Issuu

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February 2022

inside: LINEAR MOTION: Using air bearings in your

next design p.

3D CAD:

Immersive Design—

A virtual reality case study p.

THE ROBOT REPORT: Swiss manufacturer

automates CNC machine tending

p. 58

Common applications for hybrid stepper motor linear actuators page 80

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Last month, I talked about how engineers and scientists really are kindred spirits, as they play on the same team of knowledge seekers. Hopefully, you read the fascinating “Leadership in Engineering” feature article on Dan Arvizu, the Chancellor of New Mexico State University, who has been a leader and a trailblazer his whole career. (If not, please check out the January issue’s digital edition at designworldonline.com, it’s well worth your while.) In the month since our discussion, I got to thinking about something Arvizu said to me about engineering and science, and how he saw the two disciplines constantly intertwine, based on his long career in research and development. He explained that engineering has a role to play in enabling the science to occur, but o en times, it ends up gaining new tools om the science that happens. “Think about how the National Science Foundation has contributed engineering feats,” he said. “It’s not that basic research goes to applied research, and that goes to the outcomes. It’s an iterative set of loops. And basic research is actually input into the engineering thought process and the concepts — because it’s new tools, it’s new capabilities, it’s new ways of looking at problems. There’s a fuzzy line between basic science and engineering. So even though I’m engineering trained through all my degrees, I equently refer to myself as a scientist as well, because I love the idea of discovery science.” Arvizu also made the interesting point that most everything he learned in school is obsolete based on what we know now. The idea of the engineering profession being something separate and distinct om the other disciplines is a foreign concept to him, he said, because it’s all integrated in so many different ways. I think this is a great message to pass on to our kids, too, when they ask us about our careers. Do we think engineering could be a path for them? We should tell them that engineering is a marvelous profession because it offers us so many possibilities. Whatever your interests are, there’s a place for you in engineering. DW

(510) 471-4000

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Teschler on Topic

When the big bang happens in the lab Back in the dark ages of my undergrad career, I heard about a classmate enrolled in secondsemester freshman chemistry. One of his lab sessions left oily carbon muck in the bottom of a test tube that wouldn’t come out. In his attempts to clean the test tube, he eventually tried concentrated sulfuric and then nitric acids. When the acids by themselves didn’t do anything, he tried heating them. Readers who still recall common chemical formulas from their college days may have already guessed what happened. The acids and oily carbon combined to form an unstable compound resembling nitroglycerin, C3H5N3O9. If you believe in guardian angels, you’d have to say his was on duty that day. By some miracle, that kid happened to bend over to retrieve something from the bottom drawer of his workstation just as the concoction in the test tube went off. And all the other students in the lab had already left. There was a lot of damage near the workstation, but no one was injured. This near-miss sounds suspiciously like an urban legend — it supposedly happened to a friend of a friend of a friend of a friend. But it came to mind recently when reading about the deaths of two people and injuries to nine others stemming from a lab explosion at the Nanjing University of Aeronautics and Astronautics in China. Unfortunately,

those weren’t one-off events. In March, a grad student was killed following an explosion at the Institute of Chemistry of the Chinese Academy of Sciences. A few years ago three students died conducting a seqagetreatment experiment at Beijing Jiaotong University. Three years prior to that accident, two students died in separate incidents at Tsinghua University and the China University of Mining and Technology. It looks as though China is becoming more concerned about the safety record of its university labs. Last month, researchers there analyzed 110 publically reported university lab accidents in that country that happened since 2000. Ten fatalities and 102 injuries arose from these accidents. The researchers also found that university lab accidents have been rising in China, probably because the number of graduate students enrolled in labrelated disciplines in China ballooned from 90,000 in 2000 to about 5.3 million in 2019 — and the number of labs grew along with them. Problem is, it’s hard to see whether such accident rates are good or bad compared to the rest of the world. Few countries keep detailed records on university lab accidents. According to researchers at the University of Windsor in Canada who studied academic lab safety, no organization systematically collects data about the annual incidence of academic

lab accidents. (OSHA only collects accident data on workplaces, not about mishaps involving students.) The researchers say no comprehensive data is currently available on the type or frequency of accidents or nearmisses in academic labs. Nevertheless, what data that is available is attention getting. Since 2001, the U.S. Chemical Safety and Hazard Investigation Board reported 120 academic research lab accidents resulting in 87 evacuations, 96 serious injuries and three deaths. But these represent only accidents universities have been required to report because they were severe. Which brings us back to the urban legend nitroglycerin event. An accident resembling the setup for this yarn happened in 2010 at Texas Tech University. There a grad student lost three fingers, suffered hand and face burns, and damaged one eye during an experiment on detonable materials. The student was using 10 gm of materials in experiments though the recommended amount was only 100 mg. All in all, if you managed to get through all your undergrad chemistry work without any accidents or near misses, you should congratulate yourself on your good fortune. And if the student in the nitroglycerin story is real, he should never bother buying a lottery ticket: He clearly used up a lifetime’s worth of luck in that freshman chemistry lab. DW

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

February 2022 www.designworldonline.com Lee.Teschler.Column.2-22_V3 LT MS.indd 6

DESIGN WORLD

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Green Engineering

Even pillow block bearings are getting environmental Paul J. Heney

• VP, Editorial Director

Biomimicry has long been a great shortcut for designers looking for strong, creative designs. The new igubal pillow block om igus is based on the design principles of a tree and provides an alternative to classic cast iron housings. Flattened radii ensure maximum resistance to mechanical stresses. The bionic shaped housings, made with highperformance materials om the international leader in the motion plastics industry, require no lubrication or maintenance. Cast housing bearings with metal ball bearings quickly reach their limits in dusty, wet, and dirty environments. Whether in pulleys on conveyor belts in a cement factory or in tipping devices on trailers in the field, they are prone to failure. A high degree of contamination and inadequate lubrication are responsible for 80% of premature bearing failures. There is also the constant risk of corrosion. Lubrication- ee bearing inserts made of highperformance plastic solve the problem. igubal polymer pillow blocks in the standard sizes of 20, 25, and 30 mm enable quick one-to-one replacement. Two-hole and fourhole flange bearings in the sizes of 20, 30, and 40 mm are also available. Engineers at igus use two strategies to ensure that the plastic pillow blocks are sufficiently robust in industrial applications. The first is working with fibers and fillers that reinforce the igubal plastic so that it withstands high surface pressure and edge loads even under continuous stress. The second follows a model om nature: the so-called tree crotch, a connection found between branches and trunk or where the tree is firmly anchored in the ground. The shape is considered particularly efficient and robust. The designers have optimized the shape of the housing notches and done away with constant radii in order to distribute the stress more evenly. This makes igubal housing bearings highly resilient. Their chemical resistance, eedom om corrosion, and insensitivity to dirt give the bearing inserts a significantly longer service life in numerous user 8

February 2022

Green.Engineering 2-22_Vs3 MS.LL.indd 8

applications over metallic bearings. The absence of lubricants also reduces maintenance and cleaning requirements and enhances environmental protection. There are no lubricants at any point in the system that could get into the environment or onto the product. The new pillow blocks and flange bearings are not the only products igus is adding to the igubal range. There are also three bearing inserts for the imperial market, now available in 1-, 1.5-, and 2-in. inside diameter sizes. The price for FDA-compliant iglide A350 plain bearings will also be reduced by roughly 50% in the future. This is because igus no longer manufactures the bearing exclusively by turning bar stock — but has recently added the more costeffective injection molding process. DW igus www.igus.com

www.designworldonline.com

DESIGN WORLD

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Contents 2 • 2022

•

vol 17 no 2

•

designworldonline.com

| Dreamstime

86 80 _MOTION CONTROL

90 _3D CAD

Common applications for hybrid stepper motor linear actuators

Immersive Design—A virtual reality case study

Integrated designs in motion applications offer a host of benefits across a range of applications.

Swiss manufacturer automates CNC machine

A new Adidas maker space—located inside a giant, digital sneaker— features virtual-reality 3D design tools for long-distance design collaboration.

tending

INSIDE: • Why component makers should target cobots ............... 54 • A system for general in-hand object re-orientation ....... 64 • Tactile sensing provides advantages for cobots .............. 68

ROBOT_REPORT_COVER_2-22_FINAL.indd 53

As covered in a previous Design World article, air bearings are costlier than other options but average all surface imperfections along a bearing length — avoiding any detrimental effects of track deficiencies. Here we describe how to increase their stiffness.

OnRobot three-finger gripper and Doosan collaborative robot make production processes more efficient for family-owned business. page 58

2/7/22 9:24 AM

53-78

86 _LINEAR MOTION More on air bearings in linear motion

A Supplement to Design World - February 2022 www.therobotreport.com

96 _MECHANICAL Mechanical lifting devices get a modern drive technology upgrade

SLM worked with NORD to design a CLINCHER gearbox paired with an open gearing set. GOLD REGIONAL AWARD

asbpe.org

ON THE COVER

Integrated designs, such as these stepper-motordriven linear actuators, offer benefits for a range | istockphoto.com of motion applications.

February 2022

CONTENTS.2-22_Vs3.LL.indd 10

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DESIGN WORLD

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F O K C SI

2. 22 • con t e n t s

? S G N I R P S L I O C

departments 04

Insights

Teschler on Topic

08 Green Engineering 14

We were too.

That’s why we invented the wave spring.

Design For Industry

Design Notes

Internet of Things

3D Additive Mfg.

CAE Solutions

101

Product World

104 Ad Index • Optimize Application Space & Weight • Industry-Specialized Design Support • Large Selection from Stock • Easy to Customize

Crest-to-Crest® Wave Springs

Request Free Samples at 847-719-5900 or smalley.com CONTENTS 2-22_second.page_Vs1.indd 12

February 2022

DESIGN WORLD

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DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

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

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer Senior Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel

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February 2022

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Design for Industry Material/Handling

Overload coupling protects a drive train from damage

Overload couplings play important roles in a range of applications, including agricultural machinery, conveyor systems, packaging machines, and so on. The KTR-SI FRA safety overload couplings uncouple the driving and driven side while protecting the drive train om damages. A er eliminating the overload, these couplings can automatically be re-engaged by reversing the direction of rotation for a short time. As a result, this version is suitable for positions difficult to access. The KTR-SI FRA idle rotation and automatically re-engaging overload couplings are available as a flange type FT or in combination with the POLY-Norm flexible coupling (sha -to-sha connection). The low-backlash, positive-locking ball engagement system allows for optimum overload protection for torques up to 3,000 Nm. DW KTR www.ktr.com/us

February 2022

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DESIGN WORLD

2/9/22 2:36 PM

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

PRECISION NUTS & WASHERS

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

ADAPTER SLEEVE ASSEMBLIES

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

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

-H

NS US

WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly. Visit our website–whittet-higgins.com–to peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local or a good distributor.

DESIGN WORLD

DFI_2-22_Vs3.LL MS.indd 15

February 2022

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

2/9/22 2:37 PM

Design for Industry Material Handling

A range of drive systems for

packaging and conveying needs Compact, energy efficient drive systems are designed to be precisely positioned, reduce variants and maintenance, and lower Total Cost of Ownership for packaging systems. The combination of modular gear units, motors, and variable equency drives deliver intelligent solutions for the special requirements of the packaging industry. These drive systems can power many types of equipment, including roller conveyors, belt conveyors, chain conveyors, stacker cranes, palletizers, case packers, and sealer wrappers. Custom configurations are possible. The drive solutions for packaging include:

• nsd tupH Sealed Surface Conversion Treatment. These units are a cost-effective alternative to stainless steel that is easy to clean, resistant to acids and alkalis, and is an FDA-approved food-compatible material. This surface conversion is an electrolytic process where the aluminum surface of the gearbox is sealed and inseparably bound to the substrate material, creating a new material that is more durable than paint and weighs less than stainless steel.

February 2022

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DESIGN WORLD

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• IE5+ Synchronous Motors. This motor technology offers high operational efficiency. IE5+ motors are focused on maximizing efficiency, with a compact footprint that can be installed quicky and easily, even in small spaces. With these motors in place, operators can experience energy savings, reduced product variants, and minimized operating costs for their applications, especially where operation at partial loads and low speeds is common. When IE5+ synchronous motors are used as a part of the LogiDrive complete drive system solution they create an energy efficient, maintenance- iendly solution consisting of an efficient gearbox, permanent magnet synchronous motor (PMSM), and a decentralized variable equency drive. Plug-and-play decentralized technology makes installation and maintenance easy and the LogiDrive system also maintains operational efficiency at partial load and low speeds, making it a suitable solution for intralogistics systems.

• DuoDrive Integrated Gear Unit. The DuoDrive is a revolutionary integrated gear unit/motor concept that combines a high-efficiency IE5+ motor with a singlestage helical gear unit in one housing. Due to its optimized system efficiency, high power density, and quiet operation, it is suited for intralogistics systems. Together with its simple Plug-and-Play commissioning, DuoDrive solution can provide a significant reduction in Total Cost of Ownership (TCO) compared to other drive systems.

equency drives are a reliable, economic solution for IIoT environments.

• LogiDrive Complete Drive Solution. This system is comprised of a high-efficiency 2-stage bevel gear unit, an IE4 or IE5+ motor, and a variable equency drive. This solution provides a complete decentralized drive package that reduces commissioning and engineering efforts for conveying systems. The modular design minimizes the number of system variants, is easy to maintain, saves on Total Cost of Ownership, and maintains performance at low speeds and partial loads. LogiDrive also allows for easy monitoring and control of all units within a system and can be combined with the NORDCON APP with NORDAC ACCESS BT Bluetooth stick to provide real-time drive status to predict maintenance issues before they occur.

• Condition Monitoring for Predictive Maintenance. The condition monitoring solution records drive and status data with the objective of maintaining machines and plant productivity. Data are collected om analog, digital, or virtual sensors to determine when there is a drive issue and allows for scheduled downtimes before they turn into unplanned, costly repairs. This system is also able to calculate the optimal time to change the oil by measuring its temperature over time. This enables the drive to run effectively and efficiently with minimal wear on the components. DW

NORD DRIVESYSTEMS Group www.nord.com

• NORDAC ON/ON+ Variable Frequency Drives. These variable equency drives were developed to meet the special requirements of horizontal conveyor technology and for use with the IE5+ synchronous motor (NORDAC ON+). They are characterized by an integrated universal Ethernet interface, full Plug-and-Play capabilities, and a compact, spacesaving design. NORDAC ON/ON+ variable DESIGN WORLD

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February 2022

2/9/22 2:37 PM

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Design for Industry O f f- h i g h w a y

Motor brakes provide secure hold

Aggregate and mining operations can offer challenges to conveyor applications. These motor breaks provide a secure, no-maintenance, no-adjustment, hold for such applications. In addition to holding brakes, these brakes are suitable for mining applications where the motor is stopped or reversed each cycle such as loaders/unloaders, conveyors, rail car spotters and dumpers, overland and internal tripper cars, rotary coal sweep samplers, and more. These motor brakes are available to accommodate a range of applications. Spring set torque ratings om 3 to 1250 -lb are available. The motor brakes can be sized to the correct torque value independent of the motor ame size or horsepower by changing the combination of springs and iction discs.

February 2022

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DESIGN WORLD

2/9/22 2:38 PM

MagnaShear motor brakes have a “quick mount” feature for quick and easy mounting to drive motors in NEMA ame sizes 56 to 449 or some IEC ame motors. They are shipped ready to install, with no assembly or adjustments required. These motor brakes can be furnished as a complete motor and brake assembly (assembled brake motor), or to mount on a machine ame or other special mounting configuration. They are totally enclosed om outside contaminants, with seal integrity for harsh and washdown environments. A modular design /assembly allows for ease of servicing and maintenance. Hazardous duty units for class II, Group a, b, c, d, e, and f are also available, as well as low temperature or Artic duty down to -40°. The totally enclosed motor brakes are impervious to the moisture, dirt, and dust that are common in mining applications, as well as concrete block plants, asphalt shingle manufacturing, bulk material

handling, forest products manufacturing, and more. Unlike dry brakes, oil shear technology includes a film of transmission fluid between the brake disc and the drive plate. As the fluid is compressed, the fluid molecules are put in shear — thus imparting torque to the other side. This torque transmission causes the rotating surface to come to a stop. Since most of the work is done by the fluid particles in shear, wear is virtually eliminated. Elimination of wear enables MagnaShear brakes to last significantly longer, while also eliminating the need for maintenance and adjustments which are common for dry braking systems. In addition to transmitting torque, a patented fluid recirculation system helps to dissipate heat which causes iction disc wear and eventual failure in traditional dry brakes. Along with heat removal and torque transmission, the fluid serves to continually

TRIMS AND TRIMS AND SEALS B R AT I LE N

lubricate all components of the oil shear brake, increasing their service life. The oil shear technology also provides a smooth “cushioned” stop which reduces shock to the drive system, further extending service life of downstream components. DW

Force Control Industries Inc. www.forcecontrol.com

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February 2022

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Design for Industry O f f- h i g h w a y

Sealed bearings keep motors running

Even in off-highway applications, performance can be compromised if parts cannot handle dirt and debris. Thus, a range of Powerstart hydraulic and turbine starter motors use wear-resistant sleeve bearing replacements as standard components in some 550 of these motors. The sleeve bearings replace plain bearings and replace internal and external needle-roller bearings. These could not be sealed completely, leading to dirt ingress causing bearing seizure. The affected bearing o en resulted in the need not only to replace the bearing, but the sha and even the whole cone head.

February 2022

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www.designworldonline.com

With wear-resistant Vesconite replacing the problematic external needleroller bearing, and the internal needleroller bearing, there was virtually no wear. Replacement of the sha and nose cone was eliminated and they had an overall longer-lasting bearing.v DW

Vesconite Bearings www.vesconite.com

DESIGN WORLD

2/9/22 2:40 PM

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Design for Industry Semiconductor

EtherCAT Semiconductor Working Group celebrates 10 years of success in

chip manufacturing

In 2011, nearly 100 industry experts were at the kick-off to support the ETG’s plan to develop device profiles and implementation guidelines for the specific needs of the semiconductor manufacturing industry. Martin Rostan, Executive Director of the ETG, recognized even then, “The new fieldbus standard for the semiconductor industry is EtherCAT — there is no other way to interpret the clear commitments om market leaders and the active support om the industry.” Ten years later, the TWG Semi has developed 16 documents with Specific Device Profiles (SDPs) for the semiconductor industry as well as four associated basic documents. A further nine profiles are in the approval process and, in some cases, are close to completion. More than 22,000 working hours have been invested in the development of the profiles since 2011 at the semi-annual meetings of the working group alone. 24

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The effort has been worthwhile and Rostan’s assessment has been confirmed many times to date. EtherCAT is the protocol of choice for the semiconductor industry and is used in countless tools, as the machines for semiconductor manufacturing are called. Florian Essler, who accompanies the TWG Semi om the ETG team, sees the broad support for the developed standards as the main reason for this success: “Based on the stringent working culture of the TWG Semi, profiles with enormous acceptance in the market have emerged over the past 10 years. This is particularly reflected by the development of the number of participants at the meetings, which shows that our device profiles are classified as a special value in the industry.”

In addition to the work on device profiles, new topics are always finding their way into the work of the TWG Semi. For example, they are now working on Safety over EtherCAT and its relevance in the area of functional safety for semiconductor manufacturing machines as well as their associated devices. In addition, the integration of the EtherCAT Conformance Test Tool (CTT) in the automated acceptance of devices also plays a role. Florian Essler is sure to have “actively tackled” the work for the next 10 years with the 20th meeting of the TWG Semi and is looking forward to future ideas, which will be developed and in addition to the daily business of the working group. DW

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Design Notes

How to cut your robotic system down to size Edited by Mike Santora • Managing Editor

METAL LS, the Bulgarian manufacturer of door locking systems, door and window handles, and building hardware started planning the new automated assembly of door locks in 2019. The robotic systems the company already used for other applications were too large for the planned production site, so the new solutions needed to be as compact and precise as possible, in addition to being state of the art. Door and security locks are precision parts with standard dimensions and components stipulated in DIN standards. Therefore, quality and precision were critical deciding factors for METAL LS. The robots also needed to achieve high productivity — assembling between 10 and 14 locks per minute. Additionally, the company required a high level of flexibility and the possibility of retooling to reuse the same system to 26

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To implement this project, METAL LS and Delta collaborated to develop a custom workstation for the assembly of the mechanical door lock components.

produce new locks in the future. Following a comparison of various manufacturers and products, METAL LS opted for a robot system om Delta. It was the only manufacturer to offer a complete solution including programmable logic controllers (PLC), a human-machine interface (HMI), servo systems, and robotic arms with Machine Vision. To implement this project, METAL LS and Delta collaborated to develop a custom workstation for the assembly of the mechanical door lock components. The main part of the system comprises a rotation table on which seven, six-axis DRV90L7 articulated DESIGN WORLD

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robots are installed. The robots are capable of extremely precise, quick movements and have a hollow wrist that allows them to be easily combined with the correct tool for each production step. The DOP-115MX HMI is used to visualize all processes and enables the user to select various receipts for different locks through a touch screen. It also displays system information and alerts or alarms. The AS300-series (AS324MT-A) PLC monitors the assembly line, controls the ASDA B2 servo drive, and communicates with the servo drive on the rotating platform. Two DMV2000 Machine Vision image processing systems equipped with cameras are installed to localize components on the conveyor and send accurate signals to the robot allowing it to pick up and assemble the parts. The AC servo system comprising ASDA-A2 and ASDA-B2 drives and ECMA motors ensure that the robot arms are positioned precisely and that high productivity can be maintained.

A few adjustments to the parameter settings were sufficient to quickly overcome initial communication problems between the PLC, robot, and the Machine Vision system. The careful preparation and system configuration carried out by the Delta team also ensured that all the Delta industrial automation (IA) products were soon integrated into the production processes. Alongside the quality of the compact robotic system, METAL LS is pleased with the advice and customer service it has received. The project was kicked off when the Field Application Engineering (FAE) team arrived on-site to support the construction of the assembly system together with Mechatronics, Delta’s Bulgarian partner. The assembly system is still undergoing tests, but initial results are already showing improved productivity and performance. DW

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Design Notes Built in 1938 by Ehrhardt & Sehmer, the Groussgasmaschinn is the largest gas engine ever built.

3D scanning the world’s largest blast furnace gas engine Edited by Mike Santora Managing Editor

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Until recently, 3D scanners could only be used indoors, under certain lighting conditions, with a steady power source, and a powerful computer. They were o en bulky and heavy, making them hard to maneuver while scanning. Most significantly, such scanners could only capture objects of limited sizes — something that could fit on your desk. This was the situation the team at the Luxembourg Science Center found themselves in back in 2016 when they came up with a plan: to digitally preserve one of Luxembourg’s national monuments, the “Groussgasmaschinn” or Gas Engine №11 — the world’s largest blast furnace gas engine ever built.

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Built in 1938 by German manufacturing company Ehrhardt & Sehmer by order of a Franco-Belgian consortium called “Hautsfourneaux et Aciéries de Differdange, St-Ingbert & Rumelange” (HADIR), the Groussgasmaschinn is so large it could contain an entire tennis court, and then some. It is 26 meters long, 10.5 meters wide, 6.5 meters high, weighs 1,100 tons, and could produce 11,000 horsepower, or up to 7000 kilowatts. It has four cylinders, each of which had a capacity of 3,000 liters, and an 11-meter and 150-ton flywheel, which rotated at 94 RPM. The engine was operated by 12 workers per shi , and during its lifetime (1942-1979), produced more

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than 6,000 kW of power om blast furnace gas (a waste product generated by the combustion of coke fuel in blast furnaces). Located in Differdange, Luxembourg’s industrial town 27 kilometers southwest of Luxembourg City, this 1,100-ton industrial masterpiece was one of 14 other gas machines of various sizes installed in the Differdange Gas Engine Plant between 1896 and the 1940s. A er its shutdown in 1979, the Groussgasmaschinn remained abandoned for nearly 30 years. It came back om the brink of oblivion in 2007 when Luxembourg’s Ministry of Culture designated it as a National Monument worthy of preservation and restoration. The restoration work began five years later, in 2012. During this time, the Center developed the idea not simply to restore the gigantic engine to its best shape but also to digitally preserve it for future generations. In 2016, they reached out to Artec 3D in Luxembourg, but even the best of the scanning technology available at the time wasn’t able to capture something this huge. Fast forward a few years, and with new 3D scanning options available, Artec was ready to scan. “We’ve been meaning to scan this engine for a very long time, and we’re glad that the technology is finally here to help us do it. There is no other gas engine like this one, and it’s crucial to capture it in its current state,” said Nicolas Didier, President and General Manager of the Luxembourg Science Center. “It’s the largest object we ever scanned! And much bigger than I expected,” said Vadim Zaremba, Deployment and Technical Support Engineer at Artec 3D, when he first visited the Gas Plant to assess the scope of future work in November 2020. A er examining the gas engine

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The size and complexity of the object determined the scanners to be used: Artec Ray and Artec Leo.

and passing all the required security procedures in early 2021, Vadim returned to the Gas Plant with his colleague, Technical Support Specialist Raul Monteiro, and all the necessary gear. As in most cases, the size and complexity of the object determines the scanners to be used. Artec Ray was chosen as the primary scanner for capturing the entire engine due to its ability to scan large objects om a distance with submillimeter accuracy, while the Artec Leo, a wireless, portable 3D scanner, was chosen as a second device, specifically for capturing high levels of detail om the smaller parts of the engine. The plan was to first scan the engine with Ray om as many angles as possible, capture the entire object, and

While the Ray silently scans the engine, Zaremba steps away for a minute or two of scanning smaller sections up close with Leo.

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Design Notes The final polygonal 3D model of the Groussgasmaschinn.

then go back and scan any missing, smaller, hard-to-reach sections with Leo. Because Ray was scanning at maximum resolution (point density), to save some time, the team decided to split up. Zaremba was positioning Ray at various locations, at one particular angle, 5 to 15 meters away om the engine, while Monteiro was scanning smaller sections of the engine (which weren’t in Ray’s field of view) with Leo. Then Zaremba moved on to the next spot, and Monteiro followed behind, along the same route. One of the most challenging tasks was scanning the engine om above. To do this, the team had to climb a special bridge built in the 1940s-1950s, which features a cabin hanging 10 meters above the floor, as this was the ideal spot for scanning the engine om multiple angles. This was easier said than done. The bridge was old and unstable, and under the weight of two people plus a 3D scanner, such a foundation was not conducive to creating high-quality scans. To ensure that the scan data was flawless, Zaremba and Monteiro had to remain completely still for several minutes while the scanner did its job. Overall, it took the team four working days to complete the project, with three to fourhour shi s of active scanning every day. The engine was scanned om 18 different angles with Artec Ray, and these were later combined in Artec Studio with 67 more scans made with Artec Leo. The final size of the project came to 186 GB in total, with 170 GB of Leo scans and 16 GB of Ray scans. Processing an object this big was a challenge in itself. To make sure all the data was processed correctly, Artec 3D Tech Support Engineer Dmitry Potoskuev split up the process into several batches: He started with Ray data first. He cleaned up the data by removing all the unnecessary objects that the scanner picked up while scanning the engine (using the Eraser tool), such as parts of the Gas Plant building, windows, walls, and various other equipment around the GGM11.

●

Then he focused on uni ing the flywheel and other parts data across all 18 scans by erasing specific data om some ames using

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the Eraser tool. This was necessary because several scans were done on different days, and the position of the flywheel and a few other parts changed a few times when the engine was turned on by GGM11 staff for demonstrations. This could result in some mismatches if those scans were merged as-is. A er that, all Ray scans went through Global Registration to be registered between each other. Then each of the 18 scans were processed into meshes using the “Ray scan triangulation” algorithm with Polygon edge length (max) at 10 mm. This was done to filter all the surfaces with a large distance between the vertices, and as a result, to get a more detailed and cleaner surface a erward. A er that, all the 18 triangulated meshes were processed using SharpFusion algorithm to create a single mesh aka “skeleton” of the engine’s model.

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The next step was to add all the details captured with Leo. Because of all the data (170 GB), Potoskuev broke the process down into several steps.

●

First, he duplicated and locked the original Ray mesh. The duplicated copy was simplified to 5-10 million polygons and locked too. This was done to further the registration process. Next, he uploaded all Leo scans (divided into 17 groups during scanning) to the duplicated Ray project, and each of them was registered with the separately simplified Ray project for higherquality alignment of data.

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A er all the Leo scans were registered, Potoskuev selected the original Ray mesh and 4-5 raw registered Leo scans and applied the Sharp Fusion algorithm to create a new mesh. He repeated the process until all the Leo scans were processed with the original Ray mesh into a final mesh of the gas engine.

●

The final mesh consisted of around 350 million polygons, which were then reduced to 10 million polygons for further post-processing, using such features as Hole Filling tools, the Smooth Brush, and Bridges. The total processing time was all done within two weeks. “With this gigantic engine 3D scanned, we can use this data to restore some missing parts and preserve it in its current state, so even if it loses its shape with time, we can still go back to this 3D model and show it to our future visitors, and use it for restoration purposes,” said Nicolas Didier, President and General Manager of the Luxembourg Science Center. DW

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Design Notes

How to streamline a

microgrid system Edited by Mike Santora • Managing Editor

Anyone hearing the term “microgrid” has their own interpretation of what the word means. To the layperson, the definition may be as simple as knowing that it is smaller than a traditional-sized energy grid. They may understand that a microgrid is needed because a facility is located too far away om a main power grid to efficiently obtain the continuous energy required to power their systems. For those in the energy industry, when designing systems, the definition can be much more complex and aught with further questions. Some may ask why a microgrid is necessary at a particular location. Others might question what kind of energy is collected (solar or wind) and how it is being stored. Still, others may ask how this energy is being controlled and distributed. No matter the questions, engineers are looking for microgrids that provide stability, reliability, flexibility, and efficiency for various locations and challenges. Companies such as Ageto Energy not only answer these questions but also offer additional value that people are looking for in microgrid solutions. With renewable energy, Ageto always comes back to one word, “simple.” Working toward its mission to accelerate the global adoption of renewable 32

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Ageto can now monitor battery requirements (voltage, charge, and temperature), and write a small routine for actual control of the battery storage system. This system acts as Ageto’s control interface into the storage system onsite.

energy, it simplifies the integration and control of off-grid, microgrid power systems. The company reduces complexity and integrates power systems for a future of growth with low-carbon emissions. One way they have done this is by coordinating all the elements of a microgrid and placing them into consolidated systems. Known as the Ageto ARC microgrid controller, this option allows users to monitor and manage energy resources to ensure everyone gets the power they need. The ARC microgrid controller has been defined as “the brain of your microgrid system, seamlessly integrating, optimizing, and managing diverse energy resources.” The interface makes it easy for the system operator to have full visibility of their system, energy resource health, and performance data. To deliver the reliable power they were looking for, especially in the case of off-grid systems, the Ageto team needed DESIGN WORLD

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Design Notes

to make sure that the individual components that made up the ARC controller system performed to direct specifications. “We have designed our controller to operate continuously for years with no downtime, and we look for products that can parallel that,” said Ageto COO Mike Murray. To do this, Ageto searched for specific parts that would make constructing their ARC controller as easy as it was to use. Initially he was looking for just terminal blocks, but Murray and his team found a company that provided the connectivity he needed and the programmable logic controllers (PLCs) the ARC controller required to bridge communication. WAGO, a company known for its CAGE CLAMP spring pressure technology and automation solutions, stepped in to provide Ageto the flexibility and performance required for the project. The initial solution was a bridge between an existing battery storage system that used a Controller Area Network (CAN) communication protocol. However, the Ageto control system needed a Modbus TCP/IP input. The WAGO engineering team provided a

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The WAGO engineering team provided a simple, scalable PLC with a CAN Master module and Modbus TCP port for communication with the ARC control panel.

simple, scalable PLC with a CAN Master module and Modbus TCP port for communication with the ARC control panel. With this architecture, Ageto could monitor the battery requirements (voltage, charge, and temperature), and write a small routine for actual control of the battery storage system. This system acts as Ageto’s control interface into the storage system onsite. According to Jim Ratcliffe, Regional Sales Manager for WAGO, “The Ageto system is based on a model that allows them to be energy resource agnostic, offering their customers multiple integration options across numerous existing onsite assets.” Knowing exactly what was required, a range of products could be tested by Ageto before deciding. “They were looking for a Controller Area Network Ageto’s ARC microgrid controller can (CAN) solution that they be found in locations such as The could install remotely in an

Headwaters Center in Winter Park, Colorado. Performing under the most demanding conditions, ARC microgrid controller provides Headwaters and other users the peace of mind knowing that they will get reliable, resilient energy from an independent source.

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existing battery storage system, allowing them to communicate back to their own control platform,” said Ratcliffe. A er testing, Murray knew that WAGO was the company they wanted to go with. Ageto used terminal blocks, the CAN-based PLCs, and 221 wire-splicing connectors to customize their ARC microgrid controller. They also used these products in their Battery Management System (BMS) to help with temperature monitoring and load capacity challenges. Today, Ageto’s ARC microgrid controller can be found in locations such as The Headwaters Center in Winter Park, Colorado. Boasting Colorado’s first off-the-grid gathering place, Headwaters hosts weddings, celebrations, concerts as well as educational opportunities. Most of the energy used in this Civil-War-era facility is solar energy. That energy is then stored and used om onsite batteries. Performing under the most demanding conditions, ARC microgrid controller provides Headwaters and other users the peace of mind knowing that they will get reliable, resilient energy om an independent source. The company’s unique interface, performance monitoring, and real-time controls make its microgrid solutions straightforward and easy to use. DW

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Internet of Things

In the IIoT era, previously unconnected systems are now connected over private or public networks to gain more insights and improve productivity. The downside of this connectivity is that industrial networks are no longer immune to cyberthreats. The upside is a growing chorus of experts are sharing their knowledge to help shore up cybersecurity in industrial networks. Generally speaking, two methods are available for implementing industrial cybersecurity. One method is to secure the foundation of a network in astructure and only allow authorized traffic to flow to the designated areas. The other method involves identi ing critical assets and applying layered protection. Industrial secure routers and firewalls are essential to both of these methods as they are

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|AdobeStock

The first line of defense for industrial cybersecurity deployed at the ont lines to prevent unauthorized access and traffic to industrial networks.

Key criteria for choosing industrial secure routers and firewalls Industrial control systems can apply a defensein-depth approach to protect critical equipment and secure various locations, device cells, function zones, and factory sites on an automation network. Defense-in-depth cybersecurity includes three types of controls: physical, technical, and administrative. First, implement physical controls by segmenting the network and creating boundaries between each segment. Next, apply technical controls by securing network traffic or filtering data packets. Lastly, enhance administrative security

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by managing IP addresses and adopting strong security policies. Secure routers and firewalls provide an excellent way to achieve defense-indepth cybersecurity on your network, but how do you choose the right router or firewall for your industrial application? Consider the following three criteria.

Adding firewalls without changing your network Network segmentation involves breaking down the network into physical or logical zones with industrial firewalls. A firewall is an access control device that looks at the IP packet, compares the packet with preconfigured policy rules, and decides whether to allow, deny, or take some other action on the packet. Generally speaking, firewalls can be either routed or transparent, and the type you will need depends on the requirements of your application. Unlike routed firewalls, transparent firewalls allow you to keep the same subnet so that you can easily add firewalls to an existing network. With transparent firewalls, you also do not need to change the network topology. Transparent firewalls are suitable for protecting critical devices or equipment inside a control network where network traffic is exchanged within a single subnet. Furthermore, you do not need to reconfigure IP subnets because transparent firewalls do not participate in the routing process.

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Detect threats and protect critical data Firewalls are akin to gatekeepers. Unfortunately, determined intruders may still be able to get through the gates on a segmented network. That’s why you need to constantly check the traffic that passes through the gates you have established. One way to achieve this is to filter out unwanted commands such as write or configure commands that could cause industrial processes to fail when needed or unnecessarily trigger a safe state during production. Therefore, it is important for industrial secure routers and firewalls to support industrial protocol filtering at the command level — read, write, etc. — for more fine-grained whitelisting control. To secure the transmission of confidential data, consider building secure tunnels for site-to-site communications. In some scenarios, communications over public or untrusted networks will definitely require secure encrypted data transmissions. Under such circumstances, consider VPN capability when choosing industrial secure routers and firewalls.

Getting firewalls and network under control In industrial applications, hundreds or thousands of firewalls could be installed to control data traffic and protect field equipment from malicious attacks. Furthermore, even more IP addresses

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could be on a network. As networks continue to expand, managing all of the devices, firewall rules, and IP addresses become more complicated. Therefore, network address translation (NAT) provides a very important function when deploying industrial secure routers and firewalls. NAT allows the reuse of machine IP address schemes on the same network and the connection of multiple devices to the Internet, using a smaller number of IP addresses. This not only significantly reduces maintenance efforts and administrative overhead, but also provides simple network segmentation. In addition, it enhances security for private networks by keeping internal addressing private from the external network. Finding the right secure router or firewall for an application brings you to the halfway mark in successfully beefing up industrial network security. Using these criteria to help you make the right choice can remove some of the guesswork. For instance, a highly integrated industrial multiport secure router with firewall/NAT/VPN and managed Layer 2 switch functions provides everything that is needed. Nevertheless, whatever solution you ultimately choose, it should fit the specific application requirements. DW

Moxa www.moxa.com

February 2022

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Internet of Things

Rapid roaming wireless technology addresses sensor-cable connectivity issues

Increasingly, modern factories are relying on Artificial Intelligence (AI) driven processes to optimize every step of production. Previously, sensors used to collect data for AI were connected with slow cable-driven serial protocols with RS-232 cables or twisted pairs for RS-422/485. With the development of newer technologies, however, there has been a transition to Ethernet-based communication. Two main factors played a key role in this process: one, the price of Ethernet nodes went down with the advent of cheap microcontrollers that included fully integrated Ethernet communication hardware in one 38

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chipset, and two, sophisticated new sensors came to market that were not compatible with old serial buses. WIFI communication has become a key technology to deliver metrics om sensors, providing eedom om cables and to allow unrestricted 3D movements by a client in motion such as a vehicle or robot. The trouble is that 802.11ac wireless communication extends only 100 meters, a distance normally not sufficient for reliable service and requiring multiple access points be installed to cover a large area of operation. A moving vehicle or robot needs to constantly switch over www.designworldonline.com

communication to the next strong signal access point. The best solution is the implementation of 802.11r across the in astructure that manages the switch-over mechanism with below 50 ms transition. However, some areas of a factory or warehouse may not support 802.11r. To address this this situation, the ARS-7235-AC-T is an enhanced WIFI client that monitors surroundings and prepares new possible access point connection opportunities before die-down and drop-off connection processes take place. This unit is a dual-radio industrial WAP, with Rapid DESIGN WORLD

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Roaming protocols to seek a new AP when communication is still healthy, assuring superior throughput and faster transitions with below 150 ms switch time. IEEE 802.11R wireless roaming Roaming has been a desired feature in wireless devices for decades. In 2002, the IEEE 802.11r standard was introduced and is still under heavy development with major fundamentals published in IEEE 802.11r-2008. The main goal of 802.11r was to hand over wireless connections between numerous APs along a client travel path without significant delay. It has been particularly important for Voice over Internet Protocol (VoIP)

applications where human conversation requires 50 ms or better of transmission time to avoid undesired noticeable interruptions. The 802.11r standard allowed for speed with secure and seamless handoffs where authentication and Quality of Service (QoS) configurations were preconfigured ahead of switching to the next AP. It made for a stable throughput of data without delays caused by the regular authentication process. To implement 802.11r, the wireless infrastructure needs to support this standard. This typically will require significant additional investment as most systems that support 802.11r must have a Wireless LAN Controller in addition to the APs that are then controlled by

the Wireless LAN Controller. Applications where necessary infrastructure does not exist and there are cost restrictions, then Rapid Roaming technology can provide many of the same advantages at lower cost. Infrastructure requirements for rapid roaming The following is needed for the infrastructure: 1) Same Service Identifier (SSID) 2) Same Password 3) Same Security Mode 4) Sand Band 5) Same Channel Width For the rapid roaming technology to work correctly, it is necessary to use an access point with the same SSID and security key. When rapid roaming is enabled, the client device will be

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Internet of Things

Warehouse wireless system

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configured to scan for the surrounding APs. It is necessary to set slow scan time intervals to speci relatively slow scans when Received Signal Strength Indication (RSSI) signal levels are high and the client device can comfortably concentrate on delivering the maximum data throughput. Next, speci the RSSI threshold level that will indicate an imminent need for a new connection. When this level is reached, the client device will be performing fast scans looking for a new AP. When it is detected, it will authenticate and auto-connect to the new AP while simultaneously dropping the current connection. This active process eliminates weak signals deprived of links and prepares a new connection ahead when needed. Additionally, there are two modes of channels for scanning. One mode is “standard” and it works when all the channels are scanned. The other mode is “intelligent” and it works when a client device, for example, goes back and forth along the same APs. In this scenario, it can learn those APs channels and look for them automatically, further speeding up the reconnection process.

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Warehouse wireless system One example of where this scenario plays out is in a warehouse application with autonomous robots that move about the warehouse stocking shelves and fulfilling orders. Here, a legacy WIFI network was already in place to support employees connecting their PCs, tablets and phones, but the network did not have the necessary equipment to support 802.11r. Antaira was able to provide the solution by fitting each of the robots with an ARS-7235-AC wireless router that could implement Rapid Roaming technology at a action of the cost of installing an entirely new wireless network. DW

Antaria www.antaira.com

DESIGN WORLD

2/9/22 2:56 PM

REGISTRATION IS NOW OPEN

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D e s i g n for Additive Manufacturing •••••••••••••••••••••••••••••••••••••••••• •• ••

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Desktop Metal qualifies commercially pure copper for its Production System Desktop Metal has qualified commercially pure copper (> 99.95% purity) for additive manufacturing on the Production System platform, and its Single Pass Jetting (SPJ) technology. Users can now leverage SPJ technology for the production of high-performance copper parts at scale across a variety of industries, including automotive, aerospace, and electronics. With its excellent thermal and electrical conductivity, commercially pure copper is a suitable material for applications requiring heat or electricity transfer, such as cold plates, pucks and manifolds, heat sinks, heat exchangers, and bus bars used in power-intensive electrical applications. It is the thirdmost-consumed industrial metal in the world. Desktop Metal’s materials science team has qualified and fully characterized commercially pure copper (C10300) printed on Production System technology. Manufacturers can now print copper parts on the Production System with significant geometric complexity in a single step instead of brazing multiple conventionally produced copper components together. With the geometric eedom enabled by binder jetting, engineers can also explore new, high-performance designs not possible with conventional manufacturing methods, such as the lattice structures and conformal cooling channels to improve heat transfer. An example of a key application is a liquid cooling plate. Liquid cooling plates are used to regulate temperature on high-performance microprocessors. Coolant flows through the fins, which provide a large surface area to transfer heat om the passing fluid to the heat sink in order to

February 2022

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DESIGN WORLD

2/9/22 3:00 PM

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cool the chip that is attached to the outer body. These cooling geometries typically require capital-intensive, long lead time, and skilled labor-intensive production processes, such as skiving and machining, given the challenges associated with achieving precision and repeatability in such a small form factor. In addition, these commonly used conventional manufacturing processes are subtractive and produce excess scrap material, greatly increasing the associated part costs. Whereas conventional production methods for this liquid cooling plate required machining and assembling multiple separate components due to restrictions on tool access, binder jetting on the Production System can produce the part as a single component, reducing manufacturing and operational complexity, part cost, and lead time. The Production System unlocks the capacity to print hundreds of cooling plates per day, enabling cost-effective volume production. Copper is the ideal material for heat exchangers due to its excellent conductivity, maximizing heat dissipation from the electronic chip to the cooling fluid. The Production System platform consists of two printer models: the P-1, a solution for process development and serial production applications, and the P-50, a large form factor mass production solution for enduse parts. The Production System combines Desktop Metal engineered binders with an open material platform, allowing customers to produce high-

DESIGN WORLD

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performance parts using the same low-cost metal powders used in the Metal Injection Molding (MIM) industry. An inert processing environment enables compatibility with a variety of materials, including high-performance alloys and even reactive metals, such as aluminum and titanium. In addition to copper, the materials library for the Production System platform has expanded to include D2 tool steel, 420 stainless steel, nickel alloy IN625, 4140 low-alloy steel, 316L stainless steel, and 17-4PH stainless steel, each of which have been qualified by Desktop Metal. The platform also supports several customer-qualified materials, including silver and gold, and Desktop Metal plans to add additional metals to its portfolio, including tool steels, stainless steels, superalloys, and more. DW

Desktop Metal www.desktopmetal.com

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800-461-4161 sales@cshyde.com

2/9/22 3:00 PM

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D e s i g n for Additive Manufacturing •••••••••••••••••••••••••••••••••••••••••• •• ••

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Formlabs introduces new 3D Printers and resins At the recent CES 2022, Formlabs, launched the Form 3+ and Form 3B+ printers, available and shipping globally now. These printers feature improved Low Force Stereolithography technology that was first introduced in 2019 with the Form 3 and Form 3B. These new iterations also feature enhanced hardware components and so ware updates that improve print speed, print quality and support removal. The Form 3+ and Form 3B+ leverage powerful, higherintensity lasers and new material settings to optimize laser exposure and print up to 40% faster than earlier models. The new printers include the next generation Build Platform 2, which uses patented Quick Release Technology and a flexible

February 2022

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print surface to instantly release parts om the build platform. Users can quickly and easily remove parts om the print surface without tools in seconds. Formlabs also announced ESD Resin, the company’s first static-dissipative material, developed for applications that require ESD-safe parts to protect objects and electronics sensitive to unregulated static discharge. DW

Formlabs | www.formlabs.com

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DESIGN WORLD

2/9/22 3:01 PM

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Improve the accuracy of additive

manufacturing part production Before

A typical part printed on a FFF system shows significant deviations from the design. Red areas are oversize, blue areas are undersize and grey areas match the design. A histogram shows error distribution.

A er

A warp-adapted-model (WAM) generated with Riven and printed on the same printer shows 10X lower total deviations.

Riven, a 3D reality intelligence for digital manufacturing company, has developed Warp-Adapted-Model (WAM) capability that enables higher accuracy Additive Manufacturing (AM) part production. WAM uses full-part 3D data om an initial part to identi errors and produces a corrected model in minutes, one that eliminates warp, and is up to 10 times more accurate when printed. WAM capability has been tested extensively and has shown improvement across a variety of additive manufacturing technologies including FFF, SLA, metal binder jetting and MJF. WAM improves parts made by nearly any AM technology or machine and is available to select customers and partners now. DESIGN WORLD

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February 2022

2/9/22 3:02 PM

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D e s i g n for Additive Manufacturing •••••••••••••••••••••••••••••••••••••••••• •• ••

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WAM enables users to deliver production parts with tighter tolerances and saves weeks by eliminating process iterations. WAM works for any additive technology without the need for detailed knowledge of the specific machine or material parameters. It is complementary to simulation-based approaches and can be used alone or in combination to correct remaining errors related to environmental conditions or imperfect simulation input. In a comprehensive FFF trial, average print errors were reduced by over 2.8 times where the accuracy score improved om 80% to 93% (where errors are defined as areas with deviation over 0.25 mm). Trials were conducted with three different part types and in three different materials.

WAM is scalable, making additive manufacturing a viable option for customers with projects that only need a few units to those that require thousands or more. Riven is developing joint solutions with leading AM equipment and AMES partners to open new markets for AM production across industrial, automotive, aerospace and consumer applications. Riven is also pre-release testing PWAM, a predictive, machine-learning driven version of the technology which creates pre-adjusted models automatically and will deliver even greater economies of scale and minimize production of scrap parts. DW

Riven www.Riven.ai

Stratasys adds Origin One dental 3D Printer to its portfolio Stratasys Ltd. introduced the newest printer in the company’s growing portfolio of 3D printing solutions for the dental industry, the Stratasys Origin One Dental. The new printer is the second 3D printer resulting om Stratasys’ acquisition of Origin in December 2020, which was a key milestone in the company’s strategy to be the leader in polymer 3D printing for manufacturing. The Stratasys Origin One Dental and the recently introduced Stratasys J5 DentaJet 3D printer provide dental labs with comprehensive additive manufacturing solutions to meet the needs of the growing dental customer base. The Stratasys Origin One Dental 3D printer is powered by a proprietary print technology called P3 Programmable PhotoPolymerization, an advance on digital light printing principles that enables accuracy, part-to-part consistency, and throughput. The Origin One Dental offers an open material in astructure that supports a variety of applications for higher throughput at a lower cost per part compared to competing technologies. The printer is intended for flow production, small batches of a single material 46

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requiring short print time, maximizing the output of each application, and streamlining the production process. In March 2021, Stratasys launched the J5 DentaJet, a multi-material dental 3D printer capable of printing mixed dental parts in a single print tray without sacrificing accuracy. Based on PolyJet technology, the J5 DentaJet can also produce multi-color realistic case presentations. This printer is suitable for large batch printing, especially when printing mixed trays of parts overnight or unattended. Together, the printers give dental customers the ability to streamline their processes while increasing production to meet the demands of the dental industry. DW

Stratasys www.stratasys.com/dental

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DESIGN WORLD

2/9/22 3:03 PM

DeviceTalks Tuesdays is a weekly virtual event that brings the insights and energy of our in-person events to your desktop. Each DeviceTalks Tuesday will kick off with a quick brieﬁng from the editors of MassDevice and Medical Design and Outsourcing. These presentations will give attendees insights on what trends will be moving medtech in the days to come

presented by:

Topics include:

TUESDAYS

devicetalks.com

• • • • •

Innovation & Finance Manufacturing & Sourcing Medtech People New Tools & Technology Prototype & Product Development • Regulatory/Reimbursement

@DeviceTalks

Sponsorship opportunities are available for future DeviceTalks programs.

For more information, contact Courtney Nagle. 440.523.1685 | cseel@wtwhmedia.com

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February 2022 www.designworldonline.com

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DESIGN WORLD

2/9/22 3:18 PM

CAE Solutions

Combining aerodynamics and hydrodynamics in “flying boats” On November 7, 2021 – just three months a er its initial launch into water – the Trimaran SVR-Lazartigue le the starting line of the Transat Jacques Vabre in Normandy for its first offshore race, arriving in Martinique on November 23 a er completing a 7,500-mile journey across the Atlantic, finishing in second place in the 15th edition of the Transat Jacques Vabre sailing competition. Designed and assembled by MerConcept, which contracted the whole project, the Trimaran SVR-Lazartigue belongs to the new generation of “flying boats” in which aerodynamics is as important as hydrodynamics. The development of new technologies in all areas of design makes the Trimaran SVR-Lazartigue a unique and revolutionary boat. In particular, MerConcept was able to benefit om Dassault Systèmes’ 3DEXPERIENCE platform, distributed by Dassault Systèmes’ business partner CT Mer Forte. Using the platform’s “Winning Bid for Sea” industry solution experience on the cloud, MerConcept created a virtual twin of

DESIGN WORLD

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the boat and performed high-fidelity simulations that enabled it to optimize the boat’s aerodynamics and significantly improve its performance. MerConcept used the “Sea Boat Builder” industry solution experience to carry out the design of the boat’s systems. “The efficiency of the 3DEXPERIENCE platform enabled us to significantly optimize our performance during the study and design phases,” said Antoine Gautier, Trimaran SVR-Lazartigue Director, MerConcept. “With each new sailing race, we are able to witness new technical feats that enable boats of different classes to go faster, with unprecedented strength and resilience,” said François-Xavier Dumez, Vice President, Marine & Offshore Industry, Dassault Systèmes. DW

Dassault Systèmes www.Dassaultsystemes.com

February 2022

2/9/22 3:18 PM

CAE Solutions

A closer look at COMSOL version 6.0

Version 6.0 of the COMSOL Multiphysics so ware introduces the Model Manager, a new workspace in the program that enables efficient simulation data management and collaboration. Also introduced is the Uncertainty Quantification Module. This is a new add-on product that uses probabilistic design methods to quanti uncertainty in analyses and predetermined safety margins. Version 6.0 further brings improvements to the solvers with performance speedup by a factor of 10 in engineering areas such as heat radiation and models subjected to nonlinear structural material behavior. The Model Manager provides structure, version control, and effective collaboration. The Model Manager is fully integrated in the COMSOL Multiphysics user interface and is designed for simulation data management, version control, tracking changes, and advanced search functionality within models, CAD data, and other related external files. It provides a structured workspace where colleagues and teams can collaborate within their organizations and even with external parties, putting the focus on effective product design and innovation. Efficient data storage that keeps only changes made to previous versions and the easy setup of branches and merging them for parallel model development, also

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2/9/22 3:19 PM

contribute to an organization’s efficient modeling and simulation workflow. To allow full collaboration across enterprises, COMSOL’s floating network license type allows users om anywhere within and outside of the license holder’s organization to access a centralized Model Manager installation. This also includes collaborators across geographical and territorial borders. Additionally, a local Model Manager installation is included with all licenses — even those that are not floating-network based — to provide a platform for building an individual user’s file storage structure, while updating versions and tracking changes of their modeling projects. Sensitivity and reliability analyses are enhanced through the Uncertainty Quantification Module. While the Model Manager expands COMSOL’s footprint within the world of engineering design and development, the Uncertainty Quantification Module makes it possible to produce more complete, accurate, and useful multiphysics models. Based on probabilistic design methods, users can, with reliability analysis, look at questions such as how manufacturing tolerances affect the intended performance of

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the final product, to prevent overand under-designs of devices and processes. Screening and sensitivity analyses reveal which parameters are more important than others, which can be used to efficiently test the validity of basic model assumptions, for example, and uncertainty propagation is used to assign probability distributions to the output quantities of interest. The Uncertainty Quantification Module reveals how variability of input parameters affects the simulation results. “A strength of the Uncertainty Quantification Module is that it can be applied to any physical simulation covered by COMSOL Multiphysics,” said Jacob Yström, technology director of numerical analysis at COMSOL. “You are not limited to a certain field or application area, such as structural analysis, but can perform the same types of uncertainty analyses on applications based

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on acoustics, fluid flow, electromagnetics, and so on, and even when these phenomena are coupled.” COMSOL Multiphysics version 6.0 includes important updates to the so ware platform and add-on products. This includes performance improvements through speedup and memory consumption by a factor of 10 for certain engineering applications. Feature enhancements include more efficient electromagnetic simulation of PCB designs and a new realm for acoustics modeling: flow-induced noise. COMSOL version 6.0 delivers performance improvements and simplifies simulation of many important applications, such as printed circuit board (PCB) design. DW

COMSOL www.comsol.com

February 2022

2/9/22 3:20 PM

5G TECHNOLOGY WORLD Delivers the Latest 5G Technology Trends

5G Technology World is EEWorldOnline’s newest site covering 5G technology, systems, infrastructure, and wireless design and development. Get caught up on critical 5G information, check out the following articles on 5GTechnologyWorld.com: Massive MIMO performance testing: Emulate the channel Performing MIMO testing using real-world conditions is critical for successful 5G deployments. www.5gtechnologyworld.com/massive-mimoperformance-testing-emulate-the-channel

5G is hot, keep your components and systems cool 5G’s antennas and the devices that drive them generate more heat than their LTE predecessors. That creates new cooling problems for wireless devices and systems. www.5gtechnologyworld.com/5g-is-hot-keep-yourcomponents-and-systems-cool

5G moves into production, causes test issues 5G Technology World talks with Teradyne’s Jeorge Hurtarte, who explains components and over-the-air production test of 5G components. www.5gtechnologyworld.com/5g-moves-intoproduction-causes-test-issues

IEEE 1588 adds timing performance while reducing cost and risk GPS and GNSS have been the standards for network timing, but they have security issues. A Master clock and IEEE 1588 reduces the risk and lowers installation costs. www.5gtechnologyworld.com/ieee-1588-adds-timingperformance-while-reducing-cost-and-risk

For additional content, go to: www.5gtechnologyworld.com

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A Supplement to Design World - February 2022 www.therobotreport.com

Swiss manufacturer automates CNC machine tending

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OnRobot three-finger gripper and Doosan collaborative robot make production processes more efficient for family-owned business. page 58

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The Robot Report

Why component makers should target cobots Collaborative robots are expected to see high growth in the years ahead, with end effectors representing the largest component market. By Tim Dawson • Interact Analysis

February 2022

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www.therobotreport.com

THE ROBOT REPORT

2/8/22 7:37 AM

Recent years have been tough for the robotics and automation sector. Even pre-pandemic, the situation was challenging. That’s because, in 2019, automotive – a key consumer of industrial robots – saw weakened demand for traditional internal combustion vehicles. Additionally, the electronics market was also stuttering, as was the machine builders’ market. And the expected 2020 rebound was stymied by the COVID-19 crisis, with the global industrial robot market falling by 11.1% in revenue terms, and by 5.9% in shipment terms. But we are seeing a strong 2021 rebound as end customers resume much-delayed industrial automation projects. Beyond 2021, although activity will not be so enzied, we predict continued strong growth, not least because the experience of operating factories along social distancing lines has made even the most conservative production line managers think hard about the potential that automation offers. By 2024, the market for industrial and collaborative robots should achieve its previous 2018 revenue peak of $10.5 billion, with 410,000 units shipped. Cobots expected to see 15%-20% annual growth Before we can understand the robot components sector, we need to look at the changing landscape where industrial and collaborative robots are concerned. In 2020, articulated robots accounted for nearly 75% of the combined $8.6 billion market value of industrial and collaborative robots. But by 2025, we A pin insertion predict that share will drop to 70%, while the combined market will exceed $11.1 billion. The reason for this application using an drop is that revenues om automotive, the biggest OnRobot RG2-FT gripper end-user of articulated robots, will fall om 33.4% and Universal Robots of the total market share in 2020 to 31.8% in 2024. collaborative robot. Over the same period, the market for collaborative and SCARA robots will see faster than average growth, | Credit: OnRobot owing to the emergence of a range of new industries which will constitute strong new markets for these types of robots.

THE ROBOT REPORT

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www.therobotreport.com

February 2022

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The Robot Report Key Components In Industrial Robots - Revenues By Major Product 3000 2018

2020

2025

2500

Revenues ($M)

2000 1500 1000 500 0 rs

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es ox

b ar

Source: Interact Analysis

While the overall industrial robot market is forecast to see annual growth of the order of 4%-5%, the collaborative robot sector is expected to enjoy 15%20% year-on-year growth. We are seeing a trend towards smaller, lower payload robots, as industries such as electronics continue to automate, and new industries such as battery manufacturing and PV manufacturing increasingly come on stream. SCARA robots with a payload usually of <10 kg, for example, are already the most widely used robot solution in the electronics sector, and have a broad range of applications, including material handling, assembly and inspection. This clear trend towards smaller robots will heavily impact the robot components sector. Market for end effectors to top $2.5 billion by 2025 In our latest industrial robot component research, we consider all the key robot components: motors, drives, gearboxes, controllers, machine vision, sensors and end effectors. 2021 saw a strong double-digit rebound for components used in robots, and this year the market will exceed its 2018 size of just under $8 billion. This is due in no small part to prices being forced up by a number of factors including the semiconductor shortage and inflation. For 2022 and beyond we anticipate lower but still strong levels of growth, with a 4.1% CAGR out to 2025, and

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revenues projected to hit $9.3 billion that year. As we can see on the chart above, end effectors represent the single largest component market. They will continue to do so for the foreseeable future, growing om a market value of $1.8 billion in 2020 to over $2.5 billion in 2025. The combined market for motors, drives and gearboxes is predicted to exceed the value of the end effector market. There is a significant point to be made here: much of the motors/drives market is captive, with robot manufacturers usually producing these components for themselves. It’s the same story for robot controllers. But markets for other components, including end effectors, teach pendants, sensors and precision gearboxes are far more open to third party suppliers. Machine vision and end effectors are seeing the highest growth as their penetration is increasing owing to the growing complexity of automation solutions being installed in manufacturing facilities. We are also seeing a slightly above average increase in market share for sensors as the more sophisticated and higher cost absolute encoders see increased use in applications requiring a high degree of accuracy. The trend towards more compact robots with lighter payloads is creating a demand for smaller and lower power

www.therobotreport.com

motors, drives and gearboxes which command lower market prices than their larger, more powerful counterparts. So, though these components will continue to dominate in terms of their combined market share, revenue growth will be at a slower pace than for other types of components. Meanwhile, the market for robot controllers is expected to keep pace with the overall industrial robot market. Teach pendants, already well established in the cobot segment, are likely to see slightly increased growth as they are deployed in other robot applications. Component manufacturers need to target ‘open’ market segments While the articulated robot sector, by virtue of its size, appears to represent the biggest single opportunity for component vendors, a significant part of the market is captive, with vendors enjoying strong, if not unbreakable, ties with their end customers. Instead, the eyes of component manufacturers hoping to grow their market share should be turning towards the more ‘open’ market opportunities offered by the burgeoning collaborative robot market where revenues are expected to exceed $1.1 billion by 2025, surpassing even the $865 million in revenues derived om SCARA robots. RR About the Author Tim Dawson is the senior research director and principal analyst for Interact Analysis’ industrial automation team. He uses his 20-plus year experience to develop best-inclass research for the manufacturing sector and is a equent speaker on all things research at conferences and industry trade shows across the country.

THE ROBOT REPORT

2/8/22 7:38 AM

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The Robot Report

Swiss manufacturer automates CNC machine tending

OnRobot three-finger gripper and Doosan collaborative robot make production processes more efficient for family-owned business.

By The Robot Report Staff

February 2022

OnRobot Case Study_RR_2-22_Vs3.LL.indd 58

www.therobotreport.com

THE ROBOT REPORT

2/8/22 7:44 AM

At the WEFAG production facility in Fällanden, Switzerland, production is supported by a collaborative application featuring a Doosan robot and the three-fingered 3FG15 gripper from OnRobot, loading and unloading a CNC machine. | Credit: OnRobot

WEFAG AG, a company based in Switzerland, has offered comprehensive CNC machining services for the last 35 years. It focuses on the CNC production of components and parts for the fluid technology sector. Challenge: Shorter delivery times and smaller batches “We are increasingly dealing with extremely short delivery times and smaller batch sizes,” said Damian Hediger, managing director, WEFAG AG. “Besides, process reliability must be guaranteed – for all components.” When machining workpieces with CNC machines, both absolute positioning accuracy and repeatability are crucial. This family-owned company focuses on precision and meeting the highest quality standards. WEFAG is able to offer its clients a wide range of CNC machining services in an almost unlimited variety and combination of materials. The components go through various machining steps within the CNC machines, including turning, milling, drilling, vibratory finishing, assembly, refining and the final machining of the workpieces. At WEFAG, an employee would spend the entire day placing workpieces in a machine and removing them. This made the company look for a way to make its production processes more efficient, without hindering employees’ tasks. Solution A er much research and consideration, the company finally decided to automate. With modern technologies, many processes are already automated: loading and unloading, for example, which previously needed to be supervised by an employee. Today, WEFAG automates part of its process using a collaborative robotic arm om Doosan Robotics and an OnRobot 3FG15 gripper.

THE ROBOT REPORT

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www.therobotreport.com

February 2022

2/8/22 7:45 AM

The Robot Report

OnRobot’s three-fingered 3FG15 enables precise gripping of objects of different shapes and sizes and was developed as a response to existing pneumatic three-finger grippers that are bulkier and less flexible. Its fingers can be mounted in three different positions, enabling different gripping forces and diameters with maximum stroke of 150 mm and a 15 kg (33 lb) payload, providing a strong, stable grip for both form fit (internal) or friction fit (external) gripping. | Credit: OnRobot

February 2022

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Due to the limited space between CNC machines at the production facility, WEFAG was faced with another challenge: the process had to be automated in the most space-saving way possible. Furthermore, the solution had to be

www.therobotreport.com

accurate enough to precisely place a variety of components in the machine and remove them without damaging them. Since the implementation of the automation project was not feasible for WEFAG alone, the company turned to cobot solutions AG, a Swiss company

THE ROBOT REPORT

2/8/22 7:48 AM

DEVELOPMENT TIME Performance, reliability, low-cost, and faster time to market. For over 20 years Performance Motion Devices (PMD) has been helping engineers and managers like Mike integrate high-performance motion control into their machines. PMD gives OEM’s the ﬂexibility to choose powerful motion control ICs, modules, or boards—whatever they need to get their automation products to market faster, and stay there. au

MOTION CONTROL FOR YOUR DESIGN

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The Robot Report specializing in comprehensive automation solutions using cobots. “WEFAG approached us with a request to develop a solution that would allow them to quickly and easily automate CNC machine tending,” explained Beni Zimmermann, managing director, cobot solutions AG. “Based on this request, we researched, tested and validated various grippers. The main challenge was the variety of workpieces, as it placed enormous requirements on the gripping range and flexibility of the gripper.” WEFAG and cobot solutions decided on an application in which OnRobot’s 3FG15 gripper is mounted on a Doosan cobot arm. The electric, three-finger gripper stands out due to its high accuracy and flexible gripping range. The 3FG15 enables precise gripping of objects of different shapes and sizes. Its fingers can be mounted in three different positions, enabling different gripping forces and diameters. Thanks to its symmetrical rotational motion, the 3FG15 places objects precisely. It is also IP67 certified, which ensures that the device is dust tight and protected against temporary immersion. This makes the 3FG15 the perfect solution for CNC machine operation.

Results in workpieces processed in less time. Before the application was put into Employees now only need to load the operation, WEFAG and cobot solutions trays of the Easy Robotics Pro Feeder carried out various test runs. with the workpiece blanks and enter the “OnRobot let us use the gripper for necessary parameters in the software test purposes. This allowed us to test input screen. and validate the overall application The application then automatically beforehand,” said Jérôme Perdrizat, pulls out the trays of the Pro Feeder, development engineer, cobot solutions takes out the raw material and accurately AG. “The gripper’s firmware enables places it in the CNC machine. Once the various external interfaces. In this case, workpiece has been machined, the cobot we employ a serial communication arm removes the finished component interface, which allows us to use the from the machine with the help of the gripper in a very flexible manner. Since 3FG15 gripper and places it back in a free the gripper no longer needs to be set spot of the tray. manually, even employees with no prior “Thanks to automation, our processes knowledge can easily set up and operate are now much more efficient, and we the robot cell.” are able to reduce the workload of our To make the application even more employees. We expect the investment intuitive, cobot solutions developed to be paid off within a few months,” said software with input screens that can Hediger. be used to configure and automate a By employing the collaborative new task in just a few minutes. Thus, the application consisting of the Doosan application developed by cobot solutions robot arm and OnRobot 3FG15 offers a real added value for the robot gripper, WEFAG AG proved small and cell, including the initially mentioned medium-sized family businesses can small batch sizes. make production processes Once the application was up and substantially more running, it ran day and night to efficient using fully optimize the use of the automation. RR machines. This resulted in a significant increase The 3FG15 gripper is specifically

developed for machine-tending tasks and automatically centers workpieces, resulting in a strong, stable grip and precise placement in machine chucks. With a gripping force from 10 N to 240 N, the 3FG15 competes with much less flexible finger grippers. | Credit: OnRobot

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A system for general in-hand object re-orientation Model-free framework for robotic hand performs in-hand reorientation of 2,000-plus objects without prior knowledge of the object’s shape. By Brianna Wessling • Associate Editor

February 2022

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Most robotic end effectors don’t look or operate like human

hands. They’re designed for limited, specific purposes, and need to have intimate knowledge of the object they’re handling. Researchers at the MIT Computer Science and Artificial Intelligence Lab (CSAIL) are working to create a model-free framework for a robotic hand that performs in-hand reorientation of 2,000-plus objects without prior knowledge of the object’s shape. In-hand object reorientation has been a challenging problem in robotics due to high dimensional actuation space and the frequent change in contact state between the fingers and the objects. MIT’s learned policies show strong zero-shot transfer performance on new objects. There are two core frameworks at play in CSAIL’s program: studentteacher learning and gravity curriculum. Student-teacher learning is a training method in which researchers give a teacher network specific information about an object and its environment. The teacher learns information that a robot wouldn’t easily be able to gather in the real world, like the specific velocity of an object.

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The teacher then gives this information to the student in the form of observations that a robot could make in the real world, like depth images of an object and joint positions of the robot. The student network then has the ability to learn from those observations and apply those techniques to a number of objects. It was important to CSAIL’s team that a robot could handle objects with its hand facing upwards or downwards, which required extra training. Robots struggle to handle objects when having to counteract gravity and without the support of a palm under an object. Scientists taught the robot to counteract gravity gradually. First, they learned in a simulation without gravity. Then, researchers incrementally began to account for gravity, giving the simulation

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The Robot Report more time to learn how to hold objects even when gravity is at play. With these frameworks, researchers found that their program was able to learn strategies for holding and manipulating objects that don’t rely on knowing the specific shape of the object. “We initially thought that visual perception algorithms for inferring shape while the robot manipulates the object was going to be the primary challenge,” said MIT professor Pulkit Agrawal, an author on the paper about the research. “To the contrary, our results show that one can learn robust control strategies that are shape agnostic. This suggests that visual perception may be far less important for manipulation than what we are used to thinking, and simpler perceptual processing strategies might suffice.” CSAIL isn’t the first research lab to try to create anthropomorphic robot hands that operate like human ones. In 2019, OpenAI developed a program that trained

S U M M I T

a robot hand to solve a Rubik’s Cube. While other developers had already trained robots to solve Rubik’s Cubes in seconds, OpenAI looked to train one to solve it without already knowing all possible orientations and combinations first. OpenAI researchers hoped teaching a robot to solve a Rubik’s Cube could help it to develop dexterity that could be used in handling a variety of objects. However, OpenAI recently disbanded its robotics research team due to the lack of large enough data sets to effectively generate reinforcement models. CSAIL’s program was the most effective with simple, round objects, like marbles, with an almost 100% success rate. Not surprisingly, the program struggled the most with complex objects, like a spoon or scissors. The success rate for objects like these was 30%. CSAIL’s program operated entirely within simulated scenarios, but the researchers are optimistic the work can

be applied to real robotic hands in the future. “Our results show that model-free RL with simple deep learning architectures can be used to train policies to re-orient a large set of geometrically diverse objects. Further, for learning with the hand facing downwards, we found that a good pose initialization obtained from a lifting policy was necessary, and the gravity curriculum substantially improved performance.” “The most surprising observation is that information about shape is not required despite the fact that we train a single policy to manipulate multiple objects. Perhaps in hindsight, it is not as surprising – after all, humans can close their eyes and easily manipulate novel objects into a specific orientation.” RR

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DIGIT is a low-cost, compact, highresolution tactile sensor Meta (Facebook) designed for robotic inhand manipulation. | Credit: Meta

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Touch sensing technologies are quickly evolving to increase both the applicability and safety of cobots, especially for demanding applications that require handling delicate materials.

Tactile sensing provides advantages for cobots

Claudia Jarrett • EU Automation

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The first collaborative robot (cobot)

was manufactured in 1996. The system was designed for basic pick and place applications, and communicated with operators using motion resistance. Cobots have come a long way since that time, working safely with humans. They are able to detect objects and people in their environment using vision sensors, and can even slow down, or stop functioning, in case of an unintended contact. Modern cobots possess the ability to take corrective actions and minimize risks, but other sensing technologies, along with sophisticated so ware, allow them to do much more. For example, touch sensing technologies are quickly evolving to increase both the applicability and safety of cobots, especially for demanding applications that require February 2022

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The Robot Report handling delicate materials safely and precisely, such as healthcare. Tactile sensors Currently, there are several types of tactile sensors used in cobots, including piezoelectric, piezoresistive, capacitive and elastoresistivity types. Piezoelectric technologies are used for gathering data from the cobot’s joints and transmitting it to the controller. In contrast, capacity sensors can act as proximity sensors, allowing the cobot to slow down when it detects the presence of an obstacle. Although digital cameras have improved dramatically in the past decade, there has been remarkably little progress in tactile sensing since the 1980s. However, Meta (Facebook) recently launched a major initiative to develop tactile sensors using internal optics that are accurate, reliable, fast, and inexpensive. According to Ken Goldberg, William S. Floyd Jr. distinguished chair in engineering, UC Berkeley; co-founder & chief scientist, Ambi Robotics, the research community is excited to explore how Meta’s sensors could enhance robot manipulation. Preventing collisions For some applications, detection sensors are placed outside of collaborative robots. These devices are used to recognize human workers when they enter the workspace, signaling to the system to slow down or stop on those occasions. Although collisions can still happen, traditional cobot sensing modalities ensure that the impact is minimized. To improve the reliability (and hence safety) of collaborative robots, tactile sensors empowered with smart software can be embedded at the end of the cobot arm, which improves collision avoidance and increases movement efficiently. Precise object handling and more Touch sensors are also useful for applications requiring precise object placement, such as loading parts into a fixture for machine tending. The sensing technology can find the exact part location and correct changes in the position or size of the raw stock material by measuring the insertion force. Modern touch sensing systems use tactile sensors to capture information about an object in real time, such as its shape,

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The Robot Report size, and texture. The resulting data can then be used to produce a highly accurate description of objects, as well as the ability to recognize defects and changes. For example, early research from the USC Viterbi School of Engineering used embedded tactile sensors with conductive fluid to simulate human touch, resulting in a robot differentiating between the texture of wool and that of cotton. With a more effective sense of touch, cobots can also be used in applications where they interact with more fragile or deformable objects. For example, tactile technology in surgical robots can be used to enhance precision and accuracy. For this to be successful, multiple tactile sensors would have to be integrated using AI and machine learning.

increased productivity and efficiency for an increasing range of application types in an equally increasing number of markets. About the Author Claudia Jarrett is the country manager for industrial automation components supplier EU Automation. In that role she oversees the operations of the company’s affiliation in the United States, while helping to develop new business and deliver growth via a multi-channel approach that has a significant positive impact on business.

Physical sensations With state-of-the-art sensors, actuators and software, cobots are now capable of experiencing physical sensations, allowing systems to ‘feel’ and identify many classes of objects – hard, soft, rigid, flexible, etc. – in the process. Continuing tactile sensor advancements will allow cobots and humans to perform increasingly complex tasks while working in a collaborative manner. The result,

The DIGIT touch sensor is based on the GelSight style of sensor that was first conceptualized at MIT over a decade ago. | Credit: Meta

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It’s not a web page, it’s an industry information site So much happens between issues of R&D World that even another issue would not be enough to keep up. That’s why it makes sense to visit rdworldonline.com and stay on Twitter, Facebook and Linkedin. It’s updated regularly with relevant technical information and other significant news to the design engineering community.

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M o t i o n

C o n t r o l

Common applications for hybrid stepper motor linear actuators Integrated designs in motion applications offer a host of benefits

| istockphoto.com

across a range of applications.

Danielle Collins, Miles Budimir • Senior Editors

February 2022

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•• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• ••

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hen it comes to electromechanical linear actuators, integrated designs offer

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space savings, reduced complexity, and lower total cost of ownership with fewer parts required for repair or replacement. One such design that’s found multiple uses in medical, 3D printing, and assembly applications is the hybrid stepper motor linear actuator, which combines a ball or lead screw with a hybrid stepper motor. However, don’t confuse hybrid stepper motor linear actuators with can stack stepper motors linear actuators. The force vs. speed characteristics, efficiencies, and cost differences between actuators that incorporate hybrid stepper motors and those that use can stack stepper motors can be substantial, although each technology has unique strengths and best-fit applications. Hybrid stepper motor linear actuators — also referred to as linear hybrid stepper actuators and stepper linear actuators — offer a wide variety of options, not only in features such as custom machining and materials, but also in their basic

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The hybrid stepper motor linear actuator provides good force and speed capabilities with high positioning accuracy. | courtesy of ElectroCraft

Hybrid stepper motor basics Of the three primary stepper motor designs — permanent magnet, variable reluctance, and hybrid — hybrid stepper motors are arguably the most common in industrial applications, combining the best performance characteristics of permanent magnet and variable reluctance types. Hybrid stepper motors are constructed with a rotor made of two sections, or cups, with a permanent magnet between them. This causes the cups to be magnetized axially — with one cup polarized north and the other cup polarized south. The surfaces of the rotor cups have preciselyground teeth (typically 50 or 100 teeth per cup), and the cups are aligned with an offset of ½ tooth pitch between the two sets of teeth. In a hybrid stepper motor, the stator poles are also toothed, and when pulses are delivered to the stator by the stepper drive, these poles are magnetized, causing the rotor to turn so that the teeth of the rotor and stator align (N-S or S-N). This hybrid design — with teeth on both the rotor and stator — allows the motor to optimize magnetic flux, and therefore, produce higher torque than permanent magnet or variable reluctance designs. Hybrid stepper motors can also achieve step angles as small as 0.72 degrees in full-step mode and operate at higher speeds than other designs.

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design and operation. Case in point: There are three main types of hybrid stepper actuators — captive, non-captive, and external (also referred to as a motorized lead screw) — with some manufacturers offering additional variations for more specific uses. Below is a quick summary of each type:

• Captive: In this design, the lead screw nut is

integrated directly into the motor. The screw is connected to a spline shaft, so when the motor turns, the screw is prevented from rotating, and linear motion is produced, allowing the screw to extend and retract from one end of the assembly.

• Non-captive: In this type of actuator, the

ball or lead screw nut is integrated into the motor (or mounted to the face of the motor) and doesn’t travel along the screw. Instead, the screw must be prevented from rotating (typically by the attached load), and when the motor and nut turn, the screw travels linearly, back-and-forth “through” the motor-nut combination. Alternatively, if the screw is fixed so that it doesn’t travel, the assembly essentially becomes a driven nut design, where the motor’s rotation causes the motor-nut assembly to travel back-and-forth along the stationary screw.

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•• •• •• •• •• • • • • ••

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When it comes to electromechanical linear actuators, integrated designs offer space savings, reduced complexity, and lower total cost of ownership

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In a hybrid stepper motor, both rotor cups have teeth (red and blue) as do the stator poles (green).

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motor with a hollow shaft and integrate one end of the screw directly into the motor, so the nut remains external to the motor. Like a traditional screw-motor setup, the motor’s rotation causes the screw to turn, which advances the nut (and the load) along the length of the screw shaft. In this design, the opposite end of the screw (not attached to the motor) is unsupported, which is acceptable for light loads and short stroke lengths. However, many applications will require support for the free end of the screw, along with a linear guide to support any radial loads.

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M o t i o n

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The high positioning accuracy of hybrid stepper systems make them a good choice in CNC machines and 3D printers. | courtesy of Thomson

Like the stepper motors on which they’re based, hybrid stepper linear actuators are sized according to the NEMA ICS 16-2001 standard, which specifies the motor mounting dimensions, such as flange size and bolt circle diameter. The most common sizes for hybrid stepper actuators in general motion applications are NEMA 17 and 23, although some manufacturers offer sizes ranging from NEMA 8 up to NEMA 34. Because the NEMA standard doesn’t address the length of the motor, manufacturers can offer several torque ranges for the same NEMA frame size by increasing the stack length of the motor — in other words, multiple rotors and stators can be “stacked” in the same motor housing. The result is a motor

Precision metering and dosing pumps take advantage of the small footprint of hybrid stepper actuators. | courtesy of Thomson

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with the same frame dimensions (albeit slightly longer) that has higher torque and force capability. However, it’s important to note that in multiple stack stepper motors, torque production falls off more quickly as motor speed increases than in single-stack designs. For applications that can benefit from even further integration, with reduced complexity, assembly time, and cost, some manufacturers offer hybrid stepper linear actuators with drive electronics and controller functions integrated into the motor. And recall that hybrid stepper motors can operate with microstepping control for even higher resolution and in closed-loop mode when position feedback is required. With their wide range of designs and options, it’s not surprising that hybrid stepper motor linear actuators are used in all types of industries and applications. Here are a few examples of applications where these actuators excel, thanks to their compact size, precise positioning, and good speedforce characteristics. Precision metering and dosing pumps Whether for the medical, semiconductor, or assembly industries, hybrid stepper actuators are an ideal solution for driving small, precise pumps, thanks to their extremely compact footprint and ability to move at high speeds with high precision.

CNC machines and 3D printers Although one takes material off (CNC machines) and the other adds material (3D printers), both applications require high positioning accuracy and reliability — two performance areas where hybrid stepper motor actuators excel, especially when used with microstepping control in a closed-loop system. Diverting and sorting In conveyor applications, there are often stations that require diverting or sorting products for quality issues or manufacturing flow. In these applications, hybrid stepper linear actuators provide fast extension and retraction with good thrust force and simple controls. DW

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L i n e a r

M o t i o n

More on air bearings

in linear motion

As covered in a previous Design World article, air bearings are costlier than other options but average all surface imperfections along a bearing length — avoiding the detrimental effects of track deficiencies. Here we describe how to increase their stiffness. Danielle Collins • Lisa Eitel | Engineer editors

February 2022

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Air bearings are common on the stages of coordinate measuring machines or CMMs for precision inspection of machine metal parts. |Dreamstime

Air bearings impart a variety of benefits to precision

positioning machinery — including frictionless motion for negligible motion variability and hysteresis (reversal errors) as well as zero wear. A surface-averaging effect and controllable yaw, pitch, and roll render air bearings better at complementing precision actuation than linear bearings based on conventional mechanical designs. Of course, linear bearings are assumed to be those based on mechanical rolling or sliding elements. But linear (as well as rotary) bearings can use thin films of pressurized air to support a load. With no mechanical elements to generate friction or heat, air bearings are suitable for applications that require extremely high precision and stiffness. According to the American Society of Mechanical Engineers (ASME) stiffness is the capacity of a mechanical system to sustain external loads without excessive changes of its geometry (deformations). When engineers think of stiffness in traditional bearings with rolling elements, they typically conjure carriage deflection when a load is applied. For air bearings, which use a thin film of pressurized air to support the load, stiffness represents the bearing’s ability to maintain a consistent airgap — in other words, to resist changes in the airgap due to compression of the air

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caused by an applied load. Because air is a compressible medium, any change in loading will change the thickness of an air film between two surfaces — for air bearings, this means that an increase in load will cause a decrease in the airgap, due to the compression of air. Thicker airgaps are more compressible than thinner airgaps, so air bearings that are designed for high stiffness typically operate with extremely small airgaps, on the order of a few microns. In addition to the size of the gap, another factor that affects air bearing stiffness is compensation, which is the method by which airflow into the airgap is controlled. Compensation works to create a restriction of airflow thru the orifice and into the gap, before the restriction of the gap itself. This restriction provides a restoring force when a load is applied or increased, allowing the bearing to resist compression of the airgap due to the increased load. In other words, the restricted airflow through the orifice provides “reserve” pressure that can maintain the airgap when external forces attempt to compress it.

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Automatic coordinate measuring machine (CMM) |Dreamstime

Like rolling element linear guides, air bearings can also be designed with preload to increase stiffness. There are several methods for creating preload on an air bearing: adding mass (weight), applying a vacuum to the air bearing, installing magnets on the moving and stationary parts, and combining two opposing bearings to create preload between them. Regardless of the preloading method, the result is the same: as a load is added to the bearing, the airgap compresses and the pressure increases, and so does the stiffness of the air film. While it’s difficult to compare the stiffness of an air bearing with a rolling element bearing (due to functional and size differences), it’s important to note that the air film supporting the load in an air bearing provides a continuous area of support. In contrast, rolling element bearings — whether they use balls or rollers – rely on multiple, very small areas of contact to support the load. And the stiffness of a rolling contact bearing depends on several non-linear factors that are difficult to model or predict, whereas air bearings have very predictable, linear stiffness characteristics. Deeper dive on vacuum-preloaded air bearings Air bearings provide several advantages over rolling element bearings, including higher travel accuracy and reduced friction and heat generation. But because air is compressible, air

bearings can be less stiff and exhibit more deflection under load than similar rolling element bearings (although the stiffness characteristics of air bearings are very linear). However, the compressible nature of air can be used to create a preloaded air bearing, which increases its stiffness. Just as preload in a rolling element bearing is a load induced between a rolling element and its raceway, preload in an air bearing is a load induced between the bearing and its guide surface. There are four common methods for inducing preload on an air bearing: • By adding mass to the bearing • By applying a magnetic force • By applying vacuum • By mounting two air bearings facing each other on opposite sides of a guide surface. Regardless of the preloading method, as the load is applied to the air bearing (whether via added mass, opposing forces, magnetic force, or vacuum) the air film that supports the bearing compresses, the airgap gets smaller, the pressure in the air film increases, and the air film becomes stiffer. Each preloading method has advantages and drawbacks, but for applications where added mass would significantly compromise acceleration and settling times, where space constraints make it difficult to mount two air bearings in an opposing orientation, or where adding magnetic material

Shown here is a high-precision PIglide IS XY planar scanner from Physik Instrumente that serves as an alternative to stacked XY stages. The XY nanopositioning system has air bearings and a compact design to save space in machines with limited installation space. | Courtesy Physik Instrumente

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AIR BEARING OPERATION

AIR FED THROUGH POROUS MEDIA

AIR BEARING STIFFNESS • LOAD VERSUS LIFT FLAT AIR BEARINGS AT 60 PSI AND ON GRANITE SURFACE 1,750

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AIR FED THROUGH SHAPED ORIFICE

In air bearings, gas can be fed through orifices or through a porous media.

STIFFNESS (N/μm)

to the surfaces would be too costly, vacuum preloading offers a relatively simple solution that doesn’t add mass or require special assembly and mounting considerations. Although it might seem that air pressure and vacuum would work against each other, the level of vacuum used for a preloaded air bearing is relatively low compared to the bearing pressure, so the bearing is still lifted from the guide surface by the applied air pressure. To achieve preload, vacuum is applied to a portion of the bearing surface — typically the center portion. This means that the bearing pressure is applied around the perimeter, creating a seal to contain the vacuum area and prevent the vacuum from drawing in any contamination from the environment. A groove between the vacuum area and the bearing area is connected to ambient pressure and prevents flow between the exiting bearing air and the vacuum. The preload force is equal to the size of the vacuum area multiplied by the differential between the bearing pressure and the amount of vacuum. The pressure at the area where vacuum is applied is independent of the bearing flying height — the distance above the mounting surface. Therefore, preload remains constant even if the flying height changes. For example, if the flying height increases, the pressure in the bearing area decreases, so that the bearing experiences a higher pulling force (preload). This interplay between the air pressure and vacuum ensures an equilibrium between the preload force and the pressure for a given flying height. Not only do vacuum-preloaded air bearings have high stiffness, by adjusting the differential between the bearing pressure and the vacuum, the thickness of the air film — and in turn, the flying height — can be adjusted, making vacuum preloaded versions ideal for applications that involve ultra-fine, precise vertical positioning, such as lens focusing. DW

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Immersive Design— A virtual reality case study

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A new Adidas maker space—located inside a giant, digital sneaker — features virtual-reality 3D design tools for long-distance design collaboration. Jean Thilmany • Senior CAD Editor

When Adidas designers were tasked with

creating a seamless sneaker, they donned their Oculus headsets and got to work in the virtual world. The team met regularly in a large, footprintshaped studio that existed only in a virtual world entered through the Oculus. Of course, each team member was really in separate physical spaces, but with the help of the headsets and the immersive world, they felt as though they were meeting in real life. The move dramatically slashed time spent creating an initial mock-up: from 21 days to less than one day, says Paul Sholz, Adidas senior footwear designer. “In the design process, you create boards to inspire you and you brainstorm together. What we did in this virtual environment was the same, but we designed the actual product,” When Adidas designers he said. were tasked with creating Scholz and his colleagues spoke in a seamless sneaker, November 2021 at the online Around they donned their Oculus Conference. The conference sponsor, headsets and got to work in Gravity Sketch, makes a 3D-design platform the virtual world. hosted in virtual reality, which is the tool | Source: Gravity Sketch Adidas used to help design its Futurenatural shoes. The company gave the same name to its range of tools accessible within the immersive environment. DESIGN WORLD

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In what looks like a virtual reality game, designers move between a series of “stations” — the same way they would in any virtual reality game in which avatars work together.

The one-piece, seamless sneaker line just debuted, about 18 months after the design team’s initial virtual meeting. The Futurenatural sneakers are molded rather than sewn. That is, the upper is fused to the sole with high pressure and heat to create what looks like one continual shoe, with no obvious break between the top and the bottom. Traditionally, footwear designs often work in two-dimensions, extrapolating 2D lines to form lateral views of the proposed shoe. But buildingout designs in the 3D virtual environment makes a mockup materialize more quickly, said Robert Stinchcomb, Adidas creative designer. He played a lead role in bringing the virtual system into the company. “Now it’s down to showing up at work at nine and at 3 pm having a mockup at the point where you could see everything and talk about ‘let’s switch the layering here,’” Stinchcomb said. The mockup is an early-stage design “almost like a napkin sketch,” he added. “This is a place we sketch out designs before fleshing them out, before we make a sample. And we’re doing it in a room that is super collaborative where we can talk to each other even though we may not even be in the same country.” The team can quickly come up with 10 or 15 sneaker concepts, said Arnau Sanjuan, Adidas design director, footwear innovation. “It’s easy to see how designs would look, to play around with them, to brainstorm ideas together quickly,” he said. The Futurenatural studio looks much like a virtual reality game. Designers move about in the virtual world — moving between a series of “stations”— the same way they would in any

The Harden Vol. 5, the debut shoe in the Adidas Futurenatural line of molded, seamless sneakers. | Adidas

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virtual-reality game in which avatars work together. The first stop is for design. Here, designers create the 3D model of the shoe. Surfaces are added at a second stop. Then it’s on to detailing and rendering. All before a physical prototype is created. Because the shoe is easy to see and understand, the finished mockup can be immediately shared with manufacturers and marketing people for their feedback. They needn’t have an Oculus, as the designs can be captured and shared via other methods. Suggested changes are quickly made within the virtual environment. James Harden’s foot The mockup starts with the human foot. But for Futurenatural, the company took another tack. Like many shoemakers, the company had been using a generic last — the term for a 3D model of the foot — meant to represent the common sneaker wearer. For the Futurenatural line, Adidas wanted a better fit. Adidas scanned thousands of people’s feet, including those of professional athletes. Of course, the popular shoemaker already had prints of athletes who have promoted their own Adidas sneaker in the past. James Harden, basketball player for the Brooklyn Nets, is among those elite players. The Supernatural line debuted with the player’s fifth-signature basketball sneaker, the Harden Vol. 5. The engineers pulled together all types of feet — large sizes, small, narrow, wide, to best represent the foot. From that, they developed a new “last.” Designers make their first foray into the Gravity Sketch virtual environment to fit the last with experimental sneaker concepts. Here is where they play with articulated lines in the 3D environment, rather than extrapolating view and fit from a 2D print, Stinchcomb said. They can rotate the view to see how the shoe would look, from the top, bottom, and sides. DESIGN WORLD

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Designers wear Oculus headsets to design in 3D with Gravity Sketch software. They feel as if the design is floating in front of them, inside a virtual world, and they can easily make updates and changes to that design. | Gravity Sketch

At this first stop in their virtual environment, Stinchcomb and fellow designers work out new ideas for a sneaker’s footpad and play around with ways the upper might be molded and pressed. They sculpt arches and add padding to the sole in areas where the foot would benefit from reinforcement. Collaboration is a key part of this design, with the designers talking back-and-forth in the virtual world as they gesture at parts and play around together with design, Stinchcomb said. “We take a shoe and explode it and invite people into the space and spec out every single detail. We can blow it up to the size of warehouse and they can swim around the shoe, doing a deep dive on every part,” he said. “At such an early stage, we can discuss complex details within the form,” he added. In fact, these early iterations hold enough information to be fleshed out even further, which takes place at the next stage, or station: surfacing. This is where the skeleton comes together and where volumes are defined, Stinchcomb said. Here, designers wrap their shoe to simulate the material they have in mind for end use. At this step, they create a continuous, lifelike surface with the help of SmoothKit software to sharpen effects. The team also uses Adobe Substance Painter to “get the feel of the material” and to shade the image so it looks “as realistic as possible,” said Marius Jung, senior design. Because the footwear industry makes heavy use of Adobe Photoshop and DESIGN WORLD

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Illustrator, these new tools were a bit of a departure for the team, he said. “In the past, we’d spend hours creating the right shadows and lighting, and now we’re able to speed that up and dive right into detailing like we’ve never been able to before,” he said. When designers are satisfied with the shape and look of the shoe, they move to the next area within the virtual design space. At this juncture, they add details like laces and lace loops to their continuous surface. The team then renders the illustration with KeyShot software to give the image a photorealistic, lifelike quality. At this stage, the team can share the image with other Adidas departments, mainly marketing and manufacturing. These teams offer their suggestions long before a final virtual prototype, much less a physical prototype, is created, said Marius Jung, senior designer. Their input is important, because the Supernatural line is a step apart from the usual.

Designers need to know, and need to know early: can the manufacturer make a mold for this shoe using the designated materials? Will buyers be delighted or dismayed with this form for a new integrated sole? Members of those teams can be invited into the virtual world if they have access to an Oculus. If not, the images can be shared on a desktop, Jung said. Adidas worked with one of its factories to develop a new production process for the new shoe. During design, representatives from that manufacturer weighed in with tooling ideas. They also offered feedback about how they might produce the welting and lace loops. Marketers made suggestions on brand placement and other features. Mutual maker space The Futurenatural design team had been working together for almost a year in March 2020 when the COVID

Gravity Sketch makes a 3D-design platform hosted in virtual reality, which is the tool Adidas used to help design its Futurenatural shoes.

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better products. better solutions.

Modular Conveyors Piece and Product Handling Conveyors Pallet-Handling Conveyor Systems Since 1988 we’ve been providing not only a better product, but also a better solution for all types of design applications.

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pandemic forced many companies to move employees to home offices. Some engineering and design businesses stuttered a bit as they found new ways to collaborate outside an office. Even people regularly tied by collaboration software might have felt a hiccup as they accessed software on their home computers, in their home spaces. Meanwhile, the Adidas team stepped right back into their familiar space — the virtual office and maker space within the virtual shoe, said Arnau Sanjuan, design director of footwear innovation. “I’ve always been one to be in the workshop figuring things out with my hands and working with materials,” he said. “I found my work in 3D could replace those things. We work together in that world so closely.” Scholz too emphasized the inventive atmosphere that prevailed within the digital footprint. “The virtual space kept the creativity and the spirit alive during the pandemic,” he said. “It’s just a fun, intuitive and playful way to create serious products.” And that playfulness showed with the debut of the Harden Vol. 5 in January 2021 and the ensuing Futurenatural products, which feature polka dots, splotches and paint-like splurges in a number of patterns and colors, wavy soles, and an upper that melds seamlessly with the bottom of the shoe for an almost sock-like look. In the future, the line is expected to include more materials and new designs. The shoes will, of course, be designed within the digital shoeprint using Gravity Plus 3D design technologies. “The virtual reality system definitely demonstrated its value,” Sanjuan said. “Now everyone wants to try it. Because the learning curve is so easy, it’s spreading like wildfire to put 3D in anyone’s hands who wants it.” Those newcomers are welcome, he added. “Especially at a big, grand company like Adidas, it’s important to inject new processes into footwear and to look at things in a different way,” Sanjuan said. DW

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Mechanical lifting devices

get a modern drive technology upgrade Edited by Mike Santora

• Managing Editor

Oil and gas, grain and timber, iron ore, and coal — these are just a few of

the raw materials that keep the wheels of civilization turning each day. However, how they get delivered to the mills and refineries that convert them into usable products is something few of us give much thought. Kent Phillips does. The president and CEO of the Superior Lidgerwood Mundy Corporation (SLM Corp.), he and his team spend their days manufacturing a host of advanced equipment that makes barge traffic possible. Chat for a few minutes with Phillips or his brother Sean Tenerelli, responsible for commercial business development at SLM, and you’ll be left with the impression that this is a very young company, one filled with modern ideas and bold plans. In reality, the Superior, Wisconsin-based provider of winches, hoists, capstans, and barge positioning systems will soon celebrate its 150th birthday. SLM has been involved in the design and implementation of winch, capstan, and hoist solutions for the US government since the dawn of the war department. “Look at any of the military vessels built over the last 150 years, and the chances are excellent that you’ll see our equipment,” said Tenerelli.

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SLM synthetic rope barge breasting winch with NORD gearmotor at an inland grain elevator.

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SLM barge haul winch ready to position barges safely and accurately for loading grain.

SLM has been involved in the design and implementation of winch, capstan, and hoist solutions for the US government since the dawn of the war department.

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Despite this proud history — or perhaps because of it — SLM has begun to transform in recent years. After the retirement of several key employees, the company started looking for ways to combine their unique experience in mechanical lifting devices with modern drive technology. This includes state-ofthe-art control systems, hydraulicallyactuated leveling equipment, and automated solutions that make SLM products more cost-effective, reliable, and above all, safer. “To accomplish our goals, we had to find the very best drive technology available and the application support necessary to integrate it with our winches and hoists, said SLM’s engineering and external affairs manager Kenneth Behrman. The company turned to NORD DRIVESYSTEMS, a global mechanical and electronic drive technology manufacturer. “We soon found that

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NORD has both, with a broad product selection and excellent availability, and the price points we needed to be competitive,” added Behrman. One of the first examples of this collaboration was on a funicular hoist used to transport personnel to and from a hydroelectric dam located in the southeastern United States. SLM built the original system in 1912, and while it was still functional, the user asked that it be upgraded to modern operational standards. One of the challenges, however, was that the facility is protected by historic preservation laws, so the replacement equipment had to be minimally invasive. “To design a hoist that would fit into the original space but meet today’s much higher safety factors, SLM worked with NORD to design a CLINCHER gearbox paired with an open gearing set,” said Behrman. “CLINCHERs are typically used for agitators and mixers or conveyors, but the unit they DESIGN WORLD

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3D CG rendering of an artificial satellite.

recommended possessed the required characteristics for in-line operation with an open gearing set as well as the capacity to transmit the required power generation, all in a small footprint.” In another example, SLM addressed the need for more efficient and standardized barge positioning systems. Behrman noted that legacy positioners are often unique to each loading facility, based on decades-old technology that requires a high level of experience to operate. Given the current labor shortage and the fact that many dock workers are approaching retirement age, these skills are increasingly hard to find. What’s more, much of this work is manual — personnel must hoist heavy lines and walk along the sides of barges and docks, even in inclement weather. “It’s a difficult and unsafe job,” said Behrman. “Because of this, it’s tough to find people today that are willing to do it, and those who are willing are usually only familiar with whatever system they were trained on. We wanted to develop a standardized, largely automated system that someone can operate with minimal operator training.” Tenerelli agreed, noting that one of the primary challenges to these systems is to balance operational needs with a cost-effective solution. “We found early on that facility owners were asking for better safety and efficiency but usually balked at the price tag,” he said. “This led us to develop our S-Series of standard winches, which is NORD-based and offers a great ratio of cost, efficiency, and the desired safety improvements.” Engineering manager Behrman added to this, stating that “In this and countless other examples, NORD’s engineering team has provided sizing and application advice that keeps us on the forefront of design improvements. We are now able to apply gear motors in unique applications with the full support of the manufacturer’s engineering team, allowing us to offer solutions that most cannot.”

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To design a hoist that would ﬁt into the original space but meet today’s much higher safety standards, SLM worked with NORD to design a CLINCHER gearbox paired with an open gearing set.

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Similarly, operation of the tripper conveyors used at the tops of these grain, coal, and fertilizer facilities is not for the faint of heart. Here, a worker must manually engage a hydraulic clutch to activate a tripper device, dumping whatever material the belt is carrying into the elevator or railcar waiting below. When the tripper stops, the only thing holding it in place is a series of brakes that are notoriously unreliable given the extreme loads and extended service of such equipment. Adding even more risk to this scenario is that operators are often required to work hundreds of feet in the air, where any slip or equipment malfunction might send them toppling to a rapidly moving belt or the ground below. On top of this is the constant exposure to grain dust, which is not only hazardous to the workers’ lungs but is also explosive. “For us here at SLM, this sort of working environment is intolerable. But by using a pair of right angle, vertically-mounted winches equipped with the new gearboxes and an advanced positioning control system, we’ve developed a system that gives operators full control from a remote station. This eliminates the need for personnel to work on or near the tripper and provides much greater accuracy, avoiding the spillage that so often occurs with old-fashioned equipment,” said Behrman. “Whenever possible, we use completely enclosed gearing in our solutions. This decreases the possibility of human injury, drastically cuts maintenance and inspection time, and significantly extends equipment life. Because NORD products allow us to accomplish most of our solutions without open gears, chains, or belts, we’re able to provide offerings that are safer and have higher ROI than our competitors,” said Behrman. Phillips summarized the relationship with NORD as follows. “Around ten years ago, we made the decision to take all that we’d learned during our www.designworldonline.com

years working with the military and various government agencies and bring it to the commercial market. We wanted to have customizable solutions that are built off a standardized platform, giving us the flexibility to arrange everything the way we wanted and deal with different levels of geometry and environmental constraints, but without the need for a fully customized package.” DW

NORD | www.nord.com

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Product World Mini terminal blocks WAGO wago.us WAGO has expanded its TOPJOB S Mini terminal block series to include a version for 12 AWG. Like the rest of the Mini family, this version has all the advantages of the TOPJOB S terminal block line but comes in at a 60% smaller than the standard terminal blocks. The 12 AWG variant can operate at up to 600V and 20 A and has UL 1059 approval and AEx, ATEX, and IECEx for hazardous locations. Featuring the Push-in CAGE CLAMP connection technology used throughout the TOPJOB series, this Mini terminal block is available with an open tool slot or the easy-to-identify orange push buttons that can be actuated with any standard tool. It can also be mounted in various ways — miniature rail, snap-in mounting foot for chassis mount, or direct mount with fixing flange.

UV-cured acrylic adhesive Shurtape Technologies ShurtapeTech.com ShurGRIP UV-Cured Acrylic Adhesive is a new formulation explicitly designed to enhance the performance and longevity of materials used in the building envelope — including flashing tapes, water-resistive barriers (WRBs), sheathing, and roof underlayments. Designed to help improve the durability and energy efficiency of the buildings where it's used, the new ShurGRIP UV-Cured Acrylic Adhesive is a solvent-free acrylic adhesive formulated to provide an exceptional bond to an array of building materials and for high performance in any climate. It has excellent cold-temperature performance, including primerless adhesion to exterior glass-faced gypsum, plywood, and OSB at 0 F (-18 C), making installation easier, faster, and less susceptible to delays due to inclement weather.

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Product World Operator terminals Rockwell Automation rockwellautomation.com/en-us PanelView 5510 terminals now support up to 500 screens, display video, and other content following Studio 5000 View Designer software updates. Machine builders can now create more advanced humanmachine interface (HMI) applications on the PanelView 5510 operator terminals from Rockwell Automation. New versions of the Studio 5000 View Designer software and PanelView firmware expand the amount and types of information provided on PanelView 5510 terminals. A new web browser functionality allows the PanelView 5510 operator terminals to support a broader range of content. For example, they can now display videos to show operators how to perform certain production tasks. They can show IP camera feeds to give operators visibility into locations like the remote or dangerous areas of a facility. And they can display content like hyperlinked help files and online scheduling systems. The PanelView 5510 operator terminals can now support up to 500 screens. This can help machine builders create a wide range of screens for setup and operation activities for more complex applications. Users will also see design time and runtime performance improvements, like the ability to switch between screens up to two times faster.

Timer relays AutomationDirect automationdirect.com The ProSense T2 series of multi-mode, on-delay, offdelay, fleeting, and on-interval timer relays have a compact design with easy-to-use potentiometers, rotary switches, and DIP switches for selecting time delay functions and timing ranges. The T2R-M series multi-mode timer relays provide four functions in one unit, including on-delay, off-delay, interval, and single-shot with timing ranges of up to 1000 minutes. The T2R-ND on-delay, T2R-FD off-delay, and T2R-SST fleeting timer relays are encapsulated to protect internal components and have timing ranges of up to 100 minutes. These timer relays all have 10A SPDT relay output contacts that can handle most pilot duty and fractional horsepower loads. The T2L-ND on-delay timer relays are encapsulated and offer timing ranges of up to 100 minutes or 10,230 seconds. The T2S-ND on-delay, T2S-FD off-delay, T2S-SST fleeting, and T2S-TT on-interval timer relays have timing ranges of up to 100 minutes. These timer relays feature a 1A continuous/10A inrush solid state relay output suitable for high duty cycle and long-life applications.

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AC laminated frame ABB global.abb/group/en Baldor-Reliance industrial electric motors are available for most generalpurpose applications and processes. However, some AC Variable Speed applications require high-performance capabilities, including constant torque down to zero speed, wide constant horsepower range, high response applications that require low inertia rotors, or high-speed capabilities. The RPM AC motor is most suitable for tough variable speed industrial applications where high performance and power density (compact size and weight) are most important. RPM AC laminated frame motors are available in both standard induction and high-density Interior Permanent Magnet (IPM) versions. Features

• Extensive HP range (up to 1750 Hp or 1305 kW) • Square laminated steel frame • Wide CT (constant torque) speed range is standard; wide CHP (constant Hp) is available • Power Density: up to 3 frame sizes smaller than traditional AC motors • IPM rotor design delivers IE5 level efficiency

HMI software platform Adisra adisra.com/download/ ADISRA SmartView V4.0 Service Pack 1 (SP1) is a human-machine interface (HMI) and supervisory control and data acquisition (SCADA) package designed for machine builder OEMs and discrete part manufacturers to develop effective interfaces for monitoring and analyzing machine operation. SP1 adds a host of development and usability features, making it even easier for users to create applications with greater flexibility. SmartView already delivers a comprehensive and easy-to-use development environment. New development enhancements include templating functionality supporting re-use of advanced graphic objects and screens across multiple applications and the added flexibility of using tags to dynamically adjust the file and pathnames for recipes and reports. The display resolution of an application is now easily changed to match any target deployment. Screens can now incorporate animated GIFs, improved button functionality for screen navigation, an added corner radius property for many graphic objects (used for creating a more organic look), and a new MultiTagViewer object for conveniently displaying array data based on offset and size. There are now built-in statistical process control functions for visualizing the min, max, median, and standard deviation of tags within trend objects. Alarm objects are now even easier for users to configure.

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Ad Index AllMotion ........................................................................ 4 Altech Corporation ........................................... 1,18,19 APEC 2022 ...................................................................41 Automation Direct .................................................. IFC Bay Associates Wire Technologies, Inc. ..........25 Bodine Electric Company ......................................35 Canfield Connector ..................................................30 Clippard ....................................................................... BC CMT ..............................................................................23 CS Hyde .......................................................................43 Del-tron ........................................................................83 Digi-Key Electronics ................................................... 11 Dodge Industrial ......................................................... 7 Dorner .......................................................................... 99 Exair Corp ...................................................................... 5 Interpower ............................................................. 27,85 Keystone Electronics Corp ..................................... 3 mk North America, Inc. .......................................... 94 Novotechnik ................................................................. 9 OKW Enclosures, Inc. ...............................................13 PBC Linear ..................................................................33 Permco ....................................................................... IBC Pyramid Inc. .................................................................31 ROLEC Enclosures, Inc. ........................................... 17 Smalley Steel Ring ....................................................12 Trim-Lok ........................................................................21 Whittet-Higgins ..........................................................15 Zero-Max, Inc. .............................................................. 2

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LEADERSHIP TEAM

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World - February 2022 www.therobotreport.co m

Follow the whole team on twitter @DesignWorld

The Robot Report

Swiss m anufacturer automates CNC machin e

AHS1 ..................................................................... 74 CGI Inc. ................................................................70 Chieftek Precision ...........................................60 FESTO ................................................................... 71

tending

INSIDE: • Why component makers should target cobots ............... 54 • A system for general in-hand object re-orientatio n ....... 64 • Tactile sensing provides advantages for cobots .............. 68

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Honeywell Intelligrated Corp ...........77 (online only)

OnRobot three-finger

gripper

and Doosan collabor ative robot make production processe s more efficient for family-o wned business. page 58

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maxon .................................................................. 57

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New England Wire & Tubing Technologies ................................ 72

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DESIGN WORLD (ISSN 1941-7217) is published monthly by: WTWH Media, LLC; 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Periodicals postage paid at Cleveland, OH & additional mailing offices.

Techman Robot, Inc. ......................................67

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numbers don’t lie

72 PERMCO 2-22.indd 1

108 YEARS operating continuously as a family business 72 YEARS providing hydraulic pumps, motors and accessories #1 QUALITY #1 DEPENDABILITY

#1 RELIABILITY #1 CUSTOMER SERVICE

If you like our numbers, you’ll love our products. Contact us now for a distributor near you. permco.com | (800) 626-2801

Home of the American Champ 1500 Frost Road Streetsboro, OH 44241

2/9/22 9:12 AM

Take Control with Cordis E L E C T R O N I C P R E S S U R E R E G U L AT I O N

• Resolution ≤5 mV • Accuracy ±0.25% of full scale • Real-time adjustable PID control • Integrated 0 to 10 VDC, 4-20 mA signal, or 3.3 VDC serial communication

The future of proportional control has arrived— and it’s digital. The Clippard Cordis is a revolutionary microcontroller primed for escape velocity from a proportional control market that has grown stagnant. With unparalleled performance and flexibility not possible with current analog proportional controllers, the Cordis makes everything from calibration, to sensor variety, to future development opportunities more accessible and less complicated.

• 0 to 10 VDC feedback pressure monitor • Virtually silent • No integral bleed required • Multiple pressure ranges from vacuum to 150 psig • 2.7 to 65 l/min flow control

Precise, Linear Digital Pressure Control Contact your distributor today to learn more about how the Cordis can provide precise, real-time control for your application, or visit clippard.com to request more information.

877-245-6247 CINCINNATI • BRUSSELS • SHANGHAI

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