never modified, data integrity is better preserved, and having a history of changes allows us to debug exactly how a Document came to be when a user has a problem or when we detect a problem through our logs.”

New cloud-native database architecture changes everything What makes all this possible and practical?

Much of the answer lies in Onshape’s being built on MongoDB, one of the new “NoSQL” databases widely used in cloud-native applications, instead of any of the relational database management systems (RDBMS) used in most engineering applications until now. “Relational databases were not designed to cope with the scale and agility challenges that face modern applications,” MongoDB said, “nor were they built to take advantage of the commodity storage and processing power available today.” MongoDB functions as backend software for Craigslist, eBay, Foursquare, LinkedIn and many other massively deployed cloud-based services.

Besides being fast, scalable and designed to exploit cloud computing resources, NoSQL databases have a capability called “schema-on-read.” This allows data to be captured, stored and subsequently acted on with almost limitless freedom, without the application developer having to create a schema for the data in advance. Having to create such a schema as the first step in creating a database, a requirement of traditional RDBMS technology, is known as “schema-on-write.”

Joe Pasqua with MarkLogic, another NoSQL database provider, explained the benefits of schema-on-read: “For decades www.designworldonline.com

CAE Solutions_Simulations 2-16_Vs3.LL.MD.indd 43

now, the database world has been oriented toward the schema-on-write approach. First you define your schema, then you write your data, then you read your data and it comes back in the schema you defined up-front.

This approach is so deeply ingrained in our thinking that many people would ask, ‘How else would you do it?’ The answer is schemaon-read. Schema-on-read follows a different sequence—just load the data as is and apply your own lens to the data when you read it back out.”

What’s the advantage? “More and more these days, data is a shared asset among groups of people with differing roles and differing interests who want to get different insights from that data,” Pasqua said. “With schema-on-write, you have to think about all of these constituencies in advance and define a schema that has something for everyone, but isn’t a perfect fit for anyone. When you are talking about huge volumes of data, it just isn’t practical. With schema-on-read, you can present data in a schema that is adapted best to the queries being issued. You’re not stuck with a one-size-fits-all schema.”

But that’s not all. “One of the places where projects often go off the rails is when multiple datasets are being consolidated,” Pasqua continued. “With schema-on-write, you have to do an extensive data modeling job and develop an über-schema that covers all of the datasets that you care about. Then you have to think about whether your schema will handle the new datasets that you’ll inevitably want to add later. If you’re lucky enough to get through that process, Murphy will strike again and you’ll be asked to add, change or drop a column (or two or three). With schemaon-read, this upfront modeling exercise disappears.”

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Those underlying capabilities of Onshape’s database architecture—together with its ability to import, operate on and archive data from other engineering applications—begin to suggest the true scope and scale of the company’s long-term ambitions and vision.

February 2016

DESIGN WORLD

sensors on the market.

43

Call 1-800-544-7769 or visit info.turck.us/sensors

2/5/16 1:32 PM

»»

» CA E S o lut i o n s

Indeed, it has made no secret of this. Around the time of Onshape’s public unveiling last year, a user posted in its online discussion forum: “Is Onshape intending to develop PLM eventually, or are they going to go the route of partners to provide that? I ask because Onshape is a database system with the correct platform to seemingly handle this functionality.”

In reply, Steve Hess from Onshape’s UX/ PD team posted: “As you know Onshape was built with data management in mind. The data management features of Onshape are at the core of the product and will become more exposed as Onshape matures. In time, Onshape will be the system of record for all types of data and meta-data…The data stored in Onshape will be visible and accessible to your other enterprise systems.” (Our emphasis.)

Already, the ways in which Onshape lets multiple users work simultaneously on the same design serve to eliminate many problems that established PDM and PLM providers have spent years “solving”—and at the same time perpetuating, because of the database architectures their systems were built on. As Onshape founder and chairman Jon Hirschtick told us, “For starters we eliminate 50 to 60% of all the functions of traditional PDM—they simply have no role (copying files, managing directory structures) in our world.”

Far from being a throwaway line, we think Hirschtick’s phrase “for starters” is in dead earnest. To date, Onshape’s best-understood benefits are how it removes many of the headaches and costs of locally installed software, and of CAD collaboration and

data management. But we believe its larger goal is to evolve a next-generation product development platform that “in time,” as Hess said, “will be the system of record for all types of data and meta-data.”

Onshape’s ability to do this is grounded in two key benefits of schema-on-read. First, it “gives you massive flexibility over how the data can be consumed,” explained Tom Deutsch, Solution CTO with IBM, and second, “your raw/atomic data can be stored for reference and consumption years into the future.” These position Onshape to extend its radical simplification of CAD collaboration and data management to more and more areas of PLM, where users have had enough of complexity and expense and are ready for something new. DW

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February 2016

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» CA E »Solu CA Et iSo onlut s ions

MecSoft releases VisualCAD/CAM 2016 VisualCAD/CAM 2016 is a stand-alone CNC programming software. VisualCAM runs integrated inside the VisualCAD base CAD platform and addresses the CNC manufacturing market with modules VisualMILL, VisualTURN, VisualNEST and VisualART. VisualCAD/CAM 2016 has been enhanced. These changes include: • enhancements to geometry construction and design functions in VisualCAD • enhancements to 2-, 3- and 4-axis milling methods • enhancements to tooling, feeds/speeds and knowledge bases • utilities for cabinet makers to help in programming toolpaths for cabinet manufacturing • enhancements to the NEST module VisualCAD/CAM 2016 emphasizes the automation of programming tasks. DW MecSoft Corporation mecsoft.com

Introducing ZNEO32!

Zilog’s Line of 32-bit Cortex-M3 based Programmable Motor Controllers ZNEO32! uses high performance 32-bit computing, 3-phase PWM generators, and high speed ADC units to provide an effective, low-cost system solution for motor applications.

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Speed 1.5MS/s 1.5MS/s 1.5MS/s 1.5MS/s 1.5MS/s 1.5MS/s

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» CAE Solu t i ons

Create specialized simulation apps COMSOL Multiphysics software is now available on Rescale simulation platforms. The simulation suite is further expandable with more than 30 add-on products for simulating electrical, mechanical, fluid flow and chemical applications allowing for unlimited multiphysics combinations.

Simulation experts can use the Application Builder within COMSOL Multiphysics to create specialized simulation apps that can be run by engineers and others not well versed in simulation. These apps are hosted and run on the COMSOL Server software, which is also available on Rescale’s cloud.

Now users can run computationally demanding analyses on high-end hardware that matches the power and flexibility of their solvers. Users submit simulations using their existing COMSOL Multiphysics licenses with on-demand high

performance computing (HPC) hardware, making use of the software’s automatic and sophisticated parallel processing capabilities.

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» Inter n et

.......................................... ................................ ........................ ................... .............. ........... ........ ...... .... .. o f T h in gs

EtherCAT servodrives for brushless motors OPENdrive OD700 is an EtherCAT compatible servodrive for brushless motors.

A key feature is automatic recognition of connected motors and configuration through “ODM,” a browser executable on PC and on machine board. This feature makes the servo system easy to commission through the EtherCAT channel without modifying machine connections. ODM enables visualization and modification of drives and motor characterization parameters in addition to drive analysis through diagnostic graphics.

ODM also enables drive functions, such as digital filters, for the compensation of mechanical imperfections and the actuation 48

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time of the brake motor to synchronize it with axis motions. A multi-track oscilloscope allows execution of detailed analysis of axis behavior for better machine performance.

Six OPENdrive models are available with current ratings of 1, 3, 6, 12, 18 and 36 A in three sizes. Each model has internal sampling times (50 sec for the current loop and 100 µsec for velocity and position loops) for dynamic management.

This also allows connection to an auxiliary encoder transducer for increased position accuracy control of the mechanical system.

All models have integrated SIL3 certified safety function controlling power to the drive during machine operation.

Drives are equipped with two encoder inputs managing multiple primary and secondary transducers. OASI brushless motors, when coupled with the drives, provide high inertia and dynamic operation. All motors are equipped with thermal sensors and are available with an optional brake. They are available in 3,000, 4,000 and 6,000 rpm with a stall torque range of 0.2 to 66 Nm. DW OSAI USA osaicnc.com

www.designworldonline.com

2/5/16 2:08 PM

Mean Well 2-16.indd 49

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» Inter n et

o f T h in gs

Smart remote data acquisition devices with WiFi Both the ioLogik 2542-WL1 and ioLogik 2512-WL1 feature 802.11a/b/g WiFi connectivity. The ioLogik 2542-WL1 supports analog I/O connections over WiFi, whereas the ioLogik 2512-WL1 supports digital I/O connections over WiFi. Both ioLogik units feature automatic tag generation and reporting for connected sensors and devices. This helps operators monitor a large number of field devices efficiently. This function can also work in conjunction with the MX-AOPC UA Server on the cloud to minimize network bandwidth and latency. Data communication is protected with the highest commercially available security (WPA2/802.11i), which features advanced encryption and authentication.

In addition to WiFi, the ioLogik 2542-WL1 and 2512-WL1 both feature a 4-port unmanaged Ethernet switch and two serial ports for a seamless connection to a variety of field devices. The serial ports support data polling from devices using the Modbus RTU protocol. This data can be converted into Modbus TCP or AOPC tag format before sending it out over the Ethernet network.

Depiction of Frequency Waves

INNOVATING SHOCK & VIBRATION SOLUTIONS

The units also support communication with multiple remote I/O devices under a single IP address. The slave Ethernet port can link up to eight daisy-chained ioLogik E1200 expansion modules and convert more than 100 channels to one IP address. The other three Ethernet ports can connect to any Ethernet-driven field device.

The ioLogik 2542-WL1 and 2512-WL1 can withstand -30 to 70° C (-22 to 158° F) operating temperatures. Both units offer industry-leading EMI protection and rugged, shock-resistant housing. DW Moxa Americas moxa.com

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» Inter n et

.......................................... ................................ ........................ ................... .............. ........... ........ ...... .... .. o f T h in gs

Extended 5-port PoE+ gigabit unmanaged switch line The LNP-0500G and LNP-0500G-24 series unmanaged switch line expands the low port count gigabit connectivity product line for industrial applications. The LNP-0500G Ethernet switch is rugged and reliable and suits applications involving surveillance systems, data centers, research labs or any location that requires simple gigabit speed network expansion.

The low-voltage input and ability to provide high-power PoE allows the LNP-0500G-24 to fulfill transportation, factory automation vision inspection, solar and remote location surveillance applications.

These 5-port industrial PoE+ gigabit unmanaged Ethernet switches have a 48-to-55-Vdc high voltage power input (LNP-0500G) and a 12-to-36-Vdc low voltage power input (LNP0500G-24). Each gigabit Ethernet port is IEEE 802.3at compliant (PoE+) on ports 1 to 4 (data and power output maximum 30 W/port) and backward compatible with IEEE 802.3af.

The series supports MDI/MDI-X functions and a 10-KB jumbo frame.

This product series provides high EFT, surge (2,000 Vdc), and ESD (6,000 Vdc) protection to prevent any unregulated voltage and can support the power redundancy feature using a dual power input design with reverse polarity protection. There is also a built-in relay warning function to alert maintainers when power failures occur. DW Antaira Technologies antaira.com

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WHAT DO YOU THINK?

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

February 2016

www.designworldonline.com

2/5/16 2:17 PM

Cloud data services Yokogawa Electric acquired Industrial Evolution to strengthen its ability to deliver solutions to the process industries. Industrial Evolution is a provider of cloud-based plant data sharing services.

Based on Industrial Evolution’s cloud business environment, Yokogawa will provide Data-as-aService (DaaS).

Using its cloud-based DaaS technology, Industrial Evolution collects real-time process data from devices and systems at a variety of industrial facilities, and provides this in a direct or custom form to the companies that operate such facilities, as well as their customers and vendors. Industrial Evolution’s service can collect data from firewall protected systems and securely shares this with authorized users through website or mobile access.

Industrial Evolution is a pioneer in this field and its data collection and sharing service is used by a range of companies, including a number of Fortune 100 companies. This service can be used in a variety of applications, such as the sharing of data on oil and gas field operations among authorized users at multiple companies and the real-time sharing of data with investors on facilities that are operated by third parties. DW Yokogawa Venture Group yokogawa.com/us

Advance to the IIoT. Connect devices and ignite productivity.

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February 2016

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+1 (717) 767-6511 I info@redlion.net I www.redlion.net © 2015 Red Lion Controls, Inc. All Rights Reserved.

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Two positioning components speed

OEM

Innovative components help OEMs revolutionize designs. In

product development

fact, some original equipment can now benefit from zero-backlash actuators and integrated gearhead encoders. These give designers multiple options for demanding applications.

Robert Gloeckner • Advanced Engineering Group • MICROMO

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Performance, cost and size requirements for motion applications vary widely. In some

cases, performance trumps all and the budget must simply tolerate the result. In others, the application demands performance but at reasonable price. As we’ll explore, if an application requires absolute accuracy, a gearhead encoder is an economical and compact solution. For applications that cannot tolerate any backlash, zero-backlash actuators remove it mechanically.

Consider a perfect motion system in which the controller sends a signal, and then the hardware delivers the load to the commanded position. In reality, error sources such as mechanical hysteresis and backlash compromise performance. With enough design time, effort and money, it’s possible to minimize these effects.

However, motion is an enabling technology rather than an end in itself—which means OEMs generally aim to focus on their product’s unique value proposition, and not on matching gear teeth and damping vibration, for example.

Now, new technology simplifies performance optimization and makes it cheaper, too.

Preventing lost motion with tandem gearing As mentioned, some zero-backlash actuators ensure stable performance for applications that cannot tolerate lost motion. To remove error caused by vibration, compliance and shock load, the gearhead encoder drives deviation to zero. That frees OEMs to focus on the development of innovative products of their own.

Even the best gearheads have small gaps between the teeth to let them mesh and maintain

lubricant between contacting surfaces. The downside is that this space introduces a bit of lost motion called backlash. This shows up as positioning error, especially in precision applications with frequent reversals. Even for high-accuracy or precision gearheads, backlash still amounts to a few degrees of arc-min, and normal wear over the lifetime of the machine only worsens it. This is not a problem for a case packer or palletizer, but even that small amount of error is too much for applications such as robotics, optical positioning and gantries.

Over the years, motion vendors introduced designs to mitigate backlash using plastic spacers, split

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>> Zero-backlash actuators can have

a central gear flanked by two pinions.

Consider this generic CAD rendering: During normal operation, the pinions (green) drive the motor shaft. When the move completes, one pinion drives forward while the other reverses to introduce a counter force to mechanically remove backlash. Applications for such actuators are optics, photonics, medical devices and small robotics.

gears and springs to apply a preload that maintains contact between the gear teeth. But none are ideal, because they still exhibit a few arc minutes of error, and the preload needs adjusting for wear and environmental changes to maintain performance.

To address the problem, some zero-backlash actuators use an integrated assembly. These deliver fast and accurate positioning without backlash, which in turn delivers loads to commanded locations with minimal error. Compact and robust, the plug-and-play actuators also speed assembly and eliminate scrap.

Consider one specific setup with two motors.

This design uses a gear flanked by two motordriven pinions. One pinion positions the axis, and the other engages the opposite tooth flank and takes up backlash. During normal motion, the motors drive the load with combined torque.

At the end of the move, the first pinion holds the

>> In robot-guided surgery, even a

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millimeter of error can drastically impact patient outcome. Here, zero-backlash actuators with encoder-equipped gearheads at the robot end effectors let surgeons accurately position equipment.

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>> Shown here is a dual-band fluorescent microscope from

position while the second pinion reverses to apply the counterforce. This effectively removes backlash mechanically. Such actuator gearheads perform equally well during acceleration, deceleration and reversals. They’re flexible in that the servo controller can adjust the preload to be softer or stiffer. Plus, it’s a scalable design.

In addition to two-motor setups, this design concept also implements with four or even six motors to increase torque while adding redundancy, especially in highreliability applications.

Zero-backlash actuator options Design engineers can choose from rotary and linear actuator configurations with myriad performance levels and form factors. For example, through-hole versions

Kessler Optics and Photonics Solutions. Actuators with a through-hole design can be useful in similar applications to position optical components while beams shine through an aperture. The result is precise performance in a tight system, and an aperture that lets cables run through the center to save space and reduce cable fatigue.

are useful for optical systems that operate in space-constrained applications. More specifically, through-hole zero-backlash actuators can position optical components while a laser beam shines through the aperture. The result is precise performance in a compact system. The aperture also lets users run cables through the center as a way to save space and reduce cable fatigue.

Such actuators also excel in gantries for pick-and-place operations, where backlash can cause binding (and compromise performance while making the system wear prematurely). Here, zerobacklash actuators ensure symmetrical motion so carriages can travel faster while handling heavier loads.

Just consider how the position of a solar cell on a satellite can mean the difference between a functioning device

and a useless lump of space junk. In one real-world setup, the reliability and functionality of a zero-backlash actuator lets engineers optimize solar cell positioning. The actuator has also maintained solid performance, even under launch and orbital conditions.

Another approach: Driving error toward zero In standard servo systems, an encoder mounted to the motor shaft monitors the number of rotations to estimate the position of the load. However, compliance, hysteresis and backlash all introduce error between predicted and actual load positions. This error can be as much as 2 to 3° in some cases. While that’s acceptable in many standard designs, demanding OEM

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applications can’t tolerate such error.

Precision OEM machines need an encoder mounted to the output shaft of the gearhead, not just the motor shaft. Such systems can operate on a dual control loop.

They first close the loop around the motor encoder and then around the gearhead encoder. This configuration lets the controller measure the difference between predicted and actual location of the load (and compensate for the error). This process introduces a small amount of latency, but makes for highly accurate and precise output.

It’s particularly effective for ultra-demanding applications such as micro-robotics.

3D printing and aerospace Dual-control-loop techniques can be challenging, though. Space can be a factor.

After all, adding an encoder to the gearhead won’t do much good if the assembly won’t fit. Mounting an encoder to a gearhead shaft involves mechanical, electrical and controls interfaces. That’s a non-trivial task that consumes time that would be better spent working on the actual product being designed.

As one solution, some motion vendors offer magnetic gearhead encoders. These 60

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integrated packages are assembled in the factory and fine-tuned to optimize performance. Based on a Hall-effect sensor, they deliver 0.022° resolution— and excel in applications subject to vibration or shock loads, and those that can’t tolerate settling times. It can work as stand-alone feedback for configurations that lack the space around the motor to install a conventional shaft encoder. Coupled with a stainless-steel housing, the encoder makes the gearhead encoder robust enough to handle tough contamination and vibration conditions.

It’s also compact—just 15 mm in diameter—so it fits in tight spots.

Such encoder setups work in myriad applications. In robot-guided surgery, even a millimeter of error can drastically impact patient outcome. Using the gearhead encoder in a robot end effector lets surgeons position their equipment with absolute accuracy. 3D printing demands the same level of performance to fabricate parts with fine detail.

Consider another example: In electronics assembly, accurate positioning of components during pick-and-place operations can mean the difference

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Retrofitness

between a finished circuit board and expensive pieces of scrap. The gearhead encoder’s accuracy and small size make it suitable for these uses. DW

MICROMO micromo.com

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A comparison of conventional and emerging technologies for valve actuation and automation in process industry applications reveals more options than ever for designers.

Selecting

linear actuators for

valve automation

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2/5/16 3:16 PM

With the demand to improve productivity, increase efficiency and lower downtime in the process control industry, some valve automation applications require increasingly sophisticated motion control solutions.

To meet these demands, engineers can select from a variety of valve automation options, depending on the valve type, industry and required function. One emerging technology in valve actuation is the brushless servomotor, which offers an alternative to more traditional methods including pneumatic-actuated systems, hydraulic-actuated systems and electric-valve actuators driven by conventional brush motors.

Broadly speaking, control valves operate in two different

ways: linear motion (rising stem) or rotary motion (half turn or quarter turn). Each method is designed for specific functions and applications. Here the focus is on rising stem valves, which are typically used in mission critical areas of a process where reliability, repeatability, accuracy and responsiveness are all desired characteristics.

For quick response in valve and process control, an integrated electric linear servo actuator provides efficient force in a compact, lightweight design. The actuator’s precise control of acceleration speed and torque improves flow rate and works well with water valves, oil and gas valves and any type of valve with linear movement.

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excess pressure, which can create a rapid movement once the valve is in motion. The resulting overshoot can delay settling on the specified set point or make it difficult to achieve the set point at all.

In addition to stick slip, other common problems that can negatively affect pneumatic actuated systems include:

System demand—Where there are large numbers of control valves or varying degrees of system demand, the available air pressure and air flow may be limited, reducing speed and response time.

Air quality—Conditioning and air quality can cause components such as cylinders to operate below their peak performance and efficiency, which can lead to premature component failure.

for encountered static friction.

Ambient air temperature—Where climate temperatures are not controlled, freezing temperatures can cause control valves, actuators, air lines and controllers to seize. The presence of ice due to freezing moisture in the system in some or all of these components could incapacitate an entire control system. Poor air quality and system demand will still affect overall performance regardless of the climate.

Pneumatic actuation Pneumatic-actuated systems have been a primary technology for valve operation for many years. They are simple, low-cost and easy to maintain. By design, pneumatic operation does not create a spark and is often specified for hazardous applications.

Compressed air is also readily available in many manufacturing and process control environments.

These systems, however, do have some limitations. Generally, a valve requires more shift force in a static state than when in motion. This trait is commonly referred to as “stick slip.” To overcome stick slip, pneumatic-actuated systems build up

These conditions, in conjunction with operating in an outdoor environment, can further impact system performance due to extreme cold temperatures.

Another challenge with pneumatic actuation is the recent shift in some industries to focus on the cost of operating a pneumatic-actuated system compared to buying and installing the system (cost of ownership versus cost of acquisition). It’s widely accepted that pneumatic systems have operating efficiencies between 10 and 30%. Leaks and pressure losses through hoses, fittings, poorly maintained valves and air preparation components, as well as improper settings, all contribute to overall inefficiencies.

Pneumatic slip stick is caused by excess air build-up in the actuator to compensate

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Sustaining even these low operating efficiencies can require continual maintenance, which also adds to the total cost of operation. This high operating cost, coupled with the need for increased precision and reliability in valve operation, has led some engineers to weigh cost of operation as more important than the cost of acquisition for some applications.

Hydraulic actuation By comparison, some research suggests that hydraulic-actuated systems are in fact the most expensive to operate because they require continuous power to maintain pressure. However, there are compelling reasons why hydraulic-actuated systems continue to be deployed for valve automation processes:

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Hydraulic-actuated systems can be designed as self-contained systems, allowing them to be deployed in remote locations.

The cost of acquisition can be low to moderate, depending on the size and sophistication of the system.

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As with pneumatic-actuated systems, hydraulic-actuated systems

do not require significant technical

ability to install, configure and deploy.

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Hydraulic cylinders have a high power density.

Tolomatic’s compact, heavy-duty integrated electric linear servo actuator integrates a servomotor into a ball- or roller-screw-driven actuator. This compact, lightweight design allows for speeds up to 58 in./sec and forces up to 6,875 lb, even in high duty cycle applications.

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The oil used in these systems is nearly incompressible, so overall stiffness, positional repeatability and accuracy are improved over pneumatic-actuated systems.

At the same time, environmental and system contamination can still negatively affect overall performance in many of the same ways a pneumatic-actuated system would be affected. Oil leaking from a system will also diminish performance over time. If the level gets low enough, a leak

“Electric-valve actuators, which use an electric motor to power the actuator, are a cost-effective alternative to pneumatic- or hydraulicactuated systems.”

can create a risk of component damage.

Substantial leaks can be considered an environmental hazard. As with pneumatic systems, hydraulic systems also require a high degree of maintenance to ensure proper performance.

Another notable difference between hydraulic- and pneumatic-actuated systems is the effect of ambient air temperature on efficiency due to variations in hydraulic oil viscosity. In the case of AW32 hydraulic oil, viscosity increases or decreases with extremes in air temperature. At -20° F (-29° C) its viscosity is high, which makes the oil harder to push. As temperatures increase beyond room temperature, oil will start to lose viscosity and become thin.

As a result, oil can flow through smaller openings, requiring more flow and thus more power. Oil heaters or heat exchangers are used to regulate oil temperatures based

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In both hydraulic and pneumatic valve control, latency due to actuators and control circuits operating below their peak designed efficiency can decrease overall performance in a process control environment. Both pneumatic- and hydraulic-actuated systems require continual maintenance to assure optimal performance and efficiency, and to avoid unexpected component failures. The costs associated with maintaining these systems should always be considered when

Static friction is produced from valve packing materials and components and causes the valve to overshoot the set point, resulting in fluctuating valve performance.

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evaluating true system cost. Systems installed in remote locations or in hazardous environments may receive little or no maintenance until a component fails, which can often cause a shutdown.

The cost of unexpected downtime due to component failure can be exponential compared to the cost of replacement components or deploying an alternate technology in the same application.

Electric actuation with conventional brush motors Electric-valve actuators, which use a conventional brush motor to power the actuator, are a cost-effective alternative to pneumatic- or hydraulic-actuated systems.

Because they require fewer components (there’s no need for a filter, regulator, air lines, flow controls, control valves, and other associated components such as hoses, fittings and gages) all-electric systems require minimal maintenance. Overall, brush motors offer an inexpensive means of achieving the increased performance, reliability and safety required in many process environments. As a result, they’re widely used on valve actuators in the process industry. Electric actuation with brush motor technology has been timetested in the field and considered by some to be the de facto standard. Electricactuated valves can have good resolution (less than 0.1% of span) when used with mechanical gear reducers to increase force.

However, the resulting high reduction ratios caused by these devices also limit the actuator’s ability to close a valve quickly.

Even with these limitations, electricvalve systems with brush motors can offer a significant improvement over traditional fluid-driven systems. What makes conventional brush motors in electric actuators a cost-effective solution is also the source of their limitations. As the name implies, these motors have physical brushes that contact a commutator and armature. Frequent cycling of power to start motion (for instance, in a modulating

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application) exposes the brushes to inrush current repeatedly and can cause the motor to wear out quickly. Because of this, typical duty-cycle ratings for actuators that use brush motors are measured in starts and stops per hour. It’s not uncommon to see these actuators with a duty cycle limited to a given number of starts and stops per hour, whereas a servo can be operated continuously with no restrictions when appropriately sized for the given application.

In addition to worn or damaged brushes, brush motors are also susceptible to poor performance due to:

arcing between the brushes and • commutator holders not being equally spaced • brush brushes • surface too far from commutator overloads and underloads • current improper • brushes spring pressure on the foreign material on commutator • surface On the plus side, these systems are relatively simple to integrate into most control schemes. Field bus communication protocols such as HART are available as a standard feature or option. Bluetooth, along with infrared capabilities, is also available on some systems to allow for wireless set-up and communication. This is beneficial to actuators operating in remote or harsh environments. Diagnostics, programmability, safety limits and data logging capabilities have also become available as part of an electric system.

Electric actuation with brushless servomotors Many of the challenges and limitations using brush motors are typically not found when using brushless servo technology.

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and have proven to be a reliable and robust means of controlling linear actuators.

They cost more than conventional brush motors typically used with electric-valve actuators, but brushless servomotors are becoming more prominent in process control industries because of their proven reliability and increased performance capabilities.

Brushless servomotors don’t operate in the same way as brush motors. Unlike brush motors that pass current through an armature, brushless servomotors use a permanent magnetic rotor and a wound stator. Power is passed through the wound stator, which creates an electric field in the phases of the motor. The magnetic poles of the rotor react to this electric field, which creates rotary motion.

of feedback adds complexity, it’s also the component that communicates position to the controller, which, in turn, achieves high resolution, accuracy and repeatability.

This increased complexity also requires a more sophisticated means of control.

However, this more sophisticated control, in conjunction with the feedback device, provides increased performance over conventional brush motors. Position, speed and torque can be precisely controlled and continuously monitored. These abilities allow brushless servomotors to automatically compensate for varying conditions exerted upon the mechanical end-effector attached to the stem. Using a rotary servo to create this linear movement with mechanical components, such as a rack and pinion, planetary gear sets, or

“On the plus side, these systems are relatively simple to integrate into most control schemes.

Field bus communication protocols such as HART are available as a standard feature or option.”

Because no physical brushes come into contact within the motor, mechanical or electrical breakdowns are rare. Instead, external elements or damage from impact or improper use are more likely to cause motor failure.

Brushless servomotors must have some form of continuous position feedback from the rotor to maintain proper phasing and function. This is typically provided by an integrated feedback device, such as an encoder or resolver. Although this form

more complex assemblies like a linear ball or roller-screw-driven actuator, provides motion system efficiencies of approximately 75 to 80%—much higher than pneumatic- or hydraulic-actuated systems.

Some of the more notable performance benefits of brushless servomotors are: duty-cycle rated • 100% significant increase in efficiency •

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available to operate in extreme • designs temperatures and environments positional repeatability and • improved accuracy over brush motors to compensate for increased • ability resistance or changes in external forces • response dynamic performance and quick or no maintenance • reduced condensed installation times • Brushless servomotors can operate more smoothly and at greater speeds (6,000+ rpm) than other motor types used on valve actuators. Monitoring speed and torque through the controller enables brushless servomotors to compensate for increased force requirements (stick slip, pressure surge, contamination or blockage in a valve) and complete a move without sacrificing speed. This capability lets servo systems execute push-to-force moves (full seat), or maintain a position within a dynamic circuit (burps or pressure spikes).

The only real downside to servo systems is that they have a higher purchase price than electric valve actuators with conventional brush motors.

Even with all the benefits and advantages that brushless servo technology offers, pneumatic-, hydraulic- and electricactuated systems using conventional brush motor technology are still the appropriate solution for many valve applications.

With the cost going down and reliability going up for brushless servo systems, there are now more choices than ever for optimizing existing processes, choices that can improve performance and reduce maintenance while lowering the cost of operation and improving overall system performance. DW

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to get the best adhesive The process of evaluating and choosing an adhesive is easier when you consider a few key parameters.

Paven Patel • General Manager Barry Siroka • Business Development Manager EpoxySet

Choosing the best adhesive for a specific application can be complex.

There are many variables to consider and numerous types of chemistries with different capabilities. An understanding of the following parameters will help narrow the choices. Selecting the correct adhesive will reduce the number of products you need to evaluate and increase the likelihood of success.

1

Substrates. Knowing the materials that you will bond is important.

Certain adhesives adhere better to ceramic or glass. “Metal” and “plastic” are generic terms that encompass many different types of materials, so knowing the exact substrate is essential for determining the correct adhesive. For example, ABS and polytetrafluoroethylene (Teflon) are both plastics, but PTFE requires an acid etch to achieve a bond whereas ABS can usually be bonded with just an alcohol cleaning.

2

Cleanliness of the parts. Most adhesives require that the substrates be prepared properly. Whether it’s just a simple cleaning or the ability to do more complex operations (such as abrasion, chemical etch or plasma treatment) will all come into play in selecting an adhesive.

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Thermal cure materials can be cured at room temperature or with heat. Heat-cured thermal adhesives can require high temperatures, which might be detrimental to components, but, in general, they will cure faster with higher properties.

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Fa ste n i ng & J o i ni ng

3

Viscosity. The viscosity must be considered.

Low viscosity, or thin, products are best for thin bonds or for applications requiring wicking.

Thixotropic materials, which won’t run, are best for use in vertical applications.

Solved.

4

Thermal cure versus UV cure. UV cure adhesives are usually one part and can be cured quickly. They must be exposed to UV light to cure, so at least one of the substrates must allow transmission of UV light. Thermal cure materials can be cured at room temperature or with heat. Heat-cured thermal adhesives can require high temperatures, which might be detrimental to components, but, in general, they will cure faster with higher properties.

5

Working life. Determine how much work life is desired. Remember that working life (time before the material gels) is generally related to cure time. For thermal cure materials, the longer the working life, the longer the cure time (at room temperature) usually. Single-part UV-cured materials can be cured quickly, and the working life doesn’t apply.

6

Configuration. The dimensions of the parts and how they fit together are important to determine the best material. Larger parts and thicker bond gaps may require a slower cure to reduce shrinkage. Certain adhesives are designed to work best with thinner gaps.

7

Required performance. Questions you should ask before selecting an adhesive:

Does the adhesive need to form a structural bond?

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Ideally, a structural bonding material will create a finished part that is as strong as the substrates. As stated earlier, knowledge of the composition of the substrates helps decide the best adhesive and preparation to accomplish an ultimate bond. Also, understanding the configuration of the parts to be bonded will determine the types of adhesives for use.

With most adhesives the larger the surface area of the mated parts, the stronger the bond.

The bond gap is also critical. Various adhesive chemistries work best with certain gaps. In general, cyanoacrylates and anaerobics need the thinnest bond line, whereas epoxies and urethanes are better with thicker gaps. Every chemistry varies depending on how they were formulated, but these are general rules.

info @ bodine-electric.com | 800.726.3463

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the right candidate. It is not often feasible to know all required parameters before choosing, but it is important to have as much information as possible to make an educated decision. There is no substitute for sampling and evaluating a product. Testing often reveals previously unconsidered parameters.

Considerations for application When evaluating adhesives and potting materials, it also important to confirm they work on a performance level and on a production level. How will material be applied? It is a common occurrence that engineers or project managers approve a product that works perfectly for the application only to find out later that processing it on the production floor is either inefficient and wasteful, or just not possible. Consider dispensing, mixing and applying concepts early to save time and money down the line and avoid production or launch delays.

Even volumetric mix ratios are available in dual barrel cartridges, like the one shown here. Cartridges eliminate the rick of weighing or mixing mistakes and can be dispensed through applicator guns operated manually or pneumatically.

How much mechanical stress will there be on the bond during use?

This may seem obvious, but the forces on the adhesive joint and the direction of those forces have a major impact on the adhesive to be used. Some chemistries have excellent tensile strength (strength in a horizontal direction) and little shear strength (strength in a vertical direction). Other considerations would be whether there are any compressive forces or torsion on the joint. Adhesives may be formulated to be more flexible or with fillers to compensate for these stresses.

Will stresses be consistent or intermittent?

Some adhesives can take extreme stress for short periods, but not withstand stress over longer periods. Others may hold up to long consistent stress as long as it is not brought on suddenly.

Other types of stresses may also be of concern. For example, autoclaving is a standard practice in many industries; however, many adhesives cannot withstand autoclaving. It is important to consider all stresses when selecting adhesives.

What are the temperature requirements during processing and use?

This can be an extremely important parameter. Materials with low-temperature cures may not withstand high temperatures

during use. Adhesives designed for hightemperature uses might only cure with heat, so the adhesive will have to be exposed to dry heat (an oven or a heat element).

The exposure temperatures during use are critical. Also consider whether the parts will be temperature cycled. Many materials that will withstand high temperatures will crack when cycled to low temperatures, and low-temperature materials might lose their strength at high temperatures.

What optical properties (if any) are important?

Optical properties may be important for certain applications. If light transmission is important, know the wavelength being transmitted and the duration. You may also want to consider the refractive index of the substrates. Certain chemistries will not remain clear over long exposure to UV radiation.

Does the cosmetic appearance matter?

Some adhesive chemistries can be easily colored, but others cannot. Some chemistries will have lot-to-lot variations, so the final appearance can change. In applications requiring specific colors (especially for consumer products), it may be necessary to ensure that lots can be color-matched.

These are some of the more important issues, although for any specific application, there can be other considerations before selecting www.designworldonline.com  

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Mix ratio One of the biggest issues facing production lines while using two-part polymer systems are the mix ratios. Mix ratios vary from product to product and unfortunately are not as simple as 1:1 by weight and volume. Some mix ratios are also less critical allowing for higher degrees of tolerance.

Alternatively, slight changes in a mix can result in changes in the physical characteristics of the product. For instance, polyamide-based epoxy systems are forgiving in mix ratios. If the product calls for a 100:80 mix ratio by weight and the actual mix ratio is off by even 10%, the finished polymer and the characteristics are not drastically different, nor should it affect its performance. A tin catalyzed silicone is vulnerable to changes in mix ratio. A 10% increase in catalyst can accelerate the polymerization process and decrease work life, not allowing operators enough time to pot or encapsulate the part, leading to waste material.

Amine and imidazole cured epoxies (as well as many urethane systems) with an incorrect ratio will result in a finished adhesive with diminished properties. If a ratio specific material is the best choice, ensure that manufacturing processes are set up accordingly to produce the best and consistent results.

While uneven mix ratios should not deter one from choosing a product, many prefer even ratios to reduce risk of mistakes. There are several options for high-efficiency application of adhesive systems. Many products that have even volumetric mix ratios (1:1. 2:1, 4:1) are also available in dual barrel cartridges. These types of cartridges come in February 2016

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Fastening & Joining

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When evaluating adhesives and potting materials, confirm that they work on a performance level and on a production level. How will material be applied? It is common to have a product that works perfectly for the application only to find out later that processing it on the production floor is either inefficient and wasteful, or just not possible.

VariMountTM assembly is comprised of standard PEM nuts, studs and standoffs mounted permanently into a base plate--available with either steel or stainless steel base plates depending on the fastener selected. Key feature is the base plate’s radial holes which provide various mounting options.

mix ratios (1:1. 2:1, 4:1) are also available in dual barrel cartridges. These types of cartridges come in different sizes and are convenient because there is no risk of weighing or mixing mistakes.

These dual barrel cartridges can be dispensed through applicator guns that can be operated either manually (like a caulking gun) or pneumatically for higher efficiency.

While evaluating, and ultimately choosing, an adhesive or encapsulating compound can be an exhausting effort, it can be made easier by considering some of the elements discussed in this article. The more information you have on the application helps eliminate a majority of options and makes it easier in filtering the variety of products available. Contacting the experts is also a major step in choosing the right product. Adhesive suppliers tend to have a vast amount of knowledge on their products and where they are best used.

Ultimately, evaluating adhesives comes down to choosing one (or a few) and testing them in your application before deciding. As mentioned before, there is no substitute for sampling and testing products on your own. DW

EpoxySet epoxyset.com

Typical Mounting Methods

Mounts On Or In:

• Composites • Plastics • Metal • Wall Board • Any Rigid Material or Panel

Features

• Base plate provides generous footprint for surface or mold-in mounting.

• Radial holes in base plates encapsulate adhesives or molded plastics.

• Radial holes accept standard sized rivet diameters.

• Radial holes accept standard sized self-clinching fasteners.

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3D CAD

If you

draw it,

can you print it?

3D printing enables you to reduce part weight, raw material used and cut total energy used in production.

But to truly take advantage of 3D printing, engineers need updated, intuitive, easy-to-learn CAD tools.

Jean Thilmany • Contributing Editor

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To keep pace with advances in 3D printing, CAD technology must move into the cloud, become easier to use, and be better able to support eccentric, not-yet-dreamed-of designs, say several design experts.

If CAD technology can evolve, in the not-too-distant future, everyday objects like your blender, electric toothbrush or even the engine within your automobile, will take the shape of nothing you’ve ever seen before, said Hod Lipson, a mechanical engineering professor and director of the Creative Machines Lab at Cornell University.

Lipson has written extensively about 3D printing and helped develop Fab@Home, inexpensive 3D printers. He published the paper “Is CAD Keeping Up?” in the December 2014 edition of the journal 3D Printing and Additive Manufacturing.

That question—is CAD keeping up with 3D printing— is one he asks himself as additive manufacturing continues to gain popularity. Most 3D printers take their printing instructions from 3D CAD files. Because the 3D printer receives its instructions from CAD files, the printers are limited in the shapes they print that those CAD systems generate, Lipson said.

The 3D printers themselves can print objects with geometries as yet unimagined. Any shape, no matter how twisting, undulating or odd, is fair game, he said.

So the future could feasibly resemble a Dr. Seuss-style landscape rather than boxy squares of today’s laptops, ovens and refrigerators.

But CAD software only allows for designers to work with recognized geometries: circles and ovals, squares and rectangles, and so on.

The recently released Fusion 360, from Autodesk, is a CAD, CAM and CAE tool that exists in the cloud. It can be connected to have 3D printing capabilities.

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3 D CA D

Products will be designed in a more collaborative way, moving through 3D modeling, then on to simulate, analyze and test, and then on to integrated CAM or 3D printing.

Guided by the design file, a 3D printer lays down layer after layer of a material to print an object in three dimensions. Some of today’s printers and materials can create objects that can immediately be used, doing away with the need for another manufacturing step, Lipson said.

While CAD continues to evolve, changes to that software are mainly seen in the way engineers interact with the software rather than in the shapes and designs they can create with the software.

Take, for example, sketching applications that allow engineers to draw their designs as they would on paper, rather than pulling or piecing together existing geometries.

Catchbook, from Siemens PLM, is one example. While these aren’t CAD applications, in some cases, such as with Catchbook, these designs can serve as precursors to CAD designs.

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erase and insert images and share content with other people,” said Ken Hosch, director of strategy at Siemens PLM.

Other examples of freehand-drawingstyle applications include SketchUp, Sketches and Drawing Pad. Though SketchUp can be used on a desktop, most of these drawing applications are intended for the tablet, with your finger or a stylus acting as the pencil.

But even these freehand design programs come with drawbacks that mean they can’t be used—yet—to print odd and eccentric shapes on a 3D printer.

The industrial drawing engine behind Catchbook, for instance, automatically turns the individual parts of a drawing into recognized geometries. If a Catchbook user sketches a lopsided circle, the engine creates a perfect circle, Hosch said.

What we need to see for the printed shapes of tomorrow to be possible, Lipson said, are programs that allow freehand

drawings to be printed in 3D without the need to change drawings into recognizable geometrical shapes. If you can draw it, you can print it, he said.

What’s more, conventional CAD software imposes its own limitations on designers, who may not be able to think outside the “because it’s a computer it must resemble a box” box, Lipson said. So even as CAD changes, designer mentality may be slow to catch up.

Which is a particular lag at a time when 3D printing allows many advantages to large and small manufacturers, including the capability to build one-off and custom parts at remote locations, he added.

Another recent trend in 3D printing has been from printing prototypes to printing end-use parts, according to Terry Wohlers, president of Wohlers Associates, a Colorado-based additive manufacturing consulting firm.

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Recently, for example, GE Aviation announced plans to include 3D-printed parts in its CFM Leap aircraft engine platform beginning in 2016. The engines, produced jointly by GE and partner Snecma, will include 19 3D-printed fuel nozzles in the combustion system.

Last May, printer manufacturer Stratasys announced that its printers had been used to produce more than 1,000 flight parts for the Airbus A350 XWB aircraft, delivered in December 2014. Similarly produced components are also included within in-service jetliners in the A300 and A310 family, according to Airbus.

The parts weigh 30 to 55% less than traditionally manufactured parts, reduce raw material used by 90% and cut total energy used in production by up to 90% compared to traditional methods, according to Peter Sander of Airbus’s Innovation Cell, which investigates and promotes emerging technologies.

But for these trends to continue, engineers need updated, intuitive, easy-tolearn CAD tools, Lipson said. And without them, it will be even harder for mainstream designers and consumers to fully adopt 3D printing, even as desktop printer prices drop, according to John Darlington, a computing professor at Imperial College, London.

“While there is little doubt 3D printing technologies will have a highly transformative effect in the coming decades, consumer adoption of these technologies still remains rather low,” Darlington and his colleagues wrote in an August 2015 paper in the Journal of Engineering and Technology Management.

“Making an object requires more than just a 3D printer and advanced knowledge of 3D modeling software,” the researchers wrote in the paper “Co-creation and User Innovation: The Role of Online 3D Printing Platforms.” Darlington fellow authors are Ludmila Striukova, senior research associate in the University College, London, school of management, and Thierry Rayna, a professor of economics at Novancia

Business School of Paris.

One area in which 3D printing and CAD technologies are both moving forward are within the cloud. This tandem momentum will help small manufacturers take advantage of 3D printing, said Amy Bunszel, Autodesk VP of AutoCAD products.

3D printers, along with CAD software that exists “in the cloud” (that is, not on users’ networks but on remote servers into which they can tap), will allow for smallscale, custom manufacturing, Bunszel said. Because they don’t need to maintain expensive software and hardware in house, companies, small designers and hobbyists can

“Some of today’s 3D printers and materials can create objects that can immediately be used, doing away with the need for another manufacturing step, Lipson said.”

Autodesk Autodesk.com quickly and easily design and print parts.

3D printers may not strictly exist within the cloud, but they could be—and often are today—housed at service bureaus, away from the engineer or manufacturer, but can still be used to print their files. Printed pieces can then be sent to the original engineer or manufacturer, or could be sent directly to a customer.

With access to 3D printers and to CAD programs in the cloud, engineers could also design a part and have it printed in small batches of many variations rather than manufacture parts—as is done today—using CAM files in a mass-produced, one-sizefits-all method, Lipson said. “That was not economically viable before,” he added.

Or, as Bunszel put it, “The cloud changes everything; mobile, social, everything.”

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Her company, CAD-vendor Autodesk, recently released Fusion 360 a CAD, CAM and CAE tool that exists in the cloud.

“So it could be connected to have 3D printing capabilities. It connects your entire product development process,” Bunszel said.

“You have 3D modeling capabilities, then can simulate, analyze and test, and then take into integrated CAM functionality or to 3D printing.”

Products in the future will be designed in a more collaborative way, she predicted.

“People are designing things together with access to new techniques, like 3D printing, which are accessible to all of our customers, not just big manufacturers.”

The tools designers have used in the past need a refresh to be useful in the future, she added. The cloud offers an easier way to access and work with CAD technology, she said.

For his part, Lipson wants to see CAD and 3D printing technologies work together for a future in which engineers can create in 3D anything they can envision—and even shapes and objects that can’t be envisioned today. In other words, the computer of the future won’t be square in shape. DW

Siemens PLM plm.automation.siemens.com Stratasys Stratasys.com

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Key standards to know when specifying sensors Ted Tomita

Global Product Marketing Manager Honeywell Sensing & Productivity Solutions

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Everything from an excavator to a thermostat is getting smarter and the demand for more intelligent and connected systems is driving more demand for sensors in nearly every industry. A report by market research firm BCC Research anticipates the sensor market will grow by more than 10% by 2020.

Implementing more sensors into a system may bring more value to a customer through data, but it may also introduce more variables that could cause a system to fail. A faulty sensor that is unreliable or inaccurate may be costly to replace, difficult to troubleshoot and even impact an end user’s operation. Choosing a sensor that performs reliably and accurately is crucial to protecting both OEMs and end users from potential system failures. But how can an engineer confidently assess and choose the right sensor for their system?

Industry standards have helped set expectations for performance and reliability for today’s sensors. Understanding these standards can help engineers specify a sensor that meets the needs of their systems, and ensure that the overall system will meet customer expectations. In the transportation industry, standards serve an especially important role as they influence sensor qualities related to environmental sealing, noise immunity, temperature range and vibration.

Let’s examine these four standards and how each can affect an OEM and design engineer.

Environmental sealing Environmental sealing refers to a sensor’s ingress protection against water and dust while in operation. A key standard engineers should be aware of is the Ingress Protection (IP) rating published by the International Electrotechnical Commission. The highest rating a sensor can achieve is IP69K under the IP standard ratings. The IP69K test specification was initially developed for road vehicles, especially those that need regular intensive cleaning (dump trucks, cement mixers and so on) The first number indicates the sensor’s solid particle protection from a range of 0 to 6, with 6 indicating that the sensor is completely dust tight. The second number indicates the sensor’s water protection rating from a range of 0 to 9K, with 9K indicating that the sensor is protected against close-range, high-pressure, high-temperature spray downs.

For example, an engineer who is specifying sensors for a combine harvester may refer to these ratings to ensure the sensor he or she uses can withstand potential dust and soil exposure in a field, and water protection from a power washer that could be used to clean the equipment.

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Engineers can refer to these standards to ensure they will not require designing additional protection layers for the sensor. For instance, an engineer may unnecessarily design additional O-rings to protect an excavator’s sensors against water exposure if he or she is not aware that the sensors are already rated 9K and protected from such environments.

Electrical noise immunity Electrical noise immunity and electromagnetic compatibility (EMC) are among the most important standards in the industry today. Every cell phone, radio tower and wireless device emits electrical noise and the interference is becoming more pervasive as consumer devices become smarter and more connected.

Implementing a sensor that falls short in or lacks electrical noise immunity may cause sensor failures that are often difficult to diagnosis. In a real-life example, an executive at a car manufacturer decided to take the company’s new prototype vehicle to the airport where he received a phone call as he arrived. At the moment the call came in, the car’s engine immediately stalled, then firedup again when the call ended. After rounds of testing and weeks of investigation, the engineering team found that the electrical noise from the airport combined with the cell phone exceeded the noise immunity in the engine’s feedback loop sensor causing it to fail and the entire engine to stop.

When looking to protect sensors from similar electrical noise failures, engineers should look for noise immunity ratings, which are typically measured in volts per meter. Many sensors used in transportation vehicles have traditionally been rated at 60 V/m. However, electrical noise immunity is not expected to decrease over time and the industry is moving toward ratings of 100 to 200 V/m.

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Se nso rs

In addition to reviewing a sensor’s volts-permeter rating, vehicle engineers should also be aware of ISO ratings that indicate a sensor’s electromagnetic compatibility. There are seven ISO ratings to meet industry standards for vehicles ranging from passenger vehicles to agricultural and forestry machinery.

Engineers can find it difficult to troubleshoot their systems for complications due to electrical noise.

Additionally, a machine that is rendered inoperable may be costly to an end user if it’s necessary for daily production. Being aware of current and future trends in noise immunity standards can help future- proof systems and vehicles from potential failures in the future.

Temperature There are no specific organizations that standardize a temperature range in sensors. However, most sensor manufacturers adhere to industry norms.

For example, most commercial products use sensors with a temperature range of -20° to 85° F. This is the temperature threshold in which the sensor can safely and accurately operate without damaging the component.

A sensor’s temperature range may change from industry to industry. For example, in the transportation industry, a broader temperature range of -40° to 150° F is more common and necessary, especially for applications in engines and transmissions. A wider temperature range provides greater protection against equipment failure no matter what environment the sensor is operating in, and also offers more flexibility in where to install the sensor.

For example, an excavator could be used in the middle of the Australian Outback for a tunnel construction where temperatures can be high.

A sensor may be damaged or its accuracy could deteriorate if it is exposed to temperatures beyond its threshold. For example, quadrature speed sensors use magnets and Hall ICs to detect speed and direction of a rotating gear. These sensors are commonly installed in hydraulic pumps and electric motors that provide mechanical power to forklift trucks, construction equipment and agriculture equipment. The magnet in the sensor could be degraded when exposed to temperatures beyond its threshold, leading to reduced sensor performance.

Similar to environmental sealing, OEMs can design additional protection to guard the sensor from being exposed to extreme heat or cold. However, these provisions may be costly and require additional time and testing. Choosing the right sensor that meets the system’s needs can help save design engineers both time and cost.

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Vibration Vibration conditions may not seem problematic for sensors, but vibrations may cause the overall machine problems if the component is not designed to withstand them. Heavy machines experience significant vibration because of off-road travel and running large diesel engines where sensors are in sub-systems, such as hydraulic pumps, actuators and electric motors, among other locations. Sensors that lack the necessary robustness to withstand constant or random vibrations may send false signals to the operator or experience critical failure that can damage or hinder the overall machine.

There are two vibration types that design engineers should consider: high frequency and random. High-frequency vibration is commonly found in applications where the machine is running a large diesel engine. An important standard for these conditions is MIL-STD-202-204 Test Condition D, a standard established by the Dept. of Defense. It’s among the most stringent vibration standards for the heavy machinery industry. Sensors that meet this standard ensure the component can operate under such environments without worry of failure.

Random vibration conditions, on the other hand, are common for equipment that regularly moves in off-road conditions, construction sites and other rough terrain. For these applications, sensors should meet another DOD established standard called MIL-STD-202-214 Test Condition I. This standard ensures that the sensor can operate accurately under vibration conditions that affect its entire physical plain, whether from the bottom or side of the sensor.

Machines are getting smarter and using more sensors. It’s unlikely that this trend will reverse any time soon. Engineers in all industries will feel more pressure to specify reliable and accurate sensors that can withstand their system’s daily rigors and harsh environments.

Making an informed decision starts with reliable information, and sensor standards offer the best benchmark for engineers. Using this knowledge effectively can help deliver reliable performance and increased value to customers. DW Honeywell Sensing & Productivity Solutions sensing.honeywell.com

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2/5/16 4:38 PM

SEPT15 Sensors NC Ad (DW)_Design World 8/11/15 2:05 PM Page 1

Reliable Detection For Your Application

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Prod uc t World Flexible chain conveyor line Dorner Conveyors dornerconveyors.com Specifications, features and benefits of the SmartFlex Helical, Alpine and Spiral curve conveyors include aluminum single-piece frame conveyor, the ability to navigate tight corners with wheel and plain bend options, multiple product transfer options for end and side transfers and the capability for vertical incline with minimal floor space. The conveyor line is available in widths of 65, 85, 105, 150 and 180 mm (depending on model) with speeds up to 250 ft/min.

Miniature photoelectric sensors

Compact temperature sensors

Balluff balluff.us

Baumer baumer.com

R01E miniature stainless-steel, flatpack photoelectric sensors,

Based on the TE2 series, TER8 temperature sensors adopt the

with IP69K rating, offer diffuse versions with ranges up to 100 mm,

proven mechanical and electromechanical properties of this

polarized retroreflective with ranges up to 1 m, and through beam

product family. The compact TER8 sensor housing fits even into

sensor with ranges up to 2.2 m. With a precise, uniform visible red light

tight spots difficult to access. The sophisticated installation

beam, alignment is easy and objects are reliably detected. Not only

concept forgoing any elastomers but yet 3A and EHED compliant

does the small size provide flexibility in installation, but the stainless-

ensures optimum hygienic capabilities free from maintenance while

steel housing is also built to survive harsh environments, including

also cutting down on maintenance and downtime.

washdown applications. Connections are made by cable or M8 3-pin quick disconnect.

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

Circuit breaker Phoenix Contact phoenixcontact.com CBM device circuit breakers, with 4- and 8-channel options, lock in the set nominal currents electronically, preventing unwanted changes. Each channel has an individual load rated 0.5 to 10 A, with an LED status indication that lets users monitor the trip status of each circuit-breaker channel. The circuit breaker detects and signals over-voltages and under-voltages, then disables connected loads in a targeted manner. Its design enables startup at -40° C, as well as use in temperatures ranging from -25 to 70° C.

Laser distance sensor Banner Engineering bannerengineering.com With the capability to detect height changes as

Roller bearings

small as 0.5 mm and sense up to 300 mm, the Q4X can solve distance-based applications regardless of

Timken timken.com

target surface reflectivity, including black foam on black plastic, black rubber in front of metal, multicolor packaging and targets of all colors. It is also optimal

Revolvo Quick-fit split-to-the-shaft, cylindrical roller bearings assemble around

for clear object detection and error-proofing

the shaft without requiring access to the shaft ends. Once installed, maintenance

applications. The Q4X dual-channel sensor offers

personnel can easily remove support caps and housing components for quick

enhanced performance features, including window

visual inspection, saving maintenance time. The seven concentric seal designs

size and offset control for easier setup of difficult

provide customized options to meet harsh environment requirements. The new

applications. The IO-Link, point-to-point serial

design is said to reduce installation time up to 90%.

communication protocol allows complete remote accessibility to device and event data and more precise, digital data transmission. www.designworldonline.com

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Prod uc t World Ultrasonic medical weld tool Herrmann Ultrasonics herrmannultrasonics.com In its entirety, the new Medialog welder, a suction irrigation handle, is used for liposuction. Due to the size of the joining partners and their three dimensional shape, this application was challenging— especially the 12-mm difference in contour heights that needed to be matched by the contact surface of sonotrode. Together with stainless-steel, cleanroom-friendly surfaces and modified pneumatics, the Medialog uses the unique operator interface FSC, which includes a complete documentation of all actions performed by authorized users and records time stamped audit trails.

Self-cinching flush-head studs Linear position sensors

PennEngineering pemnet.com

Macro Sensors macrosensors.com

be installed automatically during the stamping process using an

PEM X-Press studs install permanently in metal sheets as thin as 1 mm. They press easily into place using any standard press or can automated PEMSERTER press equipped with in-die technology.

They are available with 5- and 6-mm metric threads and in lengths

The BBP series of air-extended, spring-loaded LVDT

from 10 to 25 mm. The studs perform reliably in metal sheets with

position sensors feature a 3⁄8-in. diameter pencil type

hardness of HRB

gaging probe that moves out and makes measurements

80 or less on the

only near the very end of the probe movement, when it is

Rockwell “B” scale

almost fully extended, and then retracts so the probe gets

and HB 150 or less

out of the way of damage. In this configuration, a short

on the Brinell scale.

range LVDT linear position sensor (0.050 to 0.125 in.) that measures a short distance can be used to get highest resolution as the full range of the cylinder stroke often does not have to be measured.

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

Audit trail for mapp technology B&R Automation br-automation.com

Liquid gap filler

B&R has added an audit trail component to its mapp technology

Henkel henkelna.com

portfolio. For applications subject to the FDA’s Title 21 CFR Part 11 requirements, this means both

Gap Filler 3500LV is a two-part material that

accelerated development and

cures at room temperature with the option of

reduced investment risk. Mapp

accelerated curing through the addition of heat.

audit automatically retrieves the information it needs about the operator from the mapp user component using the client-server principle. Audit trail data is stored in memory with a checksum mechanism for tamper resistance. The data can be output in an encrypted file or viewed on the HMI using the integrated mapp audit visualization. It enables manufacturers of all types of machinery and equipment to review operator activity to determine whether a system has been used appropriately.

While it delivers high thermal conductivity of 3.5 W/m-K and the mechanical property benefits of a silicone, it does so with minimal outgassing.

This gap filler’s low volatile content is tightly controlled lot to lot, ensuring outgassing is kept to a minimum.

Profile rail brakes Nexen Group nexengroup.com Nexen has extended its range of sizes for rail brakes from 15 to 65 mm with the new Generation II Rail Brakes. These brakes offer fast engagement at 0.049 to 0.230 sec; higher static holding force to 3,400 N (764 lb); and can be combined to provide even higher holding forces as needed. They offer maintenance-free operation and are fully compatible with all 16 major rail manufacturers.

www.designworldonline.com

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SALES

A d In dex

Mike Caruso mcaruso@wtwhmedia.com 469.855.7344

Aerotech, Inc. .............................................. 76

Penn Engineering ....................................... 77

Allied Electronics, Inc. ...........................Cover

PHD Inc. ....................................................... 37

Allied Electronics, Inc. .............................3,87

Proto Labs, Inc. ............................................. 9

All Motion ....................................................... 4

QA1 ............................................................... 16

AMETEK PMC ............................................... 15

Red Lion Controls, Inc. ...............................53

AMETEK/DFS (Windjammer) .................... 59

Ringfeder Corp. ...........................................26

Anderson Metals Corp ................................86

SAB North America ..................................... 17

Aurora Bearing Co. ...................................... 47

Schunk, Intec .............................................. 23

AutomationDirect ...................... Gatefold, IFC

Setco ............................................................ 71

Baldor Electric Co. ...................................... 13

SMAC Moving Actuators ............................. 12

Balluff .......................................................... 19

Smalley Steel Ring Company .................... 10

Baumer ........................................................ 31

Sorbothane .................................................50

Bison Gear & Engineering Corp. ............... IBC

Suco Technology......................................... 16

Bodine Electric Company .......................... 74

Sunstone Circuits ....................................... 51

Cicoil ............................................................30

The Lee Company ....................................... 47

Clippard Instrument Laboratory, Inc. ....... BC

Tompkins Industries .................................... 2

Delta Computer Systems ........................... 61

TRIM-LOK, Inc. ............................................. 27

Del-Tron Precision, Inc. ...............................60

Turck-USA................................................41,43

Digi-Key Electronics ................................... 65

Ultra Motion ................................................. 69

Dorner .......................................................... 85

Whittet-Higgins Company ......................... 29

Michael Ference mference@wtwhmedia.com 408.769.1188 @mrference Todd Christenson tchristenson@wtwhmedia.com 440.381.9048 @wtwh_todd

Jessica East jeast@wtwhmedia.com 330.319.1253 @wtwh_MsMedia Mike Fancesconi mfrancesconi@wtwhmedia.com 630.488.9029 Michelle Flando mflando@wtwhmedia.com 440.670.4772 @mflando

David Geltman dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david Jim Powers jpowers@wtwhmedia.com 312.925.7793 @jpowers_media Tom Lazar tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom Courtney Seel cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel Neel Gleason ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

LEADERSHIP TEAM Publisher Mike Emich memich@wtwhmedia.com 508.446.1823 @wtwh_memich Managing Director Scott McCafferty smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty EVP Marshall Matheson mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

Dunkermotoren, part of Ametek ..............39 Encoder Products Co. .................................44 Epson America, Inc. ................................... 45 EXAIR Corp. .................................................... 5 Haydon Kerk ............................................... 67 Helical Products Company .......................... 7 Hitachi Cable America ................................ 25

www.de signworl donline. com February 2016

INSIDE:

LINEAR MOTION: Selecting linear actuators for valve automation PAGE 62

IXYS Corp. ....................................................46 J.W. Winco, Inc. ...........................................36

SENSORS: Key standards to know when specifying sensors PAGE 82

KB Electronics ............................................84

Two

creati motion soluti ve for demanding applications APR15-A&C Snipe_Snipe

Keystone Electronics, Inc. .......................... 1

3D CAD: If you draw it, can you print it?

PAGE 78

Master Bond ................................................36 MW Industries ....................................... 34,35 FEBRUARY DW COVER

CONNECT

3/13/15 2:39 PM Page 1

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l r fo tro d on lie C Al n & k in tio Th ma to Au

Mean Well USA, Inc. ....................................49 NB Corporation ........................................... 21

ons

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PBC Linear ................................................... 57

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