Design World January 2018 main issue

Page 1

January 2018



in Engineering JAN 2018 COV_FINAL.indd 1

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I n s ights




your engineering career

For this year’s Leadership in Engineering profile, I spoke with Jabil CEO

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Mark Mondello (see the feature story in this issue) about his company’s culture and vision. With something like 43,000,000 sq-ft of manufacturing footprint spread across the world, Mondello, who’s an ME himself, employs a heck of a lot of engineers. So, knowing how in touch he is with the changing world of manufacturing, I was interested to hear how he’d suggest current engineers and engineering students properly future-proof their careers. Mondello told me that in addition to gaining knowledge around technology, design or various engineering platforms, engineers also need to take time to complement some of their innate strengths with understanding a little bit about how business works—and to develop good written or verbal communication skills. “I see engineers with just fabulous ideas, and yet sometimes they just can’t quite articulate what they’re trying to say in a real efficient way,” he said. He also thinks that it’s important for them to realize that there are no more geographic limits in the world when it comes to business or life. “I think geographic bounds are there for politics and religion and all the things that geographic boundaries provide. But in terms of design, in terms of technology, in terms of business, in terms of life, we’re noticing more and more that the geographic boundaries are disappearing,” he said. “I think to be successful, to be fulfilled, the engineering community needs to be open to traveling, to getting out and about and seeing what’s out there, to being comfortable around lots of different cultures and lots of different people, and be open-minded about those cultures and those people.” Mondello also noted that he sees a lot of engineers who have very strong opinions, and a lot of those opinions are certainly well grounded in scientific fact. Yet, constantly holding on to those strong opinions can have a negative impact on how open individuals can be to change. “Change is exponential, so you’ve got to be open-minded to it,” he said. “You’ve got to be open-minded to new ideas because there’s a high probability that whatever products you’re working on today, tomorrow they’re going to be obsolete. And this will happen at a rate much faster than it was historically. Be open-minded to the rate at which everything is changing around you—that would be a good start.” DW

Paul J. Heney - VP, Ediitorial Director On Twitter @ DW—Editor

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

(408) 460-1345

4 January 2018 DESIGN WORLD Insights 1-18_Vs1.indd 4

1/29/18 1:55 PM

The Truth About Compressed Air! If you think compressed air is too expensive and noisy - read this. The facts will surprise you!

Compare these Blowoffs

There are a variety of ways to blow the water from the bottles shown in the photo below, but which method is best? To decide, we ran a comparison test on the same application using four different blowoff methods: drilled pipe, flat air nozzles, Super Air Knife (each using compressed air as a power source), and a blower supplied air knife (using an electric motor as a power source). Each system consisted of two twelve inch long air knives. The following comparison proves that the EXAIR Super Air Knife is the best choice for your blowoff, cooling or drying application. The goal for each of the blowoff choices was to use the least amount of air possible to get the job done (lowest energy and noise level). The compressed air pressure required was 60 PSIG which provided adequate velocity to blow the water off. The blower used had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM. The table at the bottom of the page summarizes the overall performance. Since your actual part may have an odd configuration, holes or sharp edges, we took sound level measurements in free air (no impinging surface).

Drilled Pipe

Blower Air Knife

This common blowoff is very inexpensive and easy to make. For this test, we used (2) drilled pipes, each with (25) 1/16" diameter holes on 1/2" centers. As shown in the test results below, the drilled pipe performed poorly. The initial cost of the drilled pipe is overshadowed by its high energy use. The holes are easily blocked and the noise level is excessive - both of which violate OSHA requirements. Velocity across the entire length was very inconsistent with spikes of air and numerous dead spots.

The blower proved to be an expensive, noisy option. As noted below, the purchase price is high. Operating cost was considerably lower than the drilled pipe and fl at air nozzle, but was comparable to EXAIR’s Super Air Knife. The large blower with its two 3" (8cm) diameter hoses requires significant mounting space compared to the others. Noise level was high at 90 dBA. There was no option for cycling it on and off to conserve energy like the other blowoffs. Costly bearing and filter maintenance along with downtime were also negative factors.

Flat Air Nozzles

EXAIR Super Air Knife

As shown below, this inexpensive air nozzle was the worst performer. It is available in plastic, aluminum and stainless steel from several manufacturers. The flat air nozzle provides some entrainment, but suff ers from many of the same problems as the drilled pipe. Operating cost and noise level are both high. Some manufacturers off er fl at air nozzles where the holes can be blocked - an OSHA violation. Velocity was inconsistent with spikes of air.

The Super Air Knife did an exceptional job of removing the moisture on one pass due to the uniformity of the laminar airflow. The sound level was extremely low. For this application, energy use was slightly higher than the blower but can be less than the blower if cycling on and off is possible. Safe operation is not an issue since the Super Air Knife can not be dead-ended. Maintenance costs are low since there are no moving parts to wear out.

Facts about Blowers

Energy conscious plants might think a blower to be a better choice due to its slightly lower electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of filters, belts and bearings. Here are some important facts: Filters must be replaced every one to three months. Belts must be replaced every three to six months. Typical bearing replacement is at least once a year at a cost near $1000. •

Blower bearings wear out quickly due to the high speeds (17-20,000 RPM) required to generate effective airflows.

Poorly designed seals that allow dirt and moisture infi ltration and environments above 125°F decrease the one year bearing life.

Many bearings can not be replaced in the field, resulting in downtime to send the assembly back to the manufacturer.

Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air volume and velocity are often difficult to control since mechanical adjustments are required. To discuss an application, contact: EXAIR Corporation 11510 Goldcoast Drive Cincinnati, Ohio 45249-1621 (800) 903-9247 Fax: (513) 671-3363 email: See the Super Air Knife in action.

The Super Air Knife is the low cost way to blowoff, dry, clean and cool.

Blowoff Comparison Type of blowoff



Horsepower Required

Sound Annual Purchase Approx. Annual First Year Level Electrical Price Maintenance Cost Cost dBA Cost*

Drilled Pipes



174 4,924







Flat Air Nozzles



257 7,273







Blower Air Knife











Super Air Knife











*Based on national average electricity cost of 8.3 cents per kWh. Annual cost reflects 40 hours per week, 52 weeks per year.

Exair 1-18.indd 5

1/19/18 11:08 AM

Teschler on Topic Cheap laughs: Looking inside public

recycling containers Ready for a few laughs? Peek into a recycling bin sometime. The experience can be entertaining if you are amused by widespread misperceptions of what constitutes recyclable material. Take one glance inside a recycling container and you’ll probably conclude that the public is clueless about materials that can’t be recycled. For example, your average receptacle for recyclables in an airport or shopping mall is likely to contain a lot of polystyrene cups. Though strictly speaking PS can be recycled, the process is so fraught with difficulties that it almost never happens. Among the reasons: PS can’t be reground and remolded without degrading. Additives and fillers prevent its direct recycling, and contamination with food greatly complicates any efforts aimed at reuse. Obviously, PS foam is also light and bulky, so a little bit of it takes up a lot of space. An eighteen-wheelerload of the stuff doesn’t contain all that much real material, resulting in transportation costs that are through the roof. Consequently, little of the PS thrown away escapes landfills.

But for real hilarity, try walking into a Starbucks and looking at what coffee drinkers think can be recycled. Note to caffeine addicts: Pitching coffee cups in the recyclable bin doesn’t mean they will be recycled. The problem is that the paper cups used by Starbucks (and by many fastfood establishments) are lined with a thin layer of polyethylene plastic. At paper mills that recycle paper, the plastic coating breaks up into large flakes that pass through coarse pulping screens but clog fine screens. The filter clogs are problematic, so most paper mills send the cups to landfills automatically. Published reports say that only three of the 450 paper recycling mills in the U.S. can handle plastic-coated paper. Starbucks management is well aware that its cups generally can’t be recycled – it has conducted programs at least back to 2008 aimed at making them recyclable. For a variety of reasons none of these efforts, or similar efforts undertaken by materials producers, have panned out. Consequently, most paper cups are just trashed. Unfortunately, the fun of ridiculing people who put goofy stuff in recycling bins is coming to an end. That’s because nearly all the debris in recycling bins – even the polyethylene terephthalate

(PET) and polyethylenes which are quite recyclable – is now likely to wind up in landfills. The reason is a change in policy by China. That country has been the largest global importer of recyclable materials. Much of the recyclable material generated in the U.S. has wound up being shipped there. Now, China has banned imports of 24 categories of recyclables and solid waste. And there isn’t much of a domestic market for all the recyclable plastic we generate. That situation may eventually change. Researchers writing in a recent issue of Science Magazine point to recycling-friendly developments in the works ranging from plant-based plastics, to better ways of depolymerizing plastics, to polymer designs that more readily degrade in the environment. But the authors make it clear none of these improvements will happen anytime soon. So until we reach that golden age of recycling, the most pragmatic strategy seems to be this: Just throw your debris in whatever waste receptacle is the least full, regardless of whether it has a recycling label affixed. DW

Leland Teschler • Executive Editor On Twitter @ DW—LeeTeschler


January 2018

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Technology Forward

The case for How fast could additive technology be to deliver parts? The research is just getting started. The promise of different ways to make designs is spurring innovative development. Lawrence Livermore National Laboratory, for example, is experimenting with laser holograms and special liquid materials to build parts faster in what is being called volumetric 3D printing. A special photosensitive resin solidifies when exposed to three laser light beams, enabling the build of a 3D structure in seconds. The researchers have printed planes, struts at arbitrary angles, lattices, complex, and uniquely curved objects. The three laser beams define the object’s geometry from three different directions. The laser beams activate simultaneously and where they intersect is where the resin solidifies, forming the desired shape. Benefits of this technique: it eliminates the layer-by-layer process common to 3D printing, and the mechanical and directional weaknesses inherent in layer-bylayer. Drawbacks: right now, laser hologram parts lack smoothness. There are restrictions to part resolution, and some geometries are not suitable for this method due to the intersecting laser beams.


Bonus: Volumetric 3D printing should work very well in zero gravity. Of course, this research is new and will likely require improvements in resin properties to enable wider use. Researchers at MIT are working on an opportunity they call Rapid liquid printing (RLP). This method was developed to address the needs of large-scale builds. A robotic aperture draws a 3-dimensional object in a tank filled with a gel. The gel suspends the extruded material, which eliminates the need for a base plate for the build. Support structures are also not needed. Two materials are mixed in the nozzle and chemically cure upon extrusion. Initially, this method was used to build pieces of furniture. BASF and Xaar, a world leader in industrial inkjet technology, are collaborating on a Photopolymer Jetting (PPJ) process. Here, special photopolymers are deposited by jetting droplets onto a build platform and cured using a UV light source. This process is repeated layer-by-layer, using part and support photopolymers to create the intended 3D object. Special printheads deposit up to 20 l/hr with addressability of 720 dpi.

Are similar speed improvements possible for extrusion based 3D printers? It turns out that researchers are looking into this. As electromechanical systems, the speeds possible with extrusion 3D printers are limited to the amount of vibration the unit experiences during operation. The faster the machine moves, the more vibrations the machine creates, forcing a slow down in print speeds to have a reasonably smooth finish. But researchers at the University of Michigan report on a way to potentially enable higher print speeds. They have developed a software algorithm that uses knowledge of the printer’s dynamic behavior to anticipate when it may experience excessive vibration. The software then compensates for the motions, enabling faster speeds. Through the use of this algorithm, 3D printers deliver “high-quality results at speeds up to two times faster than those in common use, with no added hardware costs.” Developments in ways to make parts faster will be a theme throughout 2018. Stay tuned. DW

Leslie Langnau • Managing Editor On Twitter @ DW_3Dprinting


January 2018

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Green Engineering Paul J. Heney

• Editorial Director

Can spuds become the new friendly paint?

In the future, indoor aluminum surfaces might be cost-effectively coated with paints based on potato starch. | Copyright Fraunhofer IAP

For surfaces that need corrosion protection, 80% of the time that’s accomplished through a paint or varnish coating. Unfortunately, the proportion of bio-based, environmentally friendly solutions in this space is quite small. Researchers at the Fraunhofer Institute for Applied Polymer Research IAP, in cooperation with the Fraunhofer Institute for Manufacturing Engineering and Automation IPA, are looking to close this gap and are developing a cost-effective coating based on renewable raw materials. And the surprising focus of their research? Potato starch. In Germany alone, 100,000 tons of coating materials for protection against corrosion are produced every year. However, paints and varnishes with bio-based binders or film formers have usually been too expensive or could not meet green requirements. But through the use of modified starch, scientists at Fraunhofer IAP have found a sustainable and cost-effective solution. “Until now, traditional industrial fields of application of starch have been the paper/corrugated cardboard and 12

adhesives industries,” said Christina Gabriel, a scientist at the Fraunhofer IAP in Potsdam-Golm. “In the field of paints and varnishes on the other hand, starch was usually only used as an additive. With starch as the main component of a water-based dispersion, we now have very promising adhesion results.” “Film formers must fulfill several tasks. They must form a continuous film, which adheres well to the substrate material, is compatible with additional layers and additives and can embed pigments and fillers as well,” said Gabriel. “In its natural form, however, starch exhibits several properties, which stand in the way of its use as a film former. For example, it is not soluble in cold water and neither does it form continuous, non-brittle films. We therefore had to modify the starch to adapt it to the requirements.” The solution, which involves esterification, results in starch esters that are dispersible in water, form continuous films and have very good adhesive properties on glass and aluminum surfaces. In cooperation with the Fraunhofer IPA, the esterified starch

January 2018

Green Engineering 1-18 Vs2.LL.indd 12

is then “cross­linked,” through which the sensitivity of the coating to water is reduced further. Tests check the long-term stability of coated materials by exposing them to rapidly changing temperature cycles in a time-compressed form—this simulates the day/night cycle and the seasons. Test objects are also exposed to electrolyteenriched water to see how the coating reacts to water—and how resistant it is under extreme conditions. New “recipes” are also being tested, so as to optimize the properties of the coating even further. “Apart from the already tested aluminum, two other important metals, steel and galvanized steel, are to be tested,” said Gabriel. “Our investigations show that with its good film forming and very good adhesion properties on various substrates, starch esters have the potential to be future alternatives to petroleum-based film formers in the coatings industry.” DW


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Contents 1 • 2018

vol 13 no 1

2018 Leadership


Pages 271-509

| Courtesy of Dorner




How to design quiet gearmotors

How to choose pneumatics in food and beverage processing

Counterfeit bearings: what to expect in 2018

What applications need quiet gearmotors? The answer might surprise you.

102 _MOTION CONTROL Customizing conveying systems

As more companies look to automate processing lines, they’re relying on conveyor manufacturers for an assist.

110 _LINEAR MOTION PID design using frequencydomain methods

With motion control applications, a PID controller is often implemented using tuning or by trial-and-error.

116 _INTERNET OF THINGS 3 trends in development for the IIoT

Despite the buzz about the IoT and the IIoT, the development of tools and programs for IoT systems and equipment are still embryonic. But there are signs of progress.

With issues such as temperature extremes, washdown capabilities and cleanliness considerations, components for this industry must be thoughtfully selected.

Year over year, the threat of counterfeit bearings remains persistent. But for the last two years bearing manufacturers are getting better at targeting counterfeiters.



How the Industrial IoT is transforming industry

Making connections in harsh places

IoT may be the “latest” big thing, but that doesn’t mean it’s accepted by customers. Here are tips on building a business case for IoT projects.

138 _ELECTRONICS Will your next circuit board come out of a mold?

Several manufacturers are exploring molded plastic and other odd-ball substrates for circuits as a way to simplify product designs and cut costs.

Connectors must meet certain criteria to survive the most extreme environments.

168 _LEADERSHIP The Importance of flexibility— Mark Mondello, CEO, Jabil Inc.

A look at how a thoughtful mechanical engineer keeps bureaucracy at bay and his company flexible.

How will engineers address the technical challenges of 2018? |


January 2018

CONTENTS 1-18_Vs3.LL.indd 14

A | S | B | P|E

A | S | B | P|E

American Society of Business Publication Editors

American Society of Business Publication Editors

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08 Technology Forward


12 Green Engineering 22 Design For Industry

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CONTENTS 1-18_second page_Vs1.indd 17

January 2018

17 Call: 1 203 756 7441 © 2017 by AMETEK Inc. All rights reserved.

1/22/18 1:38 PM


Follow the whole team on twitter @DesignWorld



VP, Editorial Director Paul J. Heney @dw_editor Managing Editor Leslie Langnau @dw_3dprinting

Your Problems

Executive Editor Leland Teschler @dw_leeteschler

With 164 different modules that connect to create a Cube67+ system, Murrelektronik can turn your problems into solutions. Cube67+ allows for absolute flexibility in system design while our One Cable Technology for bus & power saves time & money during installation.

Senior Editor Miles Budimir @dw_motion Senior Editor Lisa Eitel @dw_lisaeitel

Our Solutions Digital Input

Senior Editor Mary Gannon @dw_marygannon Associate Editor Mike Santora @dw_mikesantora

Digital Input/Output

Director, Audience Development Bruce Sprague Safety Output

Analog Input or Output

VP, Creative Services Mark Rook @wtwh_graphics Art Director Matthew Claney @wtwh_designer Graphic Designer Allison Washko @wtwh_allison Traffic Manager Mary Heideloff Production Associate Tracy Powers DIGITAL MEDIA/WEB/ DEVELOPMENT

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January 2018


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Ready for the Next Servo Revolution?

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Spanish aerospace engineering and production specialist, Indaero, manufactures aircraft panels for key customers such as Airbus and its suppliers, offering a comprehensive range of services including design, engineering, tooling, welding and painting. With much of the competition limited to only a few services, the company invested in a Stratasys Fortus 450mc Production 3D Printer. The move has enabled Indaero to extend its offering into lightweight, complex tools that cannot be produced with traditional manufacturing, further differentiating itself as an end-to-end design to production service. “Aerospace is unlike other industries, producing high volumes of tools,” explains Darío González Fernández, CEO of Indaero. “To traditionally manufacture production tools, injection molding or CNC machining would be used, but this would be very time-consuming and costly. With our Fortus 450mc 3D Printer, we can service low-volume production quickly and cost-effectively, producing many different tools on-demand to accelerate the manufacturing process and ensure we meet customer delivery deadlines.


“The importance of the ULTEM 9085 material cannot be understated either,” he continues. “It has become an integral part of our production process, as it is certified for aerospace and well known by our customer Airbus for a number of aircraft applications. With its unique combination of high strength-to-weight ratio and FST (flame, smoke, and toxicity) certification, we can 3D print robust, lightweight tools and respond to short run production of flying parts if required – giving us a unique advantage versus competition.”

January 2018

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1/20/18 3:24 PM


The Fortus 450mc 3D Printer is used by Indaero to manufacture several production tools. Crucial to achieving this is the ability to quickly design and produce complex curved geometries that perfectly fit the intricate shapes of the aircraft panels. Previously, the company was limited to producing flat shapes with traditional methods, which affected the performance of the final tool during affixation to the panel by workers. “The 3D printer has been a gamechanger for us,” says González. “The ability to 3D print curved production tools in robust materials made us realize the importance of having tools that perfectly fit the panels. Not only does it make the work of our operators much easier, it frees up resources and increases our overall productivity. This improvement was immediately recognized by a number of leading Airbus providers such as Aernnova, who previously worked with our competitors and whose business we have subsequently secured.” This is being exemplified through the company‘s work for Aernnova where the Fortus 450mc 3D Printer is being used to optimize a series of production tools for the manufacture of an Airbus NH90 Helicopter. In particular, a 3D printed manufacturing tool to fix a slide box onto the interior panel of the helicopter wing. Traditionally, an aluminum tool weighed twelve kilos and required two operators to hold it against the panel while marking the drill holes. With the complex geometries achievable with 3D printing, the team redesigned the tool with a curvature perfectly fitting the panel structure. As a result, Indaero provided


DFI 1-18_Vs4.LL.indd 23

Aernnova with a new, more effective tool, nine kilos lighter than its predecessor and capable of standing on its own. “Integrating FDM 3D printing within production tooling for this project is delivering several clear benefits,” explains González. “Firstly, from a resource perspective there’s now no need for two operators as the tool fits against the panel independently – leaving one operator to position the slide box with both free hands. Secondly, we can produce a lightweight and robust tool 66% faster than with CNC machining. As a result, this part of the project is being completed ahead of time, leading to a reduction in manufacturing cost of over 50%. The customer response has been fantastic.” Andy Middleton, President EMEA, Stratasys, concludes: “FDM has long been an additive technology of choice for the aerospace industry, particularly for customized tooling applications. Companies such as Indaero are leveraging high-performance materials, such as ULTEM 9085, to produce lighter weight, better performing tools on the production floor in less time and cost. It’s no surprise that these future-ready companies are improving business performance as a result.” DW


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January 2018

Phone (800) 528-8650 23

1/22/18 9:08 AM


Design for Industry Aerospace/military

Powering surveillance


The challenge for most battery manufacturers, particularly with military

LEMO Connectors are the Perfect Choice for Industrial Applications. Key Features:

devices, is that the final product needs to be compact without jeopardizing the quality of the power supply. The Lithium Thionyl Chloride M1 battery is helping military device manufacturers develop longer-lasting products. The battery is lightweight and can be used in remote sensing and surveillance applications. There are three variations of the M1 battery ranging in size and weight from 3.3 kg to 10 kg. A soldier’s kit can weigh anything between 40 kg and 80 kg, so the M1 battery can be attached to armoury without impacting the soldier’s speed or performance. This factor is critical to the development of batteries for military devices. The range also features an integrated one-meter length cable that can be used to connect the battery to the device. Depending on operational requirements, this allows the user to bury or covertly position the device so that the battery is easily accessible, making it easy to locate in necessary circumstances. Soldiers need their batteries to perform for extended periods of time and under challenging conditions. The temperature and operating voltage has been traditionally known to affect the performance and runtime of Lithium Ion batteries. The Lithium Thionyl Chloride chemistry used in the M1 range, however, is resilient in humid and arctic conditions. The batteries have been created at a time where remote sensors and surveillance systems or drones are more commonly used. It’s reported that $90.67 billion dollars was spent on command and control, communication, computer, intelligence, surveillance and reconnaissance (C4ISR) and electronic warfare systems in 2016. DW

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Design for Industry Food/beverage

Brushless dc drives offer efficiency,

performance and durability

A brushless dc drive is a type of adjustable-speed drive required by electrically commutated motors (ECMs), such as brushless dc, to control motor speed and torque. Providing benefits such as precise speed regulation, quiet operation, twoquadrant direction control, braking, high duty cycle reliability and reduced energy consumption, Brushless dc drives are suitable for gearmotors powering machinery in a range of sectors – including critical application medical equipment, material handling including automated guided vehicle (AGV) applications, packing, food processing and other industrial applications. A key benefit of brushless dc drives is reduced maintenance: Because motor commutation is accomplished in the drive, brushless dc motors can expect many years of reliable operation without requiring preventative maintenance. Other benefits of the Brushless DC drives include:

• Compact size • Quick and easy setup; no programming • 2Q direction control and drive output Inhibit • Torque limiting settings to protect mechanical components • Inherent high starting torque for hard-to-start loads • Optional Modbus RTU serial interface / speed profiling • Extended equipment life, reduced maintenance needs


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1/22/18 9:09 AM

Ameridrives Bibby Turboflex Formsprag Clutch Guardian Couplings Huco Industrial Clutch Lamiflex Couplings Marland Clutch Stieber Clutch Stromag Svendborg Brakes

Altra Couplings, Clutches & Brakes brands offer comprehensive drivetrain packaged solutions to optimize performance.

Ameridrives, Bibby Turboflex, Guardian Couplings, Huco, Lamiflex, Stromag, and TB Wood’s, together with Formsprag Clutch, Industrial Clutch, Marland Clutch, Stieber Clutch, Svendborg Brakes, Twiflex, and Wichita Clutch provide the most technically advanced, long-lasting drivetrain component solutions for a broad variety of industries including energy, metals, mining, marine, oil & gas, food processing, pulp & paper, packaging, aerospace & defense, wastewater, concrete, and material handling.

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Altra Electric Clutches & Brakes brands offer the largest selection of clutches, brakes and linear actuators available from a single source...worldwide.

A wide array of electromechanical clutch, brake, actuator and control technologies are offered by Altra Industrial Motion to meet the needs of the most challenging industrial applications. As recognized worldwide leaders in the industry, Warner Electric, Inertia Dynamics, Matrix International, Stromag and Warner Linear design and manufacture the most innovative, cost-effective braking and positioning systems available. Altra clutch, brake and actuator solutions are utilized in diverse global markets including material handling, packaging machinery, food & beverage, elevator & escalator, medical, turf & garden, off-highway, forklift, marine and agriculture.

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Altra’s Gearing brands are industry leaders of the design and manufacture of quality gearing solutions.

The Altra Gearing group brings decades of combined expertise and advanced engineering capabilities that allow Altra to provide unique, cost-effective solutions that meet specific customer needs. Bauer Gear Motor, Boston Gear, Delroyd Worm Gear, Kilian, and Nuttall Gear are recognized leaders for innovative, energy-efficient gearing and bearing solutions designed for demanding industrial applications. State-of-the-art, cost-effective Altra power transmission components are hard at work in many key markets including metals, food & beverage, energy, wastewater, turf & garden, pulp & paper, textile, concrete, oil & gas, material handling and aerospace.

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Power Transmission and Motion Control Solutions for Industrial Applications

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DFI 1-18_Vs4.LL.indd 31



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to coffee machines to wine coolers, require efficient performance, low operating noise, and low maintenance -all in a smaller size. Compared to standard compressor based solutions, the 12 V or 24 Vdc thermoelectric modules (TEMs) and thermoelectric assemblies (TEAs) offer reliability, design flexibility through vertical integration capabilities, and an overall lower cost of ownership. Thermoelectric coolers also operate at lower noise levels and provide an environmentally friendly solution. Unlike compressor based systems, thermoelectric technology does not use ozone depleting refrigerants, which must be phased out of new and existing equipment in the European Union by 2022. Customized air-to-air thermoelectric assemblies (AA060 Series) or direct-to-air thermoelectric assemblies (DA075 Series) offer cooling without creating condensation that can lead to mildew and unsanitary conditions. When combined with advanced temperature controllers, the space-saving thermoelectric assemblies offer precise temperature control and stability when needed. DW


January 2018


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1/29/18 9:42 AM

Design for Industry Medical

Ultrasonic motors power micro positioning stages

This family of compact linear and rotary stages is driven by ceramic direct-drive motors. The ultrasonic motors provide smooth motion with high resolution and a high dynamic range. The selfclamping motor principle locks the stage into place, devoid of creep, once a target position has been reached. This intrinsic brake-like behavior provides advantages not available with classical electromagnetic drive technologies. Two linear stages with 18 mm and 22 mm travel are available, as well as an XY stage providing 22 x 22 mm. Several encoder options, from 0.4 Âľm to 10 nanometers, are standard. All stages achieve closed-loop peak velocities to 200 mm/sec. The rotary stages come with turntable diameters from 20 to 50 mm, encoder resolution down to 17 Âľrad, and maximum velocity of 720 degrees per second. The low inertia direct drive (no gears and other mechanical components to convert motion) allows for a dynamic start-stop behavior with settling times in the millisecond range. Based on the

ultrasonic principle with drive frequencies >100 kHz the motors are silent. Displacement is generated in continuous sub-nanometric increments, leading to extremely smooth motion with a wide dynamic range. Due to the high efficiency of the ultrasonic motors, the miniature stages can be integrated into mobile measuring and medical devices. Vacuum compatible versions are also available. DW

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1/20/18 3:28 PM

Tadiran Batteries 1-18.indd 33

1/20/18 2:54 PM

Design for Industry Medical

Using high-energy lithium batteries to miniaturize medical devices

Sol Jacobs • Tadiran Batteries

In order to design a more miniaturized handheld medical device, start by examining the battery. Handheld surgical devices have unique performance requirements that are particularly well suited for lithium metal oxide batteries that deliver high voltage and high energy density, along with instant activation and extended operating life, even at extreme temperatures. Lithium metal oxide batteries deliver an open circuit voltage of 4.0 V with high pulses of up to 15 A and 5 A continuous current at 3.2 V for a limited time. Often utilized in hand held surgical power tools and cautherizers, these powerful little batteries enable hand-held devices to become lighter and more miniaturized. Here are some real-life examples: BioAccess portable small bone drills were originally powered by alkaline battery pack that performed well and offered excellent reliability. However, by substituting 6 AA-size TLM1550HP lithium metal oxide batteries for the Alkaline battery pack, BioAccess achieved a 64% weight reduction with only 40% of the volume. An equivalent alkaline battery pack would have required 3X the weight and 2.5 times the volume (15 AA-size alkaline batteries vs. 6 AA-size TLM-1550-HP batteries). Use of a lithium metal oxide battery pack also permitted faster drilling speeds, more active drill time (30 to 40 seconds at a time for up to 20 to 30 cycles), more instantaneous power, and greater stall torque, resulting in more efficient drilling cycles with less operator fatigue. The lithium metal oxide battery pack used in the BioAccess small bone drill is designed for one-time use and is then discarded. However, similar surgical power tools could also be powered by industrial grade rechargeable Lithium-ion (Li-ion) batteries that feature up to 20 year operating life with 5,000 full recharge cycles, able to deliver high current pulses (up to 5 A), and offering a much wider temperature range (-40° C to 85° C) with the ability to be discharged and recharged at extreme temperatures (10-hour rate). These ruggedized batteries outperform consumer grade Li-ion cells that can operate for 5 years and 500 recharge cycles, with a high annual self-discharge rate (up to 60% per year), and a limited temperature range (0° C to 60° C). Lithium metal oxide batteries and industrial grade Li-ion rechargeable batteries offer intelligent space-saving solutions for a growing number of medical applications that require miniaturization without compromising power or performance. DW

Tadiran Batteries | January 2018 34

DFI 1-18_Vs4.LL.indd 34


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Design for Industry Robotics

A single arm version of the YuMi collaborative robot

YuMi was one of the first collaborative, dual-arm industrial robots. Now meet a single-arm collaborative robot, which takes up a much smaller footprint. Collaborative robots work alongside humans on the factory floor to raise productivity and support the shift to mass customization. The single-arm robot will be officially launched in 2018. Like YuMi, the new robot has a payload of 500 grams. Because of its size, it easily integrated into existing assembly lines. The new robot also features lead-through programming, eliminating the need for specialized training for operators. DW ABB |

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Design for Industry Robotics

Intelligent conveying system

powered by on-board battery

The design challenges are familiar: shorter response times to new market trends, increased demands for customization, and lower costs. The modular Linear Transfer System (LTS) with Smart Carriage technology helps address these challenges with its on-board intelligence and data memory, plus freely configurable tracks. In addition, it also includes on-board battery power. Operator safety is addressed without compromising productivity: as workers approach, the Smart Carriages will first slow down, and then stop, but only in the section where is a potential hazard. Through the on-board intelligence and connectivity, the Linear Transfer System allows each carriage to behave differently and autonomously. For example, the Smart Carriages can choose the optimum route to reach next station and enable processing of the product being carried as they go along. The on-board battery system not only powers on-carriage devices such as

sensors, controllers and memory, it also drives the carriage itself. This removes the need to draw power from the track, increasing layout flexibility. There are also reliability benefits, since there are no brushes contacting the track to draw motive power for the carriage, which can create dust and require frequent cleaning. This advantage offers reduced maintenance and also makes the system suitable for use in clean environments. The safety concept allows cage-free operation and increased productivity. The implemented safety features such as Safe Torque Off (STO) and Safety Limited Speed (SLS) in combination with sensors detect when an operator is nearing the conveyor system and slow the carriages to a safe speed – but only in the local area where the operator might come into contact. Elsewhere on the LTS, operation continues at

January 2018 38

DFI 1-18_Vs4.LL.indd 38

normal speeds and productivity is not compromised. The system offers a full suite of track pieces in different lengths and bend radii to meet their individual requirements. DW

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1/22/18 9:09 AM


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Design Notes

Gearbox increases riveting rate for

robotic fuselage assembly Edited by: Lisa Eitel • Senior Editor

The newest high-torque gearbox offering from WITTENSTEIN The Galaxie Drive System 580% offers increases as high as ring ive in torsional rigidity, del improved performance in applications requiring aller precision with force in a sm footprint.


offers extreme torsional rigidity and the world’s first zero-backlash operation for applications that need superior precision in output motion. In contrast with other gear offerings that transmit power over lines of contact on gear teeth, meshing gears in the Galaxie make almost full-surface contact. This allows for tooth contact that’s up to 6.5 times that of certain types of conventional involute teeth.

January 2018

Design Notes 1-18_Vs4.LL.indd 40


1/20/18 7:15 PM

The Galaxie gearbox can combine with a motor with IIoT connectivity. It offers up to 91% efficiency. The tooth contact ensures high overload capability. How does it work? In short, the gearbox guides a large array of individual teeth along an internal ring gear. The tooth geometry follows a logarithmic spiral that lets multiple teeth transmit power at once through hydrodynamic contact — covering much larger surface areas than traditional line contact. The result is a gearbox with zero backlash, even at the zero crossing. The logarithmic spiral path of the teeth allows for synchronization accuracy that outperforms traditional hollow-shaft drives with comparable outer diameters. The Galaxie gearbox can combine with a motor with IIoT connectivity. It boasts up to 91% efficiency —18 to 29% better than traditional strain-wave and cycloidal geared arrangements. As part of a drive system, the hydrodynamic tooth contact of the Galaxie produces another performance benefit: high overload capability. Emergency stop torque is 150 to 300% better than legacy systems, and torsional rigidity is to 580% higher ... so gearboxes of other designs might need to be up to three times larger to deliver the same torque as a given Galaxie. The Galaxie’s design also allows for a very large hollow-shaft diameter in

The Galaxie imparts more precise motion control so the Broetje-Automation MPAC delivers riveting rates to 21 per minute — up from 18 per minute from legacy setups.


Design Notes 1-18_Vs4.LL.indd 41

January 2018


1/28/18 4:54 PM

Design Notes relation to the outer diameter — to 70% larger in some cases. Consider one recent use for robotic riveting. Broetje-Automation GmbH makes multi-panel assembly cell (MPAC) riveting machines, and now get 20% higher productivity from the setups thanks to Galaxie drives. In short, the MPACs fully automate the riveting of fuselage sections and aircraft struts. “These machines use thousands of rivets to join the fuselage parts of passenger aircraft made by leading manufacturers,” said Christian Heyers, head of control systems at BroetjeAutomation. Within these MPAC machines, right-angle Galaxie gearboxes go on critical axes. “The Galaxie kinematics deliver enormously improved torsional

Broetje-Automation’s MPAC machines join the fuselage parts of passenger aircraft made by the big manufacturers together using innovation that creates totally new opportunities for designers in thousands of rivets.



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January 2018

Design Notes 1-18_Vs4.LL.indd 42

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1/26/18 1:49 PM

Users of the WITTENSTEIN Galaxie get increased productivity and (in the case of machine-tool applications) longer tool life thanks to high stiffness and precision. That also makes for faster cutting and feed rates with better manufacturing quality.

stiffness and absolute freedom from backlash — even with alternating loads,” added Axel Peters, executive V.P. of fastening at Broetje-Automation. “We get significantly more precise motion control — even at reversal points — and around 30% faster positioning of the MPAC’s lower tool. That’s let us increase riveting rates from 18 to 21 per minute.” DW



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Design Notes 1-18_Vs4.LL.indd 43

January 2018


1/28/18 4:52 PM

Design Notes Edited by: Mike Santora • Associate Editor

Upgrading a baggage handling system on the fly

The designated installation space for safety and sorting systems for baggage logistics at Victoria Airport was limited.

Luggage is screened before it can be admitted onto a plane. 44

January 2018

Design Notes 1-18_Vs4.LL.indd 44

Passenger numbers and luggage volume at Victoria Airport in British Columbia, Canada, are nowhere near the numbers at large international hubs. Yet there are still plenty of challenges for the OEM that provides the airport’s baggage handling system (BHS). The airport did not have the room to accommodate all the usual modules - from check-in through security screening to sorting. To fix the problem, the airport company commissioned Glidepath, a manufacturer specializing in baggage conveying, parcel sorting, and freight logistics technology. The new handling system has a capacity of 750 pieces of luggage per hour. “The baggage handling system is made up of 85 conveyors with a total length of some 250 m,” says Jason Williams, project engineer at Glidepath. “It comprises two in-line screening CT machines. It has two decision points for sortation, DESIGN WORLD

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Design Notes

NORD AC vector drives consisting of an energy-efficient geared motor and a distributed frequency inverter power the conveyor modules.

and it has two separate infeed lines. It has four-way sorters, spiral power curves, bag alignment devices, a luffing conveyor, and Glidepath’s proprietary ploughs and power curves.� All drive tasks are carried out by IE4 AC vector drives from Nord Drivesystems. Each drive unit consists of an IE4 permanent-magnet synchronous motor, a motor-mounted NORDAC FLEX frequency inverter, and a two-stage gearbox. The hollow shaft gearboxes are secured on the drive axis with a Gripmaxx bushing. This attachment

Connecting the photo eyes to the inverters (wall-mounted) reduces the cabling effort for Glidepath.


January 2018 DESIGN WORLD

Design Notes 1-18_Vs4.LL.indd 46

1/20/18 7:23 PM

ensures safe, easy-maintenance fitting without keys. The frequency inverters are configured exactly to Glidepath’s specifications— with plug-in connectors for power, communications, encoders, and sensors. They also have an internal EtherNet/IP interface with easy feedthrough installation. The pluggable drives saved Glidepath time during installation and commissioning. The coded connectors enable quick and accurate networking. “With the field I/O capability of the NORD drives, we were able to connect the majority of our field devices directly to the frequency inverters,” said Williams. Additionally, industrial ethernet communications enable not only remote monitoring and control of all drive axes, but also seamless monitoring of connected sensors and actuators. For Williams, this was a crucial factor: “The

real advantage here is, the drives support high-speed Ethernet, which allows for reliable bag tracking on our system.” The drive systems take on various tasks at the conveyor modules. They move luggage at different speeds from one belt to the next. They ensure height adjustment when conveying diagonally. Glidepath only came to realize the full potential of the integrated positioning function of the inverters once the drives were commissioned. As they gathered parameters for various applications, NORD engineers soon found that the positioning function was the solution for the luggage sorters. DW



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Design Notes 1-18_Vs4.LL.indd 47

January 2018


1/20/18 7:25 PM

Design Notes Edited by: Mike Santora • Associate Editor

How motion platforms

improve camera design

The H-860 uses non-contact linear motors with flexure guides (in the base of the hexapod) and frictionless and backlash-free flexure joints (top and bottom of each strut) along with carbon fiber parts to further reduce the moving mass. Click for a video showing its user selectable pivot point and capabilities.

Fine tuning of image stabilization algorithms at Google: Footage of the PI’s “robotic hexapod stage” motion simulation platform testing the Google Pixel 2 starts at 08:02 min. (Credit: YouTube, “Nat & Friends”) of rivets.


In a recent Youtube video by “Nat & Friends” on how Google built the Pixel 2 Camera, PI’s H-860 “shaker” hexapod is shown in a motion simulation application. Modern cameras use electronic image stabilization algorithms to reduce side effects from motion that otherwise would blur images and video. The better a designer can simulate real-world vibration and motion, the more effective countermeasures can be devised. Vibrations and motion typically occur in many degrees of freedom, i.e. there is angular and linear motion in multiple axes often at the same time. After recording motion profiles using instruments such as accelerometers, and turning them into digital signals that can be replayed on a motion simulator, engineers can then begin to test and fine-tune different electronic stabilization algorithms to come up with the best result for each situation. A hexapod platform can provide motion in all six degrees of freedom (X, Y, Z; Pitch, Yaw, Roll), to simulate any type of motion or vibration that occurs in the real world. It is critical for the hexapod not to add any mechanical vibration of its own to affect the motion profile to be played back. PI engineers designed a direct drive hexapod with frictionless

January 2018

Design Notes 1-18_Vs4.LL.indd 48


1/20/18 7:40 PM

H-860 hexapod providing sinusoidal Z-axis scan with 30 Hz in Z, amplitude 0.5 mm. Due to the low inertia (moving mass) and high dynamics, the H-860 can simulate accelerations precisely. Measured with accelerometer at the motion platform. of rivets. drives and bearings for just that purpose. Hydraulic, or electric screw drives, always create and transmit additional vibrations onto the motion platform. This motion platform is based on non-contact voice coil linear motor drives with flexure guides and flexure joints for the 6 “legs.” This design, combined with a carbon fiber structure to reduce mass and inertia, forms a highly responsive, dynamic, and precise 6-axis motion platform. Using this shaker hexapod platform, Google engineers can simulate unwanted

motion and vibration for both still images and video recordings. The hexapod controller and GUI make it easy for software engineers to create any random motion and make the smartphone mounted on its platform move along a predefined trajectory with the frequency content that corresponds to the typical trembling of the human hand. The H- 860 voice coil hexapod can provide motion with frequencies to 30 Hz and above and provides linear repeatability of ±0.5 microns in X, Y, Z and angular

repeatability of ±9 microradians in the pitch, yaw and roll axes. The hexapod controller and GUI allow predefined motion profiles, such as sinusoidal signals and freely definable trajectories with high path accuracy. Traditional multi-axis stacks are relatively simple in their design, but parallel-kinematics has many advantages. They do however require a more advanced controller to handle the millions of math operations required to take care of the coordinate transformations. Traditional multi-axis systems are designed in a way that the top level stage has to be

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Design Notes

Parallel-kinematic motion platforms compared to traditional serial kinematics stacks of single- axis stages.

supported by all the stages below it and so on, meaning that the bottom positioner has to carry all the load, significantly reducing its dynamics. All axes carry different loads, with different dynamics making tuning harder since each component has a different natural frequency. With only one common lightweighted platform carried and actuated by six parallel actuators, hexapods provide a very high stiffness and natural frequency. The lower inertia (moved mass) leads to higher dynamics, better responsiveness, and faster settling for all axes. In a serial kinematic system, motion is confined by bearings – and the center of rotation is related to the fixed radius of each rotary stage and goniometric cradle used. In order to move the center of rotation, mechanical changes, have to be made or fixturing needs to be modified. With a PI hexapod, a single

software command can set the center of rotation to any location inside or outside the hexapod envelope. In this multi-axis hexapod systems, the center of rotation can be changed by a single software command on the fly. With traditional multi-axis positioners, as a stage moves, cables need to be dragged along. Friction and torque generated by bending forces contribute to parasitic motions reducing accuracy and repeatability. Parallel kinematic positioners, such as hexapods, avoid moving cables altogether. Stacked axes interact in complicated ways. For example, runout in the x-axis can cause unwanted motion in the y– and z-axes; angular deviation of an axis similarly imparts motion in the travel- directions of the other axes, with magnitude proportional to the distance to the moving axis. And in stacks, that multiplicative lever arm can be large. DW

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User friendly GUI – Watch video for several examples of complex motion profiles executed with the H-860 high-dynamics hexapod. The video explains the software utility and shows hexapod motion via a laser pointer.


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CAE Solutions

Innovative motor designs for electric cars come to life through Multiphysics

Figure 1. Finite element analysis (FEA) of a nonlinear-surface permanent magnet synchronous motor (PMSM)

The automotive industry is in the midst of a disruption, and the transcendence of electric vehicles from niche to mainstream products is a driving force behind this change. Yet challenges remain to improve the motor designs used in electric vehicles. One potential solution is the use of Power Magnetic Devices (PMDs), a category of devices that include motors, generators, transformers and inductors. In simple terms, these components use an electromagnetic field to convert electrical energy to mechanical energy, or vice versa. In the field of power engineering, and particularly in the design of PMDs, modern advances are targeted at reducing system losses, mass, volume, and cost, while simultaneously increasing power capability, reliability, and large-scale manufacturability.

Modeling, optimization, and collaboration come together

Achieving these competing objectives in modern applications requires advanced methods to optimize the design of various PMDs such as electric motors. These include computationally efficient device models in conjunction with state-of-the-art optimization techniques. Furthermore, the design constraints pertaining to electric motors represent


a complex multiphysics problem from a mechanical, electrical, and thermal perspective. (Figure 1) Faraday Future, a start-up technology company focused on the development of intelligent electric vehicles, is using COMSOL Multiphysics software, a multiphysics finite element analysis program, to produce state-ofthe-art electric motors with high power density. The organization is also taking an innovative, modular approach to electric vehicle design. Omar Laldin, Lead Electromagnetic Engineer at Faraday Future, explained: “My group develops motor designs for a generic set of vehicles, primarily suited to our variable platform architecture, which allows for modular development of electric vehicle powertrains. We can add or remove motors, adjust battery quantities, and collapse or increase the size of the chassis.” “To be able to do that, we have to design the motor for a variety of conditions, and need to take into account several different aspects of the motors beyond just the electromagnetic components, such as the mechanical and thermal behavior,” Laldin added. Figure 1 shows an example of an electromagnetic analysis conducted by the group. This involves completing a series of advanced optimization algorithms, which quickly model how particular designs will behave. Speed is important as

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these optimization algorithms must be run over numerous iterations to ensure a variety of designs are investigated. As a result, some aspects of the models need to be simplified. Laldin explained: “It could take several weeks to do a full CFD analysis to predict thermal behavior. There are often thousands of designs to be considered, and hundreds of operating points for every given design, making it impractical to do detailed multiphysics analysis with a computationally heavy tool. Tools like COMSOL, which allow us to conduct thorough electromagnetic and mechanical analyses along with simplified thermal analysis, work in a very stable way and give us quick feedback on each of these aspects during the design process.” The versatility of COMSOL also helps the Electromagnetic Motor Design Group collaborate with the other teams within Faraday Future, including Motor Mechanical, Inverter, Motor Control, Powertrain Control, Systems Engineering, and so forth. Collectively, these groups form the Powertrain Group within the organization. “We do all the early stage analysis before we send data to other teams to make sure we’re in the right ballpark, and that limits the number of iterations we have to do with other teams. I think that’s one of the most beneficial aspects of the COMSOL simulation and modeling tools,” he added.

Designing an actuator The EM team designed an EI-core actuator to meet certain constraints, while obtaining the compromise between competing volume and power loss objectives. While the power loss must be minimized, they did not want to increase the size of the component to do so, as package size is a critical metric


CAE Solutions 1-18_Vs3.LL.indd 53

in most vehicular systems. The actuator was made up of a coil of conducting wire wrapped around a stationary E-core, along with a movable I-core (Figure 2). They performed a 2D electromagnetic field analysis in COMSOL, coupled with a genetic algorithm implemented in MATLAB software. The model accounted for the highly nonlinear behavior of the various steel materials, while the genetic algorithm provided the globally optimized and multi-objective “ParetoOptimal Fronts,” which provided the tradeoff between reducing the volume and power loss (Figure 3). They used geometric parameters of the actuator as inputs in the algorithm, and obtained losses based on the coil resistance. This allowed for the rapid investigation of numerous designs of the electromagnetic actuator, capable of delivering 2500 N of force.

Investigating losses The team investigated the nonlinearity of the steel used in electric motors, which changes the nature of high frequency conductor losses in a slot. These losses increase at high speeds due to the increase in skin and proximity effect in the conductors, they are also affected by the temperature. Due to the geometry of the motor, some winding architectures and their conductors are more easily cooled than others. For example, the spacing of the conductors and their dimensions can affect the heat transfer in the slot. Laldin and his colleagues performed further multiphysics analysis coupling the electromagnetic components with the thermal behavior to identify hotspots in the motor that could cause catastrophic failure. They discovered that the current density within the conductors changed significantly due to changes in flux density across the slot. They calculated

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CAE Solutions the loss density in each of the conductors and then obtained the temperature distribution, which provided the maximum hot spot temperatures in different areas of the motor (Figure 4). Laldin said: “The loss in different conductors can differ even if we have the same current. We model these variations and do some approximate and quick thermal analysis in COMSOL, which allows us to study the temperature distribution.” By identifying the maximum hot spot temperatures, this enables manufacturers to determine the reliability of the design and prevent destructive motor events. This multiphysics approach brings further time savings to Faraday Future as one person can both design and analyze a motor and its components. Laldin said: “Instead of doing 10 iterations with the various teams, our tools allow us to complete the design in 1 to 2 iterations. This is one of the biggest advantages of having a multiphysics analysis tool—we can cut down on the number of iterations we need to do between different groups. It’s a lot quicker for one person to optimize the design, followed by minor

Figure 3. Left: Pareto-Optimal Front providing mass vs. loss tradeoff. Bottom: Magnetic flux distribution in the EI-core actuator.


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CAE Solutions refinements across the teams, than it is for each team to independently analyze each aspect of the physics.”

Application exchange for the future Faraday Future is a relatively young company, and yet it has achieved great strides in the electric vehicle sector as it designed, developed, and constructed a working electric vehicle within just two years. The organization has embraced COMSOL’s Application Exchange, an online community where users can upload and share their models, and discuss techniques and findings with other users, to help fuel this growth. Laldin said: “The only realistic way to achieve such innovation is to use the experience of our suppliers and the capabilities they have. In a user community, it’s a lot easier to find solutions to the tool for problems that we all have in the field.”

Laldin added: “COMSOL was a very natural choice for us as we are developing state-ofthe-art technologies and appreciate the need for speed. For example, if I need a new feature in the software, the company is very responsive in including that feature in the next release.” COMSOL’s open and responsive Application Exchange platform will also help Faraday Future keep ahead of the competition, as Laldin added: “On top of that, fostering this online community fits with the startup mentality where you’re willing to contribute non-sensitive data and know-how in an open exchange for the benefit of everyone involved. I have always felt that you always get more out of user communities and the exchange than what you put into it, especially when it’s backed by a state-of-the-art industrial partner. It’s a very good combination for a company like ours.” DW






Figure 4. Left to right: Model geometry, magnetic flux, current density, power loss, and temperature distribution in a model of a stator slot.


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CAE Solutions

Siemens’ NX expands toolset, including

additive manufacturing tools

NX Machining Line Planner uses a digital twin of the complete machining line and NX CAM feature-based machining technology to optimize the entire manufacturing process.

The latest version of Siemens’ NX software unites the next generation of tools for additive manufacturing, computer numerical control (CNC) machining, robotics and quality inspection to enable the digitalization of part manufacturing within a single, integrated, end-to-end system. Digitalization connects all of the steps of part manufacturing planning and production with a single source of information, or a digital thread. Implementing a digital strategy can enable part manufacturers of all sizes to take greater advantage of automation, adopt 3D printing for production, and ultimately expand into new market opportunities and reduce time to delivery. Advanced automation capabilities for computer-aided manufacturing (CAM), including robotic programming, adaptive milling, and tooling design, provide industry-specific technology to help deliver high-quality products to the market in less time. The new NX Machining Line Planner tool, combined with integrated NX CAM software for feature-based machining, provides new capabilities for industries with high-volume production of complicated parts, such as automotive and industrial machinery. The latest version of NX continues to support end-to-end solutions for additive manufacturing, helping manufacturers realize the goal of using 3D printing for industrial production. New automation enhancements within the latest version of NX provide ways to expand production efficiency and reduce cost. Robotic programming technology provides the ability to automate complete manufacturing cells, including programming robots to perform machining and pick-and-place operations. Adaptive milling and tube milling are new capabilities that provide 58

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Lattice structures offer stronger lightweight alternatives to traditional part design, and the unique ability of NX 12 to modify these structures without data conversion using facet modeling shaves weeks off of the design process.

Automate complete manufacturing cells using NX CAM Robotics Programming that enables robots to perform multiple operations, including pick-and-place operation (left) and CNC machining (right).

ways to automate CNC machine programming and accelerate cutting of complex parts. Adaptive milling is a high-speed cutting method that leverages automation within NX to reduce machining cycles by up to 60% while extending tool life. Tube milling streamlines the 5-axis programming process by eliminating preparation and minimizing inputs, using capabilities to create ideal tool paths and minimize errors in machining on the shop floor. Mold and die manufacturers can automatically and accurately determine tool production costs through seamless integration between NX and the Teamcenter portfolio. Engineers can use NX to automatically recognize features and parameters on the desired part, and provide pertinent information to Teamcenter, which can precisely calculate the tool cost. The newly integrated capabilities of Siemens’ product lifecycle


management (PLM) software solutions can enable tool manufacturers to win more orders and increase profit margins through automated costing and accurate quotations. New to this version, NX Machining Line Planner, combined with integrated NX CAM, enables the feature recognition, distribution, balancing, programming and simulation of operations over multiple setups and machines. For industries with high-volume production of complicated parts with many features, NX Machining Line Planner uses a digital twin of the complete machining line and NX CAM feature-based machining technology to optimize the entire process. The latest version also expands the new additive manufacturing solution in NX by including the new module, NX AM for HP Multi Jet Fusion, which is certified by HP and powered by Materialise, to prepare print jobs for HP Jet Fusion 4200

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3D printers. The NX software module will allow customers to develop and manage parts in a single software environment for Multi Jet Fusion printing solutions, avoid costly and time-consuming data conversions and third-party tools, and improve their overall design-to-finishedpart workflow efficiency. Additionally, Siemens develops applications for additive manufacturing process simulation in Simcenter 3D to help manufacturers industrialize additive manufacturing by printing components the first-time-right. These simulation applications are an integral part within the Siemens’ end-to-end additive manufacturing solution. DW


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control system through TwinCAT Vision software. TwinCAT unites a comprehensive range of machine functions – PLC, motion control, robotics, high-end measurement technology, IoT, HMI, and machine vision. Machine vision is rapidly becoming a key quality technology enabler for manufacturing machinery. This applies particularly to Industry 4.0 concepts, quality optimization and track-and-trace applications. TwinCAT Vision provides the required image processing capabilities in the form of PLC functions on a universal, end-to-end software platform, with a specially developed library of image processing functions and function blocks that are called up directly from the TwinCAT PLC. The flexible runtime system in TwinCAT executes these functions and function blocks in real-time. Now PLC programmers can create machine vision applications without support from outside experts. GigE Vision compliant cameras of almost any kind are added easily, even in parallel, using standard camera interfaces and configured in TwinCAT Engineering. The cameras can be calibrated directly, in the engineering environment or mid-process in the runtime system. With TwinCAT Vision, there is no need for specialized tools or programming languages when coding the image processing logic, because the machine vision applications are created in the PLC, using familiar PLC programming languages. DW

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Internet of Things

Is Gigabit Industrial Ethernet adoption the key to achieving Industry 4.0 goals? While there may still be some debate about what Industry 4.0 really means, there is no denying that greater interconnectivity of devices and increased network capability will be the key drivers behind achieving Industry 4.0 goals. As manufacturers examine future challenges around low volume production, increased customization and increased competition, it is easy to understand why the concepts of Industry 4.0 have come to the forefront. Industry 4.0, combined with the Industrial Internet of Things (IIoT), not only holds the key to addressing many of these challenges, but also promises to deliver innovations that today’s manufacturers have not even thought of yet. Industry 4.0 can be defined as the combination of “cyber-physical” systems with the IIoT. Underpinning it are Ethernet and Internet-based technologies that provide the connectivity for everything to communicate with everything else, regardless of ‘where’ a device or system is physically, or, ‘what’ it actually is. Today, while we talk about high levels of interconnectivity, usually there are incompatibilities in networks and technologies that mean projects are divided into separate islands. As we overcome these incompatibilities and drive ever greater levels of integration and interconnectivity, Industry 4.0 will allow production machines to provide more transparency and cooperate to a higher degree. Some say that this will ultimately lead


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to intelligent factories capable of autonomous production changeovers, reassignment of production equipment and perhaps even scaling their capacity as demand changes. By extension, this will also take in the Internet and collaboration with vendors and customers to a greater degree than is possible now. None of this can happen, though, without the networks to carry the information between the places where it’s needed, in real-time. Ethernet provides a good foundation for this infrastructure, but being able to deliver the necessary performance will require technology with greater capabilities than is common now. One network that claims it can offer such capabilities is CC-Link IE.

Gigabit Ethernet standard for automation Industry 4.0 applications need to share large amounts of data from multiple devices in real-time. Hence bandwidth is critical to the successful operation of these systems. CC-Link IE is an open gigabit Ethernet standard for automation. As such, it

offers a performance increase of around 10 times compared to any other similar protocol today. Further, CC-Link IE has a bandwidth of 1 Gbps. CC-Link IE is based on the Ethernet standard IEEE 802.3, and allows for ring, line and star topologies. In addition, the line and star topologies can be combined for greater flexibility. The ring and line connections permit simple “daisy chaining” of devices.

Addressing cyber security concerns One of the key concerns related to the increasing adoption of industrial Ethernet is cyber security. While the use of Internet-based technologies has increased the possibilities of what can be achieved in manufacturing, it has also increased the threats. Some industrial Ethernet protocols are based on a standard TCP/IP (UDP/IP) stack, which can arguably cause some security vulnerabilities. CC-Link IE combines the physical and data-link layers of the OSI hierarchy with an open protocol that extends from the network to application

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layers. The result is an open, but controlled knowledge base that CLPA partners are free to implement, but reduces the exposure to unauthorized use. Potential users may have concerns regarding CC-Link IE’s compatibility with TCP/IP (UDP/IP) traffic. While current network design practice encourages segmentation of networks for security and performance reasons, sometimes it’s still necessary to support non-control related network traffic. CC-Link IE supports this with the capability to encapsulate TCP/IP (UDP/IP) packets for transmission across the network, thus allowing this traffic to “tunnel” through the CC-Link IE system. CC-Link IE allows considerable application flexibility by supporting multiple protocol types on the same network. This reduces costs and increases maintainability. In addition to the standard I/O control, it offers safety (SIL3), motion control and energy management on the same cable. This allows the CLPA to offer a cost-effective, simplified, flat network architecture that meets the needs of nearly all applications in the discrete sector.

Speed and simplicity CC-Link IE’s basic communication technique is based on a shared memory model. All the devices on the network occupy an area of the controller’s memory. To communicate with them, it’s only necessary to change the value of the data in the area corresponding to the relevant device. The network automatically handles the traffic via the standard “cyclic” (synchronous) communication. The same process happens in reverse for communication to the controller from devices. For high priority, unscheduled events such as alarms, or lower priority non-cyclic transmissions such as diagnostic information, an alternative “transient” (asynchronous) communication method is available. Even high levels of transient traffic do not impact the deterministic regular cyclic communication, meaning normal system functions are not impaired and the scan cycle is completely deterministic. Deterministic performance is achieved with a token passing method. In practice, this allows network update times to occur in a few tens of microseconds, depending on system size and configuration. CC-Link IE also offers the ability for redundant controllers, so even a controller failure will not necessarily result in lost production. CC-Link IE can help manufacturers reap the benefits of greater connectivity across their processes, with improved network performance delivering tighter control, greater data throughput at high speed, deterministic performance and inherent security. It is also set to play a key role as manufacturers push towards models of Industry 4.0 in order to address the production challenges of tomorrow. DW

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Internet of Things

Machine analytics give insights into asset performance Mike Wagner, global segment lead for packaging, and Todd Smith, product manager, Rockwell Automation

Digital transformation is providing manufacturers new insights into their operations with smart machines and equipment that are connected throughout the enterprise. Many OEMs would benefit from tapping into these increasingly connected systems. Machines are getting smarter and OEMs can add further levels of insight into what manufacturers are beginning to learn about their facilities. These new levels of visibility can promote asset performance and simplify meeting contractual obligations. For example, OEMs that monitor a smart machine’s performance or identify critical process anomalies can expand the support they provide. But, rather than working with their customers to proactively prevent issues from happening, they often physically send help to a customer’s site. The result? Longer downtime for customers and higher travel costs for OEMs. All of the smart machines using connected technology in the plant are limited by keeping OEMs out of the digital ecosystem.


Fortunately, the days of working in the dark are over. Cloud-based machine analytics present an opportunity for OEMs to get real-time and historical insights into smart machines or equipment from anywhere. This can help them reduce customer downtime, improve collaboration, meet performance guarantees and even create new revenue streams.

Skip the do-it-yourself perils Remote analytics is not an entirely new concept for machine and equipment builders. But it typically involves building

January 2018

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remote-monitoring and analytics capabilities in-house from the ground up, which can be a time-consuming and costly process. Most OEMs, for example, do not have the IT staff or expertise required to deliver critical aspects of remote analytics, such as secure remote access, cloud-based data collection and database management. As a result, they take on the upfront costs to acquire the skills needed for developing a machine customized to their customer and supporting the equipment long term. A simpler and more cost-effective DESIGN WORLD

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PARTS? approach is available with software-asa-service applications. OEMs are looking to standardized, cloud-based analytics to gain new levels of insight into their machines. By providing analytics in the cloud, OEMs gain real-time and historical insights into how their equipment is operating from anywhere, so they can collaborate with customers to reduce downtime. The technology available to OEMs allows them to simply embed a gateway device onto their smart machines or equipment, and connect with minimal configuration between the device and selected controllers. That is all it takes to begin securely accessing actionable information with prebuilt dashboards.

Information creates opportunities When OEMs gain access to real-time performance information for their smart machines, they can serve customers in new or better ways. Rather than traveling to a customer’s site if equipment fails, smart machines provide OEMs the opportunity to remotely troubleshoot and diagnose the problem. They will also have the ability to collaborate with their customer and resolve the issue in a timely manner. It’s a win-win: the OEM can more quickly help its customer and reduce travel costs, and the end user can realize higher uptime and output, and lower maintenance costs. Performance guarantees are another big area of opportunity. By collecting data and analyzing performance analytics, such as OEE, OEMs can collaborate with their customers to optimize the performance of a smart machine and help it reach required performance levels. Additionally, cloudbased analytics provide a single, shared version of the truth about machine performance. Data collected over time can be used to reshape service agreements. Once an OEM collects enough performance data and gains a solid understanding of what a machine is capable of, they


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When OEMs gain access to realtime performance information for their smart machines, they can serve customers in new or better ways. could begin offering a wider range of agreements that promise higher levels of performance. OEMs can use cloud-based analytics to continually improve their machine designs. Whether looking at multiple machines deployed across one customer’s sites or one machine deployed across multiple different customer sites, the OEM can identify deviations in performance, trends and patterns, and best practices. They can then convert that data into engineering changes, and ultimately supply customers with better-performing, more reliable machines.

Bigger roles for OEMs Access to cloud-based analytics can also lead to new business models and help carve out bigger roles with current customers. For example, some large global manufacturers are moving away from in-house teams that specify and purchase machines or equipment. Instead, they can send production requirements to an OEM, who is then responsible for designing and delivering the right solution to meet those

January 2018

January DW






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Internet of Things

requirements. OEMs are shifting from a machine provider to a productivity provider. Once OEMs gain access to performance data, they can supplement the expertise of their customers’ in-house teams, especially as companies struggle to find and retain skilled maintenance workers. For example, an OEM could take over responsibilities for monitoring machine or equipment performance, and for servicing them as needed, with guaranteed response times built into their support contract. The OEM also could use the information it collects to begin providing proactive maintenance and training to help customers get ahead of failures and operate more effectively.

Let there be light Cloud-based, smart machine analytics are revolutionary – they give OEMs access to insights that have existed outside their field of view for decades. They empower OEMs with instant insights into how their machines and equipment are performing, and new opportunities to better serve their customers. But analytics are also central to the larger role that smart machines play in end users’ operations to help improve asset utilization, time-to-market and more. OEMs that are not supporting their customers with a digital transformation by providing smart machines and cloudbased services not only risk missing out on business opportunities, they risk being left behind entirely. DW

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Internet of Things Industrial controllers support Time Sensitive Networking (TSN) The IC-3173 Industrial Controller can act as an Industrial Internet of Things edge node in extremely harsh locations including spray down manufacturing environments, test cells and outdoor locations without the need for a protective enclosure. The IP67 rating helps ensure reliable operation in the presence of dust and water, in accordance to IEC standard 60529. These Controllers are fanless and deliver high levels of processing power and connectivity for automated image processing, data acquisition and control applications. They feature up to a 2.2 GHz Intel Core i7 dual-core processor, 8 GB DDR3 RAM, 64 GB storage, four Power over Ethernet (PoE) GigE ports, two USB 3.0 ports and two DisplayPorts in a rugged design with no moving parts, and now with an IP rating up to IP67. Industrial Controllers also include a user-

programmable Xilinx Kintex-7 FPGA, which improves system performance by providing custom I/O timing, synchronization, control and image coprocessing capabilities. Industrial Controllers are part of a growing number of products that support Time Sensitive Networking (TSN), the next evolution of the IEEE 802.1 Ethernet standard that delivers distributed time synchronization, low latency and convergence of time-critical and general networking traffic. DW

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Micro brick PLCs with Ethernet The CLICK Series of stackable micro brick PLCs come with both Ethernet communications capabilities and analog I/O built-in. 12 new units provide discrete and analog I/O including four discrete inputs, four discrete outputs, two or four analog inputs and two analog outputs. These PLC units are available with a variety of current and voltage (0-20 mA, 4-20 mA, 0-5 Vdc, 0-10 Vdc) inputs and outputs, with 24 Vdc or 120 Vac discrete inputs and dc or relay outputs. The units feature one built-in 10/100 Mbps Ethernet communications port for both programming and Modbus TCP networking, plus RS-232 and RS-485 serial ports. CLICK Ethernet Analog PLC units include a calendar/real time clock and battery backup and are configured with easy-to-use programming software. DW AutomationDirect

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Internet of Things

Dual-port GigE Vision Platform The VPS-3100, an IP40 rated compact rugged vision system powered by a 4-core Intel N3160 processor with two independent Gigabit Ethernet ports provides dual GigE vision device connections with data transfer rates up to 2.0 Gb/s. The VPS-3100 supports dual channel PWM lighting control and offers PoE (Power over Ethernet), ToE (Trigger over Ethernet), and dedicated FPGA (Field Programmable Gate Array) that delivers GoE (GigE Vision Offload Engine) reducing the CPU workload significantly. The combination of PoE and ToE provides a single cable solution (data, power, and triggering) to simplify system installation and reduce maintenance effort and features a powerful and flexible isolated digital I/O. The FPGA reconstructs images before transmitting them in real-time to the host PC via DMA (Direct Memory Access). This frees up the host PC processor and ensures zero frame or packet loss during image acquisition and transmission. Featuring ad hoc networking, the connection between the GigE vision cameras and the VPS-3100 are self-configuring and user-defined IP addresses are no longer necessary. DW


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Scalable network-based control system The STARDOM network-based control system includes a new E2 bus interface module developed for use in FCN500 autonomous controller extension units. This enables the construction of systems that have more I/O points and cover a wider area. STARDOM is a network-based control system that consists of grade"

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maximum possible transmission distance between individual units has been increased to 100 meters. Therefore, with a 9-unit configuration, the maximum transmission distance is 800 m, which is 100 times longer than what was previously possible. Using commercial fiber optic cables and media converters, a STARDOM system spanning distances of several kilometers can be constructed. The installation of extension units near sensors reduces wiring costs and maintenance workload. Three different types of base modules are available: a long base module with slots for 10 modules, a short base module with slots for five modules, and a compact base module with slots for three modules. Customers can combine these three different base module types depend- ing on the required number of I/O points and the amount of space available for installation.

2. Reliability: Duplexing of bus and improved environmental resistance The E2 bus as well as the CPU, power supply, control network, and internal bus of the FCN-500 can all be duplexed. Thus, even when a large system is configured using the E2 bus, reliability is assured. As with previous STARDOM versions, it is possible to check the operating status of the modules in the extension units and quickly detect any malfunctions using the VDS HMI, FAST/TOOLS SCADA, and other means, and any damaged modules can be replaced without having to shut down the FCN-500 controller. In addition, the extension bus interface module has been built to withstand ambient temperatures as extreme as −20°C and 70°C. (The existing interface module supports a range of 0–55°C.) This enhancement will make it possible to install extension units in locations where environmental conditions are extremely harsh. DW

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Internet of Things News

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announce their collaboration with IT-OT industry leaders to advance industrial device interoperability and to show the progress made in bringing the open, unified communication standard OPC UA over Time Sensitive Networking (TSN) to market. Leading companies active in these groups have pledged their commitment to ensuring the interoperability of deterministic industrial devices and have made significant investments in achieving this goal. Rapid developments of these technologies have been made over the last year. “With the rapid adoption of TSN as a foundational technology for automation, the community is increasingly relying on an interoperable set of network services and infrastructure. 17 market leaders are reinforcing their commitment to complete a unified communication technology,” said Todd Walter, Avnu Alliance Industrial Segment Chair. “By leveraging the liaison agreements of Avnu, IIC and OPC Foundation, we’re creating a faster process for the creation of an open, interoperable ecosystem of devices that take advantage of secure, guaranteed latency and delivery for

critical traffic. It is exciting to see the fruits of our labor in these milestones.”

The pillars of this announcement are: Conformance testing advances: •Avnu TSN conformance test plans for time synchronization of industrial devices are ready and available to test houses. A liaison between Avnu and OPC Foundation meets the needs of the industry with certification of OPC UA TSN products. At last month’s Avnu IIC Interoperability Workshop, more than 20 companies came together to demonstrate interoperability in

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the IIC TSN Testbed and to advance the conformance tests with the assistance of University of New Hampshire InterOperability Lab, an Avnu-recognized test facility. Test houses participated in preparation for their future roles to provide full conformance testing for manufacturers of industrial automation equipment.

Standards evolved, more vendors, •more devices: The Publish Subscribe extension for OPC UA is available in release-candidate form, enabling the exchange of OPC UA over UDP connections. This is the prerequisite for running OPC UA TSN. “OPC UA over TSN adds additional capability to the OPC Foundation portfolio, including enhancing controllerto-controller and machine-to-machine communication and information integration. OPC UA addresses the complex requirements of initiatives like Industry 4.0 and the IIoT, providing information integration between devices, applications and the cloud, providing the foundation for the muchdemanded seamless communication and information integration between IT and OT networks,” said Thomas Burke, OPC Foundation President.

Demonstrated interoperability between different vendors: Interoperability testing with the IIC TSN Testbed is progressing with eight handson plugfests taking place in the US and Europe over the past 18 months. More than 20 companies have participated in these face-to-face events to test and demonstrate interoperability between devices from various manufacturers and vendors – both collaborative and competitive. Many of the devices are already communicating in OPC UA data format. The results from the Testbed plugfests are fed into the conformance testing plans to ensure that the tests exercise the fundamentals of the architecture. “Our TSN Testbed stands as a showcase for the business value of TSN. The work coming out of the TSN


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Testbed is already having a direct impact on suppliers and manufacturers who see the technology as a value-add for their system structures,” said Paul Didier, IIC TSN Testbed Coordinator, Cisco Solution Architect. “Companies are invited to participate in our plugfests to test their own TSN devices for interoperability, including OPC UA Pub-Sub TSN devices.” As a next step these companies and organizations are committed to driving OPC UA TSN technology forward. By gathering test experiences in a production environment, the groups plan to develop further conformance testing for interoperability and extend the specifications for use cases that require even more precise timing. A full listing of the IIC TSN Testbed participants is as follows: Analog Devices, Avnu Alliance, Belden/Hirschmann, Bosch Rexroth, B&R Industrial Automation, Calnex, Cisco, Hilscher, Intel, ISW, Ixia, Kalycito, KUKA, National Instruments, OPC Foundation, Phoenix Contact, Pilz, Renesas Electronics, Schneider Electric, SICK AG, TTTech, WAGO, and Xilinx. DW

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Many Models, One Click of a button When Siemens added generative

design capabilities into its Solid Edge 3D CAD modeling system in 2017, it opened the door for engineers to design optimal parts that meet all their specifications faster than ever before. Generative design turns the traditional design approach on its ear and, in doing so, reduces part costs—often by reducing part weight--speeds product time to market, creates single-body parts and parts in organic shapes that couldn’t be designed or manufactured in the past. Parts with curved lines and with shapes taken from nature,


January 2018

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Generative Design turns the traditional design approach on its ear, reducing part costs— often by reducing part weight. It also speeds product time to market, creates single-body parts and parts in organic shapes that couldn’t be designed or manufactured in the past. Parts with shapes taken from nature can be printed with 3D printing after they’ve been designed with the generative process.

| Courtesy of Siemens


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January 2018


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A d v e r t o r i a l

Hall 3D printed a sample part in aluminum and found it strong enough to be used as a gas pedal in the customer’s vehicle racecar.

shapes that twist and bend, and that can be printed with 3D printing after they’ve been designed with the generative process. These unique pieces with attractive appearance stand out from the competition. Innovative products at the click of a button! Perhaps you’ve heard some rumblings about generative design though you’re not sure exactly what it is, how it differs from a traditional design approach, or why more companies are investigating this new design method. With it, engineers can design an optimal solution without using multiple CAD operations. And they can evaluate hundreds of viable options rather than a single design.

The creation from Solid Edge Generative Design tool is a single-piece assembly that is lighter than the original. Hall saw that the organic shape would have led to costly machine work to create it in the usual way, but he was using the generative approach with the goal of 3D printing.


The generative technique is a completely different approach to design. By calling upon advanced software and computing power the system runs through many possibilities based on the engineers’ design specifications and then presents the optimized design to the engineer. Engineers are involved at the beginning and at the end of the design process. If they don’t feel any of the returned designs meet their standards, they can adjust inputs such as the targeted decrease in weight of the component, and cue the generative-design system to start again. Here’s a close-up look at how engineers use generative design: Using a single ribbon on the Solid Edge user interface, engineers define a component’s material, the features critical for the simulation, and other forces and physical phenomena that will act upon the model. They also set constraints for the design areas that can be reshaped as the generative system runs through design possibilities, areas that are off limits, and areas where specific geometry such as load bearing surfaces or pivot points are required. From there, engineers press go. Solid Edge’s generative design software automatically generates design alternatives that meet all the engineering inputs. The engineer can also choose how long the design tool will run. The longer a simulation runs, the higher quality the results. Behind the scenes, the software is using an approach called topology optimization, which uses finite element methods to analyze hundreds of potential design solutions. It finds and then presents the best of the bunch—the most optimized models based on inputs—to the engineer.

Not Going Away While the process takes advantage of advanced software and computing power to optimize designs, engineers are still vital to the process. As we’ve seen, they need to understand design requirements, set design criteria, and go through the returned designs comparing optimized models in order to select the design that best meets their needs. While generative design software narrows the field, the engineer controls the final decision. After viewing results, engineers may find they need to modify their inputs and run another generative design study.

January 2018

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1/21/18 2:30 PM

Generate Ideas • Design Competition

— What’s your most interesting design idea? Let us know about your toughest component design problem and how Generative Design could help you tackle it—for a chance to win software and a 3D printer!

CAD programs continue to evolve to meet the needs of industry, Plugging pedal specs into Solid Edge’s generative design tool, including the instructions for the part to be made from a single-piece assembly, resulted in the program delivering this solution.

It’s important to know that the 3D CAD models returned through generative design use a mesh based 3D geometry representation, in which mesh that looks like a net made of flat triangles defines the model. The stereolithography method that 3D printers call upon to print parts uses the mesh method. So do the handheld or large instruments that scan a part to be reverse engineered. That method allows for the curved, shapely parts that don’t follow typical geometrical lines. But most current CAD systems use boundary representation, or B-rep, models, which serve as an exact mathematical model of a 3D part. Solid Edge allows you to combine mesh and B-rep models in one environment using Siemens convergent modeling technology. Engineers can use standard Solid Edge commands to add features to these mesh models such as cut outs, holes, or bosses to generatively designed models. The meshed results are integrated into the normal model-editing process so engineers can further optimize components and add specifc features. Also, generative models can be placed in assemblies side by side with B-rep models and be placed onto drawing sheets. Generative design is set to change the way engineering organizations work; the way engineers work. Individual engineers may eventually look like managers, only they’d be managing many software agents. They’d hand out tasks such as “go explore this design and


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January 2018


incorporating the ever-increasing computational power available to design engineers. From their humble beginnings, these programs have added helpful design tools such as FEA and CFD. Today, the groundbreaking new design tool is topology optimization. Design World is offering readers an opportunity to explore the possibilities of this type of program with their greatest component or product design challenge. Readers are invited to submit their design idea, with images, to be judged on feasibility, innovative potential and creativity. In 500 words or less, please describe in detail the problem/challenge for designing a specific component or product. Also explain why it’s important and/or how you would use the generative design approach together with 3D printing technology to design and manufacture the component or product. If possible, include images (in jpeg format). Submissions are due by February 28. Topology optimization programs use algorithms to optimize material layout and designed component performance within set spatial dimensions. Engineers use topology optimization software, like Siemens Solid Edge Generative Design, to handle applications in aerospace, medical, industrial equipment, and even consumer areas. These optimized designs cost less to make in material usage, time, and manufacturing assembly than designs made through traditional design and manufacturing approaches, and they often result in significant weight savings. The winner will receive one year’s usage license of Solid Edge Premium plus Solid Edge Generative Design Pro, as well as a desktop 3D printer from BeeVeryCreative to realize their vision. BEETHEFIRST+ is an easy-touse, plug & play, multi-material and portable 3D printer, specially designed for professionals.

Winner will be announced March 9.

1/21/18 2:30 PM


A d v e r t o r i a l Traditionally, a gas pedal often consists of five or six different parts welded together. In this example from Hall Designs, a race car components designer, two of those were machined pieces and the others were laser cut sheet-metal pieces welded together.

then generate a number of alternatives.” Engineers may have four to ten of these design tasks running simultaneously while they’re spending their time meeting with customers or suppliers, or doing any of the other myriad jobs engineers carry out in the course of the day. And when they return to their computer, they’d have many design alternatives waiting to be reviewed. In this way, generative design gives engineers more time, freeing up time traditionally spent modeling.

Opportunities Generative Design offers for manufacturing companies For manufacturing and engineering organizations, generative design holds the potential to cut the cost per part. It can, for instance, reduce the amount of material the part uses. This is because topology optimization running behind the scenes uses the

The generative technique is a completely different approach to design. By calling upon advanced software and computing power the system runs through many possibilities based on the engineers’ design specifications and then presents the optimized design to the engineer. Engineers are involved at the beginning and at the end of the design process. If they don’t feel any of the returned designs meet their standards, they can adjust inputs such as the targeted decrease in weight of the component, and cue the generative-design system to start again.


finite element analysis method to break the component into tetrahedrons and runs analyses on those tiny elements. In this way, it finds small and large areas within the design that contain more material than needed. Reducing the amount of material a part is made from is of particular importance to manufacturers that make parts in high volume, though the benefits can also apply to makers who use batch production or one-off parts. Less material in the original design means minimal downstream manufacturing material waste. Efficiency and energy consumption gains are seen when lighter-than-usual components are used for moving machine components. And of course when it comes to vehicles and airplanes, lighter components reduce energy consumption, which of course comes with environmental benefit. And those lightweight components also allow some manufacturers to meet regulatory requirements for the efficiency of their products. Another way generative design reduces manufacturing costs: the generative process results in a single, solidmesh body that can replace multibody components, such as a welded assembly. This reduces a manufacturer’s need to spend money on jigs, fixtures, welders, and welding material. And singlebody parts can be made via additive manufacturing, also called 3D printing, which also reduces the need to design and manufacture tooling.

Pedal to the Metal To see how generative design saves time and money while offering customers and consumers a wow factor, take the case of Hall Designs, which designs racecar components. Hall Designs began using Solid Edge generative design as a beta tester late last spring, says Craig Hall, company owner.

January 2018

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“I was just kind of playing around with it,” Hall says, “and then it took off and evolved into making an actual part for a customer.” Up to that point, the part, a gas pedal, had been traditionally manufactured. “Just a steel part, laser cut and bent, with machined pieces that had to be welded together,” in Hall’s words. The steel gas pedal was made from five or six different parts welded together, two of those were machined pieces and the others were laser sheet-metal pieces also welded together. He plugged pedal specs into Solid Edge’s generative design tool, including the instructions for the part to be made from a single-piece assembly. Not only did the generative tool return a design for a single-piece assembly that met all Hall’s needs, that design was for a piece lighter than the original, too, because Hall had told the tool to reduce the weight of the steel gas pedal. Hall Designs knew the part would be made via the 3D printing process and was pleased by the shapes that generative design returned. “That organic shape would have led to costly machine work to create it in the usual way,” Hall says. “I was using generative with the goal of 3D printing. From the beginning, we knew generative would save us weight and give a unique look to the part and separate itself from parts we’ve made in the past.” Hall 3D printed a sample part in aluminum and found it strong enough to be used as a gas pedal in the customer’s vehicle racecar. “We haven’t raced with it yet, but it’s a fully functional piece,” Hall says. He’ll continue to use Solid Edge’s generative design tool. “I spend my time taking customer parts and coming up with a generative shape as an option for them. When I have a lot of components on a piece, that’s when I’d really like to try to replace it, whether it be with a metal printed, or even a plasticprinted part.” All this with this new generative design technique. Engineers rejoice. Siemens PLM DESIGN WORLD

1/21/18 2:30 PM

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Traditional process - Designing a gas pedal

CAD Design


Iterate design until final choice

DESIGN ANALYSIS 3• 3• 3• 3• 3•

Complete 3D Modeling Loads and Material Run FEA Analysis Calculate Weight Iterations (1-X)


2 3

Send final to manufacturing

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Generative design process - Designing a gas pedal


Summary of Benefits Optimized Designs


Assembly: Gas pedal sub-assembly: 6 parts

Lighter Components

Lower Material Costs

Less Assembly/Welding

GENERATIVE DESIGN STUDY 3 Basic Size/Keep Out Areas 3 Mounting Points 3 Loads and Material 3 Weight Target 3 Run Study

Ready for 3D printing

Aesthetic/Organic Designs



Assembly: Gas pedal: 1 part


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1/29/18 10:53 AM

M o t i o n

C o n t r o l

How to design quiet gearmotors What applications need quiet gearmotors? The answer might surprise you — because the human ear can detect noise at 10 dB lower than ambient levels, and many gearmotors operate in close proximity to people. In this technical article, we outline recent staff engineers’ research and development into the problem (and potential solutions for) gearmotor noise.

Gabriel Venzin | President | ABM Drives Inc.


January 2018

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1/22/18 2:13 PM

Sound is the back-and-forth vibration of particles in a medium created when a traveling wave passes through the medium. Noise is undesirable sound. Sound pressure is defined with logarithms that compare sound pressure to the decibel (dB) sound pressure standard of 0.00002 Pa = 20 µN/m² near the lower limit of human audibility. One decibel is one tenth (deci-) of one bel, named in honor of Alexander Graham Bell. Gearmotor noise isn’t just a gear problem — it’s a system problem. Physical interactions between gears can excite system dynamics, so most gear noise doesn’t originate from the gears. Gear whine is created by the gears as they mesh and is amplified by resonances in the housing’s ribs, beams, and sides. Gear rattle is a sound that is excited by the driving source such as the electric motor. Each gear has its period of rotation and so a unique fundamental frequency. Why design quiet gearmotors? Consider where gearmotors must operate in public spaces. Here, motion control in churches, libraries, auditoriums and theatres need quiet gearmotors for curtains, podiums and stages that need to

rotate, lift or slide, unnoticed by the audience. In contrast, military equipment needs quiet gearmotors for Stealth operations. Medical equipment benefits from quiet gearmotors for increasing patient comfort and assurance. Residential settings — for example, in biomass heating systems — benefit from quiet gearmotors as well. Here, stored wood chips or pellets in a silo must be conveyed to a boiler by an auger via a motor-driven rotary feeder — and ash removal is accomplished the same way. Gearmotor basics: Functions and today’s design process A gearmotor delivers high torque at low speed. It’s a combination of a gear reducer and an electrical motor. In short, gearmotors take motor power and reduce its speed while magnifying its torque. The two most important factors at the gearmotor output shaft are rpm and torque. So once the input-torque requirement is known, the next step is to calculate the needed motor-input horsepower. The gear train inside a gearmotor multiplies

Simulation to optimize a proposed gearmotor design can reduce overall design time by as much as 75% — and 3D models that completely define the gearmotor can be used by quality, manufacturing, and procurement teams to analyze, build, and inspect the gearmotor. 3D illustration courtesy ABM Drives Inc.


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M o t i o n

C o n t r o l

Single-stage helical geared motors and drives with helical gearing ensure quiet operation and long life.

torque from the motor side to the output shaft. This is the gearbox ratio and is the number that determines the torque multiplication from input. 30:1 means that the output torque is 30 times the input, not accounting for internal efficiency losses. A right-angle or parallel-shaft gearbox can combine with permanent magnet dc, ac induction, or brushless dc motors. Advanced gearmotor technology includes the use of new materials, coatings, bearings, and gear tooth designs optimized for noise reduction, strength and longer life, in smaller spaces. Gearmotor designs are for specific operating conditions and load ranges. So at the start of a machine build with known problems or opportunities for improvement (including possible economic gain or improvement in how personnel or users perceive the gearmotor)

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consider the motion components and features (including gearmotor options) that might work. Then narrow down the options to feasible alternatives. Next identify those with the best balance of performance and economics to reach a design target. Finally, integrate the most feasible, risk-reduced, and economically viable features and capabilities into products with both form and function. Such a design approach is now easier than ever. In the past, designs often started with mechanical engineers and then passed to the team’s electrical engineers and finally onto the control engineers. By the end, all the flaws were baked into the design. In contrast, today the standard is integrated design supported by mechatronic modeling. But with holistic design approaches, engineers must understand the accuracy requirements of the entire electromechanical system. Another caveat is that control system, drives, and gears and mechanical linkages must be carefully chosen to leverage all the components’ full capabilities. That necessitates a design approach that starts from the drive back to and including the motor. More thorough and detailed design objectives boost the odds of project success. So keep the motivation behind the project top of mind and allow that motivation to guide engineering decisions. The goal is to have a system to serve humans and not the design itself. The old adage, “You’ll never get there if you don’t know where you’re going” certainly applies to the design process. One indispensable tool in engineers’ arsenal — especially in the work of making machine builds as quiet as possible — includes simulation to optimize proposed designs. Such software can reduce overall design time by as much as 75%. In the case of gearmotors, 3D models and associated data help engineers analyze and virtually build and inspect their gearmotors — and completely define the assembly to improve quality, manufacturing techniques, and procurement.


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Noise generated when gears engage Selecting gears and motors is a science. Even suitable gears make noise. Complicating matters is that gear noise comes in many types. To solve gear-noise problems, the first step is to determine the type of noise that is objectionable. What’s considered gear noise depends on the speed of operation. Use qualitative and quantitative terms to describe how design factors and manufacturing mistakes play into the noise equation. Then discuss with the design team (and potential suppliers) the problems of gear noise, dynamics, measurement, and modeling. Another starting point for gearbox design is to define a service factor — including hours per day and shock or vibration requirements. A gearbox with an irregular shock profile (as in a military design, for example) requires a higher service factor than a gearbox that runs intermittently. Gear noise is generated by tooth-to-tooth load transfer that causes pressure-pulse trains radiating through the gearset and motor housing. The noise’s frequency is the product of gear rotational speed and the number of gear teeth. Most types of gear noise occur at tooth mesh frequency or harmonics in the audible range. That said, noise can also occur as a lowfrequency modulation of the higher tooth-mesh frequency noise. This results in a phenomenon called sidebands. Gear noise can be very annoying — even when it isn’t the most significant noise source. That’s because it occurs as pure tones that the human ear can detect even at 10 dB lower than the overall noise level. The asymmetric gear noise spectrum arises from amplitude and frequency modulation of gear-mesh excitation produced by low-frequency manufacturing and assembly errors. Gearmotor sounds from gear mesh, bearing rotation, lubricant movement, motor vibrations and interaction of the housing all contribute to the overall sound generated. Vibration tendencies can be minimized with high-quality helical gearing and optimized gear engagement. Helical teeth engage gradually over the tooth faces for quieter and smoother operation than spur gearsets and have higher load capacities. Shuttling force is the side-to-side oscillation of the tooth mesh force along the profile as the tooth pair undergoes the engagement process. The oscillating force can cause dynamic


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excitation to the gearbox system. Since it occurs at the mesh frequency, it contributes to the gear noise response. With double helical gears, this axial force is eliminated. The tooth finish contributes to the sound generated. Helical gearing that has only been hobbed is louder than helical gearsets that have been shaved or ground to remove rough tooth-surface finishes that hobbing generates. Use noise optimized gear geometry to minimize the impact of individual gear engagement impulses. Designing and analyzing gears as a system lets engineers improve and optimize microgeometry for the reduction of gear noise. Pitch: A gear system with normal pitch of the driving gear a very small amount larger than the normal pitch of the driven gear delivers more silent transmission. Minimum noise requires a contact ratio smaller than 2 or 1. Even under a slight load, the influence of torsional stiffness is important.

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Contact ratio: The gear contact ratio is the average number of teeth in contact. It usually varies between 1.2 on the low end to 1.8. Spur and straight bevel gears with operating contact ratios under 2.0 create more noise than gears with larger contact ratios. Helical and spiral bevel gears have total contact ratios well above 2.0 and produce less noise. A smooth, quiet and higher speed gearset may have more teeth, finer diametrical pitch, lower angle pressure, and a higher contact ratio. Changing one of them can change many of the other design elements. Optimizing the entry and exit points of gears reduce vibration, noise, sliding friction and heat generation. All gear designs are a compromise to reach the target results. It’s clear then why quiet gearing must be very precisely manufactured. High-quality gearing guarantees quiet operation. With high precision manufacturing, gear noise can be cut from an average level of 82 dB to 77 dB measured 300 mm away from the pitch point. Torsional modes may be excited by low order harmonics of shaft rotation; the magnitude of excitation is directly related to gear machining errors. No matter the design, make the normal pitch difference as small as possible. The profile form error should be as close to the theoretical involute as possible. The key is in the finishing method after hardening to ensure final accuracy.


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Traction drive systems as the one here from ABM Drives can be configured as bevel gearboxes, helical gearboxes, or hub wheel drives and offer high efficiencies and quietness.

Indexing and positioning elements

Also keep in mind that it’s impossible to eliminate all gear noise, because it’s impossible to cut perfect gears. Even if one could, it’s impossible to limit the effect of system dynamics. One can only minimize and control gear noise to the extent that it won’t be considered problematic or audible.

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Minimize gear noise in high-speed stages by fine machining and grinding. Gearmotor rotation speed plays a significant role in noise generation. There’s very little difference between a hobbed-only gearset rotating at 30 rpm versus a groundfinished gearset. But at higher gearset speeds they exhibit a more noticeable sound difference. During gear manufacturing, hobbing is a roughing operation that produces smooth and accurate gear teeth. Shaving and hardening are finishing operations improving dimensional accuracy, surface finish, and hardness. Shaving removes small amounts of material to correct profile errors. Final DESIGN WORLD

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M o t i o n

Compact parallel-shaft motor and drive designs are excellent for small space and quiet running requirements.

grinding operations produce a high surface finish, correcting any distortion following heat treatment. Precision ground gearing provides for low noise and extended life. Quiet operation requires minimal gear backlash. Backlash is clearance between mating gear teeth and should be enough to allow lubrication film between the teeth. The easiest way to reduce backlash is to shorten the distance between gear centers with low or even zero clearance. Such an approach lessens variations in center distance, tooth dimensions, and bearing eccentricities. Variables such as manufacturing errors, mounting tolerances, and bearing play often increase backlash in a gearmotor. Precision gearmotors minimize such imperfections by incorporating close-tolerance parts. Typically, they combine hardened precision


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gears, quality bearings and machined housings with close tolerances. To minimize noise, all gearbox components should be optimally tuned to each other. Three types of gear tooth transmission errors are spacing errors, random errors, and elastic deformations, which combine with mean profile deviations. Gear resonance can be reduced by identifying excitation mechanisms; using finite element analysis to determine the natural frequencies of individual gears; eliminating torsional modes from operating range; detuning and damping helical and bevel gears; and identifying remaining resonant problems with other elements of the gearmotor such as housings and accessories. Vibration is generated at the gear mesh because of time-varying mesh stiffness, manufacturing errors and assembling errors. This vibration is transmitted to the housing through shafts and bearings. The radiated noise is induced from the vibration of the housing. Because geabox vibration and noise significantly degrade performance of gear transmission, the prediction and control of gearbox vibration are paramount to design output-motion reliability as well. Simulate the radiated noise of a gearbox using software that uses the finite element method (FEM) and boundary element method (BEM). Such software helps identify the assembly’s mode order and which housing sides make the maximum acoustic contributions. Here, one solution for especially noisy portions of the housing is to add ribbing to reduce the radiated noise. Reduce natural resonance by optimizing housing designs with ribbing and nonsymmetrical components — especially on parallel-shaft gearbox types. Motor housing and gearbox covers should be single die-cast components to eliminate the tolerances on motor-gearbox interfaces (a common problem area for noise and vibrations). They should harmonize ideally with each other. Depending on housing design, parting lines can fall on the top or bottom and be stepped or angled. For silencing, trimmed and precisely machined aluminum die-

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A smooth, quiet and higher speed gearset may have more teeth, finer diametrical pitch, lower angle pressure, and a higher contact ratio. cast housings additionally reduce noise emissions. Tight-fitting housing covers and flanges prevent distortions that can amplify noise. Aluminum housings absorb harmonics and other vibrations better than cast iron. Even a 10% increase in wall thickness can boost stiffness by 33% or so. But adding ribs, corrugations, and curves to die-cast housings keeps material costs low while maintaining rigid strength and durability — even in assemblies with thinner housing walls. Effective rib arrangement positions are in arcs on the panels with large acoustic contributions. The ribs are effective when placed along the lines from the effected location to the nearest fixed points of the housing. Arranging ribs on the housing surface is one of the main techniques to stiffen the gearmotor housing. Next to metal selection, maintaining uniform wall thickness is critical. Wall thickness is a balance between strength and weight. Wall thicknesses dictate the consistent flow and thermal properties during the die casting process. Size, geometry and wall thickness requirements have an impact on tolerance.

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Thicker walls produce larger shrink rates depending on the material. Generally speaking tight tolerance parts for die-casting is + /- 0.002 inches. Many factors are put into play such as materials, part complexity, tooling and the die casting process. Excitation from the motor’s electromagnetic field can transfer to the rotor, so look for motor rotors that are sturdy and robust. Stator magnetic forces vibrate the rotor as any ring when struck. The stator vibrates in one or more of its flexural modes; models represent the core as a beam supported on both ends and flexing due in response to applied forces. Analysis demonstrates that vibration arises from electrical imbalance or mechanical unbalance (in the motor, coupling, driven equipment); mechanical effects (in the form of looseness, rubbing, and imbalanced bearings); external effects (in the base or driven equipment or from misalignment); and excitation of critical resonance speeds. Tip: During analysis, list all possible causes for the frequencies under examination. Then eliminate the causes one by one until all that remains is the true source of the problem.


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Two and three-stage helical motors and drives from ABM Drives are quiet, durable, and offer high efficiency for low energy consumption.


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Key to quiet operation is high-quality rotor balancing. All types of rotating machinery need balancing at operating speed. Rotor balance involves the entire structure — shaft, rotor laminations, end heads, rotor bars, end connectors, retaining rings, and fans. Only careful control of the design and manufacture of these motion components ensures stable and precise motor balance. If the motor’s operating speed coincides with the housing resonant frequency, amplification will occur. The only option is to change the resonant frequency of the housing — usually by changing the stiffness or weight of gearset, housing, or motor. When choosing manufacturing partners during a machine build, remember that there are two methods for choosing a gearmotor. One is selecting a preengineered unit and the other is choosing a


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gearbox-motor combination and integrating them into the equipment. Pre-engineered gear solutions are suitable if a design engineer doesn’t have the time or engineering resources to build a gearmotor in-house — or if the design needs a quick setup. New modular approaches to support OEMs (and enable new machine tools, automation, and design software) now let engineers get reasonably priced gearmotors even in modest volumes. It’s true that one benefit to selecting a separate motor and gearbox and then combining them can less expensive than choosing a pre-engineered gearmotor. Another benefit to this approach is that one may be able to design the most optimized gearmotor for the application at hand … because this approach also gives the design engineer the most control over the final configuration and cost.

No matter the approach to gearmotor selection, be sure to continually improve the design by comparing predictions of noise with measurements of noise by using spectrum analysis. Then use the result of the analysis to improve next gearmotor iteration. DW ABM drives |


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Customizing conveying systems As more companies look to automate processing lines, they’re relying on conveyor manufacturers for an assist. Here’s why. Mike Hosch | Vice President | Industrial Products | Dorner Mfg.


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demands efficiency, and conveyors are one technology to enhance the productivity of processing lines. No wonder then that conveyors have become integral components in all phases of the automation, assembly, and industrial markets. What’s more, while some of the dominant global brands have been early adopters to embrace the full potential of conveyors, more companies of all sizes are taking a closer look at how they too can better integrate conveyor systems to ultimately improve entire lines. Though integrating such conveyor systems can be daunting — especially those meant to become an integral part of larger processes — manufacturers offer help. The first step is to evaluate application and determine the expectations for conveyor system. Even for this step, resources about to make this process easier. Pallet conveyors coordinate tasks: The manufacturing environment inside facilities is much different than what it was a generation ago. Automation is now a prime driver behind the way products are produced. Many applications include both manual processes and robotic interaction … so conveyors today

must be engineered to meet these challenges. That’s why pallet system conveyors have become a popular choice. Pallet system conveyors are suitable for many automation-focused applications that need exact movements and positioning of parts, as they can be setup or programmed to start and stop at specific intervals to synchronize with robotics or other processes. These conveyors dominate

New waves of technologies are transforming not only the way products are produced and packaged, but manufacturing facilities as a whole. Flexibility and connectivity are paramount to equipment design, and that’s perhaps most true for conveyors. The conveyor here serves a bank of robots that assemble commemorative products.


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Pacing conveyors to stagger items:

There’s a suitable conveyor system for every installation. Shown here is a precision palletsystem conveyor from Dorner.

automotive-component manufacturing and other industries — including medical devices, electrical and electronics, and product testing and inspection that require automated and manual assembly (or handling) of products. Pallet system conveyors typically come on three different platforms to convey the pallet:

• A dual-belt configuration powered by a common drive • A flexible plastic chain or belt design • A linear motor Pallets can stop and raise up off the belts or rotate the pallet 90° or 180° to reposition product as needed. Companies using palletsystem conveyors are leveraging their accuracy. These conveyors put products at exact locations — and conveyor lift and location stations deliver repeatability of 0.002 in. Pallets can come in either square, rectangle, or octagon shapes; they can make tight turns and travel up inclines or down declines as well.

Pallets can stop and raise up off the belts or rotate the pallet 90° or 180° to reposition product as needed. 104

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Another type of conveyor that’s increasingly common in manufacturing automation and packaging are pacing conveyors. These conveyors take randomly spaced products and orientate them into even spacing for packaging, machine infeed, or other processes. The system usually has two variable speed belts and a moveable conveyor junction. This two-belt design allows pacing conveyors to operate at a faster rate than a standard one-belt conveyor. As randomly spaced products enter the conveyor, a photo eye detects the product spacing. Then a servomotor control automatically varies the conveyor speed and conveyor junction placement to evenly space product. Pacing conveyors are completely noncontact sand contain no guides, diverts, or plows. Usually these conveyors have HMI interfaces to let operators set the spacing, speed, and orientation of products. That in turn helps applications that require the merging multiple lanes together without product stops or gates. Flexible chain conveyors for tight spaces: Some application designs need products moved in and around equipment and machinery. Here, conveyors must be flexible and make tight turns. Flexible chain conveyors are a good fit here. Automated applications within processing and packaging, industrial, medical, life sciences, and health and beauty industries often operate in tight spaces or in plants that require product elevation changes (for storage and space management) so are benefit from integration of flexible chain conveyors. In fact, the flexibility of these conveyors extends past the platform itself. Their ability to twist, turn and snake around tight places gives design engineers and plant managers the flexibility to easily integrate the conveyors with existing equipment.


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Dorner SmartFlex conveyors are capable of taking discrete products around curves, through jogs, and over inclines and declines.

Precision timing-belt conveyors: Many industrial automation, product assembly, manufacturing, and packaging applications need product in exact spots on the conveyor at the right time. Precision timing-belt conveyors excel here. Powering the conveyor to deliver accurate alignment of time and distance are servomotors that provide indexing repeatability of ±0.040 in. at a rate of 100 indexes per minute. This level of precision is critical — especially in robotic applications.

This is a Dorner Precision Move Pallet System.


Selecting the right conveyor system Clearly there are many conveyors engineered for automation-type applications, but the objective is to select the right one for a given application. Conveyors built to specification improve productionline efficiency and output. So there’s no reason to settle for a conveyor that’s shoehorned into application, especially when a system can be engineered to seamlessly integrate into a larger process. But to do that requires an understanding of what the goals and expectations are for conveyors. In other words, what must the conveyors to do? Knowing this upfront establishes a good foundation for a successful conveyor installation. Whether the conveyor system is to serve the operations of an OEM or integrator, a small family-owned shop, or a multinational business, there are common design concerns regarding new conveyor installations. Begin to outline the conveyor objectives by answering these questions:

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Some Switches Need Wires. • How will the conveyor system integrate with what the plant is trying to build? • What is the height, weight and shape of the product(s) being moved? • What’s the targeted rate of production? • How much space is available for the conveyors? • Is space likely to be tight, needing conveyors to make sharp turns or go up inclines? • Is the machine or production line manual or automated? • Is the anticipated flow of production linear or oval? Quantifying this information upfront helps get a more complete picture of the application — and define the project scope to let the conveyor supplier streamline the quotation process.

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Application expertise for conveyors Consider the above questions to envision how conveyors should interact with the processing line or project into which they’re integrating. All components within an assembly automation application (including conveyors) should work together optimize the overall operation. Answering the above questions can also identify where improvements in product flow and handling can be made. Such analysis may determine no improvements are necessary — and that’s great. But if a planned conveyor system isn’t quite meshing with other application systems, or it appears as though the target output is in jeopardy, reviews can help ... and in fact, this is where reputable conveyor suppliers prove their worth.

Perhaps more valuable than the actual conveyors are supplier knowledge and experience integrating designs for material handling and industrial automation. Collaborative discussions with conveyor suppliers and identifying potential design roadblocks is a great way to start. Some suppliers accept responsibility for the ultimate design and do heavy lifting to supply conveyor systems that are specifically optimized for the application at hand. Of course, collaboration doesn’t necessarily result in custom conveyor designs — because after all, standards offerings are less costly than custom. But good supplier recommendations are typically based on using standard products as much as possible while integrating custom designs where

needed to ensure reliability and flexibility. That’s why a one-size-fits-all conveyor isn’t always the best choice. The goal of a welldesigned conveyor system is to serve the process ... and not to fit the process to the conveyor. DW Dorner Mfg. |


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Dorner SmartFlex Pallet Systems are suitable for product routing, control, and inspection. They accurately position product for assembly automation (in medical, electronics, and more) and come in modules to maximize flexibility in design and layout.


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PID design

using frequency-domain methods With motion control applications, a PID or proportional + integral + derivative controller is often implemented using tuning or by a trial-and-error process on the shop floor. But modeling of the motion control system allows analytical derivation of the PID controller terms.

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Modeling a motion control system begins

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At the summing junction, feedback is subtracted from the target position R(s) and the result is an error E(s) that is sent to the PID controller. In motion-control applications the PID controller operates in discrete time with a sampling period. Every sampling period, the digital controller takes the error signal and produces an output within ±10 volts. It does this using a zero-order hold and a DAC or digital to analog converter. The zero-order hold refers to the process of sampling the signal and then holding between intervals; this introduces a delay into the system. The digital to analog converter then takes the output of the PID controller and converts it to an analog voltage. The amplifier takes the voltage signal and produces an output current to the motor. The linear actuator takes the output current and produces a linear force which translates into output position. The linear encoder provides position feedback to the controller typically using a quadrature signal measured in counts. While the model is a mixture of discrete and continuous time elements, let’s execute an analysis in continuous time to simplify the model. In fact, the modeling of the motion control system takes place in the s domain using Laplace transforms to derive the transfer functions. The s-domain transfer function for

with a block diagram. Diagrams show this model includes several different elements. Those of a closed-loop motion control system include an output position C(s) that’s constantly monitored using


feedback … in this case, a linear encoder.

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Note that these calculations are not a guarantee of system stability. The engineer must check the system response to a step input using the closed-loop transfer function … and must also check system stability using a Nyquist plot. the PID controller in ideal form is:

Where Kp is the proportional gain, Ti is the integral time constant, and Td is the derivative time constant. Letting Ki be the integral gain and Kd the derivative gain:

The amplifier is modeled as a constant gain Kam. To account for its limited bandwidth fb a first-order low-pass filter is added. The time constant of the filter is tam:

Letting Kam = 2 amps/volt and fb = 2,000 Hz:

With these terms, the parallel form of the PID controller can be implemented:

The zero-order hold transfer function is a first-order low-pass filter with sampling period tsh/2:

The linear actuator is modeled as a gain Kf — the linear motor force constant plus the Laplace transform of F = ma. Here, a is the acceleration and m is the mass of the actuator and payload. The model assumes no friction as the system will be using an air bearing. The actuator transfer function with output in position (meters) and input in current (amps):

Letting tsh = 0.001 sec: Letting Kf = 8.9 Newton/Amp and m = 00.5 kg: The DAC is modeled as a constant gain with n bit resolution:

Letting n= 14 bit:


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The linear encoder is modeled as a gain Ke. If the resolution of the linear encoder is 0.1µm/count, then the linear-encoder gain is Ke = 10,000,000 counts per meter. The multiplication of all elements from the zero-order hold to the linear encoder is known as the open-loop function — Gp(s) DESIGN WORLD


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L i n e a r

M o t i o n

H(s). The open-loop function in this frequency domain analysis is:

Solving for the PID derivative gain:

The response of the open-loop function to a sinusoidal input is called its frequency response. The frequency response can be calculated by substituting s by jw in the open-loop function. Steady state response is then:

Lastly, solving for the PID integral gain:

Where the difference between the output and input sine waves can be described by two parameters — magnitude M and phase f. Magnitude measures the amplitude ratio and phase measures the phase shift. The magnitude and phase can be determined with a calculator for low-order systems. For higher-order systems, the magnitude and phase can be determined using technical computing software such as Matlab or GNU Octave. First — we need to calculate the phase of Gp(jw1)H(jw1) or argGp(jw1)H(jw1). This is the addition of the phase shift for each element of the open-loop function at the specified frequency w1. The specified frequency must be chosen … let us choose 487 radians/sec:

Note that these calculations are not a guarantee of system stability. The engineer must check the system response to a step input using the closed-loop transfer function … and must also check system stability using a Nyquist plot. Finally, to match the PID gains to controller, the form of the PID must be the same. For example, the motion controller PID must take the suitable or parallel form. Otherwise the gains won’t calculate to appropriate values. For more information, read Feedback Control Systems, Fifth Edition — by Charles L. Phillips and John M. Parr. DW Advanced Motion Concepts Inc. |

Second — the magnitude |Gp(jw1)H(jw1)| is calculated as 1.749. Third — we need to specify the phase margin fm (or stability) of the system. Phase margin is the difference between the actual phase and -180° at the frequency w1 where gain equals 0 dB. We choose a 62° phase margin.


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Fourth — the argument or phase shift contribution of the PID controller can then be found:

The magnitude of q must be less than 90° … Now we can solve for the PID proportional gain:

Solving for the derivative time constant:


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Despite the buzz about the IoT and the IIoT, the development of tools and programs for the design of IoT systems and equipment are still embryonic. But there are signs of progress. Here’s what industry leaders are saying about developments in IoT technology. Leslie Langnau | Managing Editor

The Internet of Things (including the Industrial Internet of Things) is: A concept—a view that the analysis of tons of gathered data will, if all goes well, help improve manufacturing efficiencies. l A hope—The use of these analyzed data will enable a company to increase its bottom line in the form of new services, or new performance due to the analysis. l A perspective—now that we have the tools, the digitization of everything will usher in a new age of optimized systems, and perhaps even systems that adjust themselves to manufacturing needs automatically. l And sometimes, an actual hardware component—primarily sensors today, but eventually AI enabled or controlled electro-mechanical systems. l


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It is the task of the design engineer to find ways to develop products that deliver on one or more of the above four views. Despite the buzz that’s been around this industry for several years, though, the development of tools and programs for the design of IoT systems and equipment are still embryonic with sensors and preventive maintenance services being the main offerings. Analytical software is coming, but also still in development as algorithms need to mature. The most frequently mentioned applications of IoT today are services, especially preventive maintenance services. These services are an improvement over what has been available for a decade or more. Yet they are not ready to deliver on the promise of manufacturing machines evaluating themselves and implementing improvements automatically. But there are signs of progress. We asked several industry leaders about the developments in IoT technology.


What hardware trends do you see coming for designers of IoT automation systems? “One hardware trend we see coming,” says Benson Hougland, vice president, Opto 22, “is edge gateway appliances for automation systems, which facilitate communications and data exchange between OT (operations technology) domains and IT (information technology) domains.” As Hougland noted, IoT platforms, software, and applications typically do not easily or directly support industrial automation communication protocols such as Modbus/TCP, EtherNet/IP, ProfiNet, or even OPC. These protocols have served the OT world well, but the IoT relies on communication protocols, data formats, and tools more common in the IT world. These communication protocols and so on include, RESTful APIs, JSON, MQTT and NodeRED. Edge appliances that enable communication will help designers move forward in their IoT designs. While sensors are an important part of the IoT, communication is just as crucial. Notes Oscar Rojas, CEO, Weintek USA, Inc., Ethernet offers a number of advantages, including “its lower cost, faster speed, higher reliability, and better noise immunity. More

PLCs, from basic models to advanced ones, have adopted Ethernet interface as standard equipment, and it can be expected that within the next five years, Ethernet should rise as the standard communication method between HMIs and PLCs.” But Rojas sees a potential challenge with the IoT involving WiFi. “Real time access to monitoring or controlling management centers is becoming critical to industrial automation. Unfortunately it is not always easy and sometimes it is virtually impossible to install an Ethernet wiring connection between on-site machines and the upstream ERP-level applications and supervisory management center.” Thus, integration between the operations technology and the intelligence technology still is an issue to the advance of IoT applications. In addition to edge devices and Ethernet, digitization is the next feature or capability needed for IoT. “Digitization is a key megatrend impacting industrial companies today,” says Gerald Espy, Product Manager – PLC Business, Schneider Electric. “While there are parts of the industry that have been connecting devices for operational efficiency for years, the benefits of digitization for industries is only now being recognized across the entire industry. The evolution of these technologies has drastically reduced the marginal cost of connectivity, communication, and data analysis leading to greater operational efficiency and overall profitability.” IIoT-embedded devices will be key hardware components, enabling devices to connect with the other parts on the machine or plant floor, as well as cloud-based digital applications, analytics and services at an enterprise level. Espy agrees with Hougland that edge control is a critical area of focus for future automation systems, especially for managing the analytics tools to which they’re connected. “And cyber security will be a must at every level of an implementation,” continued Espy. “A chain is only as strong as its weakest link. Designers will see more encrypting features in firmware, true embedded hardware password protection, and other cyber security features for their design needs. Physical security will also be a must. “With the availability of connected systems, a natural extension is an intelligent physical

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security device to provide remote control and monitoring of access to equipment and restricted areas,” says Steve Spatig, general manager, Electronic Access Solutions, Southco, Inc. “These smart locking devices can then be controlled and monitored remotely with a cloud based control system. Data collected can provide forensics for security or safety breaches and provide simplified control and distribution of access credentials.”


What are the software trends for automation systems? “The most obvious software trend is data analytics,” says Arun Sinha, Director of Business Development, Opto 22. “The promise of the IoT includes things like preventive maintenance and prescriptive algorithms, which are achievable through data science and analytics. The good news is that the designers of automation systems don’t need to become data scientists. Many IT companies large and small are developing IoT platforms with sophisticated analytics engines. Examples include IBM Bluemix, Microsoft Azure, and Hitachi Lumada. Some now are even putting a strong focus in their portfolio on specific solutions for manufacturing intelligence. Designers of automation systems should probably familiarize themselves with these platforms’ capabilities, but focus their design efforts on embedding the communication methods and data formats that these platforms require.” “We see a shift toward more user-centric software, rather than machine-centric,” says Espy. Open and hardware-agnostic software enables manufacturers to give customers access to a full spectrum of industrial applications and services to address their own unique areas of operational efficiency improvement, no matter what devices are installed in their automation system. Putting this power in the customer’s hands allows them to get the right applications for the specific configuration and installation of their operations when they need it most. Of course, software services and 24/7 support should always be included to support the customer when needed.


Schneider Electric sees opportunities coming in the form of augmented reality and transparent cloud-based connectivity for operators. “Mobile devices empowers operators to increase productivity,” continues Espy. Tighter integration between management and what is happening on the plant floor through a suite of enterprise level applications enables more agile and accurate management decisions. Spatig agrees, noting that cloud based solutions with web portal administration versus on premise software installation and maintenance provides a cleaner user interface, without the need for software maintenance and revision control.


What new “products” do you see coming as a result of designing IoT capability into automation components, systems, and equipment? The IoT is a concept that somehow must be rendered into useful products. One key to developing such products will revolve around a business’s end-goal, such as cut downtime, improve quality, or increase security, or increase profits. Products will range from simple, single-purpose to sophisticated systems. One example of simpler IoT products involves security. “Innovative smart locking solutions will be enabled as a result of the connected facilities,” says Spatig. “Physical security will be enhanced and simplified to bring remote access control and management down to the equipment level - something previously only practical at the architectural, building level. More complex products will not necessarily fit COTS approaches, however. “IoT applications in end-user locations such as manufacturing facilities and process

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Digitization is a key megatrend impacting industrial companies today. While there are parts of the industry that have been connecting devices for operational efficiency for years, the benefits of digitization for industries is only now being recognized across the entire industry.


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IIoT opportunities are coming in the form of augmented reality and transparent cloud-based connectivity for operators. plants are different from one to the next,” explains Hougland, “so the concept of a turnkey or COTS ‘product’ from designing IoT capability into automation systems may not be common in the marketplace. Instead, the “product” may take the form of a goal or desired outcome, such as decreasing downtime, increasing efficiencies, or improving quality. The common thread is that these desired outcomes usually start with a business goal, like increasing profits.” Initially, many OEMs are exploring the “increase profits” goal by developing products that are services. “For example, a compressor manufacturer may not charge for the equipment, but rather for the CFM (cubic feet per minute) delivered by their machine,” adds Hougland. The remote monitoring made possible by IoT capability built into the automation system on machines usually through an edge gateway appliance enables such services. Another forecasted product will be “smart” machines, machines capable of reacting to a change in the market automatically and adjusting accordingly, without supervision. “These new smart machines are better connected, more flexible, more efficient, and safer than traditional equipment,” says Mark Duncan, segment manager, material handling, Schneider Electric. “They can quickly respond to new demands and participate in preventative maintenance, all while minimizing thier environmental footprint and total cost of ownership.”


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These smart machines will be selfaware thanks to wired and wireless sensors with embedded intelligence that monitor the components of the machine to avoid component failures and the associated downtime. The information gathered by these machines will also be distributed locally or to a remote cloud, automating decision making on the factory floor. “These machines must also be safe and cyber secure with embedded products like safety PLCs, light curtains, and safety cameras to keep the users and machine safe from harm,” continues Duncan. “With direct connection to the broader Ethernetbased network, the IIoT-embedded devices should have strong communication capabilities, as well as cyber security certifications like Achilles Level II. Finally, by leveraging the wireless network that these smart machines are connected to, operators can use their mobile devices to control machines and processes while moving around the plant floor. Soon, these operators will be able to use augmented reality and artificial intelligence to accomplish these same tasks in real time.” DW

Opto 22 | Schneider Electric | Southco | Weintek |


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With issues such as temperature extremes, washdown capabilities and cleanliness considerations, components for this industry must be thoughtfully selected.

How to choose pneumatics in food and beverage processing Richard McDonnell | Marketing Development Manager, Motion Systems | Parker Hannifin Corp.

Recently, a food processing OEM was designing and installing a new line of extremely high-speed filling machines intended to deliver higher performance with a smaller shop floor footprint. Redesigning the pneumatic valve system in the OEM’s machinery using collective wiring and stainless-steel filter-regulators cut the size of the overall footprint nearly in half and minimized both build and installation times. By relying on a supplier that understood their overall processes and helped them choose the right components, the OEM was able to realize a variety of bottom-line advantages:

• They halved the size of machine’s control panel. • Their costs for components decreased by almost $1,000 per machine. • Each machine required one hour less wiring time and one hour less plumbing time. • There was an operating cost savings of $2,200 per machine ($22,000 per year).


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P n e u m a t i c s

Figure 1. The “positive geometry” design of the P1D-C Clean pneumatic cylinder eliminates recesses, grooves, and pockets where liquids or contaminants could collect. Note its convex shape body extrusion, end covers without any cavities or recesses and the protruding cushioning screws. For applications where harsh chemicals may affect the scraper in the front-end cover, an optional FPM (Viton) rubber scraper can be specified. | Courtesy of Parker Hannifin Corp.


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Redesigning the pneumatic valve system in the OEM’s machinery using collective wiring and stainless-steel filter-regulators cut the size of the overall footprint nearly in half and minimized both build and installation times. The combination of timely advice and intelligently chosen pneumatic components is critical to the ultimate success of systems like these. For any given application, selecting the optimal pneumatic component depends on understanding two main issues:

• The required operating performance and parameters • The operating environment.

For example, when considering the operating performance requirements for pneumatic cylinders, design engineers first must determine parameters such as available air pressure, desired speed and cylinder power, and maximum theoretical force. This force must

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be 50-100% greater than the basic force required, to account for effects such as friction, potential lateral loads on the piston rod and braking effects at the end of the stroke. These values are typically included on the manufacturers’ datasheets; if not, the manufacturer can offer guidance on calculating them. Standard pneumatic cylinders have an end cover, cylinder, piston, piston rod and front gable, along with a piston rod bearing and scraper seals. Their general design adheres to ISO standards. In most applications, the cylinder and end caps are made of aluminum, to provide the level of strength required without adding excessive weight; chrome-plated steel or stainless steel are often used for the piston rod.

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Figure 2. Food and beverage processing equipment must often work in extremely low temperatures (such as in an ice cream production facility) or extremely high ones (such as a baking plant). Look for pneumatic cylinders that offer options for whatever conditions they will encounter, such as the P1D-X series, which employs advanced seal technology and other design features to allow it to work in extreme environments as low as -40° C or as high as 150° C.

Pneumatic cylinders’ performance characteristics are often specified for an operating temperature range of 20° to 80° C; however, more challenging applications require cylinders that can exceed these limits. To meet these demands, a growing number of pneumatic cylinder manufacturers have developed products designed for environments as low as -40° or as high as 150° C, which can require the use of higher performance lubricants and special sealing materials. All too often, the operating environment is overlooked in the process of selecting a pneumatic cylinder or accessory. Environmental factors may include ambient temperature, vibration, operating media/ chemicals and other fluids or materials present. However, a variety of other aspects of the operating environment should also be


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considered. For example, in humid operating environments or those that pose a risk of salt spray, all external cylinder surfaces need to be coated, and the piston rod should be made of stainless steel. Requirements for cleanliness Applications in food and beverage production typically require specific certification of the pneumatic cylinder and other associated equipment and special clean design features that minimize entrapment points for bacteria. Multiple national and international standards must be taken into account. For example, 3A Sanitary Standards Inc. is dedicated to advancing hygienic equipment design for the food, beverage, and pharmaceutical industries. An online database simplifies identifying vendors of components that comply with

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3-A certification. Other important standards and guidelines are published by NSF (National Sanitation Foundation) International, the International HACCP Alliance, the American National Standards Institute (ANSI), and the Safe Food Alliance. Food production environments necessitate frequent washdowns of the work area, which can lead to damage to static and dynamic gaskets and seals. Constant exposure to damp and the caustic sprays of hydrogen peroxide and other cleaning materials used in wash-down cycles can eat away at unprotected materials. These environmental challenges have made stainless steel the most commonly used material for all food processing applications. Although stainless steel is more expensive and more costly to machine than aluminum, it can resist the steam, high pressure water, and caustic cleaners often used in food and beverage production. This makes it easier for designers to meet stringent requirements for hygiene and corrosion resistance, which justifies the higher initial investment for many machine designers. Fortunately, however, some new, less costly alternatives to stainless steel pneumatic cylinders are available for food and beverage processing applications, Figure 1. They feature cylinder barrels and end covers made of anodized aluminium, with stainless steel piston rods, piston rod nuts, and end cover screws. Pistons, piston bearings, and piston rod bearings made of polyoxymethylene, an FDA-approved thermoplastic with high stiffness, low friction, and excellent dimensional stability. Polyurethane scraper rings, piston seals and cushion seals are used to seal in keep the transparent food-grade grease. No matter which component is being specified, it’s critical to understand the details of the food processing application and what is required—such as pressure, temperature, flow, and port sizes, configurations, and locations. Too often, filters or valves are chosen based on cost or size alone, forcing maintenance personnel to spend extra time on maintenance as a result of the system designer’s less than optimal choice. Longevity and repeatability are basic requirements for any good pneumatic solution. Choose components that have been thoroughly tested and designed to withstand the toughest conditions for operation, vibration, and impact. In food processing applications that involve sub-freezing temperatures, specify products designed to withstand these conditions without sacrificing performance or reliability, Figure 2. In a filter-regulator, for example, the air must be dry enough to avoid ice formation. If temperatures reach 32° F or lower, performance will be degraded because liquid particles become gelatinous or frozen. When specifying pneumatic cylinders, take a careful look at the ingredients to which they may be exposed; for example, ice, sugar crystals or dough can form deposits on piston rods that will interfere with their operation. To alleviate this problem, choose options that allow installing metal scraper rings (rather than rubber or plastic ones) with the piston rod seal to remove the residue before it can damage the cylinder assembly. DESIGN WORLD

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Watch out for water The accessories and options for pneumatic components are frequently neglected, so it’s important to ensure the entire product can withstand the environment where it will operate to avoid forcing maintenance personnel to waste time replacing parts. For example, the adjustment knob or T-handle of a typical regulator is made of a composite material. The caustic chemicals used in wash-down can corrode many types of plastic, so in addition to a stainless steel regulator, the knob should be made of stainless steel or other compatible material. Filter-regulator options such as tapped manual drains or automatic stainless-steel drains are widely used to get rid of excess liquid and prevent water from draining onto the floor. Look for non-relieving regulators that do not release gases or liquid into the atmosphere. Whenever possible, select pre-lubricated or lubrication-free mechanisms that use food-grade grease and don’t require periodic lubrication. Although some pneumatic valves meet NEMA protection standards or IEC/IP ratings, most are designed to be mounted in an enclosure to protect them during wash-downs. Check the design of this enclosure for any crevices between the valves and subplate or manifold bases and other non-smooth surfaces that can harbor bacteria. For those who use serial communications with their valves, these electronics also require protection. Components that require lubricated compressed air or periodic manual lubrication should be avoided when working in food processing to minimize the risk of product contamination. Lubricant in the compressed air can collect near exhaust ports, and manually applied lubricant can spill onto or collect on multiple components. Using dry air in non-lubricated applications is critical; condensation can corrode system components, increasing maintenance costs and reducing system efficiency. Also, unless distribution air lines are made of stainless steel, aluminum, or high-strength plastic, water can create pipe scale that can work its way into components and cause malfunctions. Water is a poor lubricant; when emulsified with residual compressor oils, it becomes a milky substance that must be drained away. Depending on the amount of liquid produced, this can lead to problems with OSHA. In addition, there should


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never be any contact with synthetic emulsions in food processing. Dry, filtered, non-lubricated air usually eliminates these issues. Making smarter choices Over and above issues related to a component’s required performance and the environment in which it must operate, food processing OEMs are increasingly demanding systems that can connect seamlessly and communicate intelligently with other systems within the facility. For example, IO-Link smart control of pneumatic valve manifolds makes process data easily accessible and allows monitoring by PLC. This point-to-point communication technology for sensors, actuators and control devices can be built into most PLC configurations or incorporated into most existing industrial Ethernet and fieldbus networks. IO-Link technology can be especially beneficial for machine applications that require frequent changeovers; both reconfiguration time and unplanned downtime can be reduced significantly. Although the choice of pneumatic components for any industrial application is often a matter of making tradeoffs to work within budget restrictions, system designers can prevent future frustration and ensure optimal equipment performance by resisting the temptation to cut corners on corrosion resistance, cleanliness issues, and long-term maintenance costs while laying the groundwork for additional expansion and enhanced system communication. DW

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the Industrial IoT is transforming industry IoT may be the “latest” big thing, but that doesn’t mean it’s accepted by customers. Here are tips on building a business case for IoT projects.

Alan Griffiths | Principal Analyst | Cambashi

The ‘Industrial Internet of Things’ involves a range of technologies from semiconductors to cloud computing and artificial intelligence. Businesses can take advantage of this technology to make their processes more efficient, and they can use the digital technology of IoT to transform their businesses and industries. The potential opportunities for IoT include customer and supplier relationships as well as internal processes. Manufacturers are defining and prioritizing IoT projects in the same way as they would treat any new technology – “it can be done” doesn’t mean “it should be done.” The proposer needs to build a business case. But IoT projects can offer whole new business models such as productas-a-service, so the right group of people need to be involved to assess the


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opportunity and develop ideas to fit their organization’s priorities, timescales, budgets and culture. For example, to introduce its “Sigma Air Utility operator model,” with pricing based on the consumed quantity of compressed air, Kaiser Compressors needed to build instrumented, connected machines. If the machines fail, the revenue stops, so as with all ‘as-a-service’ business models, there is pressure to build reliable machines and minimize maintenance downtime. This approach needs broad involvement in the decision making process. DESIGN WORLD

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Elekta, a Swedish manufacturer of medical technologies for treating cancer and brain disorders, uses connectivity and smart device technology to help differentiate their service business and expedite the way their products are serviced. Swedish medical device manufacturer Elekta partnered with PTC and ServiceMax to implement Connected Field Service. In the first year of the project Elekta carried out more than 600 preventative actions, which translates to uninterrupted treatments for more than 14,000 patients. |

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Remote access is entry-level IoT. The next step is to feed data into analysis and control systems.

Existing processes to gather requirements and define plans for projects of this type may not be sufficient. As the apocryphal quote attributed to Henry Ford explains, “My customers would have asked for faster horses.” However, what counts as transformational can depend on your point-of-view. For example a new (IoT) remote access system that allowed authorized process engineers to log in to their factory production lines triggered the comment, “It changed my life,” from a process engineer. This individual had previously struggled to accept night-shift stand-by duties. For him, the change has been transformational – even though the remote access needed is hardly new technology. Now, he volunteers for the night shift “…and if I can’t handle it online, I can usually guide the onsite team to fix problems.”

Remote access is entry-level IoT. The next step is to feed asset data into analysis and control systems. Taking an IoT approach rather than a traditional machine-to-machine approach pays off here, because in addition to solving remote and multi-site communication questions (an internet connection is all that’s needed), it also simplifies connection to suitable analysis software hosted in the cloud. The IoT approach supports many configurations, so, for example, if low latency response must be guaranteed, an IoT approach can integrate local (so-called ‘edge’) servers. The spectrum of capabilities was recently summarized by Brett Murphy of RTI as a range from ‘monitoring’ at the simple end, to ‘optimization’ where data from one or more assets can be analyzed and the results used









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by an operator to adjust settings for better performance, up to ‘autonomy’ where the IoT software makes the adjustments automatically. These monitoring, optimization and autonomy examples are happening inside a manufacturer’s organization and can be local to the production groups. They can be transformational because they may open up the next step for lean manufacturing initiatives. However, it can be easier to see transformational effects from projects that offer something new to customers. Field service and asset management are the low-hanging fruit here. For example, GE Digital and PTC have formed a partnership to provide innovative solutions to companies like Elekta. Here, the transformation is due to the connectivity of the machines Elekta sells to its customers, not the connectivity of the machines it uses in its factories. Predictive maintenance can be relevant both to machines in the factory, and also to products sold to customers. Rolls-Royce introduced its TotalCare Services some


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20 years ago. TotalCare uses a “power by the hour” model in which customers pay for service based on engine flying hours. Rolls-Royce engineers analyze engine data to manage customers’ engine maintenance and maximize aircraft availability. For security and availability reasons, ground-toaircraft communications are independent of the Internet, using a specific Aircraft Communications Addressing and Reporting System (ACARS). Since its introduction, the scope of TotalCare has grown in parallel with the growth in sensors-per-engine, and the capacity to analyze large volumes of data per engine per hour. Now, the Efficiency Insight service includes Engine Health Monitoring, and tracks the health of thousands of engines operating worldwide. Previously only relevant to low-unitvolume, high-unit-cost industries such as aerospace, the dramatic fall in sensor and communication costs have broadened the potential of these concepts to other industries. For example, food processing machinery makers Minerva Omega created the startup DSC Nexus, which has brought

In its customer story on Rolls-Royce, Microsoft quotes Richard Beesley, Senior Enterprise Architect Data Services at Rolls Royce: “With the increase in the volume and velocity of data that we’re looking at, Microsoft Azure IoT Suite has a key part to play in our ability to reliably aggregate data across our customers fleets.” This sums up the evolution RollsRoyce has experienced in the years since it introduced TotalCare® Services. From an innovative commercial approach to maintenance – known worldwide as “power-by-thehour,” this service now offers options such as Efficiency Insight, which can combine data from real-time engine health monitoring and identify emerging patterns allowing aircraft operators to see and respond to trends on aircraft, routes and airport performance. | Courtesy of Rolls Royce

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I n t e r n e t

o f

T h i n g s

The ‘Industrial Internet of Things’ involves a range of technologies from semiconductors to cloud computing and artificial intelligence. IoT capabilities to machinery, including slicing machines found on retail meat and cheese counters. For these relatively low cost machines, sensors monitor the electric current/voltage profiles during start up, during no-load, and while cutting. So a new power cord with an integrated sensor and Wi-Fi connectivity is all that’s needed to retrofit an existing machine. When the electricity waveform demonstrates it’s time for a new blade, appropriate operator or technician action can be scheduled. While predictive maintenance takes center stage in the industrial machinery sector, there are other highlights in other sectors. The common theme is business justification based on achieving goals familiar to manufacturers since long before IoT: • Reduce costs and improve operations • Achieve competitive advantage by offering customers a better experience • Open up new revenue streams The balance of these three goals varies, but they are always there, whether it’s a connected car in automotive, cloud services for voice control of consumer goods, or smart metering and smart grid architectures in utilities. In agriculture, use of equipment across the whole business network is changing, from the supply of agricultural machines to the operation of fleets in the field using GPS, automated harvest collection and product identification and tracking.

In construction, the trend towards offsite manufacturing and on-site assembly is being taken to the next level in OPTIMISED, a €7m EC (European Commission) funded H2020 Factory of the Future project focused on advanced manufacturing. According to Graham Herries, the EU ‘OPTIMISED’ Project Coordinator, this will apply a range of IoT technologies including RFID, edge computing, drones and deep learning to item tracking, personnel management using wearables, all based on building information modeling (BIM) management. In retail, IoT is helping deliver every supply chain manger’s dream of visibility and Walmart, working with IBM, is taking the opportunity to integrate ‘blockchain’ technology for distributed ledgers to ensure food security through supply networks. As success stories such as these – from the ‘early adopters’ – become common, the technology will be taken up by the majority in that industry, and it will become mainstream. But there are still challenges that need to be overcome, and different possible futures for industry. DW Cambashi


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January 2018

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E l e c t r o n i c s

Will your next circuit board come out of a mold?

Several manufacturers are now exploring molded plastic and other odd-ball substrates for circuits as a way to simplify product designs and cut costs. Leland Teschler | Executive Editor

If you looked inside a smoke detector designed by a

The conventional smoke detector, top, and a version redesigned by the Swiss firm Multiple Dimensions AG, bottom. Conducting traces are applied directly to the molded part. One notable option available via molded interconnect methods is that a capacitive switch can be integrated into the circuit to replace the previously-used mechanical switch.


Swiss company called Multiple Dimensions AG, you might at first be a little confused. You’d find the usual 9-V battery, smoke sensor, and test switch, but no wiring or circuit board connecting the components together. The reason for the lack of wiring is that the smoke detector is an example of a molded interconnect device (MID). The injection-molded smoke detector parts do double duty providing both a mechanical structure and a substrate for conductive traces between electrical components. The point of molded interconnect techniques is to eliminate the need for a separate printed circuit board (PCB). Eliminating the PCB is obviously advantageous for structural simplification and reducing the number of parts. Manufacturers say that when volumes are high, the economics can be compelling. Molded interconnects have been around in various forms for years. But they have tended to be used in niche products rather than in the main stream. “A lack of volume manufacturing is one reason molded interconnect technology hasn’t caught on. But what appears to be happening now is that manufacturing costs

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Examples of the MID process in use: (Left) Griffith University in Australia worked with Chicago-based technology application consultants Design HMI LLC on an automotive dome light using a process called circuits in plastic (CiP). Center, another dome lamp design using MID technology created by Harting SA. Right, a capacitive touch sensor integrated into the MID dome light. The overall MID dome Lamp design came from OSRAM, Microchip Electronics, IEE SA, and Harting SA.

The point of molded interconnect techniques is to do away with the need for a separate printed circuit board (PCB).

A user control panel screen-printed by Duratech Industries.


are going down and there is a pressure to deliver on form, fit, and reduced weight,” says David Wiens, product marketing manager at the Board Systems Div. of Mentor Graphics, a Siemens Business. Mentor is well positioned to have a bird’s eye view of interconnect work: It provides both PCB design and MCAD software products. Wiens says Mentor has seen interest among design engineers in software tools specifically able to handle the kinds of problems that arise in MID designs. “We find a lot of engineers working with molded interconnects now use MCAD systems rather than PCB or ECAD systems,” Wiens says. “That means the software has no intelligence about the electronics or how the electronics is built. They are trying to add intelligence about these things to an MCAD structure. Conversely, we have customers doing molded interconnects from the ECAD side, but there are tradeoffs. You must visualize in 3D, but you are still working with a planar board,” Wiens says. Difficulties may arise when conductors go on substrates selected for their mechanical properties as in MIDs. One potential problem is that materials can change consistency when they go through a molding process. The changing parameters can affect the electrical qualities of conductors deposited on top. And putting conductors on mechanical components that bend in complicated geometries can change

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electrical qualities in ways that may be hard to anticipate. Consequently, the mechanical make-up of molded interconnected parts may be sophisticated, but the electronics sitting on the part tends to be relatively simple. The complexities of molded interconnects pose problems for CAD systems because a lot of designs get recorded as AutoCad or Gerber files. For one example, ordinary PCB CAD programs can build-in design constraints imposed by specific PCB manufacturing facilities. But there are a disparate variety of processes used to devise MIDs. Consequently, CAD suppliers say it is impractical to create design software able to handle the numerous MID processes now in use. Sizing up processes One MID process that has been around since the late 1990s was devised by LPKF in Germany. Called laser direct structuring (LDS), the usual procedure is to injectionmold the part from a special polymer containing organo-metallic substances. Once molded, the part is hit with a laser beam that creates tracks on the surface of the part that will later be turned into conductive traces. These activated areas become metallized in a chemical bath to create the conductors. In a final step, a barrier layer of nickel is applied and then conditioned with a thin layer of gold to ensure good solderability. LPKF says track widths exceeding 150 μm and gaps exceeding 200 μm have proven to work well, although thinner tracks and DESIGN WORLD


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E l e c t r o n i c s

gaps are possible. The fact that laser light activates the polymer surface imposes some limitations on the maximum size of the parts that can be processed. For example, if an area of the part falls outside the angle of incidence of the laser, either the part or the laser must be repositioned to finish the job. In some cases, the component might have to be rotated during the laser processing step if there are conductors on more than one plane. And the process can’t be used to create multilayer circuits. It’s possible to create two-sided boards with LDS. To do this, the part must have vias, as with ordinary PCBs, but the vias must be conical on one or both sides depending on the thickness of the material. The internal diameters of the vias must be large enough to ensure unimpeded processing by the laser beam. Some manufacturers that employ LDS report success using even more stringent design rules. Multiple Dimensions AG, for example, says it gets trace widths down to 80 μm with a high yield thanks to its own advanced process development techniques. The smallest part the German manufacturer has produced using LDS is 2×2×0.8 mm. Multiple Dimensions says it has used several methods to design traces on molded parts. One way is through use of a software package called Target3001 that is specifically designed for 3D-MID functions. But more conventional means are used as well. Frequently, a mechanical engineer makes a projection of the plane where the components will reside from the 3D part model, then exports it as a 2D file. Then electrical engineers import the file and begin the circuit layout. Once complete, the trace design goes back to the mechanical engineer who, in turn, reincorporates it into the 3D CAD file defining the molded part. Alternatively, Multiple Dimensions may use conventional PCB packages from Mentor, Eagle, or Altium to build up a combination of flexible and rigid PCB surfaces. The design then gets completed on a 3D substrate. Multiple Dimensions says its rule-ofthumb is that applications involving current below about 1 A are candidates for its MID process, particularly those involving sensing.


Examples from EastPrint Inc. of screen-printed conductors on molded parts. The center part is printed in the flat with graphic and conductive ink. The part at right is formed and cut. The clear plastic part on the left is the same part that reveals the forming that takes place in the injection mold. The part shown makes up a control panel. The user controls are visible on the reverse side as seen at right in the top image.

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E l e c t r o n i c s

In one project, Multiple Dimensions used the MID process to create the fingertips of a robotic hand (about the same size as a human hand) with conductive traces. The surface of the robot’s palm is covered with sensors whose pressure signals route to a connector. Screen printing Not all molded interconnect techniques use lasers to create traces. An alternative method is to put traces and electronics on molded parts with a process derived from screen printing. That is the point of a collaborative effort among companies that include Sun Chemical Corp., Eastprint Inc., DuraTech Industries, AlSentis LLC, and T+ink. One goal of the collaborative effort is to more easily field MIDs for user-interface tasks such as control and display panels. Suppliers think MIDs would help pave the way for widespread use of 3D capacitive

Manufacturers say 3D capacitive touch implemented via MID could find highvolume uses in appliance and automotive applications.


touch technology resembling that in the iPhone6. As used in iPhones, 3D cap touch incorporates capacitive sensors in a way that let the electronics detect different pressures from the user’s finger. It can also detect multiple touches and calculate the difference in pressure on various points of the screen. Component makers think MIDs could bring similar capacitive touch technology to consumer appliances and white goods such as washing machines. Buttons, sliders, and rotating touch sensors all could be devised with no moving parts. The resulting controls also potentially might be cheaper because they would eliminate the several layers of materials involved in ordinary mechanical switching. Conventional membrane switches, for example, generally contain at least four layers that include a printed circuit and a spacer. This assembly could conceivably be replaced by a single MID implementing projected capacitive touch, or PCAP, technology. PCAP touch screens use a matrix of rows and columns of conductive material, layered on sheets of glass. Voltage applied to this grid creates a uniform electrostatic field. When a conductive object, such as a finger, touches a PCAP panel, it distorts the local electrostatic field at that point. This field interruption is measurable as a change in capacitance. A finger bridging the gap between two of the tracks further interrupts the charge field. The capacitance can be measured at every individual point on the grid. This system can also accurately track touches. The top glass layer of a PCAP brings more sturdiness than resistive touch technology, and it is possible for a PCAP system to sense a passive stylus or gloved finger. Manufacturers say 3D capacitive touch implemented via MID could find highvolume uses in appliance and automotive applications. Indications are MID-based capacitive touch systems could also be economical in medical devices, portable consumer electronics, and industrial controls. “Everybody likes capacitive switches better than tactile switches. Capacitive

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switches made with screen printing techniques are like an advanced version of in-mold labeling,” says Eastprint VP Tom Bianchi. Eastprint, a long-time maker of membrane switches and electronic front panels, says applications having volumes in the 50,000 to 100,000-piece range are probably fair game for screen-printed MIDs. Bianchi says designs using the technique are largely custom, so design rules can vary from one job to the next. But screen-printed conductors generally can have the same pitch as ordinary printing jobs on polyester substrates. Bianchi also says the usual approach is to screen print electronics before creating the indentations and other geometry that will appear on the mechanical part. “The silver conductive inks are stretchable. Once printed they maintain their conductivity,” he says. Bianchi says Eastprint uses ordinary flatbed screen printers to print MIDs – there’s nothing special about the manufacturing equipment. The design rules for circuit artwork tend to depend on the job at hand, Bianchi says. “There are general rules of thumb for how deep we draw conductors and how tight their radius can be, but a lot of that is application dependent.” Screen printed electronics has one notable advantage over MID techniques involving laser etching: Multilayer circuit boards are practical with screen printing. Bianchi says Eastprint has done circuit designs containing as many as ten layers. DuraTech Industries, primarily a provider of custom label printing services, has used screen printing technology to print a resistive heating element on a flexible substrate that was then molded into a headlight lens. The heating element melted snow and ice that would otherwise build up on LED headlights that generate little heat. Duratech printed electronics development engineer Steve Roellich says the voltages and currents used on screenprinted electronics the company creates generally fall in the 2 to 12 Vdc and 10 to 150 mA range. But he adds that there are variables within conductive ink and trace geometries that can be adjusted to handle


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higher voltages and currents. Low-end current capacity is generally dictated by trace resistance. Trace resistance depends on trace geometry – length, width, and thickness—as well as the amount of silver loading in the ink and ink curing, he says. Roellich says Duratech regularly prints circuits comprising three layers and has produced five-layer versions as well. He figures the practical limit on the number of layers has yet to be determined. “We run into printing challenges when we get past three layers. Real estate for routing traces becomes an issue as the number of layers rise,” he says. In the same vein, designs with smaller the trace widths and tighter spacing cost more. Also important is how the in-mold electronics connect to the outside world. If a molded-in header provides connections, for example, design engineers may need to

ensure potential witness marks don’t cause connection problems. Similarly, witness mark location can be important if visible blemishes aren’t acceptable, as in a user interface device. Because of such considerations, Roellich says design engineers planning in-mold projects should work with printing and molding suppliers that have experience doing in-mold electronics. “The most successful projects I’ve seen start with all the suppliers in the same room working through the part design and manufacture. Each supplier sets expectations for what they can provide. That helps evaluate factors that bear on manufacturing feasibility such as overall part geometry and the surface geometry of the electronics. You want to make sure the forming of the in-mold electronics applique is within the capabilities of available

forming processes. The forming geometry and the mechanical, chemical, and environmental requirements help determine the substrate material.” DW References AlSentis LLC | Duratech Industries | EastPrint Inc. | Mentor Graphics, a Siemens Business | Multiple Dimensions AG | T+ink | Target3001 MID layout software |

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Counterfeit bearings: what to expect in 2018

Year over year, the threat of counterfeit bearings remains persistent. A lucrative market and a history of spotty legal backlash keeps would-be counterfeiters emboldened. But for the last two years raids and seizures are on the upswing. Bearing manufacturers are getting better at targeting counterfeiters and creating awareness for consumers. Here’s how industry professionals are protecting customers and what customers can do to protect themselves in 2018.

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One of the most pressing challenges is dealing with counterfeit packaging. Counterfeiters lack the knowledge and resources to create passable fake components so they rely on slick packaging to create the illusion of premium products.

The National Intellectual Property Rights Coordination Center (IPR Center) is an interagency government organization that focuses on IP rights and enforcement, specifically counterfeit products. At a summit in late 2017, it was stated that in the previous year, the estimated value of global counterfeit products had risen to around 3- 3.5% of global trade. Compare that against 2013, where there was a 2.5% increase from the previous OECD study. A clear pattern of counterfeit growth has emerged for the last 10 to 15 years for all products. So why, specifically for bearings, has there been such an increase in counterfeit activity? Schaeffler’s Director IP, Americas, Antun Peakovic says it likely has something to do with risk versus reward.

“If you sell $1million of counterfeit bearings, you may get a small fine. If the theft is really egregious, you might even get some jail time. But it’s more likely a conviction would lead to a fine or something with parole. By contrast, if you sell $1million in narcotics, you’re going to get a very steep penalty.” To combat the steady stream of counterfeit bearings flowing into the market, manufacturers


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M e c h a n i c a l

Counterfeiting is a global problem with fake components coming from around the world, not just countries like China and India that have a long history of infractions. have had to get better at locating the problem and making customers aware of it. Frequent meetings with U.S. and foreign customs agencies, authorized distributors, and end users have helped target the problem. Meanwhile, groups like the American Bearing Manufacturers Association, The Federation of European Bearing Manufacturers’ Associations, and The Japan Bearing Industry Association have banded together to improve counterfeit awareness. These groups make up the World Bearing Association and its website, Created in 2006 by three regional bearing associations, WBA works to support the lawful interests of those in the industry through sustainable development, open economic engagement, and legal protection. The website focuses on prevention through creating awareness and keeping open channels of communication within the industry. The website states, “Awareness comes before action. Help your associates, customers and friends to protect themselves against counterfeits by letting them know about the problem. WBA is more than happy

to provide communication materials for this purpose. We are dedicated to informing about problems with counterfeiting of premium brand bearings and to assisting supplier, distributors, and supplier law enforcement agents in the identification and eradication of product piracy.” One of the most pressing challenges is dealing with counterfeit packaging. Counterfeiters lack the knowledge and resources to create passable fake components so they rely on slick packaging to create the illusion of premium products. “They haven’t made any improvements in engineering know-how or expertise. But their ability to copy packaging, and marking, and make products look more genuine, has improved. Part of that’s due to technology. You can scan or copy things and reproduce them so easily now, where maybe 20 years ago, you couldn’t. They are getting better at marking and packaging, which requires us, of course, to get better at marking, and packaging,

Counterfeiting is a global problem with fake components coming from around the world, not just countries like China and India, with a long history of infractions. Products are shipped from the US to South America, and vice versa and they are also shipped from Germany, and other countries.


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and knowing our products very well, so that small indicators can mean identification one way or another,” says Peakovic. While new packaging techniques might be showing up in counterfeit bearings, there is still an abundance of older products counterfeiters are trying to move. Peakovic also explained that there are plenty of stored bearings from the last four or five years that are going to pop up. “That’s the most common counterfeit we see; the counterfeiting of products that have been on the market, or labeling that has been on the market for a few years,” says Peakovic. Companies are not changing their products to combat this. They are changing how their labels look and how their boxes appear; this is an ongoing and ever evolving process. Larger manufacturers make tens of thousands of different part numbers and millions of bearings every year. Consequently, having an annual change of packaging, box type, or overall re-vamping, is certainly not cost effective. It continues to challenge manufacturers. The easiest thing that companies can change is how and what they mark. For example, individual part marking. For Schaeffler, that means each part has its own identifier, a data matrix code and the label matched to the bearing inside the box. That QR code is individual to that product, and that bearing, and that production date. It’s very specific, and very difficult to copy. Additionally, several companies now have apps that customers and can use to identify counterfeit products. Available on iPhones and Androids, users can scan codes on a product and can identify, at least, whether the code has been scanned before. This process keeps a log of whether the code has been scanned before, and whether it’s been determined to be counterfeit. Apps like this help make communication global, immediate, and more difficult for counterfeiters to adapt to, something they are quite good at. “One thing about counterfeiters is they adapt well. If they start getting caught across the border, they begin to change patterns. In some countries, Brazil, for example, they will send blank product, something that can be marked in-country and packaged incountry. They’ll send blank bearings, which are not infringing on anything other than, perhaps, customs regulations, in a sense that they’re not marked with country of origin. But they don’t have any brand on them. It’s relatively easy to find marking equipment that can mark these products,” says Peakovic.



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Counterfeiting is a global problem with fake components coming from around the world, not just countries like China and India, with a long history of infractions. Products are shipped from the US to South America, and vice versa and they are also shipped from Germany, and other countries. Once a counterfeit bearing has infiltrated the marketplace it can be sent anywhere. Nearly every type of bearing is subject to counterfeiting. Every product, size, and part number is vulnerable. The fast-moving products like small ball bearings such as a 6200 series or 6300 series ball bearing are common simply because of the product’s production volume. Means of distribution looks to have a slightly larger impact on the counterfeit market in the next few years. Smaller shipments of counterfeit products have been a problem in the last year and could continue through 2018. “10 years ago, or even, 5 years ago, we would get container shipments. We would get large-volume counterfeit products shipped to a particular distributor. If you caught those, then great, you stopped the whole shipment of counterfeit products. Now what we see is these expedited freights, FedEx, even for very large


products. Even for two-ton products, we’ll see airfreight products going through. Sometimes those are caught. But you can imagine, if you have one container with 20,000 bearings and you catch that container, fantastic. If you have those 20,000 bearings divided up among 10,000 shipments, you’re not going to catch all 10,000 shipments,” says Peakovic. The pattern is for a multitude of smaller shipments. A development that is much more challenging to stop, both at customs and for manufacturers. But manufactures maintain that continued education and communication can help keep counterfeiters guessing. DW Schaeffler |


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Making connections

in harsh places Connectors must meet certain criteria to survive the most extreme environments.

Christian Taylor | Sustaining Engineering Team Leader at Bulgin

While most of us live and work in relatively protected and safe indoor environments, much of the world’s most critical electronic systems and equipment operate in harsh conditions. Whether it’s water, dust, extreme weather, explosive atmospheres or pressure, a range of harsh environments can create challenging conditions for these systems and the connectors that operate in them. One of the most common points for damage in any electrical system is where cables get plugged in—the connector. Connectors are at the junction of system and cable, needing to have the flexibility to mate and disconnect easily yet securely, all while keeping the elements out. As the guardians of the entry points to both system and cabling, their integrity in harsh environments is critical. Since they’re at the entry point to the system, connectors face the same hazards of any electronic system, including water, dust/dirt, extreme temperatures, potentially explosive “ATEX” environments, pressure/weight, shock/vibration and salinity.


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The oil and gas industry depends on reliable rugged connectors in underwater ROVs, which provide drilling and construction support as well as exploration.


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I n t e r c o n n e c t

As the guardians of the entry points to both system and cabling, their integrity in harsh environments is critical.

What defines a harsh environment? A harsh environment for humans can be defined as an environment in which prolonged exposure to the elements would pose a danger to survival without specialized equipment. A similar definition can be applied for electronics: a harsh environment is one that would ordinarily cause serious damage to an electrical system. Wet or dirty environments with water, high humidity/water vapour, dust or dirt can wreak havoc on electrical equipment, causing short circuits or malfunctioning equipment. If salinity is a factor, such as in a seaside environment, corrosion can also be a serious issue. Electrical systems are also often sensitive to temperature extremes, which can cause components to fail

or malfunction. For data connections, electromagnetic interference (EMI) can be an issue as it can disrupt wired communication. Physical force is another hazard that can come in the form of mechanical shock and vibration, or pressure. To withstand shock and vibration, a robust mating method needs to be in place. Connectors in undersea, aerospace or pressurized environments also need additional built in ruggedness. For connectors used in explosive environments, an additional requirement is that there is no way to set off a spark, either mechanically or electrically, and cause a hazardous explosion. Rugged applications The range of rugged applications is extremely varied, and crosses many

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The move to greater automation and “lightsout” manufacturing means environmental challenges will only increase as equipment now increasingly has the freedom to operate in inhospitable conditions. industry lines. Ruggedized systems and connectors are used in industrial, marine, oil and gas, transportation and infrastructure, telecom, and more. Industrial environments feature technology such as automation, machinery and measurement that come together to create today’s hyper-efficient manufacturing systems. Industrial environments are often exposed to a variety of harsh elements including water, vibration, chemicals and temperature extremes. The move to greater automation and “lights-out” manufacturing means environmental challenges will only increase as equipment now increasingly has the freedom to operate in inhospitable conditions. Industrial equipment such as food slicers, saws, sand blasters, food processors, and coating machines can generate significant shock and vibration, as well as create dust or airborne contaminants. Sealed, rugged metal or plastic housing connectors with IP66, IP67, IP68 and IP69K ratings can withstand these harsh conditions and keep power, signal and data connections secure. Because of the noisy EMI conditions in industrial environments and the dependence on sensors and communication, EMI is also a concern for data connections. In these cases electrically shielded connectors are ideal. Marine applications are faced with challenging environmental conditions, both on the surface and underwater. Surface marine applications such as boating equipment, ship deck systems, or marina facilities face threats from corrosion due to high salinity, as well water ingress, making robust, sealed components essential. IP-rated components should be chosen depending on the level of water and dust protection needed, with IP66 and IP67 sufficient for many surface applications while IP68 or IP69K will be necessary when connectors may be submerged. For undersea applications such as diving electronics, depth loggers or undersea remotely operated vehicles, it is important to source independently tested systems purpose-designed for subsea pressures. The oil and gas industry faces many of the same environmental hazards of industrial and marine environments, but must also deal with explosive atmospheres that require the use of ATEX / IEC Ex rated equipment. For offshore platforms, both marine hazards and explosive atmospheres exist. In addition, the oil and gas industry


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Bulgin’s Buccaneer range of circular connectors provides reliable and robust connections in challenging environments.


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makes extensive use of underwater ROVs for drilling and construction support as well as exploration. These underwater remotely operated vehicles are essentially remote controlled robots. They require power, data, and often fiber optic lines, must operate in rough subsea conditions, and are often asked to go to depths beyond the possibilities of human divers. Bulgin’s ROV tether connector is designed to keep these robotic helpers working reliably in uncertain waters. Made from 316 marine-grade stainless steel, it is a Pressure Balanced Oil Filled (PBOF) cabling solution that uses oil as a compensating fluid for water pressure, allowing ROVs to go to depths of 7,000 m. In other applications, such as transportation and infrastructure, automotive, and agriculture, a wide variety of electronic systems operate in the outdoors. They require connectors that can

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the component. The first digit indicates the level of dust protection and goes from 0 to 6, while the second digit indicates liquid ingress protection. For harsh environments, sealed connectors should always be No one-size-fits-all solution dust-tight, with water ingress protection One of the first challenges for the depending on the application. manufacturers who design connectors for IP66 (protection against powerful rugged environments is the term “harsh” or “rugged”—these terms might lead customers water jets), and IP67 (immersion up to 1 m), is suitable for many above water to the assumption that there is a “holy grail” of rugged connectors that will be a one-size- applications where systems may be rained fits-all solution for all applications. The truth on, or otherwise repeatedly exposed to of the matter is that this is impossible, simply water. Connectors that may be continuously submerged should be at least IP68 because all applications have their own (immersion to 1 m or more) or greater. For subtle differences and requirements, and all undersea applications, purpose-designed customers have different budgets. equipment with independently tested The best approach will be for the depth ranges is vital to ensure complete designer to work as closely as possible with underwater protection. the client to find customized solutions. IP68 and IP69K (protection against Design engineers will first gather as much close-range high pressure and high information as possible to accurately scope temperature spray-downs) are extremely out the project and ensure that the solution effective for medical and food processing will be both wanted and fit for purpose. The engineers will then work against time, budget environments as this allows the equipment to be regularly washed and sanitized without and scope drift to ensure that the solution is adequately tested and delivered by the project harming the electrical components. deadline. Locking/coupling mechanisms — The following key features should be With many connectors being exposed to considered in this design process. environments with shock and vibration present, a robust coupling mechanism is a must. There are many different types IP rating— IP ratings define the level of of connector couplings, including ring, protection from dust and water ingress of withstand extreme temperature changes, water and dust ingress, physical duress, and more.

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I n t e r c o n n e c t

twist locking, threaded, bayonet, pushpull and quick disconnect couplings, all with different attributes for various types of applications. Some—like the bayonet connector—provide better security against shock and vibration, while others like pushpull and quick disconnect provide greater ease of use when connectors may need to be disconnected often. Housing and insulation — The material that a connector is made of helps it resist the challenges of its environment. For applications with extreme temperatures as well as plenty of moisture and dust, a corrosion resistant metal housing may be appropriate. If lightweight and flexibility is key, temperature-resistant plastic composites will be more attractive.

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Connector design — The connector’s shape, mating mechanism and pin positioning also play a part in its ruggedness. Circular connectors have the benefit of easy engagement/disengagement, as well as the capacity to fit a wide variety of contacts within the connector body. Circular connectors also are easy to seal and less likely to wear out. An intelligent “scoop proof” design can be used to avoid pin damage while trying to mate the connector. Making the right connections Our world is becoming increasingly connected. From outdoor cellular base stations to connected factories and to IoT sensors on oil and gas platforms, electronics are being placed in every environment imaginable. The electronic systems have to be guarded against all the forces of nature. As the point of entry to the system, connectors have to be robustly designed to seal off and protect against all environmental challenges present—from shock and vibration to dust and water, or EMI. Through choosing the right IP rating, locking mechanism, housing material and connector design, almost every rugged electrical system today can be made to work reliably with the right connector. DW

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January 2018

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R S H I P At the helm of the massive 190,000-employee manufacturing giant, you’ll find a thoughtful mechanical engineer dedicated to keeping bureaucracy at bay and his company flexible.

Importance The

of flexibility —

Mark Mondello, CEO, Jabil Inc. Like many of us, Mark Mondello didn’t grow up wanting to be an engineer—he simply liked to tinker. Raised on the south side of Chicago, his family didn’t have much money, so his father (a meat packer) fixed anything that broke. Mondello watched over his dad’s shoulder and quickly learned the mechanics of how things worked. Soon, he could fix most anything from sprinkler heads and motors to air conditioners and cars.

Paul J. Heney | Editorial Director DESIGN WORLD

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January 2018


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L e a d e r s h i p

“I’ve got an endless amount of energy, and I love people, and I like technology, so it has all fit together, and I’ve really been blessed.” Even in college, the engineer calling wasn’t immediately obvious to him. An athletic student, Mondello focused on intramural sports his first couple of semesters. But then in his sophomore year, it dawned on Mondello that “engineering was probably a good thing, and I really liked the mechanical program.” After flirting with the idea of getting a master’s in mechanical engineering, he decided that his BSME was sufficient and took a job with Moog in East Aurora, N.Y. At the time, Moog aimed to open an engine-controls division in Florida. The company wanted to physically separate its aircraft-controls and engine-controls teams, and Mondello joined the group to start the controls division down south. “It was a great group of folks and very engineering intensive. We went from a small leased facility to a really beautiful building,” not too far from where Jabil’s St. Petersburg, Fla. headquarters are now. “I got to work on some neat projects and move between Florida and Buffalo for work,” he said. Then through a softball league, Mondello befriended a group of people who worked for Jabil. Over drinks after games, the group chatted about work and exciting new projects. After five successful years at Moog, Mondello was intrigued by the idea of making a switch to Jabil, but not that drawn by the work. “Compared to what I was doing at the time—stuff I could see—just trying to figure out ones and zeroes and analog electronics didn’t seem all that interesting to me.” But one thing lead to another, and he agreed to interview and then hire on at Jabil, more out of curiosity than anything else. As a Production Supervisor for Jabil—then a tiny fraction of its size today—he got truly hands-on learning. “We were small, a bit disorganized, and worked hard to take care of our customers … which has been an approach embedded in our culture forever,” he said. “There weren’t a lot of rules, which worked well for my personality. Whatever you could grab onto and get done, you could do it … so I did. It gave me really authentic [exposure] and a kind of first-row view of what we do. Spending every day from early morning to late in the evening on the manufacturing floor was great—and it was hands on … building


January 2018

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Your Global Automation Partner

product and learning the product.” Mondello was supervising people from day one, and he was infatuated with the disorganization of the growing company. He wanted to help put a bit of process around the disorganization, “but not too much”— because he felt the lack of formal process actually fed Jabil’s entrepreneurial behavior, an important competitive strength of the company. He continued to advance at the company while working to understand the manufacturing processes, what Jabil was building, the planning process, and the quality system. He investigated issues that arose with certain end products as well as challenges with various hardware types. The company was experiencing hockeystick growth and opening international manufacturing plants, so corporate leaders began to ask Mondello his opinion on areas of expansion in Mexico, Asia, and Europe. Soon, he was interacting with various customers and products and end markets … and that led into a move into management. In fact, Mondello assumed the role of Jabil COO in the early 2000s and has been CEO since 2012. And that entrepreneurial way of doing things? The company strives to keep that spirit today, though Mondello noted that Jabil

requires more rigor and process due to its size. Even so, he endeavors to keep too much bureaucracy at bay. He also loves his current position. “I’ve got an endless amount of energy, and I love people, and I like technology, so it has all fit together, and I’ve really been blessed,” he said. “The foundational platform of the company has allowed me to see a lot and travel the world. My wife often says, ‘you’ve been everywhere and seen nothing,’ because I spend most of my time working. But what I do get to see is the 190,000 employees we have today.” Mondello said his favorite part of business travel is spending time with Jabil employees in the evenings, over breakfast, or walking the factory floors and seeing what they’re doing. He’s often amazed at how much more factory-floor workers accomplish today than what they did in the 1990s. Jabil also has a culture where people have access to the senior leadership, and Mondello loves that. “People are very open,” he said. “Other than looking at a dashboard of metrics, the best barometer for me is getting out with our folks. It doesn’t matter if that’s a city in the U.S., Mexico, Brazil, Eastern Europe, Western Europe, Southeast Asia, or China—I love the interaction.”

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January 2018


Call 1-800-544-7769 or visit

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L e a d e r s h i p

...will manufacturing plants soon become fully robotized lightsout operations? Mondello doesn’t think so, at least not anytime soon ... in some cases the human touch is a superior and more efficient solution than pure lights-out automation.


Engineers as managers? Mondello thinks that many times, engineers are characterized as “introverted nerds who like to sit in the lab.” But he said that description doesn’t do many engineers justice. “Regardless of formal education or background, I think there’s an interesting blend of introverts and extroverts in all fields,” he said. “I see a lot introverts in finance and accounting, yet I see some are extroverted as well. I interact with a ton of engineers, and I’m fascinated with the career paths they carve out for themselves.” According to Mondello, Jabil’s leadership gave a lot of thought to functional career paths versus managerial career paths about a decade ago. The goal is to retain the best and brightest employees, some of whom may love working in teams, but may have no desire to lead teams. “We’ve got good paths today at Jabil to let people create wonderful careers here, and the aspiration doesn’t have to be ‘I want to be an executive in a big company.’ It can be ‘I want to be a thoughtful contributor that makes huge difference at the company where I work,’” he said. Mondello went on to point out that engineering degrees aren’t too different from law degrees. “I think both degrees teach people how to think logically. I think that the law degree can be a little more abstract, and the engineering degree can be a little more process, but they teach people how to think. They teach people how to problem solve,” he said. Jabil culture: Focus on efficient builds Mondello describes Jabil as “building everything”—and in fact, the company has approximately 43 million square feet of manufacturing space around the world. But Jabil must also handle an array of challenges ranging from varying geographies to different currencies. “We build stuff, and I think we build it in ways that are efficient … not as optimally as I’d like, but we’re getting it. Yet, we do so much more than build stuff, because we also design stuff. In fact, we have a kind of progressive digital thread coming through the company, if you will, although, I think the word digital is grossly overused today, and I think a lot of people don’t even know what it means.” Mondello feels that many companies shouldn’t focus on building, because it’s not their core—it’s not where they excel or where they make their biggest investments. Instead, their priorities should continue to be things such as product R&D, branding, marketing, and touching customers. “Our core is building stuff, so I take a lot of pride with my leadership team on being really, really good at what we do,” he said. “We invest in manufacturing, and we invest in the systems around it, and we invest what we know of being real, fundamental, digital things … What we do in engineering and manufacturing is our core. That’s our livelihood. That’s what we do. If we’re not great at that then we’ve got real problems.” Mondello has been quoted as saying, “Take great care of our people, and our people will take great care of our customers,” a phrase that seems to have existed almost as long as businesses have. But Mondello’s earnestness in saying it makes you believe that it’s part of his and Jabil’s central belief system. “This prophetic quote is simple on its surface. But people don’t care what you know if they know you don’t care. I carry that around in a few slide decks,” he explained, and then smiled sheepishly. “People around here make fun of my slide decks, because they are not very advanced.”

January 2018

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Your Global Automation Partner

“Why wouldn’t you have a culture where you talk constantly about taking great care of the people? We don’t have a brand that you see on TV. It’s not a brand you’re going to see when visit or walk into Walmart or go to a grocery store. We’re the brand behind 350 of the greatest brands in the world, and how exciting is it to be doing a lot of the heavy lifting for the greatest brands around?” While Mondello noted that the corporate culture is absolutely one of caring, it’s also a culture of what he calls thoughtful accountability. As an example, he describes a business review where an executive asks a manager why he only achieved a financial number of 98 instead of the 100 he’d promised. “In many cultures, the conversation ends there … and then theatrics begin with leadership pounding the table, saying ‘you said you’d do a 100, you need to do 100. Leave the room, and come back when you can do 100, or we’ll get someone else to deliver the 100.’” “I think that’s really a poor way to deal with individuals, especially people who care and are working really hard. When I say thoughtful accountability, it might be saying, ‘okay, we’re clear that you said you were going to do 100, and you’re telling us now you’re going to do 98—so why are you doing 98? How much of what drove you to

deliver 98 was within your control? How much was out of your control?’ Many times, you’ll discover what that individual did to deliver the 98 was Herculean—because they really should have delivered 89. But they delivered the 98 because of six variables, two were in their control and four absolutely were not. Maybe they were customer-driven, market-driven, macro-economic-driven, geopolitical-driven. “That’s why I always want to be sure we do our best to understand why something is what it is. Why the result was what it was, and being sure that we think through that, and act accordingly. Yet, when you run company at 4% operating margins and very low SG&A, it would be impossible for us to be sitting here being a 20 or 22 billion-dollar company if we didn’t have a good process around accountability—because we can’t have people who aren’t working hard or who are unfocused on their task or who are delivering poor results despite full ability to deliver better results.” Customers and manufacturer define design cycle together The world of design engineering has changed during Mondello’s career. Design is more of a joint exercise today, and the speed of engineering has quickened. “15 or 18 years ago, a customer would come in—there wasn’t much email back

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January 2018


Call 1-800-544-7769 or visit

1/22/18 4:47 PM

L e a d e r s h i p

then—and they would drop a 300-page data pack on an engineer’s desk. Within that 300 pages would be a perfect description detailing in words, numbers, and drawings exactly what they wanted.” “Back then, seven times out of ten it was some type of electronic module or submodule destined to go into something. Now with all communications digitized, these days we usually work with engineers and product-development folks as well as our customers’ marketing folks. They say, ‘Here’s our product roadmap at a macro level for the next two to three years. What do you think, Jabil? What ideas would you have to make our product roadmap better? What ideas would you have to not jeopardize what we’re thinking for product function?’” According to Mondello, customers want early input from Jabil on serviceability,

reliability, cost, and producibility. Conversations tend to be higher-level; then Jabil engineers often discuss possibilities among themselves. Next, they return to the customer with a multitude of ideas for product functionality, size, power efficiency, customer interfaces and touchpoints to the product … and even the conceptual “feel” of the product, which (according to Mondello) is a significant part of the business today. Tomorrow’s manufacturing plant Mondello said that having great factories is an absolute must for Jabil, or else they’d have no business. “We can’t continue compete day-in and day-out on price without ensuring we do a great job on cost,” he said. “Key here are efficiencies in how we run our factories. That means technology in the form of

robotic intellect, firmware ... automation … augmented reality, and virtual reality is all around us. The objective is taking all the systematic pieces related to processes, automation, and robotics and identifying those pieces for which we want to own the IP or design ... and which parts we’ll create by piecing together our investments with what exists out in the world today to make a beautiful quilt.” Ironically, Jabil has different customers that own different parts of the “pieces” that Mondello described, so his team has been able to have some pretty deep conversations on where their roadmaps are heading. That lets Jabil pick companies from its customer base for partnerships to keep its factories cutting edge. As he explained, “we build a lot of the robots, we build a lot of automated equipment for our customers, and then we end

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Whether it’s our industry leadingCARLO solid state relays and con- Contact us today, and one of our field sales representatives will GAVAZZI Automation Components tactors, our our vast range of sensors, motor controls, energy show you why we are one of the fastest growing automation USA Tel: 847.465.6100 Fax: 800.222.2659 meters and current-, voltage- andCanada 3-phase monitors, CARLO companies worldwide. We’ll even provide a free evaluation Tel: 888.575.2275 Fax: 905.542.2248 Tel and Fax:needs 55.5373.7042 GAVAZZI has the solution for your Mexico application sample to qualified OEMs. • • 847.465.6100 • 174

Visit our website for downloadable data sheets, brochures and pricing:

January 2018

LEADERSHIP Mark Mondello 1-18_Vs5.LL.indd 174


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[ Giving You More ] More accuracy. More speed. More repeatability.

Delivering On Time Shorter design cycle? We can help. Our design engineers are involved from day one, so it’s right the first time.

Ready to Help Want easy access to our Design Engineers? Our Engineers actually answer the phone, live and in-person, every business day.

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You make great machines. We make your machines even better. Precision Linear & Rotary Positioning and Holding Select yours at or call 800.843.7445.

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L e a d e r s h i p

up selecting those devices to use in our own factories.” So, will manufacturing plants soon become fully robotized lights-out operations? Mondello doesn’t think so, at least not anytime soon. “Customized automation robotics don’t belong everywhere,” he said. “I’ve observed a lot of companies talk about it, and some implement it but never make a fair return on the ROI—for the capital expenditures, robotics, and automation that they apply to factories. With the appropriate upfront investments, there are investments of time and training, and then the facility must run the assets long enough to get them through the depreciation cycle for a reasonable ROI.” “What’s more, in some cases the human touch is actually a superior and much more efficient solution than pure lights-out automation. We have factories that are largely human-touch factories as well as lights-out factories and everything in between. But I think the most suitable setups is specific to the economics of the product business sector. Mondello predicts that in the next three to five years, manufacturing will continue to see efficiency increases thanks to the combination of automation, robotics, additive manufacturing, digital, higher intelligence, augmented reality, virtual reality, and connectivity between factories. “Manufacturing will adopt all of these approaches, but to varying degrees depending on the products being built and their lifecycles. In short, there’s no one generic peanut-butter answer … so adoption of automation is going to depend on the factory, its geographical location, and the products being made in it. But there will be advancements combining six to eight technological themes that’ll look much different than they do today.” DW

Compact, powerful performance enables innovative product design.

Introducing the

LRPX Series Brushless Planetary Gear Motor ElectroCraft motion solutions are driven by a combination of engineering innovation and manufacturing expertise. Global engineering collaboration has led to the groundbreaking LRPXSeries Gearmotor. The LRPX-Series brushless motor and low-noise planetary gearbox family was specifically designed to address the miniaturization trend in motion control applications without sacrificing performance. The LPRX integrated gear motor solution can achieve the equivalent output torque and speed performance of current industry leaders with 25% more efficiency and nearly 40% smaller package size. Features: • High torque density, small form factor • High load capacity • Low noise, Low heat generation • Wide range of voltages and ratios available • Up to IP65 ElectroCraft, Inc. 1 Progress Drive Dover, NH 03820

Phone: (844) 338-8114 Fax: (603) 742-9080


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


EC-HalfPageIslandAd.indd 5 LEADERSHIP Mark Mondello 1-18_Vs5.LL.indd 176

January 2018


12/22/17 4:15 PM 1/22/18 4:50 PM


oem pressure transmitters

The LC and LD lines of OEM pressure transmitters employ Keller’s revolutionary chip-in-oil (CIO) technology that combines microprocessor-based signal conditioning with a proven piezoresistive silicon pressure sensor, all within a miniature environmentally-sealed housing. For more information, contact Keller America toll-free 877-253-5537 or email

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Product World Servo motors with IP67 connectors Delta These small size servo motors now integrate IP67 connectors to provide more options to machine designers. Servo motors within this line range from 100 W to 750 W, include standard spring-bound shaft seals and use Intercontec connectors that are shielded throughout. The motor comes plug-n-play with the A2 Intelligent or B2 Economy series servo drives for a complete servo motion solution because of its integrated serial encoder. With a 10-pole rotor as standard, it’s possible to achieve up to 25% lower cogging torque, reducing overall power usage with smoother control. An improved IP rating eliminates the need for additional water shielding components.



Turn your design challenges into next-generation, marketleading medical devices with our extensive manufacturing capabilities and engineering expertise. We have facilities in Fremont, CA and Santa Ana Sonora Mexico.

Cardiac Monitoring Device Generator Interface Cable


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Endoscopy Camera

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

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

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1/26/18 11:47 AM

We have all the drop-in interchanges you need.

See them on our Instant Online Configurator. (Results in 60 seconds or less)

Now you can configure Fabco-Air products anywhere. On the shop floor. At the airport. At a remote job site. And you can do it with almost any device. Even your smart phone! The Fabco-Air configurator is the most comprehensive, user-friendly, and dynamic program in the industry. It generates everything you need from one location. A few clicks instantly give you: • Product Part Numbers • List Prices • Availability • CAD Files • Seal Part No's & Prices • Repair Kit Part No's & Prices • Mounting Hardware • Accessories & Attachments • Switches/Sensors

Let us help ! Tel (352) 373-3578 • Fax (352) 375-8024 • • e-Mail:

Fabco Air 1-18.indd 179

Additionally, the program includes an unprecedented DECONSTRUCTION feature. Simply input a valid Fabco-Air part number to display all relevant information. DECONSTRUCTION can also be used to re-configure a basic part number for different mounting, stroke, added options, etc.

Try it out now at WWW.FABCO-AIR.COM

1/26/18 11:49 AM

Does Your New Machine Need More?

The New AKM® 2G Servo Gives You More.

Connector Options: • Speedtec • ytec

Cable Options: • Single Cable SFD3 / Hiperface DSL / ENDAT 2.2 • Dual Cable Variant for Resolver

Low Friction Shaft Seal Option For High Protection Class


higher performance


faster operation


more options to match needs


reduce energy consumption

and provides those features in a

Feedback Options: • SFD3 • Hiperface DSL • ENDAT 2.2 • Resolver

• SMALLER FOOTPRINT Holding Brake Option

Thermal Sensor Options: • PT-1000 + Avalanche PTC • PT-1000 • Avalanche PTC • KTY84-130

reduce machine space

Average continuous torque increases of 30% or greater

AKM® 2G represents the latest evolution of the industry leading AKM® motor product family. Find out more at ©2017 Kollmorgen Corporation. All rights reserved. KM_AD_000319_RevA_EN Specifications are subject to change without notice.

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Product World

Micro clutches Miki Pulley

These CYT clutches are designed for compact precision applications and may be easily mounted to a driven shaft. Further custom variants are possible by pairing a sprocket, timing pulley, V-belt pulley or shaft to the armature. The clutches connect and release power by being located between the input shaft and the load. The CTY stator is a bearing mounted type of clutch. It provides a connection between a motor and a load with low inertia, minimal drag and long service life.

The CYT Clutches are durable and versatile with a straightforward

design, consisting of clutch stator, rotor and armature. The clutch assembly features an integrated bearing design making mounting fast and easy while ensuring application concentricity and system runout. CYT Clutches operate well in temperatures from 14° to +104° F (-10° C to +40° C). They have a speed range up to 3,600 RPM.


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Product World Incremental and absolute encoders Automation Direct AutomationDirect has expanded its Koyo encoder product line to include additional incremental encoder output options and higher resolutions for absolute encoders.

The TRD-S Series of 6 mm solid shaft and TRD-SH Series of 8 mm hollow shaft

incremental encoders now have 5-12 Vdc open collector output versions in addition to the existing 12-24 Vdc open collector or 5 Vdc line driver output versions. These light-duty industrial grade incremental encoders have an IP40 environmental rating with resolutions available from 100 pulses per revolution to 2500 ppr and up to a 200 kHz maximum response frequency.

NEMA 4X/IP66 Nonmetallic Enclosures for your Toughest Applications

HMI Cover Kits & Prop Arm

• Fiberglass Reinforced Polyester (FRP) or Polycarbonate material • Lightweight • Non-corrosive • Non-conductive NEMA 4X Vent Kit

12" x 12" AM & AM-R Series

• UV resistant • Custom modifications • Premium accessories • 3D model library for easy download ULTRAPLUG® Hole Plugs

Connect with us online!

222 North Union Street • Bryan, Ohio 43506 Ph: 800-722-2679 • Fx: 800-237-7269 © 2018 Allied Moulded Products, Inc.

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Scan to learn more about Allied Moulded and the latest in nonmetallic enclosures & accessories. 1/26/18 1:59 PM

For further information about products on these pages visit the Design World website @

Distributed servo drive system saves space Beckhoff The AMP8000 distributed servo drive system breaks new ground for modular machine concepts. The AMP8000 integrates a servo drive directly into a servomotor and has an compact design. By relocating the power electronics directly into the machine, a control cabinet only needs to house a single coupling module in order to supply power to multiple servo drives with a single cable via the distribution module.

With the AMP8000, space requirements for

drive technology inside of electrical cabinets are reduced to a single coupling module. Via EtherCAT P technology, which provides EtherCAT signals and power over one cable, such a coupling module can control up to five distributed AMP8000 Servo Drives via an IP 67-protected AMP8805 distribution module. Since the entire AMP8000 system is cascadable, even complex motion systems can be implemented with a remarkably simple topology.

1 step

nameplate fastening! No prep. No drilling. No metal chips.

GRIPNAIL Metal-Tacks® are engineered to attach nameplates, wiring clips and components to pressurized devices and equipment — without drilling. Drive into virtually any metal to create a durable blind displacement anchor that will hold over 200 lbs. Metal-Tack fasteners also ensure that your product will never be compromised by over penetration.

401 216 7900 Visit for a video demo MADE IN USA


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Product World General purpose low-voltage drive ABB

better products. better solutions.

The ACS580 is an all-compatible generalpurpose drive that provides user-friendly, energy-efficient motor and process control. It is designed to control pumps, fans, conveyors, mixers and many other variable and basic constant-torque applications. The wall-mounted drive is available in power ranges from 1 to 350 HP at 460 volts, in both UL Type 1 and 12 enclosures. The

Regardless of what makes your material handling application unique mk can provide a standard or custom solution — that meets your needs and keeps your business moving.

UL Type 12 drive has a reduced footprint providing more mounting flexibility in harsh environments.

h Aluminum framed conveyors h Featuring plastic modular belt, roller, chain and belt conveyors h Pallet-handling conveyor systems h Stainless steel conveyors h Extruded aluminum t-slot framing 184

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We believe in partnerships that produce high quality, cost-effective products that help you grow your business!

Why work with Maryland Precision Spring? • • • • • •

Strategic partnership • Leverage spend with one supplier • Joint end-user calls Quality / Made in the USA DoD Certifications • DD 2345 and NN 801 Extensive inventory Same day and next day service Standard catalog pricing

• • •

Volume discounts/ rebates Quick quote turns Product support • Training • Engineering Support • Consignment • Blanket PO Management • Special Packaging Maryland Precision Spring • 8900 Kelso Drive • Baltimore, MD 21221 • P (410) 391-7400 • F (410) 687-9223 •

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Don’t stress

Product World Speed reducers Gearing Solutions The FlexFrame 5 HP face mounted speed reducer has patented adaptors creating compatibility with either IEC or NEMA motors. This allows users to quickly switch or replace motors, interchange IEC and NEMA motors for export applications, add face, flange or foot mounts, and use GS convertible shaft adaptors to match any motor to any gearbox.

designs function as gearheads. Built on the Nu-Lobe gear design, they are available

Central supports your discrete product and solution needs. Products:

• Diodes • Rectifiers • MOSFETs/JFETs • Transistors

Consisting of a face mounted speed reducer with a hollow shaft input, these

in standard ratios of 3:1, 4:1 and 5:1, making them suitable for a wide range of industrial and commercial applications, including use on mixers, parking lot gates, wind turbine yaw drives, conveyors, hoists and other material handling equipment, food processing equipment, robotic drives, and more.

• Thyristors • TVS • Silicon Carbide devices


• Custom device configurations • Special packaging • Custom wafer metallization/diffusion • Multi-Discrete Modules combining multiple devices • Super Industrial solutions for extreme environments. TM



w w w. c e n t r a l s e m i . c o m 145 Adams Ave • Hauppauge, NY • 11788 • USA

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For further information about products on these pages visit the Design World website @

Sensor for automation applications Balluff The BES Q40 sensors are an application solutions with a common compact form factor. With the addition of the Basic BES Q40, these sensors expand the line of cubic 40x40 sensors beyond the existing Factor1, extended range and ceramic coated versions. Designed for general factory automation applications, they provide two flexible active sensing surfaces with 20 mm of operating distance with flush mounting capabilities. Features: • Select the active sensing area to be on the front or side of the sensor by part number for flexible installation. • IP 67 for dusty and wet environments • Electrical: PNP Normally-Open output, 2m PVC cable, Short Circuit Protected


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Product World Small STO-certified servo drive Elmo

Highest Torque in the Smallest Space

Elmo has doubled the power of its servo drive, the Gold Twitter, to suit demanding applications in the era of Industry 4.0. With a weight of only 33 grams and continuous currents of 160° (80 V) and 140° (100 V), the Double Gold Twitter delivers over 10,000 w

... or the largest.

of qualitative power, a great fit for applications that require a reduced footprint and high

Maxitorq clutches and brakes deliver power, reliability and are customized to meet your exact needs. Land, sea and air – CJM is everywhere.

tooling, large printer rolls and more.



power, such as large robotic vehicles, antennas and tracking systems, high power machine

The Double Gold Twitter is among the smallest STO-certified (IEC 61800-5-2, SIL-3)

servo drives on the market. It has a proprietary Fast and Soft Power Switching Technology (FASST), which ensures optimal power-device switching and delivers over 99% efficiency and negligible electro-magnetic interference (EMI).

Universal-voltage motor thermistor relay Carlo Gavazzi The DTA04 motor thermistor relay has universal input voltage, giving it the flexibility to be installed in a

Clutches, Brakes & Power Transmission Products • electrical, mechanical, pneumatic & hydraulic models • system design and integration • expert engineers working on every order

variety of control panels. This is a DIN rail mounted thermistor relay for protecting electric motors from overheating, ensuring continuous production and preventing machine downtime.

Simplicity, versatility, and reliability are crucial

for most users as they select monitoring controls to protect motors and equipment. The DTA04 meets these criteria with key features that include an operational mode that can be configured as Auto

Engineering Solutions for Clutches & Brakes

or Manual reset, giving the user the ability to select the option that best suits their requirements. The universal input voltage and multiple NEMA B300 relay outputs also provide users with the choices, which they usually require. Phone: 860-643-1531 291 Boston Tpke, Bolton, CT 06043 188 January 2018 Product World 1-18_Vs6_MS.LL.indd 188


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New Planetary Gearmotors from Bodine The high-performance 24A4-60P PMDC gearmotor features our all-new 60mm planetary gearhead, and provides up to twice the torque of conventional helical/spur parallel shaft gearheads. Its rugged design, high torque density and high efficiency make it an ideal drive solution for industrial automation applications, packaging equipment, and for a wide range of solar- or battery-powered equipment. Metric and US models are available.

SPEED RANGE 11 to 658 rpm

TORQUE 5 to 226 lb-in.

GEAR RATIO 4:1 to 162:1

VOLTAGES 90/130, 24, 12 VDC | info @ | 7 73.478. 3 515

BOD designWorld Bodine 9-17.indd 24A-P 189 full page 2017.indd 24

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Product World

Fully Integrated Display

Self-calibrating temperature sensor Endress+Hauser The iTHERM TrustSens hygienic RTD is the world’s first selfcalibrating temperature sensor. TrustSens’ self-calibration process functions in situ and provides the necessary documentation to meet the conformance requirements for various regulatory agencies.

Traditionally, calibration cycles for standard temperature

sensors in critical service are every six to twelve months. This leaves the potential for undetected drift in the sensor between cycles. Such undected drift could lead to product quality issues or even a complete loss of the production run.

Data Image USA - - 407.478.4064

Many hygienic and aseptic processes require equipment

cleaning on a regular basis with Sterilize in Place (SIP) procedures, typically after every batch. With TrustSens, the temperature sensor is calibrated after every SIP cycle. TrustSens, therefore, eliminates the risk of an undetected calibration drift and the risk of bad batches. It also reduces

Need a Sensor for a Unique Requirement?

the need for frequent calibrations by verifying the sensor is working as designed in between manual calibration cycles.

HBM is a leader in the development and production of strain gage based sensors for thousands of static and dynamic applications. Catalog sensors rarely fit OEM applications, so look to HBM for a custom-designed sensing solution.

HBM ■ Tel. +1 (800) 578 4260 ■


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G E T YO U R F R E E T H R E AD ID G U IDE NEED HELP IDENTIFYING AND MEASURING FITTINGS? We’ve created a helpful 28 page guide that includes illustrations, tips and a thread chart. To get your free physical copy, go to


Brennan stocks roughly 4 times the selection of our competitors. That means large or small sizes, unusual jump sizes or end combinations, as well as popular sizes are all readily available. And if we don’t carry it, we will make it for you! Because we control the manufacturing process from end-to-end, we can offer the widest variety of sizes, materials, platings and coatings - even custom engineered solutions.

CALL US AT 800.331.1523

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SEAL and


Product World Encoders for electric automation Heidenhain The ECI 4000 is an absolute inductive rotary encoder for hollow shaft diameters of 180 mm. Not only is this encoder robust and accurate, but, as a modular system with a scale drum and a separate scanning unit, it also has suitable mounting characteristics for use in robots. The ECI 4000 rotary encoder, as well as the

Don’t Get Caught In a Labyrinth of Bad Seals Our Patented Centrifugal Pressure Seals: ✓ Keep lubricants in and contaminants out ✓ Reduce down time ✓ Support horizontal and vertical applications ✓ Prevent friction and overheating with a non-contact design ✓ Create a dynamic pressurized barrier ✓ Support extremely low-viscosity fluids

ECA 4000 angle encoder, significantly improve the absolute position accuracy of the tool center point on industrial robots by up to 70 - 80%.

Proportional valve electrical actuators Danfoss The PVE series 7 offers fast, accurate, and intelligent operation with plug-and-perform design and works in conjunction with high performance proportional valves — PVG 32, PVG 100, PVG 120 and the new PVG 128 and PVG 256, as well as steering valves EHPS, EH, EHi and OSPE. Standard for all proportional PVE S7 is the use of a spool position feedback signal to close the loop on the PVG/ steering valve main spool position, ensuring it is in the right position at a given input signal. This ensures high precision of the valve flow with high repeatability which leads to improved machine performance and productivity as well as less operator fatigue.

A Carlyle Johnson Company 860-643-1531 192 January 2018 Product World 1-18_Vs6_MS.LL.indd 192


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For further information about products on these pages visit the Design World website @

Midsize heavy-duty safety couplings R+W

Ballscrews & Rollerscrews

These two new smaller STN series safety couplings with conical clamping hubs bring heavy duty industrial style overload protection into midsize applications. The two new sizes, 2 and 5, cover disengagement torques ranging from 200 to 5,000 Nm, and shaft diameters from

Industrial Robots

45 to 80 mm (1.750 to 3.125-in.).

Using the ball-detent safety element system, the driving and driven ends separate

within milliseconds of a torque overload, releasing the motor inertia from the driveline, and reducing expensive repairs and costly downtime. The driveline is free to coast to a stop after disengagement, and re-engagement simply requires that a force be applied to the back sides of the plunger modules, either with a mallet or pry bar. Disengagement torque values are adjustable

Linear Motors

in the field and multiple ranges are available depending on the module configuration.

OD frameless, brushless servo motor kits

Linear Actuators

Maxon The EC 45 Flat Frameless Brushless Servo Motor Kit has only a rotor and stator – with no bearings

Linear Guideways

or motor shaft. With an outer diameter of only 43 mm, these pancake servo motor kits are extremely compact.

Available in size ranges from 30 to 70 Watt, these EC (electronically commutated) frameless

slotted motors have low voltage windings, high pole pair count and are shipped as BLDC

Linear Encoders / Positioning Measurement Systems

frameless motor kits. Features: • Low voltage windings • High accel/decel capabilities

AC Servo Motors

• Low rotor inertia • High pole pair count

Hiwin D1 and D2 Servo Drives

For more information visit


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SYSTEM SOLUTIONS HYDAC technology plays a key role in the challenges of improving machine performance while controlling cost. We provide solutions and components for: • Entire hydraulic systems - filters, accessories, plus all boom, steering and suspension control valves • Cooling solutions - a combination of high performance cooling elements and long life DC electrical powered fans for extended trouble free operation in mobile hydraulic applications. • Portable data recorders for simple measurement and data capturing tasks involving hydraulic and pneumatic systems. • Touch and non-touch machine displays with integrated controllers • Welded diaphragm accumulators offer reduced vertical motion (bounce) and a smooth ride • One stop keeps you moving! | HYD1712-1948

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For further information about products on these pages visit the Design World website @

Dc brushless motor Portescap The 22ECP35 two pole brushless dc motor has 30% more continuous torque and 100% more WE Series Linear Guideway Wide Series Ball Type.

power over similar comparative motors without compromising the operation and long life required from a brushless dc motor. The 22ECP35 brushless dc motor has patented Ultra coil technology which provides torque and power density, with limited core losses over a range of working speeds without friction and brush wear. The 22ECP35 can be adapted to most applications in the medical and industrial markets, enhancing the life and reliability of a device without compromising on power and machine throughput.

PG Series Linear Guideway Integrated Magnetic Encoder.

Valve connector Canfield Connector The Series 5K DIN valve connector enhances two exiting product lines. The 5K connector is now offered without the integrated gasket design

MGN / MGW Series Linear Guideway Stainless Steel Miniature Linear Guideway Size 5 Now Available.

to promote version compatibility with the company’s MCCR (Multiple Control Connector Receptacle) and its ILW (Interposed Lighted Wafer). Both products are used primarily in the hydraulic valve industry. Features: • Provides snug and secure pin contacts on solenoid spades. • Runs one wire rather two from the MCCR device to the control box. • Can be manufactured in a range of plastic housing materials for compatibility with

HG / EG / RG Series Linear Guideways Ball and Roller Type.

high temperature and various chemical applications. • Allows the ILW module to plug into a molded connector to provide a convenient indicator light


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Product World Roller pinion system in stainless steel Nexen The RPS engages two teeth simultaneously for accuracy with zero backlash at any length. The system is also quiet, and 99% efficient. Stainless steel makes the system corrosion resistant, with a life of up to 36 million meters. The RPS provides a low maintenance, durable alternative to rack and pinion, ball screw and belt drive technology. The RPS is used for a range of applications including laser cutting, plasma cutting and gantry applications. Features: • Speeds: 11 m/s (36 ft/sec) • Accuracy: +- 50 um • Zero backlash • Unlimited length (custom lengths and modular components available)

Custom Precision Indexing Solutions: UNMATCHED RELIABILITY AND FLAWLESS OPERATION Our Fixed and Flexible index tables are free of backlash allowing for smooth, continuous and maintenance free operation, eliminating the need for shot pins to get high accuracy and repeatability.

RT Series: Rotary Index Table

Trunnion Index Drives Parallel Index Drives

Extensive range of sizes and offered in both fixed cam indexing solutions up to 108 stations or fully programmable. The RT series robust design will ensure to maintain high precision in intense automation settings.

The RT, TMF and TR series can all be equipped with any make of AC motor with absolute or incremental encoders for positioning. Our programmable trunnion index drives can be adapted to fit the proper size robot motor for auxilliary axis.

Manufactured in a large range of sizes and variety cam profiles and fixed number of stations. Built with aluminum housings that can be treated to suit any automated environment and case hardened internal components to extend the indexer’s life.

Precision Indexing Conveyors

Pick and Place

Ranging in size from LFA035 to LFA150. Engineered to give precision in XYZ. Each link has multiple cam followers that are traveling in case hardened guideways. LFA systems can be purchased as fixed linear stroke or fully programmable.

Ideal for high-speed and high-accuracy assembly jobs with 100% repeatability and synchronization on every index cycle. Options include cylinder, disk cam, disc groove, globoid, pneumatics and servo technology.

TMF Series: Rotary Index Table Fully programmable index table, designed with large center thru-holes, low profile and a large rotating diameter, with a strong four-point contact bearing assembly. Size for size could be the strongest most accurate programmable rotary index table on the market


1204 East Maple Rd Troy MI 48083 • • • P. 248-743-9999

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, ter, ng


For further information about products on these pages visit the Design World website @

Linear position sensors Posital LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

LINARIX linear position sensors now have low-cost versions of these industrial measurement tools. These components have compact, inexpensive plastic draw wire assemblies in place of the metal components used in earlier models. They are suitable for monitoring the linear position of components in medical equipment, hoists, forklift trucks and other material handling systems intended for indoor use.

KA Type Linear Actuator / SAR Ballscrew or belt driven, exible design.

The low-cost sensors are available in three measurement ranges: 1.25,

2.4 and 7.5 m. These designs are compact and easy to position in complex machines. The linear position sensors are part of Rockwell Automation’s Encompass network of complementary products.

KK Type Linear Actuator / SAR Ballscrew driven, high accuracy and reliability.

Molded-in aluminum threaded inserts Spirol The design of the Series 60 Blind-End and Series 61 Through-Hole Inserts consists of axial grooves to maximize torque resistance,

KS Type Linear Actuator / SAR Ballscrew driven for clean room applications.

balanced with radial undercuts for high-pull out force. These moldedin inserts are designed to be placed in the mold cavity prior to plastic injection, and offer performance due to unrestricted plastic flow into the retention features on the outside diameter of the inserts. These lightweight threaded inserts for plastics are manufactured from 2024 grade aluminum which provides the best combination of

AC Servo Motors.

strength, corrosion resistance, machineability and cost.

The Series 60 and Series 61 molded-in inserts are lead free,

40% stronger than brass, and 1/3 the weight of the same Insert manufactured from brass. Standard inch thread sizes include 8-32, 10-24, 1/4-20, and 5/16-18, and M4, M5, M6, and M8 for metric

Hiwin D1 and D2 Servo Drives for Servo Motors, Torque Motors and Linear Stages.

thread sizes.


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Product World Custom suction cup PIAB This suction cup is specifically designed to handle thin and brittle food items such as the sheets of pasta used in lasagna or very thin slices of cracker bread. A tailormade solution, the food contact approved F-BXT cup is designed with an extra-long and thin lip enabling it to handle fragile pasta sheets with special care. Approved for direct food picking, the nimble cup will guarantee safe, secure and hygienic automated procedures for, for instance, lasagna sheets or similar items.

The detectable, blue cup is suitable for use with visual inspection systems favored by the food industry.

The cup and its fittings also comply with metal detectors available on the market. The combination of 2 ½ funnel-shaped bellows and a stable body with a large vacuum flow orifice enables a steady hold on products, even at high speed and in quickly accelerating systems.

200V Ultra-Junction X3-Class HiPerFETTM Power MOSFETs With low-noise fast recovery body diodes and lowest on-resistances FEATURES TO-264

Lowest on-resistance RDS(ON) Ultra-low gate charge Qg Low-noise fast recovery body diode dv/dt ruggedness Superior avalanche capability International standard packages


Battery chargers for light electric vehicles (LEVs) Synchronous rectification Electric forklifts Motor control (48V-110V systems) DC-DC converters Class-D audio amplifiers


Part Number TO-3P






TO-263 TO-220

TO-268HV TO-252

Overmolded TO-220

IXFA36N20X3 IXFP36N20X3 IXFP36N20X3M IXFY36N20X3 IXFA72N20X3 IXFP72N20X3 IXFP72N20X3M IXFQ72N20X3 IXFA90N20X3 IXFH90N20X3 IXFP90N20X3 IXFP90N20X3M IXFQ90N20X3 IXFH140N20X3 IXFQ140N20X3 IXFT140N20X3HV IXFN220N20X3 IXFH180N20X3 IXFT180N20X3HV IXFH220N20X3 IXFK220N20X3 IXFT220N20X3HV IXFK300N20X3 IXFN300N20X3 IXFX300N20X3



(V) 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200

TC = 25°C (A)

RDS(on) max TJ=25°C (mΩ)

Qg(on) typ

trr typ

RthJC max




36 36 36 36 72 72 72 72 90 90 90 90 90 140 140 140 160 180 180 220 220 220 300 300 300

45 45 45 45 20 20 20 20 12.8 12.8 12.8 12.8 12.8 9.6 9.6 9.6 6.2 7.5 7.5 6.2 6.2 6.2 4 3.5 4

21 21 21 21 55 55 55 55 78 78 78 78 78 127 127 127 204 154 154 204 204 204 375 375 375

75 75 75 75 84 84 84 84 85 85 85 85 85 90 90 90 116 94 94 116 116 116 170 170 170

0.71 0.71 3.5 0.71 0.39 0.39 3.5 0.39 0.32 0.32 0.32 3.5 0.32 0.24 0.24 0.24 0.32 0.16 0.16 0.13 0.13 0.13 0.1 0.18 0.1

Package Type TO-263 TO-220 OVERMOLDED TO-220 TO-252 TO-263 TO-220AB OVERMOLDED TO-220 TO-3P TO-263 TO-247 TO-220 OVERMOLDED TO-220 TO-3P TO-247 TO-3P TO-268HV SOT-227 TO-247 TO-268HV TO-247 TO-264 TO-268HV TO-264 SOT-227 PLUS247

EUROPE: IXYS GmbH,, +49 (0) 6206-503-249 | USA: IXYS Power,, +1 408-457-9042 | ASIA: IXYS Taiwan/IXYS Korea,,


January 2018

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9th Replacement 3rd Replacement

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It’s Lights Out Again.

Do You Really Want To Take Your Brand Integrity Down This Road? Bergquist Thermal Clad® keeps your LEDs intense, bright and reliable wherever they go. Built for long-term reliability. Choosing the right IMS (insulated metal substrate) can make the difference of a successful product or not. Knowing the long term performance and reliability of the materials in your design, will give your customers a quality product and protect your reputation. This includes: • Thermal impedance, not just thermal conductivity • Long-term dielectric strength, not just breakdown strength • U.L. Listed • Long-term temperature testing

A balance of innovative thinking and expertise. Not all substrate materials have the Bergquist company’s 25+ years of testing and proven field performance. Our testing is geared to the

application, not just numbers, which give a true performance picture you can count on in your design.

Bergquist delivers cooler performance for Power LEDs. Dielectrics: Bergquist offers a wide selection of dielectric and thickness choices to meet the demanding specs of high performance applications (Bergquist HPL and HT versions), as well as, lower performance requirements (Bergquist MP, HR T30.20 versions). Base Plates: Bergquist offers a wide range of thicknesses, aluminum for packaged components and copper base for high power density and COB applications. Circuit Copper: From 35µm to350µm (1/2oz. to10 oz.) Call or visit us to qualify for a FREE T-Clad Samples Kit: 1.800.347.4572 9 5 2 . 8 3 5 . 2 3 2 2

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Product World Thrust reverser brakes for aviation SEPAC These thrust reverser brakes are used to prevent the thrust reversers on an airplane from being engaged in flight. SEPAC’s thrust reverser brakes are suitable for any aerospace application, and are currently used on platforms such as the Airbus A380 wide-body jet and the Irkut MC-21 Russian airliner. Features: • RPM up to 20,000+ • Dual coils for superior reliability • 28 V for usage in standard aircraft or customizable voltage for other applications • Multiple discs for high torque in a small package • Aerospace-rated coatings and corrosion protection


January 2018

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1/26/18 2:49 PM

The American Champ Dump Pump

Paving the Way The American Champ Dump Pump is built in America with quality globally sourced parts

1500 Frost Road Streetsboro, Ohio 44241 | 330.626.2801 | PERMCO 1-18.indd 201

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Product World Incremental encoders for outdoor use Kuebler Sendix 5000 and 5020 incremental encoders are designed to overcome two common threats to encoder lifecycle: heavy vibration loads and misalignment due to installation errors. This design integrates interlocked bearings, strengthened outer bearings and large bearing size relative to the size of the encoder. Additionally, the encoders’ solid die-cast housing, with its IP67 protection rating, stays sealed even when subjected to harsh environmental conditions. Features: • Temperature range of -40 to +85° C • Shaft load capacity:100 N (radial) and 50 N (axial) • Maximum speed of 6,000 revolutions per minute • Magnetic field resistance • Optional seawater-resistant version



RollBeam Telescopic push-pull

LinearBeam guided push-pull Press-mounted dual push-pulls


SERAPID Inc. | 34100 Mound Rd. | Sterling Heights, MI | Tel +1 586-274-0774 | | January 2018

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4/12/2016 2:17:33 1/26/18 2:52 PMPM

Tensility 1-18.indd 203

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3D Printing

Product World

UlteM® pei w/ 3M™ adhesive pre-applied

Brushless dc motor with integrated drive Allied Motion

“The ultimate 3D printing surface”

The KinetiMax 42 EB is a 42 mm diameter outer rotor, brushless dc motor with an integrated drive. The KinetiMax 42 has a bearing system capable of handling high side loads. It has a minimum operating life of 20,000 hours. The KinetiMax has an integrated speed control loop with speed set input to adjust motor speed from 150


to 5,000 RPM.


• •

• • • • •

Perfect for ABS & PLA Filament Ideal for heated print plates: Glass or Aluminum Easy Applicable: Backed with adhesive liner for remove and stick application. High Temp- 3M™ 200MP Acrylic Adhesive Adhesive can be laminated to either side of film: Gloss or Matte Dimensions up to: 47” wide Custom sizes available

PEI Thickness: 3 mil. (.003”) 5 mil. (.005”) 10 mil. (.01’) 20 mil. (.02”) 30 mil. (.03”) 40 mil. (.04”)

(800) 461-4161

The external rotor and iron-core stator minimize cogging and maximize output

torque. The higher inertia of the outer rotor design enables a smoother running motor even at low speed. The KinetiMax 42 is equipped as standard with thermal overload protection with automatic recovery, and reverse supply voltage protection.

Self-clinching free-running locknuts PennEngineering S-RT self-clinching, freerunning locknuts have a modified thread angle for easier tightening of mating screws and better vibrationresistant locking performance in thin metal assemblies.


modified thread formation allows mating screws to spin freely during the attachment process until clamp load is induced during the screw-tightening process. The applied clamp load then engages the locknut’s vibration-resistant locking feature, which locks the screw in place.

S-RT self-clinching locknuts install into aluminum or steel sheets as thin as 0.030-

in./0.8 mm and become permanent parts of an assembly. These carbon steel locknuts can be specified with thread sizes from #4-40 through 5/16-18 and M3 through M6 and in a variety of shank lengths. Zinc plating finishes are available in standard colorless or optional yellow.

204 January 2018 Product World 1-18_Vs6_MS.LL.indd 204


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Go ahead, push us to your limits.

We love a good challenge. If you need a fluid handling component for whatever reason, no matter how extreme, talk to The Lee Company. We’ve been solving complex fluid control problems in all kinds of industries for more than 60 years. Our extensive family of precision fluid control products offers unsurpassed reliability in just about every configuration you could imagine, including:

• Miniature Solenoid Valves

We’re not just talking about off-the-shelf solutions, either. A Lee engineer will be happy to discuss your application, and develop a custom design if needed. From managing nanoliter droplets to creating fully integrated fluidic systems, we’re unsurpassed in breadth and experience to deliver the precise, reliable performance you require. Whatever problem you face, make the solution easy. Contact The Lee Company today.

• Fixed and Variable Volume Pumps • Atomizing and Dispense Nozzles

Innovation in Miniature

• Micro Dispensing Valves • Integrated Fluidic Manifolds


• Custom Engineered Designs

The Lee Company 2 Pettipaug Road | Westbrook, CT 06498-0424 Tel: 860-399-6281 | 800-533-7584 |







See us at Lab Automation 2018, Booth #545 and MD&M West, Booth #2278 Lee_DsgnWrld_8-13.indd 1 The Lee Company 1-18_booth numbers added.indd 205

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Product World Combined load monitoring and 24 Vdc power distribution Weidmuller With maxGUARD, the electronic load monitoring ELM devices combined with distribution terminal blocks can be customized to provide selective load protection in 24 Vdc power distributed systems for industrial automation applications. With combining load monitoring and potential distribution, this offers users time-savings during installation, increased safety against failure, and DIN-rail space savings while being highly service friendly.

The modular maxGUARD system is designed to meet specific

requirements for automation control panels. It contains three main cross-connection channels– positive, negative and internal signaling. This design increases the number of possible contacts from the electronic load monitoring device outputs (positive and negative) into the terminal blocks, providing efficient connections for the distribution board loads, as well as reduced wiring.

XEL40xx Series

Low Loss Power Inductors Extremely low DCR ... and ultra-low AC losses Optimized for high frequencies ... up to 5+ MHz Superior current handling ... up to 24.0 Amps Soft saturation ... withstands high current spikes Compact footprint: 4.0 mm 2 with profiles as low as 1.2 mm


Free Samples @

January 2018

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For further information about products on these pages visit the Design World website @

Food safe motors Baldor These food-safe stainless-steel motors are designed around sanitary equipment principles and compatible with clean-in-place (CIP) procedures. The motors are also designed with smooth contours, advanced sealing, and exceed IP69K for water to maximize motor life in high pressure, sanitary cleaning environments.

The product line spans single and three phase ratings in foot mounted

and footless configurations, providing flexibility for OEMs and end users to choose the right product for their equipment and applications. Foot mounted designs meet NEMA standard mounting dimensions with continuously welded independent feet allowing easier access and clearance for proper cleaning procedures.

Buck LED driver Analog Devices The LT3964 is a dual channel, 36V, high-efficiency, synchronous, stepdown LED driver with internal 40V, 1.6A power switches and an I2C interface that simplifies LED dimming control. The LT3964 operates with a 4V to 36V input range, and has two independently controlled LED drivers that switch at up to 2MHz.

The LT3964 uses fixed frequency, current mode control and operates as a constant-

current and constant-voltage source with accurate current regulation for LED lighting in automotive, industrial and architectural lighting applications. Synchronous operation results in efficiencies above 94% with both channels at full current load.


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1/26/18 3:05 PM

Product World Zero backlash Compact Ring Drive Nexen The CRD 250B includes a built-in zero backlash locking/brake design that has twice the nominal torque without increasing the CRD footprint. It is durable, with a brake life of 1 million cycles, and requires little to no maintenance. The CRD 250B is suitable for applications including cutting systems, automated welding, medical packaging,robotics, and semiconductor. The CRD 250B brake is spring engaged and pneumatically released so that it will default to lock in a power failure or emergency situation. Features: • Holding torque: 800Nm • Maximum release pressure: 60 psi • Thru hole: 31.7 mm ~ 1.25-in. • Fully sealed IP65-rated housing • E-stop capable



Gefran, a leading global designer and manufacturer of sensors for position, pressure, temperature, and force measurement, now offers a complete range of devices for earthmoving and lift equipment.

Gefran sensors use leading edge technology (Hall effect, MEMS, and magnetostrictive) to achieve the demanding requirements in operator and vehicle stabilization, rotation, reach, and inclination.


GEFRAN INC - 8 Lowell Avenue Winchester, MA 01890 Toll free 1-888-888-4474 -

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1/26/18 3:06 PM

Questions about encoders & motion control? We’ve got answers. For almost 50 years, EPC has been providing encoder solutions for reliable motion feedback. From industrial logging equipment to packaging to conveying – almost any kind of machinery – we have the encoder solution you need and the expertise to help you find it. And, as always, we provide you with: Expert Technical Support When you call EPC, you talk to engineers and encoder experts who will help you find what you need. Highly-Configurable Encoders From linear measurement solutions, to our full line of thru-bore and shaft encoders, to our new line of programmable encoders, we’ll get you the right encoder, custom configured for your application.

Industry-Leading 3-Year Warranty EPC is known for exceptional quality and we’ve got an industry-leading 3-year warranty to back it up. Fast Lead Times We offer same-day shipping on many models – and our standard lead time is just 4 to 6 days.

Call us today.

We’ll help you find the motion feedback solution you need. Configure Your Encoder in 3D

1-800-366-5412 |

Encoder Products 1-18.indd 209

Configure & download 3D files of encoders at

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Product World Torque limiters Rexnord

Precision Components

Autogard Torque Limiters are suitable for overload protection with bi-directional protection, lower total cost of ownership,

See us at:

Photo Etched Parts

DesignCon - Sa nt MD&M West - a Clara, CA Anaheim, CA MDTX - Secauc us, NJ

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

increased accuracy of torque limitation, and longer life at high speeds. The most recent update to the Autogard Torque Limiter range— the XG Series —provides better protection from unexpected torque spikes for extruders. Designed to disengage the driving motor from the extruder gearbox in the event of a

Download Capabilities Brochure

process jam, the XG Series was developed with leading machine builders and users. Able to instantaneously separate

Flex & Rigid-Flex Circuits

damaging inertias over a pre-set level and featuring easy-to-adjust torque

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

setting, drop-out options, simple manual disconnection and disengagement sensors, the XG Series is the mechanical fuse for extruders.

Download Flex Circuit Design Guide

EMI/RFI Shielding • Global supplier standard and custom products • Commercial and military markets • Over 100 finger stock gasket profiles • Shielded vents and filters • Conductive foam and elastomer gaskets • Board level shielding Download Shielding Catalog TECH-ETCH, INC., 45 Aldrin Road, Plymouth, MA 02360 TEL 508-747-0300 • FAX 508-746-9639 •

ISO 9001 AS9100C



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Accumold 1-18_DW.indd 211

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Product World Electrically conductive die attach adhesive Master Bond

No Kinks No Hose Twisting

Simplified hose configuration, less hose and adapters combine to reduce repairs and downtime cutting the overall cost of hydraulics.

Available In BSPP

Custom Design & Sizes Available

Hydraulic Live Swivels Inline & 90°

EP3HTSDA-1 is a single part, no mix epoxy adhesive designed primarily for die attach applications. It exhibits a die shear strength of 20-22 kg-f and has a thermal conductivity of over 40-45 BTU•in./ft2•hr•°F [5.7-6.5 W/(m•K)]. This 100% solids formulation has a suitable viscosity and flow for die attach, will not “tail” and can be easily dispensed automatically. Additionally, it has an unlimited working life at room temperature and will cure in 20-30 minutes at 250° F or 5-10 minutes at 300° F.

EP3HTSDA-1 is NASA low outgassing approved. Dimensionally stable, it has a Shore D

hardness of 75-85 and is engineered to withstand thermal cycling and shock. This epoxy system adheres well to metals, ceramics, and silicon dies. Service operating temperature range is from -80 to +400° F.

Heavy Duty Ball Bearing Design • Rated To 10,000 P.S.I. • Heat Treated • Available In 304 & 440 Stainless Steel • Custom Design & Sizes Available • Rebuildable Ball Bearing Design • Withstands Heavy Side Loads • Superior Quality Alloy Steel • Full Flow — Low Pressure Drop

Quality Products Made In The U.S.A. Patent No. 5547233 Fax: 1-763-784-7423 Email:



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212 January 2018


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Small Parts Assembly

Switch Testing

Smart Capping

Fragile Parts Handling

Touch Screen Testing

Automated Thread Checking

The ability to perform tasks and verify its quality at the same time. SMAC 1-18.indd 213

1/26/18 1:04 PM

Product World Industrial PC Beckhoff With the addition of the C6030 IPC, the advantages of dramatically reduced space requirements, universal applicability and easy installation are now also available for complex automation applications.

This multi-core computer, with a size of only 132 x 132 x 67 mm, integrates Intel Core

i-series processors of the 6th and 7th Generation for maximum performance with up to 3.6 GHz per core. Also, the C6030 IPC is only half the size of the closest comparable control cabinet PC, the C6930, yet it offers more interfaces even in its basic configuration.

Stepper motion control products IDEC This AMCI by IDEC product line includes controllers, stepper motors, an integrated controller/drive, an integrated drive/stepper motor, and an integrated controller/drive/stepper motor.

The iSM2340 NEMA 23 stepper motor comes in

standard frame sizes with output torque of 130 or 240 oz-in.

The integrated controller/drive unit can control one

to six axes of motion, and it combines all the features of AMCI’s 1-axis controller and a 4.0A stepper drive into a single unit.

The iSMD23 integrated drive/stepper motor unit provides up to 240 oz-in of torque,

and can be paired with the iANF2E to provide a complete solution. The unit can also be controlled by the PLC.

THe iSMD23E integrated controller/drive/stepper motor unit provides all-in-one

motion control with all the features of AMCI’s 1-axis controller, drive and stepper motor. No heat sinks are required due to its thermally efficient design. The integrated unit can operate over a wide range of input power, from 24-48 Vdc.

214 January 2018 Product World 1-18_Vs6_MS.LL.indd 214


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Maple Systems 1-18.indd 215

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Ultra Versatile Edge Welded Bellows S TAN DARD COM P ON E NT OFFE RIN G Durable • Precise • Flexible Features: • • • • • • •

Highest stroke length (90%) Highest cycle life Customization Repeatability Media compatibility High temperature SS, Titanium, alloys, etc.

Free Engineering Assistance for Custom Designs

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Product World Cameras, software and lighting accessories in one


B&R This is the world’s first image processing solution to be seamlessly incorporated in the

Visit for Design Guide and Technical Data

automation system. The solution comprises cameras, software and lighting accessories.

At the heart of the solution is a broad



selection of intelligent camera technology.

Options at the lower end will replace simple machine vision sensors, while the top of the range will harness the full potential of high-

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Product World Alternatives to screws for attaching top panels in assemblies PennEngineering Aluminum and stainless steel microPEM TackSert pins from provide cost-effective alternatives to micro screws for attaching top panels to base panels or chassis in compact electronic assemblies. They will

You NEED Flow Ezy!

attach top panels of any material to a base or chassis manufactured from common cast metals (such as magnesium and aluminum) or plastics (such as ABS and printed circuit boards). The pins eliminate

Flow Ezy Filters, Inc is the leader in supplying filters, strainers, and accessories for hydraulic applications. If you need it, we have it. Our product line includes: • Sump Strainers • In-Line Filters • Tank Mounted Strainers • Tank Breathers • Suction Screens • Flow Diffusers • Lube Oil Filters • Spin-On Filters • Cartridge Filter Housings • Interchanges for Parker, Marvel, Schroeder, Vickers, and many others...

many of the costs and issues associated with screws and integrate unique design features promoting reliable and effective performance.

TackSert pins have multiple advantages over screws by

eliminating needs for mating threads from tapped holes or inserts and the rework frequently required due to screw cross-threading and driver bit “cam-out.” Patches intended to prevent fastener loosening in service are unnecessary.

FLOW EZY FILTERS, INC Tel: 800-237-1165


January 2018

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Michele and Pasquale apply a LEGO® approach to automation. Festo helps them build customer trust. Flexibility and reliability. They’re the building blocks for IASE’s modular approach to robotic packaging systems. For Michele and Pasquale, choosing the right components is critical. To them, they’re not just building systems; they’re building their customers’ trust. That’s why they rely on the superior automation products and support they receive from Festo. Making customers competitive. That’s what moves Michele and Pasquale. What moves you?

Access Our Latest Best Practices Report.

Visit Michele & Pasquale D’Egidio Owners, Industrial Automation Systems Engineering (IASE) © 2017, Festo Group. All rights reserved. LEGO is a trademark of the LEGO Group, which does not sponsor, authorize or endorse these products.

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Motor Feedback Systems for linear and rotative drives

Product World Mini connector WAGO The D Sub Mini connector breakout modules for field termination provide connections without soldering. Each module is designed to interface directly with

Absolute and incremental magnetic measurement ■ ■ ■ ■ ■

a fixed mounted D Sub or with a cable when using

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

DIN rail or a panel mount. These can be used for connections to operator workstations, motor drives, laptops and other peripherals.

The compact D Sub Mini Connector breakouts

are RoHS compliant and have clearly labeled terminals. Fast, easy Push-button CAGE CLAMP S termination technology results in reliable and maintenance-free connections. A multi-mount hardware kit is provided, including captive screws,

SIKO Products Inc., Phone +1 (734) 426-3476,

jackscrews, and snap-in 35 mm DIN rail feet that can also be trimmed and used to provide a stable, non-marring wiring platform, for free-hanging

The Pioneer in High-Performance PCB Wireform Technology


For over 70 years, Components Corporation’s PCB Interconnect Products have ensured the highest standards of performance in the most demanding wireform interconnect and testing challenges. • PCB test points

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Product World Compact drive Delta

Create Design Connect

Designed for compact VFD applications up to 30 HP for 115 Vac, 230 Vac and 480 Vac, the MH300, which is smaller and more energy efficient than similar models, operates with up to 2,000 Hz output frequency for induction and permanent magnet motors. Features include built-in PLC with 5000 steps, Electromagnetic Capability Filter, Integrated Safe-Torque-Off, Built-in USB port, 5-digit LCD keypad with shuttle dial, spring terminals for Input/Output, energy savings mode and applicationbased parameter grouping. The MH300 Drive has built-in Modbus and CANopen communications. Network expansion capabilities include EtherNet/IP, PROFIBUS DP,

Pursue Quality Products That Can Power Your Business

DeviceNet, Modbus TCP and EtherCAT.

Interpower® is the premier supplier of power system components worldwide and offers a wide selection of power cords and cord sets for global use. • Made in Iowa, U.S.A. • 1-week U.S. manufacturing lead-time on non-stock Interpower products • Over 50,000 cords in stock for same day shipments • No minimum order or dollar requirements • Cords to your specifications • Interpower manufactured cords are 100% tested • Value-added options available



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3441-42000 1 motion, vibration, noise, or safety

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2X 2-1/2-12 UN-2A


solution fast.















Quiet-running bearings for conveyor applications














.37 9.4 5.50 139.7 mm



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CB-14 Series conveyor bearings are designed to operate quietly and

8.91 226.2 mm


7 4 mm

dependably in the most demanding material handling applications.

1.91 48.5 mm TOTAL MECH. STROKE

The CB-14 bearing design combines two major features that act SIZE DWG NO.




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spreading or splitting under load.

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Hardened raceways improve anti-

1.91 48.5 mm TOTAL MECH. STROKE

Download any product for free from our CAD database.


CB-14 bearings use a one-piece, precision




3441-42000 C friction performance. 1REVISIONS The ball REV PCO


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Learn more about our products online 24/7.Enertrols DATE




03 2X 1.26. 2 mm


75 O .19. 0 mm

· CAD downloads 88 O 1.47. 9 mm 25AUG2016 ·25AUG2016 YouTube tutorials INSTALLATION 3441-42000 C 1 8.91 LENGTH REVISIONS · Free VibroChecker app REV PCO 226.2 mm EXTENDED DESCRIPTION SALD1-1/8X2-P5.50 3.41 N/A for iOS 139.7 mm 86.5 mm

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00 O 2. 50.8 mm



· Online sizing tool N/A 8.91 & calculator EXTENDED 2X 2-1/2-12 UN-2ALENGTH 03 226.2 mm 2X 1.26. 2 mm · One-on-one support from 3.41 EXTENDED ROD POSITION 1. 0 0 an application expert 86.5 mm 25.4 mm FLATS .37 9.4 mm





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DATE 24AUG2016

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Get assistance selecting the right product for your needs.





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1/29/18 1:27 PM

Linear Motion Systems


IKO’S SUPERIOR COMPONENTS HAVE ENDURED MARS—IMAGINE WHAT THEY CAN DO FOR YOU HERE ON EARTH... To learn about customizable solutions for your specific application, or our maintenance-free (C-lube) lubrication (up to 5 years or 20,000 km), visit:


Ball Spline

New York: 800-922-0337 • Chicago: 800-323-6694 • Minneapolis: 800-252-3665 • Atlanta: 800-874-6445 Dallas: 800-295-7886 • Los Angeles: 800-252-3665 • Silicon Valley: 800-252-3665

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Product World

“The Company in Motion”

Custom seals for pharmaceutical industry COG The special material in the HygienicSeal series has been granted approvals for application in highly demanding industries. As well as the harmlessness test according to FDA 21. CFR 177.2600, AP 306 is approved according to USP class VI in chapter 88 up to +121 °C and chapter 87. The EPDM compound also successfully passed the cytotoxicity test (according to ISO 10993-5:2009). This EPDM compound has low migration values, which are in particular demand in applications in which there is a risk of contamination with the media to be sealed, e.g. in cell cultivation or insulin production. This material,

OMS Motion brings your ideas to reality through motion control, for more than 35 years.

furthermore, has strong resistance to contact with CIP and SIP media and is suitable for applications with WFI water. Owing to the operating temperature range from -40° to +150°C, AP 306 is adaptable to the particular requirements of the production process. (800) 707-8111 226

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Angle Measurement Made Easy

RFC 4800 Series of touchless sensors use a magnet attached to your application’s rotating shaft. Now with IO-Link output option, analog and IO-Link versions of RFC 4800 sensors can be easily connected with three wires—power, ground and signal. Touchless angle sensing technology excels in many applications including: • measuring through a wall or plate • shaft with limited play • sealed-shaft environments • low friction torque • high-vibration shaft • driveshaft misalignment

Magnet size selection and mounting as well as output choice are about the only parameters that need to be decided beyond those of track/wiper technology rotary sensors. Our technical specialists are happy to discuss your application needs.

Key specifications:

• Repeatability to 0.1° • Measures 0 to 360° • Resolution to 14-bit

• Linearity ≤ ±0.5% of F.S. • 2-ch. version option • speed output option

Free touchless angle sensors primer: Novotechnik U.S., Inc. Telephone: 508-485-2244 Email:

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Product World Stepper motion control products IDEC This AMCI product line includes controllers, stepper motors, an integrated controller/drive, an integrated drive/stepper motor, and an integrated controller/drive/stepper motor. When combined with an FC6A PLC and its embedded motion control macro instructions, these products allow users to implement single- and multi-axis motion control in a range of industries and applications.

Many industrial applications require motion control but

users are often frustrated by the complexity and high cost of implementation, particularly with servo systems. Macro instructions embedded in the PLC WindLDR programming software can be configured with drag and drop commands to perform control of up to 12 axes.


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247 Lynnfield Street, Peabody, MA 01960 • 800.921.3332 • Harmonic Drive is a registered trademark of Harmonic Drive LLC. Robonaut image courtesy of NASA/JPL-Caltech.

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Product World Helix conveyors for layout flexibility Dorner The tight turns and small footprint of the SmartFlex Helix Conveyors provide facilities with greater flexibility in layout for applications such as accumulation, buffering, cooling product and more. Features: • Conveyor widths: 85 mm, 180 mm and 260 mm • Spiral diameter: 55.12-in. at centerline • Maximum infeed height: 18-in. • Maximum outfeed height: 132-in. • Maximum number of tiers: 4 • Maximum distance between tiers: 30-in.

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MiniMax 06 & USB 3.0 ■ High density ■ Signal & power

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UltiMate High Power ■ IP68/69 or hermetic sealing ■ Blind mating

USB 3.0 Rugged Flash Drive 5,000 mating cycles, IP68 ■ Secure mobile data storage ■


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Product World Digital differential impedance transducer Kaman

COFFEE or TEA? You also have a choice for hydraulic cylinder positioning

The Digital Differential Impedance Transducer (DDIT) is designed to provide a digital interface for high-speed eddy current measurement systems, with resolution in the micro-inch range, at bandwidths as high as 60 kilohertz

Non Contact Operation

Miniature Mounting

Inside the cylinder? Compact, robust design

No Deep Drilling Costs

25g RMS Vibration Rating

for reading data, power, and control signals, the system operates from a single power supply with a voltage range of 8-28 volts.

The DDIT is available in three

Or Outside the cylinder?

configurations: The Digital System is designed

Easily field replaceable for maximum machine uptime

with a master serial peripheral interface (SPI)

Ideal for steering cylinders

analog voltage, with a full range output signal

Ideal for long cylinders

of 0-5 Vdc with a null position of 2.5 Vdc. The

to interface directly to an embedded controller bus. The ANA (analog) System provides linear

FE System is designed for field-programmable

Our Hall Effect Transducers Give You A Choice Tank Level Transducers

Also from Rota

gate array (FPGA) interface for high speed operation, with data rates as high as 128 kHz, 48 bits of data, 60 kHz bandwidth, and no internal firmware.

3 in 1 - Capable of Position Velocity Temperature Up to 6 metres High Accuracy



control, shaft vibration, image stabilization, and adaptive optics. Using a standard 9D connector

Short Length Maintains Pin to Pin Dimensions

On Site Replaceable

steering mirrors, magnetic bearing active

Maintains ASAE pin dimensions ECE-R10 Automotive Approval Magnet Works Through Carbon Steel

(kHz). It is suitable in applications for fast

Rota Engineering Limited

UK Tel: +44 (0) 161 764 0424 US Tel: 972 359 1041 Manchester, UK


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Since 1895


Signal Quality Analyzer-R MP1900A High Performance BERT The Signal Quality Analyzer-R MP1900A is an 8-slot modular, high-performance BERT with excellent expandability supporting measurement applications by installing 32 Gbit/s multi-channel Pulse Pattern Generator (PPG), Error Detector (ED), and Jitter/Noise addition modules for signal integrity analysis of increasingly faster devices. In addition, the MP1900A has built-in Link Training/LTSSM analysis function supporting all-in-one measurement of high-speed network interfaces such as 200GbE/400GbE, and bus interfaces such as PCI Express. To request a quote or a demo, visit us online at:

1-800-ANRITSU Š 2018 Anritsu Company

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Product World Inductive sensors Balluff The M18 Factor 1 sensors have more flexibility in welding applications where longer sensing ranges are needed or when the user is working with nonferrous materials.

A common application includes mig

welding where ferrous or non-ferrous material is used. The M18 Factor 1 sensors are available with weld spatter resistant coatings and weld-field immune circuitry for hostile welding environments. Features: • Extended ranges for ferrous and non-ferrous materials • IP68 for harsh application environments • Weld Spatter resistant coating • Expanded temperature rating (-40 - +85°)


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ROSS CONTROLS A Global Leader in Pneumatic Safety Valves

ROSS Pneumatic Safety Functions Energy Isolation

Safety Exhaust

Safe Cylinder Return

Safe Cylinder Control

Lockout & Lockout with Soft Start L-O-X® & L-O-X® with EEZ-ON® Valves

Control Reliable Energy Isolation


Internally and Externally Monitored

Internally and Externally Monitored

M35 & DM2® Valves

RSe & CRoSSMiRRoR® Valves

Cylinder Stop & Load Holding CRoSSCheCkTM & Po Check Sensing Valves

Pneumatic Solutions to Complete Your Safety Systems 1-800-GET-ROSS

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Product World Servo motors, motion controls, and servo converters AMK This portfolio includes ihXT servo motors, iSA motion control, iC and iX decentralized servo converters. The ihXT servo motors are suitable as decentralized auxiliary drives in applications such as format adjustment, material feed, cross-cutting, or gantry drives. The compact design integrates the inverter and has a cabling concept which can save up to 90% in cabling costs.

The iSA motion controller is suitable for modular machine builds or as a standalone motion controller.

It integrates easily into existing systems and doesn’t need a control cabinet, saving installation time and investment in cable pulling, in addition to cabinet enclosure costs.

If point A is your design concept and point B your finished product, then you can consider this the straightest line for pumps and compressors.


® PYRATHANE BELTS With Lifetime Warranty Against Manufacturing Defects LINE SHAFT CONVEYOR BELTS - Original Equipment & Connectable CUSTOM MADE IN INCH, METRIC & O-RING SIZES Round, Flat and Connectable Polyurethane Belts • Very Clean Operation • Eliminates Tensioning Devices • Exceptional Abrasion Resistance


Try our Pyrathane Belts


The advantages are pointed: • Exceptional reliability y • Low noise & vibration n • Long service life

on your conveyor ...

the standard of the industry!


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10:43:58 AM DESIGN2/9/2017 WORLD

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By specializing in delivering the best in photo-etched formed and stamped metal components, Fotofab has enjoyed incredible customer retention. With tolerances exceeding the demands of the aerospace industries, print-to-prototype-part in 1 day, knowledgeable technical team and a can-do attitude, we should be your go-to source. We're experts at producing stamped or formed board-level RF shield­ ing, optical encoders, electrical contacts, fine-pitch filters and much more. Fotofab can work with exotic metals that others shy away from.

Visit today for our FREE Design Guides!

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Product World High temperature epoxy for sealing and bonding Epoxy Set The EB-119M is a long work life, high-temperature epoxy for optics, electronics and engineered applications where a fast cure is required. The EB-119M is a heat cured polymer that can operate continuously at 230°C without degradation or damaging sensitive parts. It provides strong bonds to glass, metal and ceramic making it a suitable choice for electronic modules, fiber optic terminations, probes or lenses used in hightemperature environments.

EB-119M is low viscosity and has an 8-hour working time. It can be cured as fast as

5 minutes at 175° C. When fully cured, this dark amber adhesive produces a glass transition temperature of 158° C which translates to very little movement during temperature cycling. It is also chemically resistant including solvents, aviation fuels and other petrochemicals.


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Hengli Hydraulics A World-Class Hydraulics Leading Manufacturer

Hengli factory and branch

■ Headquarters in Changzhou,China

Hengli after-sale service network

■ 8 R&D and manufacturing facilities are located in the US, Japan, Germany and China

■ Business established internationally in over 20 countries and regions ■ Business relationships with over 1200 reputable companies Hydraulic cylinder

Heavy duty piston pump (Made in Germany)


Variable axial piston pump

Pneumatic products

Hydraulic motor Manifolds and Industrial Valve

Hydraulic system and test bench

Mobile control valve

Hengli America Corporation

580 W. Crossroads Parkway, Bolingbrook, IL 60440 630-995-3674

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Product World Pneumatics shop Aventics Aventics will now offer United States customers an upgraded service and product portal. The portal helps to quickly and easily find information on components and solutions tailored to the requirements of engineers and purchasers. At the same time, the portal’s lean structures and processes speed up online order processes. The cross-industry portal is intended for manufacturers, including OEMs, users, distributors, and engineering firms for industrial automation, as well as the commercial vehicle, food, railway, medical, energy, and marine technology sectors.


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Product World

Prototype of motor feedback sensor SIKO

> Performance > Power Density Size < Energy Costs <

The MSAC506 sensor works with an SSI interface for position detection of the motor and an additional analog 1Vss interface for control. Both interfaces are integrated into the sensor as standard and work in parallel. Absolute position information is provided with this combination at all times and exact commutation is possible even in dynamic

Find the right SiC MOSFET, diode, or module to reduce system size and bill of materials while increasing power density, performance, and reliability.

operation. In particular, the drive can be started easily from any position with the aid of the absolute SSI data. By contrast, a system that “only” uses incremental sensors would tend to start jerkily or suddenly, or “stumble.” Development objective: At a maximum rotational speed of 6,000 rpm, the sensor should be able to record data up to a circumferential speed of 32 m/s. It should be possible to use the sensor and an associated ring (MRAC506) without problem in a working temperature range of -20-85°C, suitable for outdoor use.

Learn More: 242

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See Us at MD&M West Booth #2383

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Many OEM models and configurations available.

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Product World Stepper motor driver with EtherCAT Oriental Motor The AZ Series Multi-Axis Drivers with EtherCAT is a dc input, multi-axes controller and driver designed for applications demanding 2 or more axis of control and integrating EtherCAT communications from an upper lever controller.

These drivers come in 2 axes, 3 axes

or 4 axes configuration. It is compatible with all of the dc input AZ Series family of products, including dc input stepper motors, linear and rotary actuators. The advantages of consolidating up to 4 drivers into 1 unit includes space saving benefits, reduced cost and simplified wiring. The AZ Series Multi-Axis Drivers supports EtherCAT communication and is compatible with the CiA402 drive profile.

TSUBAKI. BRANDED TOUGH! TSUBAKI BRAND BACKSTOPS WILL LEAVE A LASTING IMPRESSION With a reputation built on quality, durability, reliability, and service & support, it’s no wonder why the leading global companies insist on using Tsubaki products. We’ve been making our mark with Tsubaki backstops for over 50 years and we know what is at stake when it comes to your operation. In the most critical applications and toughest environments, Tsubaki backstops will keep your application running at its best. So make the choice you won’t regret, get Tsubaki Tough. ROLLER CLASS CHAINS • BACKSTOPS • SPROCKETS • CABLE & HOSE CARRIERS • POWER TRANSMISSION PRODUCTS ROLLERCHAINS CHAINS• •ENGINEERING ENGINEERING CLASS CHAINS • CAM CLUTCHES • SPROCKETS • CABLE & HOSE CARRIERS • PT COMPONENTS


©2016 U.S. Tsubaki Power Transmission, LLC All Rights Reserved.


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Product World Highly flexible addition cured silicone



Master Bond


MasterSil 151TC was developed to improve thermal management for electronic assemblies in bonding and gap filling applications. This 100% solids silicone compound has a thermal conductivity of 10-12 BTU•in/ft2•hr•°F [1.44-1.73 W/(m•K)]

Real CNC

and strong electrical insulation properties. Volume resistivity is >1014 ohm-cm. This

for shops of all sizes

two-component, room temperature curing formulation contains a blend of ultra-fine

Tormach machine tools are fully capable of cutting aluminum, plastics, and steel, giving you the ability to bring all your prototyping and light manufacturing in-house.

thermal conductive fillers and can be applied in very thin sections, enhancing its heat transfer capabilities. Thermal resistance for MasterSil 151TC is 7-10 x 10-6 K•m2/W.”

Additionally, this compund was designed

to guard against hostile environmental

Tormach Personal CNC mills are designed to be value driven to enable your ideas.

conditions. It has resistance to water and can withstand exposure to rigorous vibration, impact, shock, thermal cycling, salt spray, and airborne contaminants. MasterSil 151TC has good flow properties, an elongation of

ill C m t CN g a rtin sta

$ 4950


Functional prototypes without the wait


Iterate new ideas fast


Cut real metal


Plug in anywhere with 120 Vac


Compact footprint fits any space

90-110% and a Shore A hardness of 80-90. It adheres well to most substrates without the use of primers. Serviceability is from -65 to +400°F.


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Call us: Charlotte, NC 980-299-9800 Neugart 1-17.indd 247

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Product World SmART Banner This latest addition to the VE Series has the same ease-of-use, robust housing, and on-board display as other VE Series Smart Cameras, but provides finer levels of detection and a wider field of view. It has a 5MP (2592 x 2048) CMOS imager and can detect very small objects as well as fine details and minute flaws on complex targets.

The 5MP VE Smart Camera’s wide

field of view makes it possible for a single camera to perform a detailed inspection over a large target area in a single image capture. The ability to cover more area in one inspection can reduce or even eliminate the need for additional inspections as well as the equipment needed to perform those inspections.

VE Smart Cameras are also available in

2MP (1600 x 1200 pixels), 1.3MP (1280 x 1024 pixels), and WVGA (752 x 480 pixels) models.


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Welcome To Our World


State Of The Art Testing ~ ISO 9001:2008 ~ Mil-45-208-A ~ 0 to 5,000 PSI Testing Hydraulic Pumps ~ Hydraulic Motors ~ Hydraulic Cylinders ~ Actuators Dead Slug Cylinder Testing Up to 40000 Pounds ~ Cylinders 8� bores and Up Nuclear/Fossil Energy Plant Beach Russ Vacuum Pump Remanufacture Computer Generated Test Reports ~ Graphs ~ Plots Full Flight Simulator Motion Platforms ~ Military ~ Commercial Turn Around Times Based on Unit Condition When Received

3716 Plaza Drive ~ Ann Arbor, MI 48108 Ph: 734-996-4996~Fx: 734-668-6630~TF: 800-824-0808 Call Today Ask For: Debbi

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Product World Slewing ring bearing for equipment monitoring Igus Slewing rings are used in applications that handle high cycle speeds and loads, including control desks, welding equipment, indexing tables and chainsaws. Therefore, slewing rings need to be extremely durable and reliable. iglide slewing ring bearings have plastic sliding elements between aluminum or stainless-steel inner and outer bearing rings. These sliding elements are made of the self-lubricating iglide J plastic, making them maintenance-free and friction and wear resistant. Further enhancing the slewing ring, igus has now developed an intelligent slewing ring bearing (SRB) that is installed with an isense PRT.W sensor.

ISO 9001




Stock and Custom Mechanical Components One Convenient Source

Tim ing

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Get the NEW Inch Master Catalog, D820

We Provide Motion Control and

Small Power Transmission Solutions Design ► Engineer ► Manufacture ► Assemble

CONTACT US FOR A QUOTE TODAY a Designatronics company


Phone: (800) 819-8900 •

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Brushless DC Motors

Piezo Motors

Stepper Motors

Linear Actuators

FAULHABER coreless (brush) DC motors feature compact dimensions, low power consumption, high efficiency, and low noise, making them ideal for challenging medical equipment applications requiring high precision and smooth motion.


Your solution, optimized. As the exclusive provider of FAULHABER products for North America, MICROMO creates value through advanced design and engineering services. Precision Actuation Systems Design & Integration of Components Drive & Control Integration Performance & Cost Optimization

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ISO 9001, ISO 13485 certified

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Product World Mountable shaft collars Ruland This line of mountable shaft collars with flats and tapped holes or tapped holes only in the outer diameter, allows for easy mounting of shaft collars to each other or adjacent assemblies. Clamp style designs are used allowing for benefits such as not marring the shaft, indefinite adjustability, and high holding power. These mountable shaft collars are manufactured from high-strength 2024 aluminum, 1215 leadfree steel, and 303 stainless steel in bore sizes ranging from 3/8 to 2-in. and 10 to 40 mm. This diverse range of sizes and materials allows designers to match shaft collars to application needs. The fastening hardware tests beyond industry standards for maximum torque capabilities and holding power.

Custom Features: • Integrated linear position sensors

• Special materials for high strength / weight savings

• Integrated valves for load-holding & counterbalance

Cylinder Manufacturing Capabilities.....

Cylinder Manufacturing Capabilities: • Bore sizes ranging from 1” to 20” (even larger bores are possible)

• Strokes up to 50’ • Operating pressures up to 6,000 PSI

• Internal Cushioning options for deceleration of motion

• Multi-stage telescopic

Visit us at:

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Metal Bellows Flexible Shaft Couplings S TAN DARD COM P ON E NT OFFE RIN G Durable • Precise • Reliable Features: • High cycle life • Low leak rates • Various material options (Nickel, copper, gold, silver) • Thinnest wall constructions • Assembly services

Free Engineering Assistance for Custom Designs

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Product World Materials with high dielectric strength Minnesota Rubber Qmonix Elastomer 912T is for medical developers in need of a USP Class VI certified material for bio-compatible applications. Developed for use in bio-compatible applications where mechanical durability and tear resistance are crucial to product performance, the Qmonix Elastomer 912T is low compression set and is resistant to water and steam environments. Qmonix 912T exhibits high dielectric strength and has been tested in accordance with ISO-10993-5 and USP Class VI requirements.

Bearing Protection that Outperforms all Others

HydroClean: Sanitary Conveyors

Superior performance for maximum peace of mind. Helwig’s Bearing Protector extends the life of motors by keeping shaft voltage to a minimum. Prevents pitting and costly damage to bearings. The best choice for the motor industry.

HydroClean conveyors feature a stainless steel, sanitary design, manufactured to NSF standards and designed to eliminate opportunities for bacteria growth. For fast, efficient cleaning, pull pins provide a tool-less solution to belt, tail and drive end removal, as well as activating a flip up tail.

• •

513.753.6000 ·


Easy installation One size fits all Reliable performance


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• • •

Low maintenance Excellent conductivity Cost effective

Call 1-888-354-9914 or visit our website at


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Need easy access to engineering information?

Simplify Your Engineering. Service PLUS.

Service PLUS for your engineering. Trelleborg Sealing Solutions offers an unrivalled range of apps and online tools that make the lives of engineers easier. From engineering calculators to product selection tools, aids to seal configuration to material compatibility advisors, our ever expanding range of exclusive digital services help you work smarter rather than harder. Discover Service PLUS at

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Forming the Future



Product World 1.3M camera Teledyne DALSA Genie Nano cameras are built around ON Semiconductor’s Python P3 1.3M CMOS image sensors. These models have a global shutter, with 1280 x 1024 resolution, and image capture of up to 83 frames-per-second.

Developed for cost-conscious imaging applications that don’t require the

higher speed of On Semi’s P1 sensors, the latest P3-based cameras are available in color and monochrome. Features:




TurboDrive for fast frame rates and full image quality

Trigger-to-Image-Reliability for easy system control and debugging

Small footprint / light weight: 44 x 29 x 21mm / 47 grams

Wide temperature range (-20 to 60°C) for imaging in harsh environments

Support for the Linux operating platform

For more than a century Newcomb Spring has been recognized as the industry leader, with unmatched capabilities and expert services. Our precision manufacturing processes produce the highest quality custom springs, stampings and wire forms with:

• • • • •

The best spring calculator - the Springulator® The largest Wafios FMU in the USA CNC forming up to .625” wire diameter 9 facilities in the USA and Canada An Innovation Department that develops custom software & equipment Product World 1-18_Vs6_MS.LL.indd 256

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Be more. Bringing to life great new solutions for complex applications. Whether you need a rotating union engineered to unique requirements, or a high-precision stock item, Deublin helps minimize your costs while maximizing your value to your customers. Visit WWW.DEUBLIN.COM to select and order your union today!

847-689-8600 | |

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Product World Direct acting stackable solenoid valve Spartan Scientific The Series 4290 Direct Acting Stackable Solenoid Valve eliminates the need to machine and inventory multiple manifolds. The Series 4290, used in water-related applications, improves on the 3923 solenoid valve series with a larger body made of polyvinyl chloride material that is available in single units or stacks. The larger PVC body provides increased flow and higher-pressure ratings than the Series 3923 and has a higher resistance to chemicals in various applications. Features: • Glass-filled nylon encapsulated coil, stainless steel plunger and stop and spring compensated plunger

seals for long trouble-free service.

• Orifice sizes from 0.8 mm to 3.0 mm. • EPDM, FKM and NBR standard seat materials.

• Full diagnostic options for reduced machine downtimes • Open communication for high flexibility • Innovative software solutions for easy configuration, programming and visualization • High scalability for individual solutions • One system for safety and automation

For further information on automation solutions from Pilz, visit:

All in One: Safety & Automation


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- Efficient Safety







Efficient Safety from Schmersal Increased productivity has always been a major focus of real world industrial applications. Machine start up, troubleshooting, and maintenance requirements are definite costs that must be considered and minimized in order to reduce downtime and improve efficiency – and today it needs to be done while preserving the highest level of machine safety. Efficient safety is now an important consideration of the design engineer and maintenance personnel.




highest level of safety – PLe per ISO 13849-1 or SIL3 per IEC 62061. They maintain these safety levels even when wired in series using standard cable (up to 200 meters), which results in reduced cabling expense and installation time. They feature LEDs for status indication to quickly troubleshoot faults which reduces machine downtime. These devices are available with Serial Diagnostic to communicate status via serial data packages for use in various network protocols.


afe Schmersal’s electronic safety devices are a key to Schmersal is a leader in the design and efficient machine safety. At the heart of these devices manufacture of machine guarding safety is an integrated dual monitoring microprocessor which switches, including electronic safety devices. We offer provides continuous internal function tests. Because of this, only electromagnetic and solenoid locks, and a variety of nonone switch is needed per guard to meet the requirements of the contact safety sensors with these efficient advantages. Contact us to find out how efficiently we can turn your workplace into a safer place.

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T urni ng Wo rp l a c e s I nt o S a f e r P l a c e s


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Product World Indexing chain conveyor mk North America

The perfect seal for an imperfect world.

The TKU 2040 is designed for indexing applications and has twin roller chains with the option of workpiece profile pallets or v-shaped fixtures in brass or polyoxymethylene (POM) to hold the products being conveyed.

Optimized for fixed-cycle operation, the

TKU 2040 is suitable for automated production applications such as integration with machining stations, marking stations, RFID tagging, painting stations, and others.

The TKU 2040 has a compact, low-

maintenance direct drive motor; high load capacity of up to 1,550 pounds; and the option for an adjustable width frame between 195 mm and 1,500 mm. Other technical features: • Operating conveyor speeds of up to

60-ft per minute

• Flexible modular design for easy change-overs • Optional lubrication stations to automatically

lubricate the conveyor chain

• Optional stainless-steel drop pans with

threaded drain nozzle

The Bal Seal® spring-energized C-ring seal lets you improve equipment performance without expensive hardware changes. Our seal combines the low friction properties of PTFE and simple, streamlined jacket geometry to achieve better sealing for more cycles in applications where tolerances, surface finishes and other design characteristics vary widely. What’s more, it installs without tools, and retrofits to o-ring grooves. Call or click today, and learn how the C-ring seal can help you design for tomorrow.

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Linear Mount Products PMK Parallel mounting kit

EPL-H Inline gearbox, with hollow output design for easy mounting to linear actuators



Bellows style distance coupling

Right angle Dyna Lite gearbox with hollow output design for easy mounting to linear actuators. Includes output adapter tailored to the actuator

For Everything Between the Motor and Actuator Linear Mount Products include gear reducers, couplings, and mounting kits designed to interface specifically with actuators. We don’t make the actuators... We make them better. Toll Free 888.GAM.7117 | |

901 E. Business Center Drive, Mount Prospect, IL 60056

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Product World

Smart hydraulic continuous positioning Balluff


Suited for continuous hydraulic cylinder position feedback, the BTL6 rod style sensor uses fieldproven, magnetostrictive technology to provide accurate, continuous position and velocity

Innovative Belt, Modular Belt and Flexible Chain Conveying Solutions

measurement at stroke lengths up to 180”. Using IO-Link as the interface in linear position monitoring applications eliminates the issues associated with implementing and managing analog signals in industrial environments. Using IO-Link version 1.1 allows more and faster data transmission, and makes it possible to incorporate advanced functionality: including bi-directional communication, sensor-level diagnostics, and network-based parametrization. Features: • Position resolution to 5 µm • Stroke lengths to 4572 mm (180”) • Simultaneous measurement of both position

and velocity

• Non-contact, wear-free operation for long

service life

We get your product to the exact location, in the exact position, at the exact time it needs to be there for the next phase in the process.

The Result? ✔ Optimal Performance and Efficiency ✔ Maximized Production Output

✔ Reduced Waste ✔ Less Downtime

Contact us today! 800.397.8664 262

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January 2018


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Searching for a partner to provide innovative solutions for your hydraulic application?

Efficient, Reliable and Durable

Variable displacement axial piston pump type V60N

Industry Leading Performance

Proportional directional spool valve PSL

Choose the right hydraulic components for your application!

HAWE Hydraulik manufactures the highest quality hydraulic components constructed to maximize space and product durability for the mobile, industrial and oilfield market place.

Partner with HAWE to always have the right solution! We are Partners. | | 704-509-1599

HAWE FPW Full Page - Fluid Power HAWE 12-17.indd 263 World - DEC 101717.indd 1

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Product World Basic panel PC Siemens The Simatic IPC377E Basic Panel PC is based on Intel Celeron processor technology and represents an IPC platform which has been specifically developed to optimize cost for PC based applications in the industrial and industry-related environments. The Simatic IPC377E combines the openness and performance of an industrial PC with a long-lasting, robust display with anti-glare glass front, analog-resistive with single-touch operation, scratchproof and resistant to chemicals. The display is available in three sizes: 12, 15, or 19-in. diagonal screen.

The Simatic IPC377E Panel PC provides a preconfigured, turnkey solution well-suited for all industrial

applications. Specifically, economical implementation of HMI applications, the acquisition and networking of production and energy data in production environments such as assembly workstations, warehouses, and logistics systems, or for standard applications in the image processing field.

Key Bellevilles, Inc.

Brushless Motors



• Hollow or solid shaft high performance housed and frameless

MANUFACTURED TO DIN AND NACE SPECS Metric and English sizes available


Immediate Delivery! 24-Hour Service 7 Days a Week!

Tel: 724-295-5111 Fax: 724-295-2570 Toll Free: Tel: 800-245-3600 Fax: 800-847-1672

Visit our Website: for a FREE Design CD-ROM

• •


brushless motors and matching drives for demanding applications. Sensorless or hall motors and drives for aerospace, military, medical, industrial, canned pumps, vacuum, extreme temperature applications. Custom drive programing and designs available. Standard or custom designs up to 98% efficient, up to 200,000 rpm. Highest power density in the industry. Slotless and slotted designs. Available with encoders and gearheads and separate or integral electronics. Quantities 1 to 10,000.

For technical assistance, 937-695-1275

100 Key Lan e Leechbur g, PA 15656, U.S.A. Visit our Website a t: www,key Email:

Data sheets at


January 2018

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Drive And Controls For Any Application Whether you’re designing a simple conveyor or planning a complex system, you can rely on Interroll for your conveying needs. Our drives and controls are crafted with precision and engineered to deliver outstanding performance and reliability. The Interroll EC310 24V brushless RollerDrive can be paired with different Control Cards, depending on your application: EC310 & DriveControl Card EC310 & ZoneControl Card EC310 & MultiControl Card

Simple motor control. Simple ZPA conveyor line, some external I/O. State-of-the-art conveying and controls, monitor signals, track packages, adjust speeds on the fly, interface to a PLC, create custom package movements. UL Listed.

Visit to learn more about our solutions.

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Product World Wear ring range expansion Trelleborg The HiMod Slydring HC wear ring range is being expanded. It is introducing over 180 additional part numbers in outer diameters from 1 to 12-in. The enhanced range becomes available early 2018, serving various fluid power applications including off-highway, material handling, industrial machines, mobile hydraulics, agricultural equipment, and other industries.

HiMod Slydring HC rings are suitable

for use in a variety of operational conditions. They have high compressive strength and wear resistance even at elevated temperatures, provide low friction performance in lubricated settings, and are easy to install due to their simple closed-grooved design. The wear rings also eliminate local stress concentrations, fretting, and seizure, while damping


mechanical vibrations and protecting against dieseling and hydrodynamic pressure problems.


-- Thousands Stocked


-- On ISO & SAE committees

DEPENDABLE -- 58 years of service



A North American Manufacturer

manufacturing products, inc


January 2018

Product World 1-18_Vs6_MS.LL.indd 267 Phone: 800.521.7918 Grand Blanc, MI USA


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Product World 35DBM can stack linear actuator Portescap The 35DBM high-power Stepper Can Stack Linear Actuator is a 35mm linear stepper motor with an enhanced design suitable for applications demanding high linear force. The 35DBM has a magnetic circuit powered by high energy neodymium magnets. The 7.5 deg step angle provides finer incremental movement with a high degree of accuracy and repeatability.

With a holding force of 112N, the 35DBM stepper linear actuator

is suited for use in applications such as auto injectors, laboratory automation, medical pipettes and valve actuation. The 35DBM high-force actuators are fully customizable for adaptor tips, stroke lengths, windings, flanges and end of motion detection sensors.

Spring Applied Brakes

From the world’s largest manufacturer of world-class electromagnetic clutches and brakes

Electromagnetic clutches & brakes for virtually every application

For holding and stopping applications A wide array of standard torque ranges (1.75in/lbs - 880 in/lbs) Custom designed and manufactured for your application Manual release, zero backlash, and adjustable torque also available Inch and metric bores available 100 Randolph Road • Somerset, NJ 08873 Phone: 732-271-7361 • Fax: 732-271-7580 Website: Email:


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For further information about products on these pages visit the Design World website @

Step-down regulator Analog Devices The LTM8065, a µModule (power module) step-down regulator has up to 40 V input voltage (42 V abs max) and can safely operate from unregulated or fluctuating 12 V to 36 V input supplies in noisy environments such as industrial robotics, test and measurement, medical, factory automation and avionics systems. The Silent Switcher architecture minimizes EMC/EMI emissions enabling the LTM8065 to pass CISPR 22 class B for use in noise-sensitive signal processing applications, including imaging and RF systems.

The LTM8065’s small 6.25 x 6.25 x 2.32 mm BGA package includes a switching regulator controller, power switches,

inductor and other supporting components. With only two 0805 sized capacitors and two 0603 sized resistors, the LTM8065’s solution occupies approximately 100 mm², about half the size of equivalent power level module solutions.

Your online resources for product innovations, industry news, and basic and how-to articles for all connector technologies. Visit regularly for the knowledge you need when specifying and installing connectors, wire, cable, and accessories.


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The International Technical Design and Development Event for Robotics and Intelligent Systems The Robotics Summit & Showcase emphasizes the design and development of commercially viable robotics and intelligent systems products – wholly new products and services that are to be used outside of laboratory environments and sold at a profit. Dedicated tracks provide technical professionals with the information they need to develop the next generation of commercial class robotics and intelligent systems products and services. Robotics Summit Tracks Technologies, Tools and Platforms Design and Development Manufacturability, Business Models and Business Development

mAY 23-24, 2018


ro b oti c s s u m m i EXHIBIT AND SPONSORSHIP OPPORTUNITIES For more information, contact Mike Emich 508.446.1823,, PRESENT ED BY:

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A d I n de x 3D Systems ..................................21 ABM Drives ...................................77 Accumold .....................................211 ACE Controls ................................224 Aerotech ........................................166 Aggressive Hydraulics .............39 Aignep USA ..................................67 Airpot Corp. ..................................128 All Motion ......................................4 Allied Electronics & Automation .................... Cover, 3 Allied Motion ................................139 Allied Moulded Products, Inc. .........................182 Altech Corporation ................. 41,43 Altra Industrial Motion Corp. ............27,28,29,30 AMETEK DFS ................................53 Anchor Fluid Power ...................158 Anomet Products .......................160 Anritsu ............................................233 Applied Motion Products, Inc. .........................121 Atlantic Spring ............................37 Aurora Bearing Company .......126 AutomationDirect .......................1 AVENTICS Corporation .............49 Backer Hotwatt ...........................67 Bal Seal Engineering ................260 Bansbach Easylift ......................46 Bay Associates Wire Technologies Corp. ..............178 Beckhoff Automation ...............75 Bel Power Systems ...................214 BellowsTech .................................216 Bergquist, A Henkel Company .................................199 Beswick Engineering ................42 Binder USA ...................................115 Bird Precision ...............................240 Bison Gear and Engineering ............................IBC Bodine Electric Company ........189 Boker’s Inc. ....................................17 Bosch Rexroth .............................11 BRECOflex CO., L.L.C. ................94 Brennan Industries ....................191 Bristol Instruments ....................130 C-Flex Bearing .............................268 Cadence Inc. ................................69 Canfield Connector ...................77 Carlo Gavazzi ...............................174 Carlyle Johnson ..........................188 CC Link ...........................................50 CEJN ..............................................200 Central Semiconductor Corp. ..........................................186 Centritec Seals ............................192 Century Spring Corp..................153 CGI ...................................................57 Chieftek Precision ................. 101,127 Chroma Systems Solutions ....119 Cicoil ................................................7 CIT Relay & Switch .....................62 Clippard ..........................................223 CMT ................................................78 Coilcraft ..........................................206 Components Corporation .......220 COMSOL ........................................61 CS Hyde Company .....................204 DATA IMAGE Corporation ........190 DEL Hydraulics ............................234 Del-Tron ..........................................92 Design-2-Part Shows ................266 Deublin ...........................................257 Diequa ............................................70 Digi-Key Electronics ...................15 Dorner Mfg. Corp. ......................262 DSM Somos ..................................159


Ad Index Jan 2018.indd 511

Dunkermotoren ...........................55 Eagle Stainless Tube .............22,23 ElectroCraft ..................................176 Elesa USA Corporation ............95 Encoder Products Company .209 Equipto Electronics .................. 250 EXAIR ..............................................5 Fabco-Air, Inc. ..............................179 Festo ...............................................219 Fischer Connectors ...................231 Flow Ezy Filters ...........................218 Fluid Metering Inc ......................243 FluiDyne Fluid Power ................221 Fotofab ..........................................237 GAM .................................................261 Gefran ........................................... 208 GRIPNAIL Corporation ..............183 Harmonic Drive ............................229 HAWE Hydraulic ..........................263 Haydon Kerk Pittman ................17 HBM, Inc. ........................................190 HELUKABEL USA .......................137 Helwig Carbon Products ..........254 Hengli America ............................239 HIWIN ................................193,195,197 HP 3D Printing .............................9 Hy-Pro Filtration ..........................228 HYDAC Technology Corporation .............................194 I-PEX Connectors .......................155 IDEC .................................................59 igus ..................................143, Outsert IKO International, Inc. ................225 Intech ..............................................230 Interpower .....................................222 Interroll ...........................................265 ITT Enidine ....................................248 IXYS .................................................198 J.W. Winco, Inc. ............................126 John Evans’ Sons, Inc. .............98 Keller America Inc .......................177 Key Bellevilles Inc. ......................264 Keystone Electronics Corp. ....13 KHK USA ........................................76 Koford Engineering ....................264 Kollmorgen ....................................180 Kuebler ...........................................151 Kuriyama of America, Inc. ........154 Lee Spring Company ................71 LEMO USA, Inc. ...........................24 Lenze Americas ..........................105 Lin Engineering ...........................123 Mach III Clutch Inc. .....................165 Madison Co. ..................................36 Main Manufacturing ..................267 Maple Systems ...........................215 Maryland Precision Spring ......185 Master Bond ................................163 maxon precision motors ...... Insert MEAN WELL .................................241 Memory Protection Devices ...63 METCASE ......................................181 Micromo .........................................251 Miki Pulley US ..............................51 Mitsubishi Electric .....................164 mk North America, Inc. .............184 MOCAP ...........................................240 Model Solution ............................163 Mohawk Spring ...........................93 Motion Index Drives ..................196 Murrelektronic, Inc. ....................18 Nason .............................................113 NB Corporation ...........................16 NBK America LLC ........................187 Neugart ..........................................247 New England Wire Technologies ..........................141 Newcomb Spring Corp. ............256 Nexen Group, Inc. .......................175

Nippon Pulse America Inc. ......129 Nitto Kohki USA, Inc. .................236 Novotechnik .................................227 NSK Americas ..............................96 Ogura Industrial Corp. ............268 OKW USA .....................................207 Omron Industrial Automation ............................ 162 OMS Motion, Inc. ....................... 226 OPTO 22 ........................................65 Orion Fans ....................................54 PBC Linear ............................... 72,73 Pelonis Technologies, Inc. ...... 146 Penn Engineering ......................131 Permco, Inc. ..................................201 PHD Inc. .........................................167 Pilz Automation Safety .......... 258 POSITAL-FRABA Inc. ..................122 Prince Manufacturing Co. ..... 252 Pyramid Incorporated ............. 236 QA1 ...................................................217 QC Industries ............................. 254 R+W America ................................152 Renishaw ......................................74 Ross Controls ............................ 235 Rota Engineering Ltd. ............ 232 Rutronik .........................................161 RYCO Hydraulics ....................... 238 Schmersal ................................... 259 Schneeberger ............................91 SDP/SI ........................................... 250 Serapid Inc. ................................. 202 Servo Kinetics ............................ 249 Servometer ................................. 253 SEW-EURODRIVE .......................BC SIKO Products ............................ 220 SMAC Moving Coil Actuators .213 Smalley Steel Ring .....................10 Smart Products USA, Inc. ........25 SMC Corporation of America .................................. 245 Solenoid Solutions, Inc. ............79 Sorbothane ..................................217 Southern New Hampshire University ................................35 STEUTE Industrial Controls ....107 Sunstone Circuits ..................... 100 Super Swivels ..............................212 Tadiran ...........................................33 Tech-Etch, Inc. .............................210 Tensility International Corp.......................................... 203 The Arthur G. Russell Co., Inc. .....................................32 The Lee Company ................... 205 THK Corporate .............................IFC Tolomatic .......................................47 Tompkins Industries ................. 109 Tormach ....................................... 246 Trelleborg Sealing Solutions ................................ 255 Trim-Lok, Inc. ................................134 Turck USA ...............................171,173 US Tsubaki .................................. 244 USA Fastener ..............................136 Veljan Hydrair ............................ 270 WAGO .............................................145 Watlow ............................................147 Weintek USA, Inc. ......................99 Whittet-Higgins ...........................31 Wittenstein ...................................45 Wolfspeed, A Cree Company ............................... 242 Xcentric Mold & Engineering ............................66 Yaskawa America, Inc. ..............20 Yates Industries ..........................19 Zero-Max .......................................2

SALES Mike Caruso 469.855.7344 Garrett Cona 213.219.5663 @wtwh_gcona Jessica East 330.319.1253 @wtwh_MsMedia Michael Ference 408.769.1188 @mrference Michelle Flando 440.670.4772 @mflando Mike Francesconi 630.488.9029 David Geltman 516.510.6514 @wtwh_david Neel Gleason 312.882.9867 @wtwh_ngleason Tom Lazar 408.701.7944 @wtwh_Tom Jim Powers 312.925.7793 @jpowers_media Courtney Seel 440.523.1685 @wtwh_CSeel

LEADERSHIP TEAM Publisher Mike Emich 508.446.1823 @wtwh_memich Managing Director Scott McCafferty 310.279.3844 @SMMcCafferty EVP Marshall Matheson 805.895.3609 @mmatheson


Follow the whole team on twitter @DesignWorld

January 2018


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January Design World Configurator Ad outlines.pdf 1 12/27/2017 7:08:33 PM









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Can’t get it off? Having a hard time removing a corroded gear unit from your machine shaft? Well, stop fretting. Wise up and get TorqLOC® from SEW-EURODRIVE.


With its stainless steel construction, keyless hollow shaft, and taper bushings, TorqLOC® disassembly is fast and easy. The same bolts used for assembly are used for disassembly. Not only does TorqLOC® reduce your maintenance headaches, it also reduces energy costs by eliminating belts, chains, and sprockets.

Disassembly | 864-439-7537

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