DESIGN WORLD JANUARY 2022_MAIN ISSUE

January 2022

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2022

Leadership in Engineering

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January 2022

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Dodge, an RBC Bearings company, is introducing a new look for a trusted name in industry. As always, our team is committed to providing expert solutions that keep industry moving forward. And we will continue raising standards and developing forward-thinking innovations for our customers to reduce downtime, improve reliability, and operate safely. Because to perform at your highest level, you need the best. That’s Dodge.

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Although I am a degreed engineer, I’ve always felt a kinship with scientists; I suppose it’s that we’re playing for the same team of knowledge seekers. As a kid, I was attracted to subjects like meteorology and astronomy, and on many nights, you could find me in the backyard or at a star party with my 80 mm re actor or my 10-in. Dobsonian reflecting telescope — viewing nebulae, galaxies, globular star clusters, and the like. But those subjects gradually faded as potential career ideas for me. Instead, focused on engineering and writing, two somewhat disparate skills that would eventually serve me in the same career.

In a strange twist of fate, one of the first big stories I wrote a er getting into the b2b magazine business was about hydraulic actuators that were being used on a telescope’s primary mirror on Arizona’s Kitt Peak Observatory. The actuators finely adjusted the optics on the mirror to compensate for minute distortions in the atmosphere, an incredible achievement of engineering that would benefit scientists for a long time to come.

And last month, a er a decades-long wait, NASA launched the James Webb Space Telescope, the successor to Hubble. Webb, which will focus on in ared light, has a hexagonal segmented mirror that’s roughly six times the size of Hubble’s primary mirror. Because of multiple constraints imposed on Webb, which had to fit inside an Ariane 5 rocket’s nose cone, engineers were forced to fold the telescope’s supporting structures, sunshields, solar panels, and even the mirror itself in an origami project unlike anything seen before. This resulted in an instrument that had 344 potential failure points once in space.

Personally, it’s been a little nerve wracking for me these last few weeks, carefully following Webb — om the lead-up of the launch itself to the mid-course correction burns. There’s been the gradual unfolding of its surrounding structures and the delicate extension of its mission-critical tennis-court-sized sunshield.

Even as I write this today, the tensioning of the sunshield is occurring, and I’ve been watching the coverage all morning. It’s truly a fascinating engineering accomplishment that is happening, as eight motors are slowly reeling in 90 cables through myriad pulleys.

If you haven’t been paying attention, I suggest bookmarking jwst.nasa.gov — it’s quite incredible what scientists and engineers can do when working together.

Here’s wishing you and yours a prosperous and discovery-filled 2022. DW

Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com

30097 Ahern Avenue Union City, CA 94587

On Twitter @wtwh_paulheney

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January 2022

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DESIGN WORLD

1/10/22 11:39 AM

The TRUTH About

If you think compressed air is too expensive and noisy - read this.

The facts will surprise you!

COMPRESSED AIR! Compare These Blowoffs

Drilled Pipe 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. 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. Velocity across the entire length was very inconsistent with spikes of air and numerous dead spots.

There are a variety of ways to dry, clean or cool products and surfaces, 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 blowoff options.

Flat Air Nozzles Th is 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 suffers from many of the same problems as the drilled pipe. Operating cost and noise level are high. For some flat air nozzles the holes can be blocked - an OSHA violation. Velocity was inconsistent with spikes of air.

The following comparison proves that the EXAIR Super Air Knife is the best choice for your blowoff, cooling or drying application.

Blower Air Knife 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 flat 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. Noise level was high at 90 dBA. There was no option for cycling it on and off to conserve energy. Costly bearing and filter maintenance along with downtime were also negative factors.

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. The blower used had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM. The table below summarizes the overall performance.

EXAIR Super Air Knife The Super Air Knife did an exceptional job of removing moisture on one pass due to the uniformity of the laminar airflow.

The sound level was very 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 with no moving parts to wear out.

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

Blowoff Comparison Type of blowoff

SEE THE AIR KNIFE IN ACTION!

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PSIG BAR

SCFM

SLPM

Horsepower Required

Sound Level dBA

Purchase Price

Annual Electrical Cost*

Approx Annual Maintenance Cost

First Year Cost

Compressed Air

Drilled Pipes

60

4.1

174

4,924

35

91

$50

$4,508

$920

$5,478

Flat Air Nozzles

60

4.1

257

7,273

51

102

$208

$6,569

$1,450

$8,227

Blower Air Knife

3

0.2

N/A

N/A

10

90

$5,500

$1,288

$1,500

$8,288

Super Air Knife

60

4.1

55

1,557

11

69

$720

$1,417

$300

$2,437

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

Facts about Blowers

Here are some important facts:

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.

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 infiltration 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.

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1/9/22 11:46 AM

Teschler on Topic

Most engineers aren’t innovators You’ll frequently find pundits today equating engineering with innovation. Typical observations: “The foundation of a nation’s common innovation infrastructure is its pool of scientists and engineers available to contribute to innovation throughout the economy,” from Harvard Business School Professor Michael Porter and M.I.T. Professor Scott Stern. “We cannot engineer solutions for the nation’s toughest problems without innovation,” says U.S. Army Corps of Engineers chief scientist David Pittman.

These viewpoints ignore one salient fact: Most engineers are engaged in maintenance rather than innovation. So points out David Edgerton, a professor at Imperial College London and founder of the Centre for the History of Science, Technology and Medicine. The image of the professional engineer as a creator and reformer is misleading, he says. Only a small minority of engineers are concerned with design and development, even among the most academically trained.

A study done in the 1980s put the tasks of the average engineer into perspective. A survey of professional Swedish engineers back then found that 72% of them worked maintaining and supervising existing entities. Indications are that things haven’t changed much in the intervening decades. Estimates

by the U.S. National Bureau of Labor Statistics are that less than 4% of today’s engineers are engaged in research.

Nevertheless, you don’t hear much about engineers working in maintenance because that role doesn’t fit the image the profession likes to project. “Professional engineers don’t relish the association made between the engineer, the oily rag and the spanner, tools of the maintenance man,” says Edgerton. “In recent times engineers have stressed their role in innovation, design and the creation of new things. Engineers, in this view, are concerned above all with the future; they are optimistic and progressive; they send new things out into the world.”

The tendency to downplay the role of engineers in maintenance probably has its roots in culture. For example, professional engineers loathe the idea of calling IT repair personnel at the local electronic store “engineers.”

Understandably, nobody who has poured their blood, sweat and tears into an engineering degree wants to be conflated with junior-collegeeducated technicians.

But there are countries outside the U.S. where engineers predominantly engaged in maintenance have plenty of clout. Perhaps the primary example comes from France where State Public Works Engineering Corps (Ingénieurs des Travaux Publics de

l’Etat (ITPE)) civil servants work for the Government of France. Its members are mainly employed as team or project managers overseeing areas such as infrastructure, environment, transportation, and energy. ITPE engineers supervise and manage public policies requiring technical and scientific skills and work in areas far beyond traditional public works. Their responsibilities can include sustainable development and managing natural and technological risks, IT and big data, and biodiversity.

Another interesting point about ITPE engineers: None of them have student loans to worry about. Most ITPE engineers are recruited during high school by taking a competitive examination in mathematics, physics, and engineering. Those accepted go to college for three years as paid civil servants in training. Then they spend a year in a professional internship. After graduation, they either go directly to work or do an additional year of specialized study which lets them occupy positions requiring specific technical skills.

The concept of an elite band of state-employed maintenance engineers may be catching on.

Greece, Mexico, and Spain have similar positions. And evidence is these engineers have a fair amount of political prestige: Former President of France Valéry Giscard d’Estaing was a once a maintenance engineer. DW

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

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DESIGN WORLD

1/18/22 10:54 AM

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Technology Forward

Trends in IoT for 2022 For designers with decades of experience in factory communications, the Internet of Things may seem like a repeat of earlier attempts (as in the 1980s and 1990s) to create a total lights-out manufacturing facility. Some in the field, though, take a different view. Arjun Chandar, founder and CEO of IndustrialML, offers insights into IoT trends he sees coming for this year.

Chandar views IoT developments as focusing on real-time communication.

“It’s not just a matter of trying to get the most advanced insight possible and trying to push the boundary of squeezing the tiny little extra bit of efficiency out of your process,” he says. “IoT, in its current incarnation, is more about making sure that for the process you have already set, that you are notified of any disruptions as quickly as possible .… and that those disruptions are communicated globally through any available means — a Slack alert, email, a mobile app, and so on.”

The use of real-time communication to enable faster problem solving within a manufacturing setting, “is one of the most important things that designers should know about in terms of how they can interact with an industrial IoT system,” continues Chandar.

Real-time communication does not have to mean management by exception, as it did in decades past.

Real-time communication includes new instructions to line operators, news and info on production order changes, and so on. IoT enables communication beyond a use as a firefighting tool. Think of it as a communication tool for preparatory and firefighting reasons.

Even with improvement in communication and potential improvement in problem solving, the IoT still faces users who are reluctant to implement it. Notes Chandar, the reality is that the vast majority of manufacturers around the world don’t have the tools to collect data. And they do not have the institutional knowledge to trust what an algorithm tells them. Which can be a good thing, because in many cases, the data analysis may point them in the wrong direction.

There continues to be a different understanding of the need for IoT between the people who work in the data analysis fields and the people who work in manufacturing fields.

For people who work on the IoT or data analysis sides, notes Chandar, “and certainly with venture capitalists, the end goal would be a completely automated factory where you don’t need humans there at all.

And computers can just solve all the problems for you. I don’t think manufacturers believe that’s ever

going to happen. They certainly can reduce the number of workers that are going to be in a factory. And there’s been a large degree to which that’s already happened over the last 30 years. But I think where the vast majority of manufacturers see the IoT as useful is in the development of human assist tools.”

There are certain tasks that require critical thinking, certain tasks that require human assembly. And that’s just not going to change for the physics of their process. But they may be able to track the information around the process in a way that makes it easier for people to respond to exceptions or to design the materials that go into a product or the assembly process in a way that’s a little bit easier for people to follow.

DW

Leslie Langnau llangnau@wtwhmedia.com On Twitter @ DW_3Dprinting

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January 2022 www.designworldonline.com

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Green Engineering

Can we ever get the lead out?

By Mark Jones

• Contributing Writer

A century is how long it took for one bad chemistry choice to run its course. The end of August 2021 was the end of what can only be described as a sad century in the history of chemistry. At the end of August, headlines proclaimed the world finally stopped using leaded gasoline. The UN announced Algeria used the last of its automotive leaded gasoline stockpile on August 30.

Much of the reporting touting the end of lead in gasoline mentioned its beginning and the role played by Thomas Midgley, Jr. Midgley’s is the name most associated with inventing leaded gasoline and its early promotion. The reporting paints Midgley as a Shakespearean villain. His story is an interesting one. Midgley is declared by some to be the person responsible for more environmental damage than anyone else in human history, the individual chemist responsible for impacting the most lives. He is even declared one the most dangerous inventors. The history is far more complex.

Midgley is a compelling villain. He invented not one, but two technologies society has come to regret. In addition to his role in introducing tetraethyl lead into gasoline, he is also responsible for the discovery and promotion of fluorocarbon re igerants, Freon.

Freons went on to become widely used. Ultimately, they were banned globally due to their impact on the stratospheric ozone that protects the earth om harmful solar UV radiation. As if two calamitous inventions weren’t enough, he ultimately was killed by another of his inventions. Midgley was paralyzed by polio. He was found strangled by the system of ropes and pulleys he constructed to allow him to get in and out of his wheelchair.

The excitement over the demise of leaded fuel is certainly warranted. Lead pollution, most of it coming om use of leaded fuel, created a heavy toll. Lead’s impact on brain development is now well documented. Exposure to lead, both prenatal and as a child, is linked to lower IQ, with estimates that 23 million people lost IQ points over a six-year study period due to lead. It is linked to aggression and criminal behavior. Learning disabilities, behavioral problems, and growth issues are all linked to lead exposure in children. Calcium uptake channels in developing 10

January 2022

Green.Engineering 1-22_Vs3_PH.LL.indd 10

children concentrate lead in the brain where it interferes with development. Adults’ calcium uptake pathways put lead in bones in place of calcium.

Pregnant mothers with past lead exposures can transfer lead to the fetus as part of the normal process of supplying the fetus with calcium. Looking through today’s eyes, knowing the damage caused by leaded fuel, it seems impossible anyone would consider putting lead into gasoline. Yet, Midgley led an effort to do exactly that.

My first encounters with the story of Thomas Midgley caused me to conjure a picture of a rogue chemist operating on the inges of the chemical enterprise. I was wrong. Midgley was awarded the Gibbs, Perkin and Priestly medals, some of the highest honors in chemistry. He was elected to the National Academy. He was president of the American Chemical Society and a long-time board member. He was a vice president at Ethyl Corp., the largest producer of leadbased gasoline additives. He was mainstream. He was lionized for his accomplishments up to his untimely death in 1944. He was arguably the leading industrial chemist of his day.

www.designworldonline.com

DESIGN WORLD

1/16/22 9:31 AM

Why lead in the first place?

Lead is a chemical solution to a mechanical problem.

Attempts to get more horsepower out of internal combustion engines prompted a move to higher compression. Pushing to higher compression ratios dramatically increased engine performance.

Uneven combustion under high compression conditions caused engine knocking. Knocking was a severe problem, not just a minor annoyance. It robbed horsepower, led to incomplete combustion and actually could damage engines. Several chemical additives were found that evened out the combustion, quieting engines — but most required high concentrations in the fuel.

In 1921, Midgley found that tetraethyl lead (TEL) proved effective at very low concentrations. Added at 0.4 g/L, about one part in a thousand by weight, it doubles the horsepower of an engine. To reach the same horsepower, an engine could be half the size, burning half the fuel. TEL effectively doubled the constrained gasoline supply of the day. It was nothing short of revolutionary … except for the toxic part.

The “dose makes the poison” is well known.

Midgley asked whether the dose, the exposure, would be sufficiently low to be safe. He suffered acute lead poisoning and required an extended recuperation. Testing showed animals survived exhaust vapors. He is quoted as saying lead levels would be undetectable in the exhaust.

TEL was oxidized in the engine, as would be expected. Lead oxides are relatively non-volatile. It could be expected that they would stay in the engine.

Tetraethyl lead alone formed problematic deposits in engines. Midgley’s solution was to add organohalides to purposely form volatile lead compounds.

Halogenated organics, like 1,2-dibromoethane and 1,2-dichloroethane, became part of the additive package. Lead would be swept out of the engine, out of the tailpipe. Midgley compounded the bad idea of placing lead into gasoline by ensuring it would be dispersed into the atmosphere. He clearly knew of the chronic impacts of lead but must have believed “the solution to pollution is dilution.”

To stop engines om knocking, to, in essence, double the amount of gasoline, he elected to put volatile lead into the environment. He had to know this was a bad idea. Yet, he and many others, concluded the benefits outweighed the risks.

It is easy in hindsight to argue Midgely was biased in favor of his invention, emphasizing the benefits while downplaying the risks. The risk of lead emissions is now well documented. Technology, both in engines and in the creation of better fuel, replaced the need for lead. Seen through today’s eyes, it is easy to see only bad.

DESIGN WORLD

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January 2022

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Green Engineering

Leaded gasoline raised performance of engines, improving efficiency. It was, in the day, a really big accomplishment. Some attribute 100-octane leaded aviation fuel, and the high-performance aviation engines it made possible, with winning the Battle of Britain. Rather than keep engines small, leaded gasoline contributed to increasing expectations for performance. Leaded gasoline unlocked performance.

Automobile engines got larger, consuming more fuel.

Following Jevon’s paradox, an efficiency improvement led to higher consumption. As Midgley conducted his research, gasoline demand was around 9 billion gallons per year. Peak leaded gas use in the U.S. occurred in 1970, placing 250,000 metric tons of lead into the environment while burning 90 billion gallons of gasoline. Cumulative leaded automotive gasoline use is estimated at 76 trillion gallons — releasing 8 million metric tons of lead into the environment.

Not the end of lead August 30 is not the day the world stopped using lead.

Lead, as the zero-valent metal, found and continues to find wide use. Whether selected due to its density, its melting point or its malleability, lead’s physical properties are unique and useful. Compounds of lead are poisonous, in some cases acute, in all cases chronic. Some now suggest no amount of lead can be considered safe. Yet, we continue to use lead in many applications. It is at the heart of batteries most of us use. It solders our electronics. It sinks our fishing line and balances our tires.

More surprising is the continued use of lead in more ivolous applications. Lead is found in some costume jewelry. Lead compounds continue to be used — and are in the news. The FDA will continue to allow lead acetate in haircare products until January 2022, but will not enforce the ban until 2023. Efforts to stop this use in 2018 resulted in objections and a public hearing request. Lead is found in more than 60% of lipsticks on the market. Lead is even found in dyes used for cake decorating.

August 30 is not even the day the world stopped use of leaded gasoline. General aviation airports around the globe still fuel piston-engine aircra with DESIGN WORLD

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January 2022

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Green Engineering leaded fuels. Use of leaded gasoline continues in aviation.

The benefits of lead and Midgley’s invention continue to outweigh the risks.

Unintended consequences derail many technologies.

We may excuse Midgley for unleashing Freon on the world.

Determining it was a problem was a surprise worthy of a Nobel prize. Developers may be justifiable excused when information they couldn’t possibly have known or predicted becomes known. Midgely both knew and experienced the dangers of lead. The growth in gasoline consumption put more lead into the environment than Midgley could have imagined. He concluded the benefits of using lead were worth the risk, but the risk equation changed with time. The amounts of lead used and better understanding the hazards posed by lead changed the equation. Decarbonization presents many challenges. The story of Thomas Midgley and leaded gasoline stands as a cautionary tale. Our actions, even when well-intentioned, come with consequences.

More choices today Running a thought experiment, suppose a potent organolead additive was discovered today that doubled gasoline mileage. It would be a sustainability boon, with the potential to halve atmospheric carbon emissions om transportation. It would be a sustainability bust due to the hazards associated with lead. What would be an acceptable level of lead leaking into the environment in order to half transportation carbon emissions? Lead was present in gasoline at about a part per thousand by weight. Clearly that was too much. Would a part per million be okay? How about a part per billion?

The answer that immediately comes to mind is there is no acceptable level, that human activity should not be placing lead into the environment even if a large tangential good comes om it. I wish it were that easy.

Electrification stands tall as one of the major ways the world will decarbonize. Many of the materials we’ll need for the photovoltaics, the wind turbines, the batteries, and the wires are metals. Those metals are equently associated with lead in their ores. The extraction, smelting and purification will release lead. Zero environmental lead is not an option. We will inevitably trade some amount of lead going into the environment in order to reduce our carbon footprint.

It feels much different than purposefully adding lead to gasoline with additives that ensure it reaches the environment. The lead reaching the environment in our quest for lower-carbon energy will be getting there in spite of our efforts to contain it. It will be due to our failings, not our intent. That doesn’t stop or lessen the environmental impact. Our actions, whether intentional or not, will be placing lead into the environment.

While we are unlikely to surpass lead emissions created by leaded gasoline use, we face a dilemma akin to Midgley’s.

We face a tradeoff. Carbon emissions or lead — pick one. DW

DESIGN WORLD

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Contents 1 • 2022

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vol 17 no 1

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designworldonline.com

2022

Leadership Pages 213-3

82

106 76 _MOTION CONTROL

100 _ADDITIVE MANUFACTURING

120 _ELECTRONICS

Managing motion-design EMI for food metal detection

Exploring extreme design with 3D printing

The Best free analog circuit simulators

Electromagnetic interference (EMI) and radio- equency interference (RFI) om ground loops and the operation of electric motor drives can degrade the performance of metal-detection equipment so essential to safe food processing. Here we look at ways to mitigate such issues.

86 _LINEAR MOTION Precision feedback for semiconductor production machinery

Semiconductor production can’t be successful without accurate and precise feedback. And that starts with the encoders you choose.

92 _INTERNET OF THINGS Virtual twins will drive the digital evolution of industrial

Rapid advancement towards digital transformation will position digital twins as crucial elements for businesses worldwide.

Take a look at how others use 3D printing systems to make efficient and functional designs.

106 _MECHANICAL Bearing life and effects of harsh operational environments

Manufacturers in nearly every industry are increasingly raising performance expectations for rolling-element bearings while at the same time exposing them to operating and environmental conditions that, when extreme, can reduce the rating life by as much as 90%.

We examined 30 ee analog circuit simulation packages to see which of them is appropriate for real circuit analysis and design work.

132 _PNEUMATICS Smart pneumatics: Gateway to higher efficiency, productivity

Open and flexible IIoT systems can pinpoint leaks and faults, reduce downtime, increase throughput and, ultimately, improve the bottom line.

144 _LEADERSHIP 114 _MECHANICAL How vibration analysis keeps your bearing system steady

Embracing the soft skills

Dan Arvizu’s long engineering journey has brought him back to his beginnings.

Implementing condition monitoring can reduce the equency and cost of equipment maintenance. Specifically, vibration analysis can provide valuable insight into machine condition, flagging up problems before extensive damage occurs.

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EDITORIAL

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

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Design for Industry Aerospace/Military

D2 tool steel fit for use on binder jetting additive processess

Increasingly, as more materials are qualified for additive manufacturing, you’ll see more applications in the aerospace industry. One of the latest additive materials is D2 tool steel. Recently, Desktop Metal announced this material was qualified on its binder jetting additive process on the Production System additive platform that uses what the company calls its Single Pass Jetting (SPJ) process.

D2 tool steel is a versatile high-carbon, high-chromium air-hardening tool steel characterized by its hardness and compressive strength a er heat treatment. This tool steel is wear resistant, dimensionally stable, and resists corrosion in the hardened condition, a key benefit for conformal cooling applications. D2 is used for many cold work tools that require a combination of wear resistance and moderate toughness, such as coining and sizing tool members, blanking and forming dies, shear cutting tools, gauges, burnishing tools, and other wear parts.

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Desktop Metal’s materials science team has qualified and fully characterized D2 tool steel printed on Production System technology in accordance with ASTM testing requirements. An example application is rotating cams.

Cams are used in oil and gas or chemical processing applications to convert rotary motion into reciprocating linear motion in a machine.

Typically, these parts require multiple manufacturing steps, beginning with CNC machining, followed by broaching of the spline on a separate machine. Binder jetting enables the production of cams in a single printing step, reducing both the cost and lead time of the part, while also supporting the production of different cam sizes in one build.

D2 tool steel suits this application because of its hardness and corrosion resistance, which ensures a longer lifetime as the cam mechanically interacts with a sliding pin. In addition, because these components are o en integrated into machines operating in harsh environments, the corrosion resistance provided by D2 ensures that the parts will perform as intended and not deteriorate.

One of the latest additive materials is D2 tool steel.

Recently Desktop Metal announced this material was qualified on its binder jetting additive process on the Production System additive platform that uses what the company calls its Single Pass Jetting (SPJ) process.

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Design for Industry Aerospace/Military

Materials for space exploration In more materials news, Solvay and Avio SpA signed a long-term agreement to supply composite and adhesive materials for various Vega space programs, including the European Space Agency’s satellite launch vehicles designed to send payloads into low Earth orbit (LEO).

Solvay will supply Avio with ablative material, RTM, resins, and adhesives. Ablative materials in space applications are used for such items as nozzles and exit cones. These materials withstand the extremely high temperatures produced by rocket motor exhaust.

Avio has over 50 years of history designing, developing, producing and integrating space launchers for placing institutional, governmental and commercial payloads in earth orbit through its Vega rocket family.

Said Carmelo Lo Faro, president of Solvay’s Materials Segment, “We are all currently seeing renewed enthusiasm and investment in the global space race.” DW

Solvay www.solvay.com

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Design for Industry Medical

3D printing used to create a fully

digital prosthetic eye If you’re a sci-fi movie fan, the idea of prosthetic eyes that can do amazing things is familiar. Thanks to 3D printing, we are a step closer to such developments. Fraunhofer IGD reports the development of a 3D printed prosthetic eye.

Fraunhofer IGD has developed a number of technologies that supersedes the current and entirely manual production of individual prostheses. It’s Cuttlefish:Eye so ware uses a 3D scan of the eye socket and a color-calibrated photo of the healthy eye, to create a prosthetic eye`s 3D model. The Cuttlefish 3D printing driver is used to print the model on a multicolor, multimaterial 3D printer.

Not only is a 3D-printed prosthetic eye produced in a action of the time taken by the conventional process, but the resulting prosthesis also looks more realistic. This is made possible by the algorithms of Cuttlefish:Eye, a so ware solution om the Fraunhofer Institute for Computer Graphics Research IGD. Working in close collaboration with the British company Ocupeye Ltd. The research team in Darmstadt has developed 26

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a unique process to create a virtual model om a scan of the eye socket together with a photo of the healthy eye.

This serves as a reliable digital platform for 3D printing. The breakthrough technology to produce prostheses will now be fitted in patients for the first time in a clinical trial to be held at Moorfields Eye Hospital London.

Professor Mandeep Sagoo, a consultant ophthalmologist at Moorfields, added: “We are excited about the potential for this fully digital eye. This has been a culmination of 4 years of development of sophisticated technology between Moorfields Eye Hospital, UCL Institute of Ophthalmology, Ocupeye Ltd., and Fraunhofer. We hope the forthcoming clinical trial will provide us with robust evidence about the value of this new technology, showing what a difference it makes for patients. It clearly has the potential to reduce waiting lists.”

Ocular prostheses become necessary whenever an eye has had to be surgically removed for health reasons, e.g. as a

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result of a serious injury or a life-threatening disease such as eye cancer. Conditions that afflict around three-quarters of a million people in Europe and over eight million worldwide. The method of individually measuring the eye socket and manufacturing the prostheses has remained largely unchanged for many decades.

The invasive molding can be uncomfortable and in children a distressing experience that often requires a general anesthetic.

The subsequent, hand-crafted, time-consuming manufacturing process leads to several months of waiting, thereby exacerbating what is already a stressful time for the patient. Using leadingedge 3D printing technologies, the new process significantly speeds up production and provides patients with a quicker, better and an overall more comfortable experience.

The patient’s 3D prothesis initial appointment begins with a 2.4 second, non-invasive, non-ionizing scan from a specially modified Optical Coherence Tomography ophthalmic scanner, which is manufactured by TOMEY Japan. The medical scanner is routinely used in a hospital environment. The resultant scan of the eye socket and color-calibrated image of the healthy eye is seamlessly and digitally transferred to Fraunhofer IGD. Tomey has optimized its capability such that the socket of the removed eye is precisely measured and additionally a color-calibrated photo of the healthy eye is produced.

Cuttlefish:Eye creates a 3D printed model from this data in an equally short time. The printers are controlled by the Cuttlefish universal 3D printer driver, which is characterized by its color consistency as well as realistic representation of even transparent materials. Fraunhofer IGD technology is used worldwide with many different types of printers. The 3D prostheses are printed

by Lupburg based Fit AG which has many years of experience in additive manufacturing, especially in the field of medical technology. Once printed, the prostheses are inspected and given final polishing by a team of experienced ocularists. With a single 3D printer, Ocupeye can potentially fulfill the annual requirement of around 10,000 prostheses required for the UK market.

Every step of the new manufacturing procedure has been subjected to strict quality controls. For example, the Cuttlefish:Eye software is certified as a Class 1 medical device. Extensive and exhaustive biocompatibility tests were performed on the 3D printing materials, before the UK Medicines and Healthcare products Regulatory Agency -MHRA- provided a letter of approval for a clinical trial. The clinical trial will recruit around 40 patients to receive a 3D-printed ocular prosthesis; they will be examined several times by qualified clinical staff over the course of a year and be asked to report back on their experiences.

This is an important step in bringing the project partners closer to fulfilling their vision. Namely, to have the ability to routinely provide a realistic medical product to patients who require a prosthetic eye. This is made possible by a highly

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Design for Industry Medical

“disruptive” innovative process that begins with an optical coherence tomography medical device, manufactured by Tomey Japan and with their European HQ in Nürnberg. From the learnings already gained during the research and development phase, Tomey has adopted the enhanced functionality as standard and applied the enhancements to their next generation devices.

With just one device per clinic, and the a small number of geographically deployed 3D printers, the estimated global market demand for eight million people — approximately 0.1% of the world’s population — could be met.

3D printing technology can already accommodate electronics, so how long before a 3D printed prosthetic eye can deliver visual information to the recipient’s brain? I would bet potentially sooner than we think. DW

Fraunhofer IGD www.igd. aunhofer.de

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Design for Industry Energy

Scientists create a triboelectric fabric that generates electricity

from body movement while remaining flexible and breathable Made of electrospun polyvinylidene fluoride (PVDF) and nylon, silver nanowires (AgNWs), and polystyrene (PS), the new all-fibrous composite nanogenerator (AFTENG) can be easily incorporated into clothing, allowing it to power small electronics through everyday movements. | Figure 1 om the original article published in Nano Energy Vol. 90 Part A

Using the movement of a body to charge electronic devices such as phones may soon become a reality, thanks to the work done on triboelectric nanogenerators (TENGs). But most current TENGs are not breathable, making them uncomfortable to wear. Now, researchers have developed a multilayered TENG made om electrospun fibers, silver nanowires, and a polystyrene charge storage layer that not only has a high electrical performance, but also better wearability.

The triboelectric effect is a phenomenon where a charge is generated on two dissimilar materials when the materials are moved apart a er being in contact with each other. Triboelectric nanogenerators (TENGs) use this effect to convert mechanical motion into electrical energy. The compactness of TENGs allows them to be used as wearable devices that can harness the motion of the body to power electronics. Being wearables, the emphasis is placed on the fabric properties (such as the comfort of the material) and the charge-carrying capacity of the nanogenerators. Generally, the triboelectric materials chosen for the nanogenerator should be safe, compatible with the human body (biocompatible), flexible, and breathable while being able to maintain a high electrical output performance.

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Among the many materials considered for TENGs, electrospun fibers are a promising candidate as they are lightweight, strong, and have desirable electrical properties. Electrospinning is a technique by which solutions of polymers are drawn into fibers using electrical charge. There are ongoing efforts to add metals to electrospun fibers to improve the electrostatic potential and chargetrapping capabilities. But this has led to compromises being made between the comfort and the output performance of the material.

In a recent study published in Nano Energy, researchers om the University DESIGN WORLD

1/16/22 10:42 AM

F O K C SI

of Fukui, Japan and Nanjing University, China, have developed an all-fibrous composite layer TENG (AF-TENG) that can easily be integrated with normal cloth. “With our work, we are aiming to provide a new point of view towards wearable energy harvesters and smart textiles,” says Dr Hiroaki Sakamoto, the corresponding author for the study.

The AF-TENG contains a triboelectric membrane made of two layers of electrospun fibers — one of a material called polyvinylidene fluoride (PVDF) and the other of a type of nylon.

Silver nanowires cover these layers. The researchers further added a layer of electrospun polystyrene fibers between the silver nanowires and the triboelectric membrane.

The mechanical motion of the body while walking or running causes the triboelectric layers to gain a charge. This way, the mechanical energy is converted into electrical energy, which can be used to power electronic devices.

Normally, the charge buildup on the triboelectric surface is gradually lost or dissipated, reducing the surface charge density and the output performance of the nanogenerator. However, in this case, the added polystyrene membrane collects and traps the charge, retaining the surface charge density of the AF-TENG. The researchers used the AF-TENG to light up 126 commercial LEDs each rated at 0.06 Watt, demonstrating the feasibility of the nanogenerator. Moreover, according to Dr. Sakamoto, “The power generation device has flexibility and breathability since all components are composed of fiber materials. This device shows great potential in harvesting the static electricity om our clothes.”

While TENGs are currently limited to powering low-powered devices such as LEDs and calculators, improvements to the wearability and output performance are integral steps towards future wearable technology.

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Reference Title of original paper: An all-fibrous triboelectric nanogenerator with enhanced outputs depended on the polystyrene charge storage layer.

Journal: Nano Energy University of Fukui

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

Sulzer Chemtech has developed a method to turn recycled polyethylene terephthalate (PET) into high-quality foam.

Turning the tide on plastic waste Much of the plastic waste generated world-wide heads into the ocean.

One company has found a way to recycle that waste before it is dumped into the ocean.

Sulzer Chemtech is providing technical support to Tide Ocean SA and the Eastern Switzerland University of Applied Sciences to open new doors in the reuse of ocean-bound plastic waste. Using its expertise in polymer processing, Sulzer Chemtech has developed a method to turn recycled polyethylene terephthalate (PET) into high-quality foams that match the properties of virgin plastics. This development will help address pollution and increase the adoption of recycled polymer-based products.

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A leader in the field of ocean-bound plastic upcycling, Tide Ocean SA collects and transforms this waste into premium raw materials, such as the award-winning #tide ocean material, for new sustainable products. The company can process a range of polymer waste including PET from plastic bottles, polypropylene (PP) and polyethylene (PE). These are currently turned into pellets, yarn, and filament which can be used in a variety of applications such as plastic injection, textiles and 3D printing.

In the search for new processes to upcycle ocean-bound plastic waste, OST – University of Applied Sciences Eastern Switzerland approached Sulzer Chemtech. Leveraging its pilot plant facility equipped with cutting-edge foaming equipment, the company has proven that it is possible to use the recycled granules to produce expanded PET (XPET) foam boards. It also defined the key processing conditions to obtain boards that are indistinguishable from conventional XPET made from virgin plastic. This will enable Tide to offer products that can be used in packaging and construction, helping to improve the sustainability of these industries. DW

Sulzer www.sulzer.com

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Design for Industry Food & Beverage

Zume packaging is made om sustainably harvested plant material le over om agricultural production and is 100% compostable

Moving away om single use plastics Manufacturers face increasing pressure om consumers and policymakers to find alternatives to single use plastic packaging. New packaging needs to be sustainable, while being easy to mold, and as costeffective as plastic. California-based Zume, a global provider of compostable packaging, offers packaging material made om sustainably harvested plant material le over om agricultural production. Agricultural le over material includes bamboo, wheat, and straw. Plant material uses significantly less water and energy and reduces CO₂ emissions when compared to the production and disposal of plastic packaging. Unlike plastic, plant-based material is 100% biodegradable and breaks down a er use.

ABB Robotics is helping Zume automate the production of sustainable packaging om these materials by supplying the company robotic cells. ABB will integrate and install more than 1,000 molded fiber manufacturing cells (MFC) - including up to 2,000 robots at Zume customer’s sites worldwide over the next five years.

“With Zume, we have the potential to remove trillions of pieces of plastic om the global marketplace, preserving scarce resources and supporting a low carbon world,” said Sami Atiya, President of ABB Robotics & Discrete Automation. “Robotic automation is expanding possibilities, making the world more sustainable through more efficient production that reduces energy use, emissions and production waste.”

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Zume developed and patented an innovative manufacturing process to make compostable packaging for anything om food and groceries to cosmetics and consumer goods.

Containers are molded om the plant material by Zume’s molded fiber cells integrated with two ABB IRB 6700 robots, with each cell processing up to two tons of agriculture material every day, creating 80,000 pieces of sustainable packaging.

Working with ABB, Zume expects to equip factories with up to 100 robotic cells each. With the automation, speed and scalability provided by the MFC, each site would have the potential to process 71,000 tons of agriculture material annually, potentially producing up to two billion pieces of packaging each year.

“By 2050, we estimate that the world’s oceans will have more plastic than fish, so it is critical that we move everyone away om single-use plastics,” said Alex Garden, Chairman and CEO of Zume.

A pilot project has been installed

by Zume and ABB at Satia Industries

Limited, one of India’s largest wood and agro-based paper manufacturers, creating a facility of 10 manufacturing cells that will process 20 tons of wheat straw daily creating 100% compostable packaging for a range of industries.

Planned pilot installations include Parason Group, a global pulp and paper machinery supplier, also based in India, and Jefferson Enterprise Energy, the first 100% renewable energy powered compostable packaging factory, based in Texas, USA. DW

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Design f o r I n d u s t r y Food & Beverage

Keep cabling connections clean Ensuring food and beverage equipment does not introduce contamination into a production process involves every piece of equipment, including cabling. These cable entry plates KEL-DPU-HD have been specially developed for the installation in food processing and packaging machines.

During the development and in accordance with the Hygienic Design guidelines, care was taken to ensure that the visible side of the cable entry plate is ee of dirt collecting recesses. The outer contour has a radius of 6 mm, twice the minimum requirement of 3 mm. The surface is smooth (Ra = 0,421 µm acc. ISO 4287). Additionally, the KEL-DPU-HD uses an FDA-compliant elastomer in accordance with food approval 1935/2004/EG and (EU) 10/2011. The easily identifiable blue colour ensures a clear visual recognition of compliance.

KEL-DPU-HD entry plates are designed to route and seal cables without connectors ( om 3.2 to 20.5 mm in diameter) in limited spaces with IP66/IP68. The cable entry plate is characterised by its solid robust ame and increased strain relief of the routed cables. The KEL-DPU-HD 24 matches exactly the cut-out dimensions of 24-pin standard industrial connectors (36 x 112 mm). The cable entry plate is mounted either by screwing it to the inside of the enclosure or by snapping it into the cut-out (wall thickness om 1.5 – 2 mm).

The design signifies an easy-toclean solution om components to machines and including the entire production systems. DW

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Design Notes

How drones are advancing metrology for fighter jets Edited by Mike Santora • Managing Editor

The F-35 Lightning II is an all-weather stealth combat aircra intended to perform warfare strike missions and electronic surveillance capabilities at speeds up to 1.6 Mach. Composites comprise 35% of the air ame weight, with the majority being bismaleimide, and some carbon nanotube-reinforced epoxy — which has a tensile strength of approximately 100 times greater than steel. Any deviations in external dimensions can interfere with stealth capabilities, and at supersonic speeds, prove catastrophic to both plane and pilot.

Therefore, it is critical that the “as-built” metrology is confirmed as “near perfect” to the design. Currently, inspection is done by hand at Lockheed Martin’s production facility in Fort Worth, Texas. Gantries are assembled above the cra , and workers use handheld scanners extended at arm’s 38

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length. This manual process introduces variables and also puts workers at risk as they attempt to straddle the smooth-contoured surfaces of the aircra .

To generate faster results while increasing accuracy and safety for all involved — factory worker, customer, and user — the transition to digital inspection is required.

“There needs to be a bold first adopter of aerial digital inspection in the industry, and Lockheed Martin hopes to fulfill that role with this use case,” said Chris Colaw, Lockheed Fellow, Quality & Mission Success. “This is important in the quality space DESIGN WORLD

1/16/22 11:16 AM

The F-35 Lightning II is an all-weather stealth combat aircraft intended to perform warfare strike missions and electronic surveillance capabilities at speeds up to 1.6 Mach.

because it helps us peel away the reliance on so much human involvement.”

Many devices currently allow for digital measurement of assemblies on a small level. However, the problem is how to scale up existing commercial equipment to inspect large, completely constructed projects, such as large-body aircra , ships, and even submarines, while still holding to tight tolerances.

“For 100 years in aviation, we have been using humans for quality assurance, DESIGN WORLD

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but roughly 75% of my costs come om inspection, and 66% of that requires humans to perform, which involves some degree of subjectivity,” noted Colaw. “But in our digital future, we need to embrace things in a different way.”

Lockheed Martin sought an automated metrology solution to confirm and document measurements to the tightest tolerances in a faster, more accurate, and more repeatable process. www.designworldonline.com

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Design Notes “We were doing our own research on what a digital future would look like, but we opted to work with CAD / CAM since they presented an opportunity to partner with a scanner company and the University of Texas on drone control,” said Colaw. “That saved us om having to do all the work on our own. The collaboration was a natural fit.”

In the spring of 2021, CAD / CAM Services won a Small Business Technology Transfer Research (STTR) award to solve surface metrology issues for the F-35 fighter jet. Its job was to assemble a team of industry-leading suppliers that would deliver to Lockheed Martin a dronemounted scanner that can accurately (± 0.025mm) measure large assemblies and transmit that data to a system that ultimately creates CAD files for

HB.

first article inspection or maintenance purposes. The company, based in Texas, has provided 3D modeling and CAD conversion services worldwide since 1988.

“We are taking various commercial, off-the-shelf components, slightly modi ing them, and tying it all together to create a new system to solve a problem that is needed by industry,” said Scott Shuppert, CEO of CAD / CAM Services.

The synergistic result started with the drone and the camera inspection so ware, which had to actively search for dents, cracks, deformations, corrosion,

NTS.

and alignment issues, and then reconcile the measured results to the design model.

“Our team decided we needed to have both a drone and a robot to inspect on the assembly line,” continued Shuppert.

“The drones will fly above and around the cra , while the wheel-mounted robot will work underneath the plane. For the drones, we went with Airgility because they had most of what we were looking for.”

Based in College Park, MD, Airgility, Inc. specializes in integrating AI and autonomy into their unmanned aerial vehicles (UAV). Their drones met

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the requirements for maneuverability (continuously adjustable tilt motors), control accuracy (ability to hold a flight path to ± 6mm), compliance (NDAA and TAA), and carrying capacity.

The guidance and control (G&C) system uses a multi-loop architecture that computes the error between a desired reference position and the current drone position and then synthesizes the desired 3-axis movements of the rotors at an 80 Hz sampling rate. This allows the drone to operate without the benefit of global positioning satellites.

“Since GPS signals can’t penetrate a heavily built aircra hangar, the drone has to rely on the internal G&C system,” said Pramod Raheja, CEO and co-founder of Airgility. “This system regulates the angular orientation of the drone via an independent thrust vectoring system so it can follow a 3-D reference trajectory based on the physical dimensions of the aircra .”

Raheja explained how situational awareness is achieved by an algorithm that incorporates data om numerous, redundant sensors. This allows the cra to fly in narrow spaces, like over and under a gantry or aircra wing. Also included in the intelligence is a self-contained on-onboard AI failsafe mechanism, so if the so ware crashes for any reason, the drone will simply back away, avoiding any obstacles and the land itself.

Collision avoidance is critical since, in addition to the aircra itself, the Lockheed Martin factory floor presents numerous physical obstacles including scaffolding, pilot ladders, auxiliary power units, tails, canopies, and people.

“Before we let a drone fly next to an $80 million jet, we wanted to test it within a lab environment,” noted Lockheed Martin’s Colaw.

This is where Animesh Chakravarthy, Ph.D., Professor of Mechanical and Aerospace Engineering and Flight Control at the University of Texas at Arlington, was brought in. Chakravarthy’s research in collision avoidance has been recognized by his receiving a prestigious CAREER award om the National Science Foundation (NSF).

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Design Notes

“The goal is to have the drone performing multiple precise orbits around the aircra , at just the right speed, while at the same time ensuring that the scanner is properly oriented towards the aircra ,” explained Chakravarthy. “The trick is not getting so close as to cause a collision, but not so far away as to distort the readings.”

Chakravarthy’s advanced students will develop the mechanical robot that carries the scanner under the plane along the plant floor. It will be equipped with its own G&C system — conceptually like that of the drone — that will autonomously track the reference trajectory while ensuring collision avoidance.

“Sometimes drone technology gets a lot of attention because it is neat and intriguing, but there has to be a business value behind it,” said Colaw.

“Using drones and this type of scanning

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Currently, inspection is done by hand at Lockheed Martin’s production facility in Fort Worth, Texas. Gantries are assembled above the craft, and workers use handheld scanners extended at arm’s length.

technology really opens the door to better understand our product and to cost-effectively substantiate the quality of our products in a way that we can’t currently do because we are limited by human bandwidth.”

The current STTR award includes options for even further advances. Of great importance to Lockheed Martin is identi ing any delamination within the composite skin of the F-35. Since the separation of the layers and voids cannot always be seen or measured om the surface, a non-destructive testing method is necessary.

This is where highly sensitive IR cameras can be used to inspect beneath the composite surface of the cra to effectively visualize and identi any anomalies.

“The IR flash lamps act as an excitation source to transfer heat through

www.designworldonline.com

the material,” said Desmond Lamont, Global Business Development Manager for Teledyne FLIR. “Since voids and gaps don’t transfer heat as efficiently as a solid does, the heat will build, and the camera identifies these hot spots and points out the adjacent fault areas.”

While there were several challenges the team encountered, the issue of removing the wiring tether om the scanner was considered one of the most significant. A wireless approach is much safer and more capable of dodging personnel and physical in astructure on the factory floor.

The Airgility team will solve this problem by using AI drones that only transmit crucial data, thus greatly reducing bandwidth.

“Since the intelligent drone knows what anomalies to look for, it only sends that info and ignores the expected

DESIGN WORLD

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Design Notes An in-flight drone inspection at the Lockheed Martin production facility.

results,” said Raheja. “Therefore, you don’t need to transmit a lot of data continuously.”

The ultimate result of this collaboration is a reliable, highly accurate (plus or minus 0.025mm) inspection platform for large body cra that removes human error and safety risk

om the manufacturing environment.

“With the F-35, there certainly is a use case to employ this technology where it has a successful chance of entry,” concluded Colaw. “The idea is to scale it across the other Lockheed Martin business units and then become a major proponent for using this technology in

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Design Notes

How positioning drives can help automate your production lines Edited by Mike Santora Managing Editor

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Automation, Industry 4.0, and Big Data are the key technology trends in the industrial sector. Braun Sondermaschinen GmbH recognized these trends early and used them for developing fully automated production lines, increased customer productivity, and savings. Building specialized machinery requires individual concepts and flexible solutions. Therefore, the company has developed the modular automation concept MAK, which includes both so ware and hardware. Smart components are also used to make the processes within the systems even more efficient and safer. These components also include AG24 positioning drives om

www.designworldonline.com

SIKO GmbH, a manufacturer of sensors and positioning systems. They enable an automated size changeover for more precise adjustments when changing products and faster refitting times.

Manuel S. Gander, M. Sc., Head of Supply Chain Management and Material Management at Braun Sondermaschinen GmbH, explains the requirements for building specialized machinery, “The automated production lines that we implement are developed according to specific and individual customer requirements — usually as a prototype and then as an adapted replica of the

DESIGN WORLD

1/16/22 11:21 AM

prototype. No two systems are alike; there are always special requirements.” To ensure a certain level of standardization remains, the company offers a modular automation concept, “The MAK system consists of an aluminum traverse and a protective housing. Depending on customer requirements, the individual processes are modularly linked in, and a so ware package is fitted over the entire system.”

Another aspect that is taken into account in system planning is the increased number of variants that machines must handle even with

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the smallest batch sizes. Compact positioning drives enable automated and fast size changeovers without significant intervention in PLC programs.

Braun Sondermaschinen always uses the AG24 positioning drives om SIKO when manual workstations requiring automation need precise size changes.

These are balancing systems (assembly and balancing machines) to produce cooling fans for the automotive supplier industry. Until now, balancing has been a manual process in which the special machine manufacturer had already used SIKO’s mechanical position indicators for

www.designworldonline.com

A fully automatic final assembly line for electric motors in the automotive sector. Optionally, fast and precise automated size changeover SIKO positioning drives can be used with such a system from Braun Sondermaschinen GmbH. | Braun Sondermaschinen GmbH

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Design Notes manual size changeover. With the AG24 positioning drive this module can quickly and precisely be converted to manage the increasing number of model variants.

The AG24 actuator was selected partially for its high torque and the associated power reserves. This power range is not always necessary for systems, but the reserve option plays a major role.

For example, if components become more difficult to move due to dirt and stress and the drive can then provide more power.

Servomotors are an alternative to positioning drives, and are justified in most processes, but less so when compactness and manual operations are important. With the AG24, all necessary functions, such as the brushless DC motor, position encoder, or power and control electronics, are already integrated into the device. It can be connected directly to the machine control, is compact, and unlike a servo motor, which requires additional components

such as variable equency drives or inverters, it does not require any wiring.

The positioning drive also has an integrated absolute encoder that records the position at all times, even when the power is off.

For Jürgen Schuh, Business Unit Manager of Changeover Solutions at SIKO, this also demonstrates the advantages for a special machine manufacturer like Braun, “Every project is accompanied by a new set of specifications, with additional possible variants, which in turn involve special requirements.”

With a maximum rated torque of 14 Nm, the new positioning drive AG24 packs a punch for size changeover. | SIKO GmbH

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Serving a World of Industries!

The AG24 also provides the possibility of controlling the drive via the fieldbus and the PLC and using the option for changing manual settings directly on the device display. In some applications, it makes the most sense to change the settings and positioning manually in advance via teach-in; in other words, to gradually travel to the appropriate dimension with the positioning drive and then save these positions as target values in the machine control system. In this way, the finely adjusted positions can be traveled to directly during commissioning. The AG24 positioning drive combines both aspects - the manual fine adjustment and the automated, efficient process.

“From an electrical design standpoint, the integration of the actuator is also very straightforward, including integration into the machine control system,” said Gander.

Gander also said another aspect that will become more essential for his customers is the collection and evaluation of data on the production lines.

Besides determining the position, the drive can also show additional diagnostic data, such as current consumption or temperature, both on the display and via the interface. Conclusions can be drawn om this data regarding predictive maintenance, allowing maintenance intervals to be planned. The drive thus also supports requirements related to Industry 4.0 and data evaluation via AI. Gander sees great potential in this diagnostic capability because his idea of the ideal automation line is “a system in a dark hall, in which production can run 24 hours, seven days a week, 365 days a year without human intervention”. This vision is not far away; human judgment is still mandatory for certain processes, but the greater the number of unnecessary, tedious, or error-prone process steps that can be automated, the more efficiently production can be carried out. For the special machine manufacturer, one thing is clear: “Not only is full automation increasing steadily, it is becoming the standard in industrial production.” Intelligent peripheral components such as positioning drives play an increasingly important role. DW

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Design Notes

How to make the telescope of the future

Edited by Mike Santora • Managing Editor

For Lockheed Martin, tackling complex challenges, pushing the limits of scientific exploration, and devising solutions are all part of its DNA. So, it is no surprise that the U.S. Defense Advanced Research Projects Agency (DARPA) selected an elite team of scientists and engineers om Lockheed Martin’s Advanced Technology Center (ATC) to create a design for a new, futuristic space telescope.

Because of traditional optical systems, today’s space telescopes are heavy, expensive, and bulky. In line with the project’s requirements, DARPA’s version would have to be lighter and less expensive to send into space. It would also have to be adaptable and even more powerful. As the ATC team soon discovered, the fundamental principles of telescope design would need to be reconceived.

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3D-printed prototype of disk for SPIDER, showing a radial configuration of lenslets.

The ATC needed to create a new, vastly condensed optical technology to tackle the challenge. It also needed a cost-effective and fast means of creating prototypes that would help the team understand how to implement this technology. With the use of researchers at the University of California at Davis, the ATC co-developed SPIDER, or the Segmented Planar Imaging Detector for Electro-optical Reconnaissance. And with the use of MakerBot’s solutions, the team rapidly and easily iterated on designs for prototypes.

To redesign the telescope om the ground up, the DESIGN WORLD

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Design Notes ATC chose a relatively new technique for collecting light, known as interferometry. In the world of optics, this technique uses many tiny lenses to collect photons which are then processed via microchips to create a high-resolution image.

Partnering with experts at UC Davis, the ATC co-developed a special silicon chip to channel light fed om tiny lenses. ATC’s new system could reduce the size, weight, and power needed for optics by 10 to 100 times while offering similar resolution. As an array, SPIDER is cheaper, faster to produce, and lighter than the optics in traditional telescopes, making the technology easier to send into space.

The SPIDER imaging technology can be fitted to any number of flat shapes; however, the best arrangement for a particular purpose will depend on the context of the application, the object or vehicle it’s mounted on, and tradeoffs between spaceflight efficiency and light collection. To explore and test these concepts, ATC engineers designed different SPIDER arrays in Solidworks, then prototyped them to further refine and iterate on their models.

MakerBot’s professional solutions have allowed Guy Chriqui, Senior Research Engineer at the ATC, and Sutyen Zalawadia, Mechatronics Engineer, to quickly accelerate the iterative design process and cost-effectively prototype for SPIDER on their own.

Outsourcing any of this work just wasn’t an option, as Chriqui explained: “We would get quotes in the thousands of dollars with an eight-week lead time for just one version of a model — I can’t imagine what 14 versions would cost.”

Chriqui and his team also have a cutting-edge machine shop in-house, but the MakerBot 3D printers nearby allow the SPIDER team to iterate new versions in only hours. Plus, since the ATC has many sensitive projects, outsourcing work to contractors would not just slow down projects and increase costs; it would also require approvals and paperwork that could be avoided by turning to a MakerBot a few feet away.

By accelerating the design process, these Desktop 3D printers have bolstered scientific experiments, enabling more tests, more insights, and more potential breakthroughs in a shorter period.

Moving more quickly om ideation to iteration and refinement gives engineers a significant competitive advantage, helping deliver better solutions faster to clients.

The ATC used the Replicator 2 and 2X to prototype parts and tooling for the James Webb Space Telescope back in 2013. They have since updated with the Replicator (5th Gen), Mini, Z18, and now the Replicator+ and Replicator Mini+.

Beyond prototyping SPIDER arrays, the team’s Replicator Mini is also a practical field 3D printer for when the engineers travel to different testing facilities. “When we test smaller rockets, the nose cones blow off and are mostly unrecoverable, so we bring the Mini to the launch site and print different nose cones on the spot,” Zalawadia said.

Data sheets at www.koford.com

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Electro-Optical Engineer, Katherine Badham adjusts instruments on an optical bench used for SPIDER testing.

MakerBot’s filament has also proved beneficial. With new materials like Tough PLA, ATC’s engineers can make entirely new products and applications possible, such as high-quality snapping joints Chriqui calls flextures. Whereas these flexible hinges and joints would typically fail when printed as PLA, they function well with Tough PLA, allowing the team to print prototypes that are closer to the final product. In testing the SPIDER technology, the team also found that MakerBot True Black PLA at 100% infill is perfect for absorbing light. Good light absorption is important so that no light leakage can affect optical tests. They also use neon PLA filament to highlight specific parts of a print.

When Chriqui and Zalawadia had the opportunity to test the Print platform,

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Design Notes

Research engineer Guy Chriqui inspects a printed part.

they appreciated its added efficiency, especially for assisting coworkers with ad hoc 3D printing requests. The Auto Arrange and multi-printer control features were used for setting up different projects on multiple build plates and sending them to other printers.

When the team’s experiments required a custom tool that couldn’t be bought off the shelf, they were able to design it themselves and print 14 different iterations in a single day. “Some little tools that were printed over a year ago are still in use in the lab,” Zalawadia remarks.

With these printers — the only FDM printers at the ATC— the team has sped up its product development cycle. Even though the ATC has access to industryleading machine shops and advanced manufacturing technology, MakerBot’s

professional solutions add distinct advantages to the ATC’s workflow that the Center’s other resources can’t.

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that could one day travel farther, explore distant planets at high resolution and look deeper into the endless depths of space. DW

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Internet of Things

Autonomous race car event proves the value of edge AI

The Indy Autonomous Challenge Powered by Cisco (IAC) challenged universities to program Dallara AV-21 race cars and compete at IMS last October.

With a $1 million prize, the Indy Autonomous Challenge Powered by Cisco (IAC) challenged universities to program Dallara AV-21 racecars and compete at IMS last October. The primary goal of the IAC is to advance technology that can speed the commercialization of fully autonomous vehicles and deployments of advanced driver-assistance systems (ADAS). It is also a platform for students to excel in Science, Technology, Engineering, and Math (STEM).

A major part of that technology is edge AI, of which ADLINK plays a part.

“We are committed to building a comprehensive ecosystem for the C-V2X platform, which is key to the successful implementation and uptake of autonomous driving,” said Joe Speed, Field CTO at ADLINK Technology.

“During the IAC, the onsite STEM Garage will display technologies that have been at the center of the IAC along with our partners GAIA Platform, The Autoware Foundation, Kvaser, Boston Dynamics, and more.”

Some of the tools provided include open source autonomous driving tools and expertise, ROS / ROS 2 robotics controllers, and rugged edge AI solutions. Every IAC university team was supplied with an ADLINK AVA-3501 series rugged edge platform for in-vehicle computing.

The AVA-3501 uses AI to work through gigabytes of image analysis in real-time to cope with the massive data load of high-speed, autonomous driving. All of this AI work must be done in-car, at the network edge. The ADLINK AVA-3501 combines the latest Intel Core and Xeon processor 56

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options with dual-slot full-length NVIDIA RTX graphics for AI acceleration. Depending on the configuration, the system can also provide 3TB of Samsung 970 EVO Plus NVME M.2 SSDs, two 512GB hot-swappable 2.5” SSD SATA 6 Gb/s system drives, dual 40GbE QSFP+ connectivity, and six CAN channels. This is in addition to a standard I/O set including DP++, DVI-I, GbE, 8-channel Digital IO, and six USB ports.

The 21 universities om 9 countries form 9 teams competing in the Indy Autonomous Challenge were: • AI Racing Tech – University of Hawai’i, University of California San Diego • Autonomous Tiger Racing – Auburn University • Black & Gold Autonomous Racing – Purdue University, United States Military Academy at West Point with Indiana University-Purdue University Indianapolis (IUPUI), Indian Institute of Technology Kharagpur (India), Universidad de San Buenaventura (Colombia) DESIGN WORLD

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• Cavalier Autonomous Racing – University of Virginia • EuroRacing – University of Modena and Reggio Emilia (Italy), University of Pisa (Italy), ETH Zürich (Switzerland), Polish Academy of Sciences (Poland) • KAIST – Korea Advanced Institute of Science and Technology (South Korea) • MIT-PITT-RW – Massachusetts Institute of Technology, University of Pittsburgh, Rochester Institute of Technology, University of Waterloo (Canada) • PoliMOVE – Politecnico di Milano (Italy), University of Alabama • TUM Autonomous Motorsport – Technische Universität München (Germany) DW

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Every IAC university team was supplied with an ADLINK AVA-3501 series rugged edge platform for in-vehicle computing.

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Internet of Things

5 tips to protect industrial networks As the Operational Technology (OT) and Information Technology (IT) convergence trend continues to gather speed, there are several attack surfaces emerging in industrial control systems.

Although some of these are known vulnerabilities, there are also some that are unknown. Therefore, everyone om the C-Suite to the plant floor needs to join forces to enhance industrial cybersecurity om the edge to the cloud.

It has been noted that cybersecurity is like a puzzle composed of hundreds of different pieces that need to be individually identified, analyzed and understood. Here are five practical tips to help organizations begin to put the pieces together.

1

Deploy secure-by-design networking devices and set up devices securely Typically, industrial operations include a variety of legacy devices that are increasingly vulnerable, as field networks are no longer always air gapped. In an ideal world, legacy equipment could be upgraded quickly with advanced solutions that have security features embedded into them. However, budget restraints and the requirement that industrial operations do not experience downtime equently leads to a mixture of old and new equipment operating together. When this scenario arises, it’s important to have a security-hardened networking device to enable connectivity for legacy devices. In order to ensure that the devices use a secure-by-design methodology, it is advisable to check that

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the embedded security functions of any networking devices adhere to security standards such as those detailed in the IEC 62443 standard. A er confirming this, devices can be set up securely. It is recommended that any unused ports and services be disabled to minimize available entry points for intruders.

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Divide networks into multiple segments Once the network nodes are configured securely, the next step is to segment the networks following a zone and conduit policy. Dividing the connected networks into segments to enhance network security helps avoid the scenario where the entire network experiences downtime due to a single network node being compromised. It is recommended to have a secured network architecture design, such as network segmentation or a Demilitarized Zone (DMZ) to reduce the risk of threats emerging om the IT network.

However, it’s also important to choose the right solutions to divide industrial networks into segments. It is not sufficient to protect an OT environment by simply placing an IT firewall in ont of the OT network. However, this advice is equently ignored. An IT firewall does not have the capability to recognize industrial protocols that allows cyberattacks to take place at the supervisory or process level. It is a highrisk decision as it leaves the system open to vulnerabilities and intruders. Firewalls that are used as solutions in industrial control systems not only segment www.designworldonline.com

networks into separated network zones to achieve vertical protection, but should also include the deep packet inspection engine function to filter unauthorized packets without affecting performance of operations and providing horizontal protection.

3

Adopt a secure communication solution for critical data and assets The purpose of OT/IT network convergence is to collect data and transform it into valuable information.

One good option is to use cloud technologies that are convenient to use and have powerful data analysis capabilities to simpli network convergence. A topic that has grown in importance recently is how to secure data access om OT to IT and om field sites to the cloud. OPC Unified Architecture (UA) brings a huge amount of security principles along with it.

This communication protocol not only features application authentication and user authentication, but also offers a security mechanism that meets the three pillars of security: confidentiality, integrity, and availability (CIA). When you are considering how to streamline communication om edge devices to cloud servers, OPC UA offers a reliable communication solution to ensure data integration is easy and secure.

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Internet of Things

maintenance. Before you are able to reap the benefits, make sure your remote access is secure by using features such as data encryption and a VPN, as this will help keep your critical assets secure.

Outsourced vendors, system integrators, and even remote service engineers are essential for daily operations, maintenance, and troubleshooting. They also play an important role to implement security policies. Any investment will become futile if these people lack cybersecurity awareness and do not know how to leverage these technologies. To avoid this undesirable scenario, it must be ensured that everyone involved in industrial processes have the same mindset and attitude to cybersecurity and only when

this has been achieved will the results become apparent.

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Enhance industrial cybersecurity awareness om management to individual levels According to the security awareness pyramid, cybersecurity can be separated into different awareness stages. Commitment and support om management form the foundations, which is followed by security programs and policies being implemented during the awareness building process. Taking security policies as an example, it is fundamental to define who has Read and Write access based on the security configurations. However, when these policies are rolled out across an entire

organization, it becomes a challenge to ensure everyone adheres to them properly. Facility managers o en find implementing cybersecurity measures cumbersome, and subsequently they do not ensure everyone follows the guidelines. Sometimes, they may end up doing things more akin to group level security, instead of ensuring each individual has their own unique log in credentials, and this subsequently opens up new cybersecurity risks.

5

Examine the configurations and settings to follow the security policies Once awareness has been established and policies have been defined, employees will pay more attention

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to their system settings. It can be a complex task to examine all the systems at one time. However, it is never too late to get started. Performing a risk assessment will help define security priorities. From this position it is easier to identi and protect critical assets. A good starting point is to examine configurations. If a large-scale network is being examined, it is recommended to leverage visualization so ware to check the security settings and adjust the configurations where necessary.

Moving forward According to the Deloitte report “Cyber risk in advanced manufacturing,” four out of 10 manufacturers have experienced security incidents with 86% of these stating that their industrial operations were disrupted. Here is a quick summary of ideas to prevent your operation om becoming a cyber attack target.

It is highly recommended to begin with developing mindsets, formulating security policies, and systematically examining configurations.

Once the groundwork has been performed, start to look at secure edge connectivity to protect the mixture of new and legacy systems.

It is important to remember to secure the network backbone that helps deliver the data that is required to achieve OT/IT convergence.

It is recommended to install industrial firewalls to consolidate vertical and horizontal protection.

Last but not least, with the increasing demands on remote connections, a hassle- ee secure remote access solution will save money and effort. DW

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Internet of Things

SOM for IIoT This SOM is powered by the AM64x processor family om Texas Instruments (TI). Featuring realtime and low-latency processing, this SOM targets industrial IoT and industrial machinery applications.

The AM64x SOM is for applications that require a combination of precise real-time processing and application processing, and comes equipped with two Cortex A53 cores for OS-level and applications processing, up to four Cortex R5F cores for real-time computing, servo control and functional safety, and an isolated Cortex M4 MCU channel for error monitoring. This SOM also includes features for missioncritical applications, such as an integrated MCU subsystem and diagnostic libraries, inline ECC, an isolated Cortex-M4 core that can work independently om the SoC, secure boot with hardware-enforced root of trust, and more.

Architected using TI’s efficient 16 nm FinFET production technology, these SOMs consume little power, support fanless designs, and are robust to extreme environments ranging om -40 to 85°C. Measuring in at just 47 x 30 mm in size, they include the AM64x processor, including onboard eMMC storage, a sub-1GHz MCU for radio communication, and up to three gigabit Ethernet physical layer transceivers.

To maximize the AM6442 processor’s multi-protocol industrial ethernet support, the SOM leverages two built-in gigabit industrial communications subsystems (PRU-ICSSG) that support industrial ethernet protocols such as Profinet IRT, Profinet RT, EtherNet/IP, EtherCAT and Time-Sensitive Networking (TSN). Paired with high-speed PCIe, USB 3.0 and integrated ethernet switch interfaces, as well as general industrial connectivity options like UART, I2C, CAN and ADC, the SOM is the ideal foundation for industrial communications systems, factory automation, industrial robot and machinery control, industrial gateways, M2M communication and much more.

The AM64x SOM family features multiple ordering options for single to dualcore A53 and single to quad-core R5F options based on the TI AM6411, AM6412, AM6421, AM6441 and AM6442 processors. Additionally, SOMs can be optioned with TI’s CC1312 multiprotocol and multiband SimpleLink wireless MCU for sub 1GHz communication. Supporting 6LoWPAN, MIOTY and Wi-SUN protocols allows the SOM to conduct advanced sensing and metering of sensors. DW

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AP&C, a GE Additive company, is working with Airbus to supply Ti-6AI-4V for use in metal additive manufacturing applications for the aerospace industry.

Key trends in the additive industry focus on the development of materials for various additive technologies and so ware programs that help designers with specific needs or that help smooth the flow of additive production om initial design to final part. Here’s a look at recent introductions.

Titanium powders for aerospace The adoption of metal additive technology in aerospace continues to gather momentum. One of the challenges, however, is keeping pace with this adoption rate and meeting the regulations required in the aerospace industry.

To help meet that need, AP&C, a GE Additive company, is working with Airbus to supply Ti-6AI-4V for use in metal additive manufacturing applications. AP&C has grown its capacity to more than 1,000 tons of titanium powder per year. This large-scale production is performed in more than a dozen powder production lines at two manufacturing sites.

Materials for medical Health systems have taken a beating since the pandemic.

According to the American Hospital Association, in 2020 hospitals lost $300 billion in revenue as a result of canceled non-emergency procedures and patients postponing care.

This led Congress to allocate $70 billion in relief funding to hospitals through the CARES Act. Despite this, EBITDA margins for hospitals are down more than 10% compared to pre-pandemic levels in 2019, even when incorporating federal aid into the equation.

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This allows anomalies to be detected and the actual process to be optimized via data analysis. With the help of OPC UA, this can be done completely without a controller using a standard protocol.

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To help solve shortages in multiple areas, the heath system is increasingly turning to 3D printing. One example is the demand for 3D printed surgical tools and medical supplies in hospitals and Ambulatory Surgical Centers (ASCs).

Traditionally, 3D printing technology was prohibitively expensive for a majority of hospitals and only available to the largest, most well-resourced medical centers.

Working to spread more solutions, such as 3D printing, into health care systems is the Healthcare Supply Chain Association (HSCA). HSCA works with GPOs, entities that help healthcare providers access savings and efficiencies by conducting due diligence on suppliers, aggregating purchasing volume, and using that leverage to negotiate discounts with manufacturers, distributors, and other vendors. GPOs manage 72% of all purchases that are made by hospitals and 97% of hospitals are affiliated with one or more GPOs. Thus, it is advantageous for vendors to be listed with GPOs. Vizient is one of the largest member-driven healthcare GPOs in the nation and serves more than half of the healthcare organizations in the United

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States, including approximately 97% of academic medical centers.

Recently, Formlabs announced Vizient is including the company’s 3D printing systems and materials in its list of manufacturers recommended for healthcare providers. Formlabs will offer its 3D printers, materials, and solutions for converting CT/MR imaging into tactile, patient-specific anatomical replicas for surgical planning, implant sizing, and patient consent.

Formlabs 3D printing systems are validated in multiple FDA 510(k) cleared processes for manufacturing of surgical tools either within the hospital or by third-party vendors.

3D printable bioresorbable material aids medical device designers One of the newer 3D printable materials available to the medical community is a bioresorbable material om Boston Micro Fabrication (BMF) and UK-based 3D printing materials company 4D Biomaterials. The use of 4D Biomaterials’ 4Degra bioresorbable material with BMF’s micro 3D printers will enable designers to work with micro-scale geometries in medically implantable devices. This achievement marks the first time a bioresorbable material has been printed using micro 3D printing.

This innovation gives designers the opportunity to develop devices ranging om micro-scale rigid orthopedic

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properties of a part. Thus, porosity is a factor devices and fixations through to micro-scale designers look for when choosing a material and so tissue applications. an additive process.

The partnership combines BMF’s Desktop Metal and Uniformity Labs, an AM projection micro-stereolithography (PµSL) company specializing in industrial 3D printing approach with 4D Biomaterials’ 4Degra resin materials and processes, unveiled a partnership inks which together will help to solve design to quali and deliver ultra-low porosity binder and biocompatibility issues for medical device jetting powders that exhibit manufacturers, opening up opportunities for exceptional sintered part implantable devices. density and mechanical Said BMF CEO John Kawola, With Parasolid “Miniaturization in medical device technology, Materialise development has been held back will add native CAD by the limitations of traditional workflows within manufacturing methods and the materials available.”

Magics 26, providing This material may open new an additional toolset avenues. on top of mesh Ultra-low porosity binder jetting powders Porosity refers to the level of solidity achieved in an additively made part, that is, whether there are cavities or holes between the layers of a part. The number and size of these cavities can affect the final mechanical

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The Carbon Design Engine allows product designers to generate advanced latticed parts quickly and easily from a solid part STL file and output STL files for printing on most 3D printers.

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exclusively for Desktop Metal additive systems, including the Production System, Shop System, and ExOne print platforms. Together, the companies are studying powder and binder interactions and will release print profiles with fully characterized mechanical properties for various materials, including stainless steels, nickel-based superalloys, and reactive metals such as aluminum.

properties when used with Desktop Metal’s AM 2.0 binder jetting solutions.

Led by a team of world-leading materials scientists and 3D printing innovators, Uniformity Labs has developed patented materials technology that enables powders with densities up to 85% that of sinter to full density, and that are more flowable than powders of comparable size. The greater flowability of these materials ensures a more uniform spread across the print bed, for a better sinter and less part shrinkage in the binder jetting process. (The binder jetting process can reduce final part dimensions up to 20%, which must be accounted for in a design.) These new materials will deliver precise parts with good material properties and surface finish.

The collaboration between the companies is to focuse on quali ing optimized binder jetting powders

So ware smooths the path to additive production As designers explore geometric complexity using additive systems, vendors are keeping up with so ware that makes this exploration easier.

Carbon3D recently announced its next generation Carbon Design Engine so ware.

The Carbon Design Engine allows product designers to generate advanced latticed parts quickly and easily om a solid part STL file and output STL files for printing on

most 3D printers. Previously, this so ware was available only to Carbon platform customers, but beginning early this year, so ware licenses will be available for individuals and teams to design, develop, and print advanced lattices on most 3D printers.

With accessibility to this latticegenerating design so ware, individuals and companies can automate the process of creating conformal, multi-zone lattices, dramatically accelerating the product development process. One example is the use of this program for such products as bike saddles, helmets, and sporting gloves.

Lattice structures require less material, while offering great performance. As a result, latticed parts can provide performance advantages, including lightweighting, flexibility, improved cushioning and dampening, heat dissipation, and unique aesthetics.

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Visit our website for downloadable data sheets, www.designworldonline.com brochures and pricing: www.GavazziOnline.com

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Health care systems are increasingly turning to 3D printing to supply surgical tools and medical supplies.

run complex computations in the cloud, design engineers can experience fast design cycles to rapidly refine lattice designs in minutes, and use most 3D printers to manufacture them immediately.

Key features of Design Engine include: ● Multi-zone: The Pro tier of Design Engine introduces the ability to tune multiple zones at once, integrating different lattice types, cell sizes, or strut diameters to create different zones of performance within a single part, using the same material. ● Powerful zone transitions: The Pro tier of Design Engine uses patentpending technology to seamlessly blend zones, producing attractive, functional lattices ready to use in real-world applications. ● No tedious tuning: Designing even simple lattices o en requires tedious, manual work that is prone to errors that can significantly impact part performance. Design Engine resolves lattice features, both large and small, while robustly transitioning seamlessly between different zones inside the same part for maximum performance. ● Precise control: Lattices generated in Design Engine can be optimized for a wide array of performance characteristics, including part volume and tunable mechanical response. ● Compatibility: Design Engine is compatible with most part fabrication techniques, outputting generated lattices in the STL file format.

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Materialise embeds native CAD workflows into Magics As the additive manufacturing industry matures, you will see a greater merging between it and CAD so ware. An example is the recent news om Materialise, which has licensed Siemens’ Parasolid so ware for integration with Magics, the company’s so ware for data and build preparation.

With Parasolid technology, Materialise will add native CAD workflows within Magics 26, providing an additional toolset on top of mesh functionality. This combination will allow users to continue iterating CAD designs in Magics to prepare for additive manufacturing processes, improving productivity and providing cleaner, more accurate and fit-for-purpose data.

“For years, the 3D printing industry has discussed whether CAD or mesh is the preferred workflow for file preparation,” said Stefaan Motte, Vice President So ware for Materialise. “We believe both offer unique benefits and a seamless integration of both formats will provide users with the optimal workflow.”

Magics 26 will enable users to seamlessly transition om design optimization in CAD to mesh-based file preparation.

This will enable users to easily review and edit parts with designers and engineers who are familiar with CAD systems before moving to mesh for platform and build preparation.

Developed by Siemens Digital Industries So ware, Parasolid is a 3D geometric modeling kernel. It is at the core of the Siemens’ Xcelerator portfolio’s open and flexible ecosystem.

Convergent Modeling technology, a core part of the Parasolid solution, enables mesh data to be mixed with traditional CAD geometry in a unified environment, removing the need for time-consuming and error-prone data translation and enabling intelligent operations to be carried out. Magics users will benefit om the best of both worlds – CAD for part editing using best-in-class technology and mesh-based operations for platform preparation using tried-and-true solutions.

Magics 26 will be released in spring 2022, powering the additive manufacturing champions with a cohesive and fully integrated workflow for 3D printing. DW

AP&C, a GE Additive company www.advancedpowders.com Boston Micro Fabrication | www.bmf3d.com Carbon3D www.carbon3d.com/design-engine.com Desktop Metal | www.desktopmetal.com Formlabs | www.formlabs.com Materialise | www.materialise.com Uniformity Labs | www.uniformitylabs.com

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Managing motion-design EMI for food metal detection

The operation of electric motor drives can degrade the performance of metal-detection equipment so essential to safe food processing.

Here we look at ways to mitigate these electromagnetic interference (EMI) and radio-frequency interference (RFI) issues.

Eric Garr • Regional Sales Manager | Fortress Technology

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The causes and effects of electromagnetic disturbances abound.

Thankfully, various measures can be implemented to reduce noise interference in metal-detecting sections of food-processing lines. Unique features of Fortress metal detectors include a Noise Immunity Structure and AutoPhase which feature on the company’s digital metal detectors can suppress some of this interference noise. In contrast, traditional systems necessitate the manual adjustment of sensitivity levels. | Dreamstime

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Though mechanical vibration problems are beyond the scope of this article, it’s worth noting that locating a metal detector on a mezzanine floor can cause mechanical noise infractions from chutes, hoppers, and conveyors.

To ensure the most reliable metal-detector performance (and avoid vibration) all support structures and reject devices should ideally be of welded construction.

Bolted connections should be avoided across the frame — as they can support the transmission of distinct electrical loops.

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| Dreamstime

found on conveyor lines to ensure the safety of consumers and protect downstream processing and packaging equipment in the facility. Here, metal detectors help lines reject contaminated product or even sound an alarm and halt operations when steel, aluminum, or other metal particles (either originating from raw food ingredients or worn mechanical elements on processing equipment) are sensed in a given food sample.

The most common metal-detector design in the food and beverage industry is based on a transmitter-receiver coil arrangement in which the former coil continuously emits an electromagnetic field. Should metal contaminants travel through the detector (typically in food riding on a conveyor belt) the receiver coils immediately sense the resulting electromagnetic field disturbance. That in turn prompts an alarm and other machine actions … most typically the removal of suspect food items off the main conveyor line.

Design elements largely determine the performance of a food metal detector. These include the metal detector’s aperture size, product effect, and operating frequency. However, environmental conditions including electrical interference in the form of static, radio, or earth ground loops as well as vibration (as that associated with moving metal) may also affect performance.

In settings where food products are being processed, main sources of electromagnetic interference and radio frequency interference include: • Motor drives for ac motors — including variable frequency drives (VFDs) • Drives for servo motors • Two-way radios (including walkie talkies) • Electrical loops, electrical contacts, and static discharges

Identifying EMI noise in foodprocessing settings The biggest challenges to metaldetector applications in food processing plants are EMI and RFI. That’s especially true for end-to-end lines incorporating food conveyors, pick-and-place or pack robots, bagging, and flow wrapping. The effects of EMI from these motor-driven systems can negatively impact the performance of metal detectors — resulting in false detections, false rejections, and unacceptably low food safety.

EMI and RFI noise occur when different electrically powered machines and peripheral equipment operating near each other are improperly shielded or filtered. Interference most commonly originates from ac motor drives on the conveyor. More specifically, the cables that power the ac motor drive will radiate EMI if shielded incorrectly.

Recall from motion design fundamentals that ac drives work on

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etal detectors in the food-processing industry are commonly

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the principle of switching line voltage to run a motor. This switching causes a fluctuating current draw on the line which in turn causes a broadcasting of RFI and EMI noise back on the ac motor drive input line. A filter can attenuate the draw to eliminate the noise. However, even when this filtering is applied, the output cable to the motor can still radiate noise. Therefore, cabling specifically designed and rated for variable frequency drives should be used on VFDs — to ensure that noise doesn’t broadcast from the cable.

The closer the source of the EMI gets to the metal detector coils, the greater the strength of the signal broadcast. The worst-case scenario is when there’s a clear line of sight from whatever is generating EMI to the metal detector’s opening. If the EMI source is off to one side, the metal detector’s body helps to shield the internal coils from the broadcast noise.

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Radio wave issues when detectors are too close together The susceptibility of a metal detector to EMI is very dependent on its sensitivity and operating frequency. If one metal detector is transmitting at a frequency very close to another and the two machines are positioned close together, they risk electromagnetic cross talking.

To prevent this happening, metaldetector suppliers typically recommend spacing metal detectors at least four meters apart or staggering the metal detectors so they aren’t directly aligned. As part of a site audit, it’s also good practice to note the operating frequencies of metal detectors in proximity so that a different frequency can be selected for any new equipment.

What doesn’t cause issue: Long and medium-wave transmitters such as walkie talkies rarely cause problems with metal detectors — provided that they are operating at 3 W or less and not used in proximity to any metaldetector receiver coils. In addition, mobile communication devices such

www.deltron.com

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EMI/RFI noise occurs when different electrically powered machines and peripheral equipment operating near each other are unshielded or filtered incorrectly.

as smart phones are never a problem for metal detectors. This is because these digital devices’ functions operate at high frequencies — well above the bands used for metal detection.

Common motion-design static electricity sources Packaging machines including paper and plastic film rollers as well as conveyor belts can create a certain amount of electrostatic interference.

However, such interference is rare — and mostly found on operations involving plastic and paper webs that run very close to the metal detector’s coils. This is usually only an issue when the slider beds and conveyor belt material through the metal detector rub enough to cause static buildup that eventually discharges to the metal detector case near its coils. Electrostatic

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interference can also occur when slider and belt material are incorrectly selected — causing static to build in the metal detector aperture.

Static electricity build-up is more likely to occur on gravity and vertical metal detection applications if the pipework has not been earthed correctly.

Finding and addressing EMI and RFI sources It’s key to identify the source of electrostatic interference problems quickly and accurately, as ongoing interference on automated processing lines can cause service disruptions. Some metal-detector suppliers can deploy a technician armed with a so-called sniffer to

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Shown here is a plot of EMI. EMI effects can degrade the performance of metal detectors.

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swiftly track the source of EMI and RFI. Like an antenna, such sniffers measure RF and can swiftly locate the source of frequencies competing with metal-detector operations. With this information, engineers can effectively shield, suppress, or alter the emissions path.

Some metal-detector suppliers also offer the option to retrofit existing metal detectors with newer hardware equipped with better noise immunity features. For busy production settings (including highly automated food and beverage plants) this solution overcomes or greatly reduces the effect of the noise on metal detectors.

User-friendly metal-detector features such as automated single-pass calibration can deliver an accurate system setup within seconds … and eliminate human errors. Additionally, built-in noise immunity structure — included as standard on high-performance digital metal detectors — can dramatically reduce the effects of external electrical noise, again resulting in fewer false product rejects. DW

Interceptor metal detector |courtesy Fortress Technology

Fortress Technology | www.fortresstechnology.com

Interceptor metal detector |courtesy Fortress Technology

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Precision feedback

for semiconductor production machinery Semiconductor production can’t be successful without accurate and precise feedback. And that starts with the choice of encoders.

Brian Zlotorzy • Business Development Specialist • HEIDENHAIN ETEL Brand

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It’s one thing to find something that works during

manufacturing. It’s another to find something that works, can keep up with the high demands, and resist wear and tear. The design stage is where the necessary components are identified, and specific ones are chosen. There may not be a better example of this than the high-precision, high-yield world of semiconductor

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production. For maximum productivity and efficiency, the control, motor, machine frame and the position linear encoder must work seamlessly together. In this high-stakes sector, the potential costs of a misfit or a component that can’t hold up can have dramatic effects that trickle down through the whole engineering process or production itself.

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HEIDENHAIN’s LIP 200 series is an optical scanning encoder using interferential scanning with diffracted light to generate its current signals allowing for a greater amount of interpolation with a finer grating period (down to 2.048 µm) that is largely free of harmonics (interpolation error of ±0.4 nm). The scale is made up of OPTODUR grating on ZERODUR glass making it both resistant to contamination and providing a low thermal coefficient down to 0±0.1. This results in a measuring step of as low as 31.25 picometers.

Optical scanning linear encoders are most often the best option in semiconductor production, but they are not created equal.

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From fabricating integrated circuits, wafer dicing and packaging testing, the robotics employed in these tasks need to move to designated positions rapidly, accurately and without overshoot or ringing. This makes direct-drive linear servo motors a common choice.

However, their superior speed and control put steep demands on feedback signals, putting a premium on linear encoders for short- and long-term performance.

Clean, precise linear position feedback reduces vibration in the machine frame, eliminates velocitydependent motor resonances, and prevents additional heat generation, allowing the motor to realize its maximum mechanical power rating and efficiency of operation.

At semiconductor-level of precision, encoder signals need to be interpolated to reach a high enough resolution for useful feedback. Interpolation error is to be anticipated with any encoder.

That is, periodic position error within one signal period of the encoder’s output signals. Even the highest quality encoders, those most often applied in these cases, include interpolation error, though just 1 to 2 percent of the signal period. That said, if the frequency of interpolation error increases too much during production, the resulting heating or noise can make it difficult for the drive to stay within its effective range.

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So if this naturally occurring error has this much impact on motor efficiency and needs to be accounted for, that shows how important the right component choices are in the design process.

Optical scanning linear encoders Optical scanning linear encoders are most often the best option in semiconductor production, but they are not created equal. These incorporate measuring standards or scales with periodic structures known as graduations. The substrate material is glass, steel, or — for large measuring lengths — steel strips. These fine graduations — periods from 40 µm to under 1 µm are typical — are manufactured in a photolithographic process. Characteristic properties are high-edge definition and excellent homogeneity which are prerequisites for accurate performance.

The optical scanning is often paired with exposed linear encoders, meaning the measuring standard is exposed.

These can reach higher levels of accuracy and resolution and take up less space. Even in fabs or inspection facilities where federal clean standards are adhered to, at such precision demands, contamination can still affect feedback (in the form of fingerprints from mounting or oil accumulation from guideways, for example), and lead to DESIGN WORLD

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poor results. While their homogeneity and definition impact accuracy, the toughness of the gratings affects contamination resistance.

Contamination on the measuring standard influences the light intensity of the signal components, and therefore the scanning signal. Its level of effect depends on the scanning method. Large, single-field scanning is the best choice. With only one field, the output signals will change in their amplitude, but not in their offset and phase position over the range of travel. They stay highly interposable, and the interpolation error remains small. The large scanning field in relation to the graduation detail reduces sensitivity to contamination. (One of the largest scanning fields deployed in semiconductor work is 14.5 mm.2 ) Even with contamination up to 3 mm in diameter, linear encoders continue to provide high-quality signals with position error below the values specified. This stable signal, even in the face of some contamination, maintains low interpolation error, high traversing speed, good control-loop performance and low heat in the drives.

Just like feedback has to resist contamination, it also has to be able to handle temperature changes to remain within the machine’s working accuracy. The “operating temperature range” is the limit of ambient temperature within which the specifications of the encoder still comply, for one, thermal expansion of the encoder’s carrier. An encoder’s specified expansion coefficient should expand or contract in a defined, reproducible manner, matching the thermal behavior of the machine frame.

The thermal dynamics of the machine should be taken into account when deciding where to mount the encoder’s scale and scanning head. So for instance, it’s generally recommended to not put feedback near heat sources. Along those lines, here are a few more reasons why semiconductor machines must be designed with feedback in mind from the beginning:

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The mounting surface must meet flatness requirements.

To facilitate adjustment of the scanning head to the scale, the scanning head should be fastened to a mounting bracket.

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• •

To keep the resulting Abbe error as small as possible, the linear scale should be mounted parallel to the machine guideway.

To avoid vibration, the best mounting surfaces are solid and stable machine elements as opposed to hollow parts.

Finally, on mounting, with small signal periods come narrow mounting tolerances for the scanning gap, the space between the encoder’s scanning head and its scale. This is the result of diffraction caused by the grating structures. Such diffraction can lead to a signal attenuation of 50 percent upon a gap change of only ±0.1 mm.

More workable mounting tolerances are possible with linear encoders that use an interferential scanning principle and innovative index gratings, a variation of optical encoders that use the imaging principle to measure displacement. DW HEIDENHAIN | www.heidenhain.us/

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HEIDENHAIN uses tough gratings manufactured in highly specialized, proprietary processes. In the company’s SUPRADUR process, a transparent layer is applied first over the reflective primary layer.

Then, an extremely thin, hard chrome layer is applied to produce a grating and is shown here on an LIF 400 linear encoder. These graduations have proven to be particularly insensitive to contamination because the low height of the structure leaves practically no surface for dust, dirt, or water particles to accumulate. This ensures the high signal quality that direct drives require.

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Virtual twins will drive the

digital evolution of industrial Saloni Walimbe • Global Market Insights Inc.

Rapid advancement towards digital transformation will position digital twins as crucial elements for businesses worldwide.

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The digital revolution is making its way across the industrial world at a breakneck pace. Various industrial sectors are adapting to this evolution by integrating key technologies like AI (artificial intelligence), VR (virtual reality), and AR (augmented reality), among others into their workflows, processes, and products. According to the Digital Marketing Institute, nearly 27% of managers consider digitization to be a tool for business survival.

Among the vast array of technologies being leveraged as solutions for digital transformation, digital twin technology is gaining increasing favor worldwide from major entities working to establish a firm presence in the modern digital ecosystem.

Digital twins, also known as digital replicas or virtual twins, refer to a digital copy of any physical process, system, or product. This technology helps bridge the gap between physical and virtual environments, by collecting data regarding physical elements through the use of sensors in real-time. These data

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Hailed as one of the most disruptive technologies of the decade, the digital twin industry, is anticipated to cross $50 billion by 2027 and will likely be a major driver for the digital revolution worldwide.

Hailed as one of the most disruptive technologies of the decade, the digital twin industry, which is anticipated to cross $50 billion by 2027 based on Global Market Insights Inc. reports, will likely be a major driver for the digital revolution worldwide.

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are then used to replicate the element in digital form, creating a plethora of opportunities for businesses to analyze, understand, control, and optimize their operations.

Hailed as one of the most disruptive technologies of the decade, the digital twin industry, which is anticipated to cross $50 billion by 2027 based on Global Market Insights Inc. reports, will likely be a major driver for the digital revolution worldwide.

Why is digital twin important for industrial IIOT? Industry 4.0, or the fourth Industrial Revolution visualizes a highly connected world reliant on smart technologies, all designed to communicate with one another using the emerging IIoT (Industrial Internet of Things) concept. In order for this concept to work, a standard approach is needed to understand the description www.designworldonline.com

of key components and the way they interact with other assets or components in a smart machine; i.e., a digital twin.

While still in the nascent stage, these precise digital models are expediting digital transformation, not just in the industrial sector but nearly everywhere.

COVID-19 has added further relevance to this technology over the past year, underpinning its importance in crucial tasks such as automated processing, remote monitoring, and predictive maintenance.

The potential benefits of the digital twin industry are vast, from reducing design and build times for machines, to optimizing performance throughout the operational life cycle to playing a prominent role in predictive maintenance, smart maintenance, and condition monitoring. Using digital replicas, engineers can merge product data with important application data to deliver comprehensive insights, and DESIGN WORLD

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when combined with technologies like AI, forecast future performance with accuracy.

3 ways digital twin technology is helping industrial automation design Over the years, the industrial world has been witnessing a marked shift towards progress through technological innovation. The emergence of critical Industry 4.0 enablers like wireless connectivity, AI, and automation facilitates the extraction of valuable data and the delivery of real-time performance insights.

Digital twin technology can help engineers to use these insights in many ways and allow them to improve operational performance across the industrial floor.

Bridging gaps between physical and virtual environments Digital replicas can help enterprises by creating holograms or digital visualizations of physical models to bridge the gap between the digital and physical environment, particularly in combination with AR/VR (augmented reality/virtual reality), IoT, and AI/ML. The technology facilitates virtual collaboration, intake of sensor data, speedy simulation of various situations, better comprehension of what-if scenarios, and more precise prediction of results, which can be used to control elements in the physical world.

Digital twin simulations and leading Industry 4.0 technologies like AI, and 5G are becoming more closely associated with the emergence of novel spatial platforms designed to give engineers more immersive access to virtual replicas of their environments.

For instance, in April 2021, UK-based vehicle battery producer Hyperbat partnered with Ericsson, BT, and Nvidia to develop the first 5G, VR (virtual reality) digital twin solution in the world. The objective behind this move was to enhance the collaboration between the remote teams of Hyperbat in the UK, through an interactive virtual 3D engineering model, allowing the firms to accelerate the production process for electric and hybrid vehicles.

The 5G VR digital twin technology, powered by technologies like CloudXR, NVIDIA RTX Virtual Workstation software, and NVIDIA RTX technology, can be used to facilitate realtime immersive experiences for teams, both remotely and on the production floor.

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Undertaking timely predictive maintenance activities Another way digital twins are able to transform the ways industries operate is by facilitating the implementation of predictive maintenance.

With the emergence of virtual twins and IoT, businesses worldwide are shifting towards advanced predictive maintenance models designed to optimize the maintenance cycle and create a balance between preventative and corrective maintenance activities. essentially, digital replicas can convert realworld data pertaining to physical systems, inputs, or objects into simulations or predictions, to show the impact of these inputs on the physical system.

To that end, Siemens Energy enlisted NVIDIA’s Omniverse platform in November 2021, to develop digital twins designed to support predictive maintenance of power plants. The digital replica technology developed by NVIDIA will help the company create a new workflow to mitigate planned shutdown frequencies through physics-based real-time simulations of steam and water in HRSGs (heat recovery steam generators), whilst ensuring optimum security.

Increasing operational efficiencies The application scope of the digital twin market is growing rapidly in recent years. In smart city development, especially, digital twin technology is playing an increasingly crucial role in the more precise designing of buildings and infrastructure, in order to circumvent the need for costly modifications afterward.

Additionally, digital replicas can help engineers decrease the cost of emergency response and integrate green building design options to facilitate energy savings in the long run.

In smart city planning, digital twins make use of physical models, sensor data, and input data to replicate and simulate the performance of the structures over their corresponding physical twin’s lifecycle. For this reason, the technology is hailed by many city governments and urban planners as the ultimate tool for cost-friendly infrastructure designing and development, The ability to run simulations on the basis of large datasets makes digital twin technology an important asset in smart city initiatives.

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Testament to this is the partnership of the researchers from the U.S. Department of Energy’s National Renewable Energy Laboratory and the Energy Department’s Oak Ridge National Laboratory with Chattanooga, on the use of digital replicas to enhance energy efficiency, whilst optimizing the speed, safety, and travel time for drivers.

With digital twins, businesses can reduce their maintenance expenses to a great extent. As a result of this new technology, the industry will benefit from enhanced revenues and a reduction of unwanted overheads that arise from problems with equipment and processes. Additionally, it streamlines and improves the production line in an organization and in turn improves customer service, which is the ultimate goal of any industry. Overall, it can be stated that the digital twin, a cutting-edge trend in technology, will play a vital role in industrial IoT application deployments. DW

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A D D I T I V E

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Take a look at how others use 3D printing systems to make efficient and functional designs.

The advantages that additive manufacturing (AM) offers

designers are widely known. Complex geometries can be realized more easily, costs can be saved, and functions can be integrated directly into designs. An interesting example of using AM to integrate functions is found in the Meristem Wall, a architecture project at Lund University led by two Swedish innovative architects David Andreen and Ana Goidea.

Meristem Wall – an homage to 3D printed architecture When science, innovation and creativity meet, a troika is unleashed that seeks the potentials of functional integration beyond the known and tested. The Meristem Wall embodies precisely this troika and stands as a symbol for the forward-thinking virtuality of 3D-printed in architecture, but can also demonstrate this troika for other industries.

A long fascination for additive manufacturing was one of the drivers that motivated David and Ana to create something completely new and unprecedented. A monolithic build, that does not only incorporate functional parts such as pipes for electrical wiring and water flow, but also an optimized surface that acts as an urban wildlife habitat as well as a highly complex ventilation network, allowing the wall to “breathe” in a controlled matter. A project of such complexity and innovation is perfectly suited for additive manufacturing.

The Mersitem Wall “While 3d printed architecture is a hot topic was exhibited today, almost all commercial applications focus at the Biennale on efficiency, speed and cost reduction” explains Architettura 2021 David Andreen “We believe that 3D printing can in Venice be revolutionary in the construction industry but this requires a complete rethink of the what as well as the how. “

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A D D I T I V E M A N U F A C T U R I N G A top view of the Merstiem Wall as it’s being built by a voxeljet VX4000 Jobbox binder jet process

A top view of the Merstiem Wall as it’s being built by a voxeljet VX4000 Jobbox binder jet process.

His partner in crime, Ana Goidea adds: “The ability to create complex and unique forms and geometries with technologies such as 3D printing, opens up a new realm of aesthetical, efficient, and functional architecture.

And that’s what we want to show with the Meristem Wall. “ En vogue: complex, unique, functional “3D printing brings two distinct advantages to the construction industry: the ability to create parts of high formal complexity, and the fact that every part

produced can be unique. It becomes possible to create building envelopes that passively harness the local microclimates by storing heat and humidity, driving airflows through convection, and similar mechanisms,” explains Ana. By combining both of the advantages, architects have the possibility to really think outside the box. Instead of literally building a box of walls, Meristem shows that it’s possible to create structures, that not only support the build of a home, but also influence the climate in and around it.

Metal parts printed on Fused Filament Fabrication architecture represent a step change in the affordability, safety, and design space, opening an entirely new application space for metal 3D printing.

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All in all, the Meristem Wall incorporates the following functions: • Structural support of self-weight (could be extended to carry additional load) • Integrated electricity and light fixtures using industry standard equipment • Integrated water pipes using industry standard equipment (PEX tubing) • Windows • Distributed ventilation system controlling heat storage and internal moisture levels. Embedded actuators and sensors for control, without moving parts.

• Rainwater run-off • An exterior wall zone that acts as a diverse wildlife habitat.

• Air filtration • Interior fabric surface The creation process Ana and David have been working on this project for more than two years.

Digitally, the wall was created in the bioDigital matter lab in Lund, and is based on a series of complex algorithms and design processes developed by Ana and David.

Many architectural explorations tend to rely on one algorithm, ultimately these projects are then limited to the logic of this one algorithm which restricts the possibilities of complexity and function. David and Ana strived for an approach that would make the wall follow its own logic in function, expression, and existing construction industry from a defined starting point.

To do so, they required a large number of algorithms, connected to and passing information to each other. With the help of modern modelling software and custom programming by both architects, the Meristem Wall began to shape and push the limits of both the hardware and software. But in the end, the CAD data was ready for 3D printing.

Here the next challenge awaited: With maximum dimensions of 1.25 x 2.1 x 0.7 meters the wall was too big for most of the existing additive manufacturing

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systems. Finally, the VX4000 from voxeljet with a building envelope of 4 x 2 x 1 meters, was designated as the right 3D printer to create the wall.

“The main challenge for us was the high degree of complexity with the fine inner structures and tubes. Since we print in a sand bed, this means, that after the printing process is completed, we have to remove all the unprinted sand from the bonded structures. So, when we print structures with cavities, that means they are always filled with unprinted sand,” says Tobias Gruen, product manager at voxeljet. “To ease the unpacking and finishing process we printed 21 individual pieces which made the finishing and handling of the parts easier. The data was sliced by David and Ana at the suitable intersections so that the parts could later be assembled.

For us it was a great experiment to explore how thin we can print and

A voxeljet employee removes unprinted sand from the part.

handle the filigree structures. With this project we really tested the boundaries of complexity for our technology.”

Since the voxeljet Binder Jetting technology was initially developed for metal casting, the printed parts are not designed for end use applications. But, since the Meristem Wall was going to

be exhibited at the Biennale in Venice a couple of weeks later, the parts needed to be stronger and more durable.

Sandhelden, a company based near Augsburg, is specialized in exactly that. Transferring 3D sand printed parts suitable and ready for end use applications such as design elements,

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A D D I T I V E

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Full scale view of parts for the Mersitem Wall.

construction parts, interior architecture, sanitarian products or art.

“I’ve never seen a project like this before, so for us it was really all about learning and testing the limits,” says Laurens Faure, CEO at Sandhelden.

“We are specialized on individual post processing of 3D printed parts. For example, we create a lot of sanitarian design products, sculptures or molds.

But the Meristem Wall was a whole different challenge for us and something completely new in terms of size and application.”

In order to strengthen the parts in their stability and tensile strength, Sandhelden deep infiltrated the parts with epoxy resin. With wall thicknesses as filigree as 0.5 mm, the parts were highly sensible and easy to break. The infiltration gave the parts a much higher strength to avoid any breaking during the transport to Venice and to endure a long-term stability while being shown.

“It took us approximately 3 days to fully cover the wall with epoxy resin but in the end, we can say that we are very happy with the end result. 3D concrete printing is currently a big topic in the construction industry and architecture

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in general. While rather classic facades are ideal for this kind of technology, as soon as slightly more complex geometries or details come into play, concrete printing doesn’t pose as a good match anymore. This is exactly where we see the strength of binder jetting. Large parts can be printed with high precision and accuracy even for filigree details. The accuracy is clearly sufficient for the market. Therefore, the binder jetting technology is suitable for all the elements, which either cannot be produced with classical manufacturing processes or are only possible with a large amount of work and costs.”

Once the parts were printed, infiltrated and packed, they made their way to Venice to be displayed at the Venice Architecture Biennale 2021.

There, Ana and David assembled the single elements to one connected wall.

With its 1.25 meters in length and 2.1 meters in height it will stay there on display until November 21st.

“The project’s ambition is to demonstrate that a building envelope can be made today using these technologies, and that the resulting structure could have significant added

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value over a conventional wall,” concludes David. “3D printing can show the construction industry a way forward to create significant market opportunities for 3D printed buildings that are rich in expression and function and are ecologically sustainable.”

The Meristem wall is unique.

It’s unique in the way it’s been designed, unique in the way it’s been manufactured and post processed and unique in all its functions and abilities.

It’s anything but “just another print of a wall.” That’s also why David and Ana will keep exploring the frontiers of generative design and additive manufacturing in architecture and maybe even develop the Meristem Wall from a unique piece into a product. DW

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Bearing life and effects of harsh operational environments Edited by Mike Santora

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Manufacturers in nearly every industry are increasingly raising performance expectations for rollingelement bearings while at the same time exposing them to operating and environmental conditions that, when extreme, can reduce the rating life by as much as 90%.

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SpaceX Crew Dragon spacecraft docking to the International Space Station.

Bearing life, explained

Under typical operating conditions, the inner and outer rings and rolling elements are constantly loaded and unloaded when bearings rotate. This produces material fatigue and eventually bearing failure. Statistically, the total number of revolutions reached or exceeded by 90% of a sufficiently large group of apparently identical bearings before the first evidence of material fatigue is called the basic rating life.

Manufacturers of ball bearings typically publish Load Ratings for each bearing they produce. The methods used to calculate ratings can vary from manufacturer to manufacturer. However, both ABMA and ISO have published standards related to load ratings.

• ABMA Std. 9 – Load Ratings and Fatigue Life for Ball Bearings • ABMA Std. 12.1 and 12.2 – Instrument Ball Bearings • ISO 76 – Static Load Ratings • ISO 281 – Dynamic Load Ratings and Rating Life Dynamic load ratings are determined by bearing geometry, number and size of balls, bearing pitch diameter, and ring and ball material. This load rating is used in conjunction with the actual applied radial load to calculate bearing fatigue life.

The static load rating relates to limiting loads applied to non-rotating bearings. The static load rating depends on the maximum contact stress between the balls and either of the two raceways. It is affected by material, number and size of balls, raceway curvatures, raceway depths, and contact angles. It is also based on using clean, high-quality bearing steel with typical hardness levels of 58-64 Hardness Rockwell C (HRC) for rings and 60-65 HRC for balls.

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Glasswork: glass melting on the side of an electric furnace.

Three common and challenging operating environments that impact bearing life are high temperature, exposure to corrosive chemicals, and vacuum environments.

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A change in the pitch circle can impact the dynamic load rating, and a change in the ball diameter or ball quantity can impact both load ratings.

Changing all these variables at the same time can result in the dynamic capacity moving in one direction and the static capacity moving in the opposite direction.

Both standards, ABMA Std.9 and ISO 281, use the same method to determine the basic rating life of a ball bearing. However, while based on similar concepts, they use different modifiers to determine the adjusted rating life. These include adjustments for reliability, unique bearing properties, operating temperature, lubrication conditions, and certain environmental factors.

For example, the life adjustment factor, a2, relates to special bearing properties, such as material. AST standard bearings are made from vacuum degassed steel, leading to an

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extended life for the bearings. The basic load ratings have been established by taking this longer life into consideration.

This increases the operating life in hours by a factor of 2.2 and an increase in the load-carrying capacity by a factor of 1.3.

When subjected to harsh operational environments, bearing life can be greatly reduced. Design modifications are typically required to maintain life expectancy (i.e., changes may include materials for rings and rollers, coatings, seals, retainer materials, and lubricants).

Before making any modifications, designers must consider all the environmental factors in determining appropriate changes.

Three common and challenging operating environments that impact bearing life are high temperature, exposure to corrosive chemicals, and vacuum environments. To meet production goals, manufacturers must account for these variables.

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High-temperature environments Custom bearings can accommodate temperatures exceeding 350°C. To design a custom bearing used in such environments, manufacturers must consider both the bearing material and lubrication.

52100 chrome steel is a common ball and roller bearing material, and it can withstand temperatures to 125°C. Heatstabilized materials must be considered for temperatures above 350°C. Also, high-temperature grease or oil that can operate up to 285°C should be added to the design.

Corrosive environments Water and chemicals can have a significant impact on the longevity of bearings. While rings and components are commonly made of stainless steel, in corrosive environments, consider nitrogen-enhanced martensitic stainless steel, which offers five times the corrosion resistance. Similarly, ceramic can be used for rolling elements, which deliver exceptional performance in corrosive environments.

Vacuum environments Finally, vacuum environments, including those encountered in space, impact retainers and lubricants, with outgassing materials condensing on optical elements (lenses, solar cells, navigation sensors).

The rate of outgassing increases at higher temperatures, requiring solid lubricants, including gold, silver, molybdenum disulfide, and polytetrafluoroethylene.

Additionally, austenitic stainless steel AISI

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304 cages are preferred in retainer materials, reducing the torque between the rolling element and the cage.

Achieving success in meeting design life requirements is essential to your bottom line. To achieve the desired results for your bearing in these extreme environments, you must ensure that an experienced and knowledgeable bearing engineer performs a comprehensive analysis. DW

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How vibration analysis

keeps your bearing system steady Edited by Mike Santora

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Implementing condition monitoring can reduce the frequency and cost of equipment maintenance.

Specifically, vibration analysis can provide valuable insight into machine condition, flagging up problems before extensive damage occurs. Chris Johnson, managing director of ball bearing supplier SMB Bearings, explains the steps machine builders should take to reduce the likelihood of bearings being the root cause.

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From a bearing manufacturing perspective, a low noise or vibration rating is achieved by paying attention to the surface finish of the raceways and balls, their roundness, and selecting the correct cage design.

With large numbers of rolling elements in industrial machines, it can be

challenging to decipher precisely what is happening inside a unit. Condition monitors often use accelerometers to measure vibration. With this device, it is possible to differentiate between vibrations by examining the individual frequencies present in the overarching vibration signal. These frequencies can then be used to match individual parts or certain malfunctions.

This analysis can warn of faults well before failure. In the case of bearings, it is possible to detect excessive rolling element wear or damage due to poor fitting techniques, highlighting the need for bearing replacement. The alternative would be to allow the bearing to deteriorate further, which could potentially cause other components to fail.

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To maintain rollability, it is vital that bearings are lubricated sufficiently and to a suitable fill level dependent on torque, speed, and load requirements.

Other problems that vibration analysis can detect are misalignment, lubricant problems, or incorrect shaft or housing fits. With early detection, it may be possible to rectify these issues well before costly bearing failure.

As a safety net, regular vibration analysis can be used to confirm bearing condition and prevent catastrophic failure. However, if the proper precautions are taken to lessen bearing vibration during machine design and bearing selection, the likelihood of faults is greatly reduced.

Expert manufacturing From a bearing manufacturing perspective, a low noise or vibration rating is achieved by paying attention to the surface finish of the raceways and balls, their roundness, and selecting the correct cage design.

Finely filtered low noise greases can also be used to reduce vibrations.

These contain fewer, small solid particles which can generate noise

when they pass between the balls and raceway.

Prevent contamination Accidental dirt or dust contamination can also increase noise and vibration levels, as this inevitably affects the rollability of the bearing. Bearing shields or, even better, contact seals are a good solution to this problem.

Choose the right lubrication To maintain rollability, it is vital that bearings are lubricated sufficiently and to a suitable fill level dependent on torque, speed, and load requirements.

Equally, the type of lubrication should be carefully considered for the application, based on temperature, speed, and environmental conditions.

If bearings are inadequately lubricated or filled with an incorrect grease, manufacturers should contact a bearing supplier to inquire about bearing relubrication.

The bearing’s internal clearance can make a big difference. Choose tighter clearances for accurate running but beware of any temperature differences that reduce internal clearances during operation.

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ERT

Pay attention to radial play The bearing’s internal clearance can make a big difference. Choose tighter clearances for accurate running but beware of any temperature differences that reduce internal clearances during operation. Choose looser clearances where interference fits are used, or there is slight misalignment between shaft and housing.

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Keep to load limits As tempting as it may be, end-users should avoid using a bearing close to its maximum load capacity. Bearing load ratings are only a guide. Bearings should be used at around a tenth of the dynamic load rating if long life is required. Heavier loads can be tolerated, but the bearing lifespan will be shortened, as identified later by vibration analysis.

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Condition monitoring is becoming more prevalent, and this technology allows for early identification of bearing problems but, by taking precautions to prevent issues arising in the first place, machine builders can ensure their bearings are fitted to last. DW

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The

Best free

analog circuit simulators We examined 30 free analog circuit simulation packages to see which of them is appropriate for real circuit analysis and design work.

Leland Teschler • Executive Editor

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Blogs and online forums catering to engineers often mention all kinds of free packages and services aimed at circuit designers. Trouble is, a lot of these free resources are mainly useful for students and hobbyists. They lack the facilities that would make them valuable for engineers designing or analyzing circuits going into manufactured products.

To help find the most useful packages from amongst the sea of online debris, we surveyed the field of free circuit simulators mentioned in posts and forums. We came up with 30 packages and online apps that seemed to offer benefits of use in actual circuit work.

A few overall impressions: Sometimes open-source simulators mentioned in older blog posts have just disappeared. Other packages labeled as circuit simulators are, in fact, just schematic capture programs augmented with some printed circuit board layout facilities. A number of programs do, in fact, perform analog circuit simulation but were created by university researchers who seem to have lost interest in supporting them. It’s easy to find simulators whose last update predates the invention of the iPhone. www.designworldonline.com

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| AdobeStock.com

Circuits created with the free version of DCAClab are quite nice looking, but visible in this one is the only transistor model available in the component library. The paid version has many more.

Academic simulators also tend to support only basic generic device models; forget about probing any part-number-specific behaviors. Nevertheless, we’ve included these simulators on our list if they still function—they may be enough if the goal is just to get a quick idea of how a circuit topology behaves.

Another class of free simulator is actually a stripped-down variant of a program offered for sale. Usually the free version has far fewer device models built in than the paid version. There may

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We’ve listed all the simulators we found —the good, the bad, and the ugly—that actually did perform circuit simulation in some fashion. They are provided alphabetically along with the most notable benefits and drawbacks we uncovered.

The list

The LTspice program from Analog Devices Inc. is among the more powerful free analog simulators. It particularly excels in modeling high-power circuits.

ADS 1.00 – This one seems to be of most value to students, and firstsemester students at that, rather than working engineers. It only contains models of passive components, voltage sources, and logic gates. And the sources are limited to voltage sources— no current sources. And no transistor models. So you would be out of luck if you wanted to simulate a circuit containing transistors—there aren’t even current sources available to create Ebers-Moll transistor models.

CircuitsCloud-- This is another package for students. Users build the circuit online using basic passive components, op amps, NPN, PNP, and NMOS transistors. Sources include dc or ac voltage and current sources and a pulse generator. But we couldn’t figure out whether it was possible to change the frequency of the ac sources or the parameters of the pulse generator. And there don’t seem to be much in the way of pre-built circuits in the library.

Micro Cap has some nice features and once retailed for about $4,500 before the closing of its creator, Spectrum Software.

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CircuitLab—This is a browser-based simulator that includes a pretty big library of circuit elements and prebuilt circuits and takes differing units into consideration when evaluating expressions. It will also do frequency domain simulations and lets users define arbitrary Laplace transfer function blocks. The ac sources seem to accept any input frequency parameter though there doesn’t seem to be any allowance in the simulations for RF radiation effects. To fix a value onto components and nodes, the user simply adds a label. All in all, extremely straightforward to use.

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Texas Instruments’ version of the Tina analog simulator.

CircuitLogix—The Student Version of this mixed-signal Spice simulator contains over 4,000 device models, about a third of the number available in the not-free CircuitLogix Pro. Student Version devices include semiconductors, displays, indicators, switches, digital primitives, digital ICs, linear ICs, transistors, FETs, optoisolators, photo diodes, regulators, references, SCRs, triacs, supplies, sources, relays, math devices, transmission lines, motors, and so forth. Users inspect circuit waveforms via virtual instruments that include an oscilloscope, digital multimeter, Bode plotter, curve tracer, data sequencer, signal generator, logic analyzer, logic probe and logic pulser.

Circuit Sims – This is a Java applet.

It has the advantage of providing numerous ready made widely used circuits that can be called up. Typical examples include filters, various rectifiers, several transistor/FET/ MOSFET circuits, op-amp circuits, and so forth. All these can be modified.

The user can set the ac sources to any frequency. Users can change the run speed and simulation speed with a slider. That said, this is probably more of a learning aid or a back-of-the-envelop simulator. The device models are all generic. Though the applet accepts any frequency you input, it doesn’t allow for high-frequency effects as input

The Tinker CAD circuit simulator from Autodesk is quite graphic but hosts only a few basic electronic component models.

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frequencies climb into the megahertz and gigahertz range.

Circuit Simulator 1.6i for Windows – This is a downloadable version of the Java Circuit Sims applet. Performance wise, the two seem to be identical.

Circuitmod—This Java-based circuit simulator is an extension of the ADS V1.00 Java Circuit Simulator that adds CMOS chips, LED arrays, and PIC programming to the library of available functions.

DCAClab—Users normally pay for access to this online simulator but there is a limited version that is free.

Visually, the user interface looks like circuit components plugged into a breadboard, and there doesn’t seem to be any limit on the frequencies used as inputs. But the free version is extremely limited. The only transistor model available is an NPN bipolar version though op-amp and gate models are included. The oscilloscope display provides up to three channels but there is no frequency domain display available, and the smallest time setting available is 0.5 µsec/div.

EveryCircuit—This online simulator carries a one-time $15 fee, but it can be run for free, and we couldn’t really tell what additional capabilities the $15 buys. One point to note is that the app will run on Android or iOS phones.

Simulations created on a phone can be saved to the cloud and then run on a desktop machine. The simulator mainly targets students but seems to be useful for professionals because of its fairly complete component library which includes voltage and currentcontrolled voltage and current sources, center-tapped transformers, MOSFETs and bipolar transistors.

Gnucap—This general-purpose advanced circuit simulator performs nonlinear dc and transient analyses, Fourier analysis, and ac analysis. Spice

compatible models for the MOSFET (level 1-7), BJT, and diode are included in the latest release. Gnucap uses an object oriented approach to modeling.

Complex models like MOSFETS are made of simpler ones like resistors, capacitors, diodes, and any other models that may already exist. One little problem for PC or Mac users: Gnucap is written to run on Linux machines. You can run a version of it by going to a free hosting provider such as OnWorks (onworks.net/ programs/gnucap-online) and using a free online workstation such as Ubuntu Online, Fedora Online, Windows online emulator or the MAC OS online emulator. idealCircuit-- This is based on a mixed circuit simulator called NL5 developed in the 1980s. The first publicly available version arrived in 2009. It uses ideal components meaning, for example, a switch with zero/infinite resistance and instantaneous switching, diodes that have a constant voltage drop when closed and zero current when open, and so forth. It represents non-linear components as piecewise-linear, or as a function (simulated with one step delay). idealCircuit includes model components such as diode bridges, comparators, diff amps, FETs and bipolar transistors, transmission lines, and sample-and-hold function blocks.

LTspice –This is a high-performance analog simulator. It was originally devised by Linear Technology Inc., a maker of precision power ICs, so it excels at simulating switching power supply topologies. Linear Technology was acquired by Analog Devices Inc. which still provides LTspice free of charge. LTspice includes an extensive library of macromodels covering most of ADI’s power management and signal chain products, as well as a library of passive components. Moreover, users can add component attributes such as component value tolerances and power ratings to make the simulation

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more closely mimic the behavior of real devices.

Micro-Cap 12—An interesting point about this simulator is that it once retailed for about $4,500.

Now free, the simulator includes a multi-page schematic editor, native robust digital simulation, Monte Carlo analysis, a 33,000-part library, worstcase and smoke analysis, Smith charts, and a built-in designer for active and passive filters. It can also read most regular Spice or IBIS models. Included as well are over 2,000 standard digital parts such as the usual 7400 families, CD4000 CMOS, and ECL. Multisim Live—This is an online version of a simulator called Multsim that runs on the desktop. Both versions come from National Instruments Inc. (now just known as NI). There is a premium version of Multisim Live that involves a monthly fee. The free version is quite limited. Perhaps the most notable limitation on the free version is a maximum limit of 25 components per circuit and far fewer components in the library. Also of note: There is no such thing as a private file in the free version.

If you create a circuit in the free version, it will be available for the world to see. naga EDA—This one is only useful if you have a C++ compiler or can run the Python language. We have neither so we couldn’t give it a spin. Also, the URL listed as the support page is a dead link. ngspice—Based on the Berkeley Spice3F5 program, ngspic accepts a combination of analog and digital components and includes numerous device models for active, passive, analog, and digital elements. Model parameters come from internal collections, semiconductor device manufacturers, or semiconductor foundries. The user adds circuits as a netlist, and the output is one or more graphs of currents, voltages and other DESIGN WORLD

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Simulator name

Where to find it

ADS Software V1.00

http://adssoftware.sourceforge.net/

Circuit Sims

http://Falstad.Com/Circuit/

Circuit Simulator 1.6i for windows

https://www.softpedia.com/get/Science-CAD/Circuit-Simulator. shtml

CircuitsCloud

Circuits-Cloud.Com

CircuitLab

https://www.circuitlab.com/

CircuitLogix

http://www.circuitlogix.com/student_version.php

CircuitMod

https://sourceforge.net/projects/circuitmod/

DcAcLab

http://dcaclab.com/en/home

Every Circuit

http://everycircuit.com/app

GnuCap

https://www.gnu.org/software/gnucap/gnucap.html

idealCircuit

http://ic.sidelinesoft.com/

LTSpice

https://www.analog.com/en/design-center/design-tools-andcalculators/ltspice-simulator.html

Micro-Cap 12

https://hackaday.com/2020/01/08/commercial-circuit-simulatorgoes-free/

MultiSim

https://www.multisim.com/pricing/

nagaEDA

http://sourceforge.net/projects/nagaeda/files/latest/ download?source=directory

NgSpice

http://ngspice.sourceforge.net/

OpenSce

https://sourceforge.net/projects/opensce/files/latest/download

PartSim

https://www.partsim.com/

PECS

http://web.cecs.pdx.edu/~tymerski/

Proteus

http://getintopc.com/softwares/electronics/proteus-8-free-download/

PSU Designer II

http://www.duncanamps.com/psud2/index.html

QSapecNG

https://sourceforge.net/projects/qsapecng/files/latest/ download?source=directory

QUCS

https://sourceforge.net/projects/qucs/

SapWin

https://www.ewh.ieee.org/soc/es/May2001/12/Begin.htm

Simulide

http://sourceforge.net/projects/simulide/files/latest/ download?source=directory

Solve Elec

http://www.physicsbox.com/indexsolveelec2en.html

Tina-Ti

http://www.ti.com/tool/tina-ti

Tinkercad

https://www.tinkercad.com/

XSim

http://libinst.com/

Xyce

https://xyce.sandia.gov/

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electrical quantities. A point to note is ngspice does not provide schematic entry. Its input is command line or file-based. There are however third party interfaces available. Also notable is that the program accepts PSpice or LTspice device model parameters and netlists for simulating discrete circuits. ngspice will also read Hspice device libraries from semiconductor foundry PDKs for simulating integrated circuits.

PSUD2--The PSU Designer software package handles the design of simple linear (unregulated) power supplies that commonly use vacuum tubes, though it will also work with solid-state components. Voltages and currents within the power supply are calculated as the power supply starts up and when it stabilizes. These results are displayed graphically and can be printed out. It was last updated in 2017.

OpenSce—This seems to be a work in progress that hasn’t been updated since 2013. It aims to aid in the design and characterization of linear circuits.

It’s status is listed as pre-alpha.

QsapecNG—This simulator was devised by students and faculty at the University of Florence EE department.

It is in two parts, the simulator itself and the user interface which was built using a GUI toolkit called Qt. Not a whole lot of information available on this one though it was updated seven months ago.

PartSim—This is a browser-based Spice simulator that also handles schematic capture and will display waveforms. A plus is that PartSim includes a bill-of-materials manager that lets users assign part numbers from the electronics distributor Arrow. The simulator has a point-and-click user interface and provides several pre-built circuits as examples. However, users must register to use PartSim. PECS—The Power Electronics Circuit Simulator was created at Portland State University about 20 years ago and is handles the time-domain simulation of switched networks that may contain nonlinear elements. Today, it seems to be used mainly as a teaching aid for Portland State EE classes. It has a pointand-click interface and includes about 30 components in its library.

Proteus—This is a suite of programs that include a mixed-mode Spice simulation with MPU models to simulate designs containing processors. Proteus is actually a paid program but there is a free trial version with no time limit.

Problem: You can’t save your work in the free version, nor use MPUs not already in the simulator. Nor can you print out any schematics.

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Qucs—The Quite Universal Circuit Simulator includes a GUI based on the Qt toolkit and handles ad and ac analysis, S-parameters, harmonic balance analysis (though comments online indicate its capabilities in this area are limited), noise analysis, and so forth. The simulation backend is called Qucsator and is a command line circuit simulator taking a network list as input and outputing a Qucs dataset. Qucs can also import existing Spice models.

Originally developed under Linux, it is said to have successfully compiled and run on Windows and Mac machines.

SAPwin—Another simulator hailing from the University of Florence. It does schematic capture, symbolic analysis and graphic post-processing for linear analog circuits. It includes several tools to create schematics, perform symbolic analysis (find the network function in the Laplace domain with symbolic parameters), and to show results in graphic form. All passive and active, bipolar and two-port, linear components are available, including RLC elements, controlled sources, op amps and smallsignal equivalent models of BJT and MOSFET transistors. The graphical

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post processor can show the network function and plot gain, phase, delay, the position of poles and zeros, timedomain steps and impulse response.

SimulIDE—This one is aimed at the hobbyist crowd, supporting PIC, AVR, and Arduino processors. It sacrifices accuracy for speed and simplicity. It also features a code editor and debugger for GcBasic, Arduino, PIC asm and AVR asm. It is still in early development but allows writing, compiling and basic debugging with breakpoints, watch registers and global variables.

Solve Elec—Aimed at physics and EE students, this is a downloadable package that handles circuit drawing, adding values and formulas for currents and voltages, equation verification, and drawing graphs. Typical supported tasks: draw and analyze electrical circuits functioning in dc, get literal formulas and values for current intensities and voltages defined in the circuit, verify circuit related equations.

Tina-TI—This is a free version of a simulator from DesignSoft Inc. called Tina. It is offered by Texas Instruments.

Besides providing all the conventional dc, transient and frequency domain analysis of Spice, the program provides post-processing capability that allows formatting results in convenient ways.

Users select input waveforms and probe circuit nodes voltages and waveforms via virtual instruments. The free version is fully functional but does not support some other features available with the commercial version. Circuit models for the free version are available after a free registration on the TI website.

TinkerCAD—This is a collection of web-app simulators from Autodesk that, true to its name, targets tinkerers.

It covers the design of 3D structures as might be fabbed on a 3D printer, a coding module, and the circuit simulator. The circuit simulator is quite primitive. It includes basic components DESIGN WORLD

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such as hobby motors and LEDs but no transistors, op amps, or related semiconductors. Its main purpose is to simulate circuits a tinkerer might power with an Arduino MCU. Xsim—This is a Windows-based program optimized for designing passive R-L-C crossover networks for loudspeakers. So the components available consist of resistors, capacitors, and inductors. Some built-in multi-part circuits can be tuned for parameters such as Q, corner frequency, attenuation, and so forth. The program lets you generate graphs of impedances, voltages, power consumption, group delay, and responses to impulse, step, and square wave inputs. You can watch the performance and/or stress on any part vary as you tune structure or component values in real-time.

Xyce—This is a high-power simulator conceived at the Sandia National Labs which is optimized to run on large-scale parallel computing platforms, though it apparently will also run on a desktop. It is designed to handle extremely large (>100,000 devices) circuit problems.

And it works strictly from commandline inputs though there are schematic capture tools that will work with it.

The program documentation says Xyce includes novel approaches to numerical kernels including model-order reduction, continuation algorithms, time-integration, and uses a differentialalgebraic-equation formulation, which better isolates the device model package from solver algorithms. All in all, there is probably a lot more horsepower in Xyce than the average user needs. DW

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Smart pneumatics: Gateway to higher efficiency, productivity Open and flexible IIoT systems can pinpoint leaks and faults, reduce downtime, increase throughput and, ultimately, improve the bottom line.

Nils Beckmann | Product Marketing Manager IIoT Integration | Emerson (All images courtesy of Emerson)

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From food and beverage processing to packaged goods and factory automation, manufacturing facilities are turning to smart pneumatics to improve energy efficiency and optimize operations.

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The AVENTICS AF2 flow sensor provides real-time insights on air flow, while also capturing pressure and temperature data in the feed line.

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rom food and beverage processing to packaged goods and factory automation,

manufacturing facilities are turning to smart pneumatics for improved energy efficiency. In compressed air systems, improvements of just a few percentage points can mean tens of thousands of energy dollars saved each month.

But smart pneumatics can offer much more than energy savings. By gathering process data from previously “unintelligent” valves, cylinders and air preparation units, a synergistic hardware and software combination can unlock insights that lead to reduced downtime, faster cycle times and higher overall productivity.

Real-world challenges In a pneumatic system, components are subject to wear that can lead to leakage. Over time, that leakage will increase, resulting in excess energy use, higher operating costs and a larger carbon footprint. In fact, the average manufacturing plant wastes up to 35% of compressed air annually due to leakage, with larger leaks contributing to significant energy loss, more machine downtime and added costs. We’ve seen some plants lose more than $50,000 per year, per machine!

For many operators, identifying and addressing the losses in a compressed air system can also impact their overall equipment effectiveness (OEE), because air leakage is often a sign of other performance issues.

OEE is a “best practices” measurement of productivity within a manufacturing process. In essence, it identifies the percent of planned production time that is truly productive.

OEE can be determined by the following variables: • Availability: This is the uptime of the machine. Is the process running continuously during planned production times?

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• Performance: This aspect relates to the speed of the machine. Is the process running as fast as possible, and without slow cycles?

• Quality: This relates to the end product, which can be affected by component wear and poor or erratic machine performance. Is the production free of defects and reworks?

An OEE score of 100% represents perfect production: a machine manufactures only good parts, as fast as possible, with no downtime.

Anything less than a perfect mark in availability, performance or quality will reduce the total OEE score. A score of 85% is considered world class, and many manufacturers see it as a suitable long-term goal.

Studies from the pneumatic systems experts at Emerson indicate a typical packaging line’s OEE is only about 45% to 55%. The good news: there is ample opportunity for improvement.

Clearly those systems operating at or near DESIGN WORLD

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design capacity are more energy efficient — and more profitable — than those that don’t. But maximizing productivity down to the individual machine level is necessary to truly understand where efficiencies can be gained and costs reduced.

Transforming the raw data from a smart pneumatic system into something actionable is the key to reducing downtime, lowering energy costs, enabling faster cycle times and increasing overall productivity. But how can you be sure the machine data you’re gathering is actionable? And Smart pneumatics opportunities how can you apply this data to improve The Industrial Internet of Things (IIoT) is shop floor operations and higher-level revolutionizing manufacturing, packaging decision-making? and related process industries and is bringing digital transformation to Straightforward approaches pneumatic operations of virtually any Smart pneumatics monitoring can easily size. This transformation allows operators be achieved on the local level — no to capture and process data from cloud required — starting with just a pneumatic and other machine elements few data points. Using components to unlock new production insights. like Emerson’s AVENTICS Series AF2 For example, compressed air Flow Sensor to measure airflow or the optimization is an IIoT-powered portable AVENTICS Smart Pneumatics advancement made possible by Analyzer (SPA), the system can identify continuously monitoring the flow of air any machine exhibiting a problem and in a system to detect leaks in real time, create alerts accordingly, presenting while also capturing other data such easy-to-use dashboards or sending as pressure and temperature in the alerts to end users in real time. By feed line. starting small on just a handful of

Digital transformation for discrete and hybrid applications

Smart pneumatics combined with an open software platform that’s programmable and scalable ensures that well-engineered monitoring systems can grow along with future needs and expectations.

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individual parts, operators can obtain actionable insights without the need for heavy data analysis — and very quickly realize a reduction in costs, improved production quality, increased throughput and, in the case of pneumatic systems, reduced energy consumption.

In one recent example, Emerson worked with a packaging machine builder to provide powerful analytics that can help deliver efficient, scalable OEE increases on palletizing and depalletizing equipment. Instead of complicated sets of data, the analytics solution — based on Emerson’s PACEdge IIoT platform — pinpoints which specific actuators or valve manifolds are underperforming and provides guidance to address the suspected issues. Easy to develop and implement, this platform can also provide predictive maintenance

suggestions based on cycle counts or other parameters. It can provide rootcause analysis in real time, along with a range of warnings or critical alerts. Data is collected and visualized independent of the main machine controller, so it is suitable for legacy or third-party controllers.

By initially focusing on a few machines or on specific pain points, project scope can be defined and the results can be easier to quantify.

Meanwhile, it’s important to ensure that the chosen monitoring solution is scalable and can grow along with future needs and expectations. A provider with a complete portfolio can help avoid stacking up devices, which adds costs over the long term.

Operators should use caution when considering partners or products that might tie them to specific equipment,

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P n e u m a t i c s

Emerson’s SPA software can be used in combination with a Smart Pneumatics Analyzer and an AF2 Ethernet airflow sensor.

It provides easy-to-read data on flow, pressure, air consumption and leakage, as well as actionable insights into areas like the costs of consumption and leakages, and CO2 footprint.

The operating effectiveness of a typical packaging line is only about 45% to 55%.

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gateways, cloud services or other confined ecosystems. Some solutions may also require significant time and up-front capital investment. For example, in one approach, data may be collected and forwarded from the programmable logic controller (PLC) through a gateway to the cloud.

Another approach may connect the pneumatics and other modules directly to the PLC. From there, data must still go to the cloud for analytics and visualization. Both scenarios involve passing through the PLC. This may require significant changes to the PLC logic to capture analytics via the cloud by way of the PLC for “local” visualization.

For manufacturing operations without the desire or infrastructure to support complex cloud scenarios,

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highly flexible and secure systems like those offered by Emerson can provide productivity and energy savings without requiring a cloud environment for realtime visualization of data. Collection modules like sensors or other edge devices can connect directly through a gateway without changing the PLC. This is significant because changing the PLC logic can require considerable time and resource investment, and many operations may not want to change their PLC programming, particularly in brownfield applications. With more flexible options like those offered

by Emerson, brownfield operations can have data contextualized either via the cloud or at the local edge device, regardless of the controller being used. And in greenfield applications, a customer can replace

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A close-up look at PACEdge

The versatile Emerson PACSystems RXi2 edge controller combines a PLC and edge technology in a single unit.

Emerson’s PACEdge IIoT platform combines edge

analytics, visualization and advanced applicationenablement software that lets end users and OEMs increase visibility into asset/machine health and performance. PACEdge simplifies development, deployment and administration with a modern open-source toolset and intuitive interface to help increase the speed and scalability of digital transformation projects. Combined with Emerson’s powerful PACSystems edge computing products, users can take advantage of a single, seamless edge solution with open, industrial connectivity capability that decreases development time and cost.

Emerson’s PACSystems RXi2-BP edge computer, RXi2-LP edge gateway and the groundbreaking PACSystems RX3i CPL410 edge controller are all supported and available with the PACEdge IIoT software stack, providing a broad set of solutions for customers’ programming, visualization, and analytics needs. In fact, Emerson has recently launched a new version of the AVENTICS Smart Pneumatics Monitor (SPM) based on PACEdge. This new Smart Pneumatics Monitor, using the RXi2-LP edge gateway, has several benefits over the previous SPM. That includes more computing power and data storage, as well as the possibility to connect multiple air flow sensors or valve systems to a single edge device. It also offers more advanced data visualization within the device.

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the PLC architecture with a versatile edge controller such as Emerson’s PACSystems RXi2, which combines the PLC and edge technology in a single unit.

Unlike traditional, consumer-based IoT items, industrial IoT equipment typically offers a high degree of cross compatibility — a factor critical to ensuring smooth coexistence using open software that is programmable and scalable, like the PACEdge platform. Open communication protocols can be cloud-based, on the premises or integrated into existing software systems.

Examples of these include OPC UA and MQTT. The AF2 Series Flow Sensor mentioned previously, for example, is compatible with OPC UA, enabling users to connect directly to upper-level systems or another IIoT gateway for advanced analytics.

Whether local or cloud-based, the best suppliers of IIoT technologies will tailor their systems based on an operator’s current infrastructure and then deliver machine insights via gateways, control systems or these open IIoT protocols.

A knowledgeable, flexible technology supplier will take a consultative approach to any IIoT implementation and will take the time to fully understand the requirements of an operator’s specific needs.

For manufacturing operations without the desire or infrastructure to support complex cloud scenarios, highly flexible and secure systems like those offered by Emerson can provide productivity and energy savings without requiring a cloud environment for real-time visualization of data.

Tangible benefits In the past, it didn’t make sense to invest in monitoring relatively low-cost pneumatic parts — the expense and associated production downtime for replacement were simply accepted as normal business. But now, information has changed the game.

A single, faulty individual actuator may contribute to a larger problem impacting the efficiency of an entire system. When properly leveraged, smart pneumatics powered by the IIoT can help manufacturers find things like deficient actuators and more — they can connect islands of automation, unlock trapped machine data and radically increase OEE. Where there are several, perhaps dozens of machines involved in producing a single product, the effect can be profound. An inefficiency in one

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machine can create a cascading effect across the entire plant. By connecting islands of information, a typical operator can expect ROI to be delivered in several ways: • Less downtime: Smart pneumatics can help better inform maintenance and production teams of growing issues within the machine by measuring usage and cycle time to monitor wear. Combined with cycle indicators, operators can gain insight into remaining system life and can use predictive maintenance to reduce production downtime.

• Greater savings: With fewer leaks the overall system will require less energy, saving energy costs while reducing the total carbon footprint.

• Increased productivity: Smart pneumatics can provide notifications and alerts that advise of leaks, anomalies or threshold breaches during manufacturing. This, in turn, can help ensure optimal OEE and maximized productivity.

Working with a group that can provide a total approach — from pneumatics to machine control and the application enablement platform — can help operators of any size optimize their processes and unlock new production insights. The knowledge to avoid unplanned downtime, reduce energy costs, improve cycle times and increase overall productivity is all made possible through smart pneumatics and the powerful insights they can deliver through a system like the PACEdge platform. DW

Emerson www.emerson.com/en-us

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Embracing the soft skills Dan Arvizu’s long engineering journey has brought him back to his beginnings.

The first time Dan Arvizu thought about anything related to science or engineering was in the sixth grade. His teacher, John Price planted the seeds about a pathway that Arvizu hadn’t anticipated when he assigned the young student to write a paper on what matter was. Price was “one of the first people who gave me some level of encouragement along the idea of math and science,” said Arvizu.

Arvizu was put on the middle-track math program in seventh grade until another teacher told him, “You’re moving more quickly than the rest of the class” and he was switched to the fast-track math program, maintaining it all the way through high school. By the time he was finishing high school in 1968, an aerospace career was on the mind of seemingly every kid.

“It hadn’t been that long since we’d gone to the moon, and so aerospace was kind of a big deal,” he said. “Frankly, I had never thought about college, even when I was in high school. I grew up as a son of immigrants. My dad finished third grade, my mom finished high school, and my dad finished his GED in the service.”

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When it comes to teamwork, when it comes to diversity, I’ve always been a big champion and advocate because I’ve experienced it, I’ve worked it, I’ve been blessed with having professional training beyond what today’s environment really allows in most companies.

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“I was influenced heavily by the fact that Alamogordo, N.M., where I grew up, is the town that supports Holloman Air Force Base. Holloman used the school system for the airmen and service people there, and as a consequence, they invested in education. A professor from NMSU would drive to Alamogordo to teach calculus in high school. I was in the faster track math grouping, so I was able to take calculus as a senior at Alamogordo High School.”

“Aerospace was what everybody wanted to do. Every one of my colleagues, my high school buddies, all said, ‘Let’s go be aerospace engineers.’ Four or five years later when I graduated, there were only two of us left that actually did it. After the first year, everybody else got weeded out by the calculus class, or the first-year math class.”

Arvizu started off as an engineer and stayed as an engineer. But over

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time, he said, the bottom fell out of aerospace engineering, and it was kind of a chaotic time in the U.S. with the energy crisis developing and long gas lines everywhere you went. He explained that those issues changed the trajectory of a lot of folks.

And they changed Arvizu’s trajectory, as well. Energy would turn out to be a critical aspect to his professional life for decades to come.

An energy-filled career path Arvizu did the co-op plan through his undergraduate degree at New Mexico State University in Las Cruces, a beautiful campus located near the base of the Organ Mountains. He worked at Texas Instruments in Dallas, which was one of several companies that made him offers at graduation time.

But his department head in mechanical engineering, who was a mentor to Arvizu, had told him about the opportunities at Sandia Labs in DESIGN WORLD

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NREL Director Dan Arvizu accompanied Vice President Joe Biden on a tour of NREL’s Process Development Integration Laboratory on Friday May 20, 2011. The PDIL has six bays where proven and experimental solar cells are made and tested in partnership with private industry.

Credit: Dennis Schroeder

Albuquerque. Arvizu was intrigued, but Sandia wasn’t hiring. In fact, the lab was actively laying people off, as it was stuck in a political seesaw between funding for defense vs. energy (something that Arvizu notes pushed Sandia to strike a better balance between the two funding sources).

AT&T ran both Sandia Labs and Bell Labs, and a Sandia recruiter told Arvizu that Bell Labs was hiring. He soon discovered that Bell Labs did not hire engineers with a bachelor’s degree, but instead at the master’s level. Arvizu did some digging and found out about the lab’s One Year on Campus program, where they paid for graduate studies, hoping to have first dibs at the brightest master’s graduates before other institutions cherry picked them.

Arvizu was chosen for the program and was told he had to go to one of

four top-notch institutions: MIT, Stanford, University of Illinois, or Purdue. Arvizu had never been outside of Arizona, New Mexico, and Texas. He was excited at the prospect, but he didn’t want to move too far away.

“I looked and I said, ‘Gosh, there’s only one that’s west of the Mississippi.

I’m guess I’m going to Stanford,’” he said.

Arvizu received his master’s from Stanford. He went to work at Bell Labs and then switched to its sister lab, Sandia, to help start its energy program. He was part of the team that built Sandia’s power tower, a structure surrounded by a field of 222 mirrors (heliostats) that focused the sun’s

energy on the central 220-foot tower. His job was overseeing the development of the heliostats.

“I was looking at everything from open-loop control to closed-loop control, and had to figure out how are we going to clean the mirrors? Each heliostat is made up of a 5x5 matrix of 5x5-foot glass facets. You had these mirror facets all situated in a configuration that allowed there to be curvature.

They’re flat mirrors, but you put them in a curvature. The mirrors closest to the tower would have more curvature than the ones farther from the tower, and essentially could generate electricity that way. All of those heliostats focus up onto a focal point on the tower.”

Credit: NMSU

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“We would calibrate at night because the disc of the moon is about the same as the disc of the sun. From the focal point, you could literally see 25 moons in every heliostat. And then you’d orient the 222 heliostats — and you could actually get a moon burn!”

Around this point in his career, he realized that all of the people getting good promotions at the lab had PhDs, so he re-enrolled at Stanford and received his PhD. He was a bit of a pioneer in distance learning, as Stanford would send massive magnetic tapes of classes to Sandia for employees to watch.

Arvizu’s work also delved into the physical design of heat transfer of dimension PBX modules. PBX is a private branch exchange — when you dial the last four digits on a phone, that unit is the internal switching gear in a particular building, such as a hotel or office building. When someone dials the last four digits, it doesn’t go back to the trunk at the central station, instead performing local switching. Bell created PBX modules and Arvizu was a physical designer for them. But he was also interested at how to keep the cabinets cool — at a time before computers were as ubiquitous as they are now. Thus, he became one of the first people in the

field working on the cooling of electronic equipment.

“Think of a refrigerator full of racks of circuit packs. Each circuit pack has electronic heat-dissipating components on it, and it heats up really fast. You put these integrated circuits in there and you plug them into the circuit packs — and you put those five levels of containers, and then you close the door. All of a sudden, you’ve got things that heat up very, very fast — and capacitors fail at 60°C. My job was to keep the electronics operating and cooled.”

“I was the first to develop forced convection cooling for electronic equipment. I would essentially put fans at the bottom of the racks … if you’re in a hot Arizona climate, somebody will put one of these things in a shed outside. I had thermostats at the top of the cabinet, and they would turn on these fans. It was the first use of forced conduction of electronic equipment in the country, even before laptops.”

I tell my team that your success is my success. Everything I can do to help you succeed is really what I’m going to do.

Credit: NMSU

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Credit: NMSU

Servant leadership Arvizu eventually became part of a team that bid on running two different national labs before finally striking gold on the third try, the NREL in Colorado.

When Arvizu became director in 2005, he was the first Hispanic to head a national DOE laboratory. He credits the culture at AT&T, which valued both professional development and diversity.

“For AT&T, it was in their DNA. They said, ‘We’re going to train leadership.

We’re going to train managers so that they understand what they do,’ and it’s a kind of whole people training. So, it’s not just about how smart are you relative to your technical competency, but your people skills as well,” he said.

“They were very good at embracing the idea that it’s important to have good communication and verbal skills in addition to being technically competent, because we all kind of know that if you just take your smartest engineer or scientist and make them a manager, they’re probably not going to do well.”

“There was a premium on diversity and on bringing skills other than your technical competency into the discussion when you started to move up the ranks in terms of leadership.

What you learn over many, many years is: tone at the top matters. The tone at the top actually does infuse throughout the institution.”

Arvizu said that his first taste of in inclusiveness was when he was at Stanford. His thesis advisor had done an informal study on graduate students

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coming out of the university. They looked at the success of these students relative to their scores, both verbal and math on the ACT, SAT, and GREs — and determined that a better determinate of success was the verbal skills, not the math or technical ability.

“That obviously implies that there’s another dimension that’s important for success beyond your technical competence,” Arvizu said. “So that was clear to me at that time.”

Arvizu had the added benefit of a love for teams, going back to his childhood when he was in little league baseball.

“I enjoyed being on teams. I always excelled — my better self was brought out — whenever I was on a team, and I would rise to the level of the team.

Sometimes the team will bring you

down too! But if you have a good performing team, it really does improve everyone. As I mentioned earlier, the tone at top makes a difference. I was inspired by what I called servant leaders. There was a number of those that I had growing up, again, within the technical ranks at Sandia.”

“The thing about Bell Labs and Sandia was your first level of supervision is called a supervisor and then you go to department manager and then you go to director. Each one of those levels is very competitive.

What you learn as you go through this process is that everybody’s smart.

That’s never an issue. But then how well are you at bringing people together?

How well are you at inspiring people?

How well are you at getting the most out of each individual? That requires

vision, it requires leadership, it requires care and feeding. It requires a variety of things that are more people skills, the soft skills. In addition to your competency, you’ve got to gain their respect first,” he said.

Arvizu said that as he moved into management roles, it became important to him to attract people that complimented his strengths and ultimately filled in his weaknesses.

“Understanding yourself is a really important thing. I’ve gotten more professional training than anyone can shake a stick at. I’ve done the social styles and Myers Briggs and a half a dozen of those. I’ve done them all more than once. So, I kind of have a pretty good feel for what my capabilities are and where my gaps are. We spent a lot of time at Sandia and AT&T looking

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There was a premium on diversity and on bringing skills other than your technical competency into the discussion when you started to move up the ranks in terms of leadership. What you learn over many, many years is: tone at the top matters.

The tone at the top actually does infuse throughout the institution.

Credit: NMSU

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at organizationally how do you fill in those gaps? When it comes to teamwork, when it comes to diversity, I’ve always been a big champion and advocate because I’ve experienced it, I’ve worked it, I’ve been blessed with having professional training beyond what today’s environment really allows in most companies. That has given me a great deal of grounding in what I think are the principles that are necessary.”

“If you’re trying to attract a diverse workforce, you need a diverse management team. You need to be able to walk the talk, practice what you’re saying. People don’t care so much what you say, they do watch what you do,” he said.

“I’ve had a very, very blessed experience in having great teams around me. Many times, people that are much better than me are doing a lot of great work — but there’s also importance in being the quarterback, being the orchestrator, being the person that sees the bigger picture, knows what people’s roles are, lets them do their job, and be their big cheerleader. I tell my team that your success is my success. Everything I can do to help you succeed is really what I’m going to do.”

“I’ve turned down at least a dozen different appointments that essentially were not kind of in line with my personal approach with my family and all that. But PCAST is particularly unique,” he said. “PCAST offers the possibility of not just doing something meaningful, but also to do it in a way that you can begin to implement and to start to really change the trajectory.”

“As you look at PCAST, it’s got five MacArthur Genius fellows. It’s got two Nobel prize winners. It’s got two former cabinet secretaries, and 20 members of the National Academies of Engineering, Science, and Medicine. So, it’s a very prestigious group, very well accomplished. I pinch myself every time I think about being on the committee.”

Arvizu said that President Biden has tasked the committee with examining some important issues for the nation today. What did we learn from the pandemic? What kinds of things do we need to do different next time? How do we respond to climate change and best use science and technology for the coming energy transitions? How do we keep leadership of the U.S. scientifically, globally? And ultimately, how do we make sure that everybody participates in some meaningful way?

Still contributing Arvizu led NREL for a decade, long by the standards of a lab director, and helped to transform the institution into the world leader in renewable energy research and development, nearly doubling its research portfolio.

He’s been busy on other fronts, too, always giving back where he thinks it’s important. He was appointed by President Bush in 2004 to the National Science Board and confirmed by the full Senate for a six-year term. In 2010 President Obama reappointed him for another term, which ended in 2016. He was recently appointed by President Biden to the President’s Council of Advisors on Science and Technology (PCAST). And while both postings were honors, Arvizu truly loves this new role.

Back to his beginnings In June 2018, Arvizu’s career took an unexpected turn, when he was asked to come back to New Mexico State University as Chancellor. Arvizu prides himself in being a bit of a turnaround specialist in other locations and in other endeavors. So, he jumped in.

“I didn’t know what I didn’t know,” he said. “Academia is harder than the public sector, the private sector, and the nonprofit sector. It’s been a rude awakening. As much as I like the idea of a meritocracy, the processes are highly political. You’ve got a legislature, you’ve got an executive branch, you’ve got elected officials, you’ve got donors, you’ve got mayors. Everybody is your boss. I used to say that at NREL, but I didn’t fully appreciate that it could even

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be more expanded in an academic institution.

Arvizu explained that creating upward social mobility is an important part of NMSU, because the school is a minority serving institution. When he was a student there 50 years ago, the Hispanic population was less than 22%.

Today it’s above 60%. And there are plenty of challenges for educational institutions today.

“Higher education has been declining in terms of enrollment, in terms of research, in terms of the things that you care about in your mission for a decade,” he said. “And problems started even before that. It is under-resourced in so many different ways. I thought, ‘Wow, the challenges are enormous.

And my alma mater is suffering. What can I do to help turn that around?’”

Arvizu feels that the changing times means the university is not so much discipline focused. He emphasized that it’s not so much about just being a mechanical engineer focused on one thing.

“It’s about being a mechanical engineer that is a problem solver that recognizes the value of teaming with the arts and sciences and the business community and the legal community — and putting all those together for solutions that actually benefit society,” he said. “That set of skills, that are collaborative, cooperation, communication, critical thinking, are part of the scientific method that we all learned, but they also now are the skill base for all of the industries of the future, no matter what discipline you’re in.”

Toward a renewable future Given Arvizu’s long and storied career in energy, he has a lot of opinions about what’s coming next in the renewables industry. But what does he think the future of energy production looks like for the planet?

“There needs to be a transition,” he said. “We need to acknowledge

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the global aspect of this. It’s one thing to live in the U.S. or in Europe, where you have infrastructure, and you have investments, and you’re moving in a particular direction. And frankly, our greenhouse gas emissions are actually dropping over time because we’re going from coal to natural gas and making those transitions. When you go to the developing world, that’s where the major issue is with anything that relates to climate. We’re talking about Asia, we’re talking about India, and then Africa is right behind them, and then everyone else — they don’t have many choices. And they look at this global energy world very, very differently than we do in the developed nations.”

“You have to acknowledge that. As someone who has really spent their entire career in renewals, I remember when I was working on 1 cm x 1 cm solar cells, and people would look at me and say, ‘That stuff ’s never going to amount to anything. What are you doing? We’re going to burn oil until there’s no more oil in the ground.’ Well, I don’t believe that. And in fact, 40 years of experience, to me, demonstrates that ingenuity, innovation, and creativity and an understanding with the right kinds of public policies, we can get to a better outcome. I’m convinced of that.”

Arvizu believes that if you can give people and countries more functionality at less cost, it’s a winner, plain and simple. Then you don’t have to worry about politics or whether you believe in climate change or not, because then it’s simply about economics.

“I’m persuaded and convinced that innovation and ingenuity, science and technology, does create the opportunity for us to advance in society, both in productivity (which we do every year in terms of GDP) and in the context of our infrastructures, whether it be health or energy. In this case in energy, the world is going to change its way in which we generate energy in the future. What I’m now persuaded and convinced by is that renewable energy will have a very, www.designworldonline.com

very, major part of our future.”

“And it’s because we now are able to harness solar. We harness wind, we harness geothermal, we harness a variety of other renewable technologies, biofuels, a variety of things that we can do — and they will make up the majority of what ultimately, is our generation mix. Whether it’s central station or whether it’s distributed is yet to be determined. I think in the developing world, you see more distributed. In the developed world, we’re already committed to central station, but they’re both compatible and I think there’s balance in both.”

“The bigger issue, to me, is what does the developed world do first?

Because people will tell you, ‘Hey, if you do everything you want to do and get to net zero, and the developing world doesn’t change what they’re doing, it’s really for naught.’ Frankly, that’s where all the growth is, that’s where all the emissions are. If you listen to the people in the developed world, they say, ‘Look, don’t penalize us with your aspirations because you grew dirty in terms of the budget of carbon that you’ve already admitted. Don’t lecture us.’”

“How do you get past that dilemma?

Well, you get past that dilemma by giving them a greater yes. You give them the opportunity to have more functionality at less cost. And so that’s why it’s important for us to keep pushing the envelope on the next generation, because ultimately, the developing world is going to adopt what is the best that we have to offer.

Emerging economies didn’t go and build landlines 10 years ago. They went and did wireless, right?”

“Our challenge is to develop as many low cost, low carbon energy approaches as we possibly can. And then the rest of the world will follow because it is in their best financial interest. You have to be able to make it in their financial interest.” DW

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2021 W

A D D I T I V E M A N U FACT U R I N G

In the category of Additive Manufacturing, this year’s LEAP Award winners are…

GOLD

HP

hp.com/us-en/home Product: Molded Fiber Advanced Tooling Solution) The recycled paper packaging market is growing rapidly as manufacturers aim to reduce the environmental impact of product packaging. Molded fiber or molded pulp, typically made from recycled paperboard or newspapers, is used today to handle and package products from food containers to the packaging of household items, industrial supplies, electronics to single-use medical service items.

What started as a push to avoid plastic straws and bags has grown into a much more concerted effort to reduce plastic consumption. In Canada, at least six types of single-use plastics will be banned by the end of 2021, and countries around the world are following suit. The need to have better options available to replace plastic is increasing daily, and for many applications in industries ranging from food and beverage to healthcare to electronics and more, molded fiber was always the answer.

Renewable in itself, molded fiber can also be made from many plant cellulose fibers, including bagasse, bamboo, and wheat straw.

While molded fiber has been a good packaging solution for decades, the investment required in the tooling process to create traditional molds has remained high.

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HP developed a solution to this problem using HP industrial 3D printing technology alongside proprietary HP innovations in digital manufacturing software and data intelligence. The HP solution enables on-demand design and creation of molds for recycled molded pulp for packaging applications.

HP’s Molded Fiber Advanced Tooling Solution delivers a fully digital design experience enabling more efficient, optimized design and replacing the need for handcrafted screens, CNC machining, and manually drilled form tools.

The solution eliminates the time-consuming and intensive manual fabrication of the traditional molded fiber tooling manufacturing process.

The HP printed molds can be turned around faster, in more innovative packaging designs, with the added benefit of high durability and ease of use.

www.designworldonline.com

DESIGN WORLD

1/17/22 12:27 PM

WINNERS SILVER

EOS

eos.info Product: EOS M 300-4 metal 3D printer

Designed for industrial applications, the EOS M 300-4 offers multiple configuration options combined with safety and security features enabling digital Additive Manufacturing. The platform has the flexibility to choose the degree of automation that best suits your needs for an optimized workflow and the option to easily ramp up as demand increases. It produces high-quality components at a reduced cost-per-part.

The 3D printer enables flexible adaptation to all individual requirements through various degrees of automation, helping to ensure optimal workflow.

The focus is on the productivity and uptime of the machine. The laser and performance stability ensure consistent part quality over the entire build space, including full coverage of overlaps. Up to four precision fiber lasers work over a 300 x 300 mm area, with each laser covering the entire space, improving productivity.

The platform is modular, comprised of the following self-sufficient modules: Process chamber, dispenser module, setup, and unpacking module, and periphery module. Modules can be changed in the future, such as a new dispensing module to connect continuous refilling setups, or open interface for 3rd party unpacking solutions, automated unpacking solutions.

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CONNECTIVITY

In the category of Connectivity, this year’s LEAP Award winners are…

GOLD

Astera Labs asteralabs.com

Product: Aries Smart Retimer Portfolio for CXL 2.0 The Aries Smart Retimers empower system designers to double the signal reach and achieve plug-and-play interoperation without compromising interconnect topologies even at 32 GT/s speeds of CXL and PCIe 5.0 technology. Astera Labs is the first to deliver working Smart Retimer SoCs for CXL applications with up to 32 bidirectional lanes. The Aries Retimers have been assigned or are being considered for eight new patents for their innovations.

The Aries Smart Retimer Portfolio • The architecture enables the Retimer platform to learn, automatically adapt, and select optimized adjustments for a robust link-up and plug-and-play interoperation.

• Delivers 2x lower power, 6x lower latency, and uses 2x fewer components than alternative solutions.

• Allows data center system designers to future-proof their systems, delivering a reach extension solution that can easily and quickly scale from PCIe 4.0 to PCIe 5.0 to CXL architecture.

• Features a powerful array of Smart Link Health Monitoring capabilities to simplify data center fleet management and improve overall resource optimization through deep system visibility. This results in a system operator detecting early signs that a signal is beginning to degrade, quickly identifying the exact location/nature of the issue, and working to replace the faulty component.

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DESIGN WORLD

1/17/22 12:28 PM

WINNERS SILVER

binder USA binder-usa.com

Product: Series 670 NCC Subminiature Connector The Series 670 NCC (Not Connected Closed) Subminiature Connector meets the growing demand for reliable circular connectors in applications with both restricted space and high protection requirements.

These newly developed 5-pin subminiature connectors feature a bayonet closure and cable bushing from 3.5 to 5.0 mm.

The flange-type socket is offered with soldered and dip-soldered contacts.

Series 670 NCC connectors use binder’s unique spring cover design to completely protect contacts against water, dirt, and penetration by foreign objects, even when disconnected. (Protection to IP67 when mated and IP54 when unmated.)

BRONZE

Harting

harting.com/US Product: har-Modular: Create Your Own PCB Connector HARTING’s har-modular series offers a unique and flexible solution for the connection of PCBs. A modular concept based on the time-tested and reliable DIN 41 612 connector family, this product allows engineers to develop custom connectors from off-the-shelf components.

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January 2022

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2021 WINNERS CONNECTIVITY

HONORABLE MENTION

Littelfuse littelfuse.com

Product: SPXI In-Line Solar Fuse The Littelfuse SPXI in-line solar fuse is specifically designed to protect photovoltaic (PV) systems. These 1500 V dc fuses protect PV systems from overloads and short circuits to minimize damage to solar panels.

HONORABLE MENTION

Molex

molex.com Product: Mirror Mezz Mirror Mezz connectors offer maximum design flexibility by allowing users to pair different connector-height versions to achieve the desired stack height for an application.

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EMBEDDED COMPUTING

In the category of Embedded Computing, this year’s LEAP Award winners are…

GOLD

Maxim Integrated Products maximintegrated.com

Product: MAX78000 Low-Power Neural Network Accelerated Microcontroller The MAX78000 low-power neural network accelerated microcontroller from Maxim Integrated moves AI to the edge without performance compromises in battery-powered IoT devices. Executing AI inferences at less than 1/100th the energy of other embedded solutions improves run-time for battery-powered AI applications while enabling complex new AI use cases previously considered impossible. These power improvements come with no compromise in latency or cost: the MAX78000 executes inferences 100x faster than software solutions running on low-power microcontrollers, at a fraction of the cost of FPGA or GPU solutions.

AI technology allows machines to see and hear, making sense of the world in previously impractical ways. In the past, bringing AI inferences to the edge meant sending camera and other data to the cloud to execute an inference, then sending an answer back to the edge. This architecture is challenging for edge applications due to poor latency and energy performance. As an alternative, microcontrollers can implement simple neural networks; however, latency suffers, and only simple tasks can be run at the edge. The MAX78000 overcomes these limitations, enabling machines to see and hear complex patterns with local, low-power AI processing that executes in real-time.

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DESIGN WORLD

1/17/22 12:29 PM

WINNERS SILVER

Infineon Technologies infineon.com

Product: SEMPER Secure NOR Flash Semper Secure is the first memory solution to combine security and functional safety in a single NOR Flash device, delivering the security, safety, and reliability required for the most advanced connected automotive, industrial, and communications systems. The proliferation of connected systems is driving the need for ever greater system security. Semper Secure NOR Flash provides a trusted solution to protect critical system information in the most demanding environments. Having a secured Flash memory device is especially important when placed outside of a processor, making it more vulnerable to various attacks.

Semper Secure is the only NOR Flash solution that serves as a hardware root-of-trust to provide end-toend security and OTA updates secured from cloud to device.

The Semper Secure NOR Flash family includes AEC-Q100 automotive-qualified devices with an extended temperature range of -40 to +125 °C, supports 1.8-V and 3.0-V operating ranges, and is available in densities of 128 Mb, 256 Mb, and 512 Mb. Semper Secure NOR Flash is designed to the ISO 26262 standard and is ASIL-B compliant and ready to be used in systems up to ASIL-D. Infineon’s endurance flex architecture simplifies system design by optimizing high endurance or long data retention partitions.

BRONZE

Sequans sequans.com

Product: Monarch 2 GM02S Module Monarch 2 GM02S is the first module based on Sequans’ second generation, 5G-ready, Monarch 2 platform, the advanced LTE-M/NB-IoT chip. The new Monarch 2 GM02S features 23 dBm transmit power and a high level of integration, stripping out complexity and cost. Monarch 2 GM02S also delivers ultra-low power consumption with a 60% improvement over the low level of first-generation Monarch. Monarch 2 GM02S is the world’s only cellular IoT module supporting a certifiable EAL5+ secure enclave for integrated SIM (ieUICC) capability that is compliant with GSMA standards. It also supports a single rail power supply starting at 2.2 V, allowing for better efficiency of the internal power management unit, further reducing power consumption and lowering battery and BOM cost. Monarch 2 GM02S is delivered with an EVK, Monarch 2 GM02S NEKTAR EVK, for fast connecting and prototyping/testing.

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HONORABLE MENTION

Ambarella ambarella.com

Product: CV5 Edge AI Vision SoC The CV5 is an artificial intelligence (AI) vision processor capable of recording 8K video or four 4K video streams. The new system on chip (SoC) will enable intelligent automotive camera systems, consumer cameras (drone, action, and 360°), and robotic camera Project1_Layout 1 1/5/2021 12:04 PM Page 1

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The choice for harsh environments

NEW i550 protec frequency inverter for decentralized operations.

The i550 protec is exceptionally tough. Its NEMA 4X (IP66) protection rating makes it suitable for even the most demanding applications. Whether dusty or wet, indoors or outdoors – it can handle it all. The housing protects the technology – and performance remains excellent no matter the conditions. Offering a compact design, it’s also the first decentralized drive in the market with IO-Link Device Interface. www.Lenze.com Visit us at: MODEX 2022 – Booth #B5014 | March 28-31 | Atlanta, GA

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HYDRAULICS

In the category of Hydraulics, this year’s LEAP Award winners are…

GOLD

Fluid Metering, Inc. fluidmetering.com

Product: The FVD Variable Dispense Next Generation All-In-One Pump

The The FMI Variable Dispense Pump (FVD Series) combines the function of priming, flushing, and dispensing into one device, providing accurate and repeatable dispense volumes of 2 μL to 200 μL in a small, lightweight package. The innovative, compact design offers unparalleled accuracy and precision with an electrical and mechanical upgrade that can dispense multiple volumes with the same pump.

From medical devices and biotechnology to diagnostics and analytical devices, there is no shortage of advantages to the FVD Pump with Cerampump technology.

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WINNERS SILVER

HydraForce, Inc. hydraforce.com Product: HydraForce IoT HydraForce IoT Solutions has changed the landscape for servicing mobile hydraulic equipment.

Traditionally, software updates and support for a fleet vehicle or machine would require a trip to the field from a service technician or engineer. The development of IoT solutions allows for internet connectivity of mobile equipment to the cloud, making it possible to operate vehicles remotely, plus perform machine telemetry and analysis – all in real-time.

BRONZE

Eaton

eaton.com Product: CMT valve section for the CMA advanced mobile valve CMT is a new valve section option for Eaton’s CMA advanced mobile valve. The CMT section uses a twin-spool architecture to independently control two separate machine functions. CMT provides highly accurate meter-in flow control. It is software configurable and features CAN communication, onboard sensors, digital flow sharing, and electronic load sensing, which provide precise flow control and high responsiveness.

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I N D U S T R I A L A U T O M AT I O N

In the category of Industrial Automation, this year’s LEAP Award winners are…

GOLD

Chieftek Precision USA Co., Ltd. chieftek.com

Product: Ultra Thin linear motor stage, Mini Robot This Ultra-thin linear motor stage is only 0.8 mm in width and is excellent for low-load biotech laboratory automation applications. The Mini robot operates within a box of A4 paper size and is excellent for space-saving automation applications.

SILVER

EZ Automation/AVG Automation ezautomation.net/index.htm

Product: EZTouch EZ7 Series Detachable Front EZ7 is the latest in EZTouch HMIs. In any HMI or Operator Interface Terminal, the most used or abused components are its touch screens and LCD displays.

They are subjected to plant conditions such as heat, humidity, oil mists, and hose-downs for cleaning equipment.

Often, the first components to wear out are the touchscreen and LCD display. EZ7 has bifurcated the HMI into two parts, the front end with the vulnerable components and the back end, which has the rest of the electronics. Additionally, there is no longer a need to have a panel cutout, only a 3⁄4-in. hole with a grommet is needed to pull through an HDMI cable to connect the two. The front end is stud-mounted to the control panel along with the back end. When the front end does go bad, it takes less than two minutes to replace it without disconnecting any cables from the back end and.

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WINNERS BRONZE

Phoenix Contact USA phoenixcontact.com

Product: NearFi coupler In industrial automation, power and data are usually transmitted with connectors. However, in many applications, connectors must be disconnected and plugged in frequently. Contacts can become dirty and bend, limiting the service life of connectors. This leads to unplanned or unpredictable production downtime and regular maintenance intervals.

To simplify power and data transfer in these applications and avoid downtime, Phoenix Contact developed the new NearFi Technology. NearFi enables contactless energy and data transmission in the near-field range across an air gap of a few centimeters and even through nonmetallic materials such as plastic or glass.

BRONZE

Weidmuller weidmuller.com

Product: Rockstar Heavy Duty Connector Today, heavy-duty connectors are used wherever safe, simple, and time-saving assembly of machines and systems is required. The die-cast aluminum connector housings offer excellent protection against dirt, moisture, and mechanical stress.

Special modular connectors make it possible to combine signals, power supply, and data connections in a single connector. With its RockStar heavy-duty connectors, Weidmüller offers a future-oriented range with many patented innovations.

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HONORABLE MENTION

Akribis Systems akribis-sys.com

Product: Punch and Pack The Punch and Pack was designed to improve the die component separation and packaging process for critical technology components. The market requirement was not only to increase throughput and machine reliability but also to improve overall component quality.

HONORABLE MENTION

Nexen Group nexengroup.com

Product: NexSafe Functional Safety Certified Rod Locks NexSafe Functional Safety Certified Rod Locks provide machine builders with a reliable, verified safety solution for emergency stopping and precision holding applications. These spring-engaged, air-released Rod Locks are compatible with almost all Pneumatic Cylinders or Round Shafts and Rails.

HONORABLE MENTION

Schmersal

schmersalusa.com Product: AZM40 Electronic Solenoid Interlock The AZM40 is the smallest electronic solenoid interlock available, with dimensions of just 1.5 x 4.75 x 0.75-in. (119.5 x 40 x 20 mm). It was designed to fit standard extruded profiles typically used in machine guard frames.

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MECHANICAL

In the category of Mechanical, this year’s LEAP Award winners are…

GOLD

BRECOflex Co. brecoflex.com

Product: BRECOroll Timing Belts BRECOflex CO. is rolling into the future with a timing belt that reduces slider bed friction in material handling applications. It’s called BRECOroll. BRECOroll has nylon rollers integrated into the teeth of the timing belt, enabling it to roll across the slider bed with all the efficiency of a high precision timing belt and a fraction of the friction of traditional systems.

If you are looking to reduce drive energy and friction, especially when conveying heavier objects over long spans, BRECOroll is a suitable solution. BRECOroll became available for distribution in the Spring of 2021.

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WINNERS SILVER

IKO International ikont.com

Product: IKO CRBTF Crossed Roller Bearings IKO Crossed Roller Bearings are compact bearings with their rollers alternately crossed at right angles between inner and outer rings. The orthogonal array of the rollers allows a single bearing to handle complex loads simultaneously from any direction, making mounting possible without worrying about load direction.

IKO CRBTF Series Super Slim Crossed Roller Bearings are built with the same technology as other IKO crossed roller bearings but feature mounting holes in both the inner and outer rings for a highly rigid, highly accurate, low-cost joint. This design allows easy mounting, eliminating complex mounting procedures and mounting plates or covers.

BRONZE

Ogura Industrial Corp ogura-clutch.com

Product: Brake & Mechanical Torque Limiter Combination for Cobots Ogura has a newly developed MCNB-TSp brake series with accurate and precise holding torque.

The same brake can also briefly slip at a given torque with negligible impact on life. Essentially, it is introduced as a mechanical torque limiter, and electromagnetic brake wrapped up in one.

The torque limiting capability adds an advantage in that safety can be improved, and surrounding components can be designed for lower loading.

The benefit is that system weight can potentially be reduced, leading to higher production speeds along with longer battery and brake life.

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MOTION CONTROL

In the category of Motion Control, this year’s LEAP Award winners are…

GOLD

Beckhoff Automation beckhoff.com

Product: XPlanar flying motion system XPlanar is an approach to automation that removes barriers and pushes the boundaries of what engineers can accomplish. Through flying motion technology, Beckhoff offers completely new ways to solve automation problems.

XPlanar gives users the freedom to intelligently adapt to constantly changing workflows and shatter all conventional thinking about automated production.

Developed in-house and manufactured by Beckhoff, XPlanar is available for purchase and ready to transform machines and processes with flying motion technology. XPlanar movers float and fly freely above planar tiles arranged in customizable layouts that enable flexible, precise, and highly dynamic applications. For machine builders and manufacturers, this results in unprecedented flexibility and throughput with simplification in machine and plant designs. We can say this because we know. Beckhoff customers are using XPlanar in the field today to transform their operations.

The XPlanar system combines the individual arrangement of planar tiles with the multi-dimensional positioning capability of the planar movers floating above them. Easy to use software tools include graphical path planning, automated jerk, pitch and yaw control, collision avoidance, and 6° of motion freedom. The movers enable jerk-free and contact-free motion in two dimensions at up to 2 m/s with 1 g acceleration and 50 μm positioning repeatability — completing movements without any noise

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or friction.

XPlanar is completely integrated into the standard TwinCAT programming environment and runtime. For communication, XPlanar systems are networked through standard EtherCAT G protocol, which itself is fully compatible with the entire 100 Mbit/s EtherCAT ecosystem.

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WINNERS SILVER

Delta Electronics deltaww.com

Product: SCARA Robot with integrated 5th axis Delta Electronics has developed a unique SCARA robot arm with an integrated 5th-axis for angled pick-n-place and 3D path execution. This patented technology allows users to accomplish similar movement of a 6-axis articulated vertical arm robot but at a lower cost. The DRS60L3 is a Delta branded SCARA robot with 600mm reach, 200mm Z-stroke, and 3kg payload and can achieve high repeatability of robotic cycle time within 0.45 sec.

The 5th-axis SCARA model includes a rotary servo gear motor mounted to the end of the Z-Axis spline, allowing the End-Of- Arm-Tooling to rotate and pivot.

The motor’s power and feedback cables are routed up the hollow spline shaft, and this 5th-axis is included in the robotic motion path to deepen the integration level for ease implementation, tool path calibration, and point teaching. This high level of integration allows OEM machine builders to add lower-cost robotics into their machines with increased system reliability and performance. With the controls included in the robot package, sensorless compliance control functions and collision detection become part of the design-in solution. The product also offers scalability up to 800mm reach, 8kg payload, and 420mm Z- stroke.

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BRONZE

Dover Motion dovermotion.com

Product: SmartStage XY Dover Motion recently introduced the SmartStage XY series for single-axis or stacked XY use to respond to the increasing throughput, resolution, and stability requirements in precision positioning applications such as automated microscopy, semiconductor inspection, laser processing, and factory automation.

BRONZE

Posital-Fraba Inc. posital.com

Product: POSITAL 22-mm diameter kit encoders for motor feedback Posital’s new miniature kit (modular) encoders are designed to fit on provide popular 22 mm BLDC motors, providing them with position feedback for servomotor functionality. These devices are compact (22 mm diameter, 23 mm height) and provide 17-bit resolution and 0.09° accuracy. Moreover, these encoders provide battery-free multiturn measurement capabilities, an industry first.

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READY. STEADY. FLOW. Introducing KNF FP 70, delivering 120 - 850 ml/min while producing up to 29.4 psig (2 barg) pressure under continuous operation. Integrated dampers provide a smooth, gentle flow and innovative 4-point valves ensure reliable self-priming even at very low motor speed.

FP 70 is well-suited for a range of applications including medical technology, inkjet and 3D printing, and analytical instruments. With its introduction, the KNF smooth flow pump series now boasts a flow rate range of 120 ml/min to 12.4 l/min.

Learn more at knf.com/en/us/solutions/pumps/innovations/fp70-smooth-flow

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HONORABLE MENTION

Bosch Rexroth boschrexroth.com

Product: Smart Function Kit for Pressing and Joining Bosch Rexroth’s Smart Function Kit for Pressing and Joining is a complete mechatronic solution that meets manufacturers’ needs now — and into the future. The system combines proven Rexroth mechanical and electrical components and software into one package that reduces downtime for engineering and commissioning, increases productivity, and captures key i4.0 data.

HONORABLE MENTION

Portescap portescap.com

Product: Ultra EC 22ECP35-2A The 22ECP35 2A brushless DC slotless motor reduces many complexities associated with typical motor operation. The motor features integrated electronics as well.

HONORABLE MENTION

Autotech Controls autotechcontrols.com

Product: Programmable Smart Encoder Autotech’s Programmable Smart Encoder.

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P N E U M AT I C S

In the category of Pneumatics, this year’s LEAP Award winners are…

GOLD

Emerson

emerson.com/en-us Product: Wireless Auto Recovery Module (ARM) The Wireless Auto Recovery Module (ARM) clip for the AVENTICSTM G3 electronic fieldbus platform enables the industry’s first embedded wireless connectivity in a pneumatic valve system.

When pneumatic valve systems are installed within a machine or located somewhere out of reach, commissioning and performing diagnostics can be inconvenient and time-consuming. The Wireless ARM clip makes it easy for technicians to perform pneumatic valve system commissioning and diagnostics from a Wi-Fi-enabled mobile phone, tablet, or laptop, regardless of where the valve system is mounted. This helps manufacturers reduce production downtime, simplifies valve system commissioning, and creates a path for using diagnostics for analytics.

Offering the visual benefits of a hard-wired human-machine interface (HMI) at lower cost and with higher flexibility, the wireless ARM generates error notifications for alarms, voltage levels, short circuits, module errors, open load errors and distribution errors to reduce system downtime.

The device has a small footprint that connects easily to the AVENTICS G3 fieldbus platform in the space of a jumper clip. Three power settings for low-, medium-, or high-distance signals ensure safe and secure access to data. Additional security is provided through a wireless signal that can be turned off during configuration, multiple password options and diagnostic and commissioning information provided with no control capability.

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WINNERS SILVER

Festo

festo.com Product: Pressure and vacuum generator PGVA Many in-vitro diagnostic, pharmaceutical, and other life science applications use air pressure and vacuum to reliably and safely accomplish critical liquid control tasks, from pipetting biological samples for clinical testing, to using precise air and vacuum to push samples and reagents through “lab on a chip” microfluidic applications.

Pressure and vacuum used in fluidic/microfluidic processes needs to be precisely controlled, frequently down to 10 millibars (mb) — much less than the air pressure changes inside a typical lab on any given day. The air must be free of particulate that might contaminate the system or clog fluid passages.

Typical solutions require large tanks of compressed gas, or using industrial compressed air, which requires extensive treatment to meet the moisture and filtration requirements for lab use.

The Festo PGVA fills all the pressure and vacuum requirements required for low volume fluidic aspiration, dispensing, and flow control in a box not much larger than an abridged dictionary. Pressure is supplied by quiet 50db pump and stored in internal pressure and vacuum cells at 750 mb pressure and vacuum. It is then filtered to -.001um purity, and finally controlled by a silent servo controlled piezoelectric regulator providing precise, clean air in a single 200 x 200 x 75mm box.

BRONZE

PHD, Inc. phdinc.com

Product: FLEXION PHD FLEXION is an innovation in gripping technology inspired by the ultimate gripper: the human hand. The act of bending a finger — anatomically defined as flexion — gives the human hand a vast range of ability and adaptability. When actuated, FLEXION’s multiple joints perform as a human finger to conform and encapsulate a part or grip it by the fingertips. Adjustment of the operating pressure allows for a wide working range of usable force, providing industrial strength for demanding applications or a delicate touch for soft and sensitive product handling.

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POWER ELECTRONICS

In the category of Power Electronics, this year’s LEAP Award winners are…

GOLD

Texas Instruments ti.com

Product: Industry’s first automotive GaN FET with integrated driver Vehicle electrification is transforming the automotive industry, and consumers are demanding vehicles that can charge faster and drive farther.

As a result, engineers are being challenged to design compact, lightweight automotive systems without compromising vehicle performance.

The new LMG3525R030-Q1 is the industry’s first automotive GaN FET with integrated driver, protection, and active power management.

The 650-V automotive GaN FETs feature a fast-switching, 2.2-MHz integrated gate driver, helping engineers deliver twice the power density, achieve 99% efficiency and reduce the size of power magnetics by 59% compared to existing solutions.

Using the new automotive GaN FETs can help reduce the size of electric vehicle onboard chargers and DC/DC converters by as much as 50% compared to existing Si or SiC solutions – enabling engineers to achieve extended battery range, increased system reliability, and lower design cost.

TI developed these new FETs using its proprietary GaN materials and processing capabilities on a GaN-on-silicon (Si) substrate, providing a cost and supply-chain advantage over comparable substrate materials such as silicon carbide.

Backed by more than 40 million device reliability hours and more than 5 GWh of power conversion application testing, TI’s GaN technology provides the lifetime reliability engineers require in any market.

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WINNERS SILVER

STMicroelectronics st.com

Product: ST60A2 — 60 GHz Contactless RF Transceiver The ST60A2G0 is a unique, contactless, RF millimeter-wave transceiver product that operates in the (unlicensed) 60 GHz V-Band. It provides a power-efficient and high data-rate wireless/ contactless link that enables freedom from physical cables and connectors for short-range, (a few cm) point-to-point communications. It uses various external antennas such as patch antennas designed on PCB or highly directed SMT horn antennas allowing both end-fire and broadside radiation patterns.

The ST60A2G0 offers best-in-class wireless performance with transfer speeds up to 6.25 Gbit/s, along with low power consumption. Its unmatched efficiency, small form factor, and architecture designed for optimized system bill-of-materials, make it suitable for a range of applications, including personal electronics, industrial, computer, and peripherals.

BRONZE

Power Integrations power.com

Product: InnoSwitch4-CZ & ClampZero InnoSwitch 4-CZ high-frequency, zero-voltage, flyback switching (ZVS) ICs enable a new class of ultra-compact chargers for phones, tablets, and laptops. Set to trigger greater consumer visibility of GaN and its benefits, the first consumer devices using the InnoSwitch4-CZ and ClampZeroTM chipset are Anker’s Nano II ultracompact 65 W USB-C charger series. Other applications for InnoSwitch 4-CZ are power tools, eBikes, meters, and industrial.

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SOFTWARE

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In the category of Software, this year’s LEAP Award winners are…

GOLD

Protolabs protolabs.com

Product: Revamped Digital Quoting Platform Product designers and engineers use Protolabs’ Revamped Digital Quoting platform to order prototypes and low-volume production parts from the digital manufacturing company.

The software drives the speed and agility that customers expect from Protolabs. But it needed a major overhaul to update code that was decades old.

Thus, Protolabs unveiled the all-new eCommerce software platform first in Europe in October 2020, followed by the U.S. in February 2021 to further streamline the front-end of the digital manufacturing process.

A culmination of four years of work involving more than 400 employees across all departments, the digital quoting platform has a modern, userfriendly interface that lets engineers better manage their project requirements and collaborate with colleagues, reducing the time it takes to get parts quoted and ordered. For example, users can now easily share quotes with collaborators, who can then adjust lead time, materials, finishing, and other options to see real-time pricing impact.

Also, users can use interactive design for manufacturability analysis to improve part designs before any actual production begins. Engineers have access to a 3D view of their CAD model that highlights any manufacturing issues that need to be adjusted. Users can also see gate and ejector pin layout before ordering injection molding tooling, quickly assign threads for CNC machining, or see the per-part pricing with itemized costs of 3D-printed parts.

A goal was to clearly structure complex decision trees required for buying custom parts to simplify the process and make it accessible to users of all backgrounds.

The new platform brings new transparency to projects. For

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example, a new Price Curve Tool compares prototyping vs. on-demand manufacturing options so you have full visibility to the total cost of ownership on molded parts throughout the product life cycle. Users also have access to a “Receive By” calendar for shipping simplicity, allowing them to choose the date they want parts shipped and see cost implications.

The new digital ecosystem also unites three of Protolabs’ services—molding, machining, and 3D printing— in one platform, providing engineers a single source supplier for multiple manufacturing capabilities.

The transformation didn’t only include a new userfacing ecommerce experience; it involved revamping much of the manufacturing and engineering systems that connect the automation software to the manufacturing floor, which houses a network of hundreds of machines.

This complete connectivity throughout the process, which is referred to as the digital thread, makes it possible to turn around parts in days.

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WINNERS SILVER

Synopsys synopsys.com Product: RTL Architect In a traditional design flow, RTL developers architect circuit behavior with little visibility into how it is physically implemented. In many cases, module owners run a quick synthesis to check for syntax errors then hand off the blocks to an integrator who oversees consolidation and final synthesis. The integrator is primarily concerned that the block interface signals connect with the top-level and that the timing and power constraints are consistent.

The RTL developer typically has little to no insight into how the logic will be physically implemented in layout.

Their logic block might communicate to another block that is physically placed on the other side of the chip. In this scenario, implementation might require the addition of pipeline registers and feedthrough nets to the RTL to meet timing. However, it could take days from the RTL handoff to feedback from the implementation. In some cases, a new version of the RTL is ready before the previous version is synthesized and implemented. Besides timing, other valuable implementation insights are power, congestion, and area.

The core differentiating technology in RTL Architect is its fast, multi-dimensional Predictive Engine that enables RTL designers to predict power, performance, area, and congestion impact of their RTL changes. RTL designers can now pinpoint inefficiencies in their HDL source code and improve its quality. The new product also provides RTL restructuring, constraints management, and cross-probing facilities to provide early insights into key quality metrics.

BRONZE

GE Digital ge.com/digital

Product: iFIX HMI/SCADA software iFIX is a flagship HMI/SCADA software product from GE Digital with a 35-year history. iFIX 6.5 improves productivity and process control with industrial-strength SCADA and high-performance HMI. The new iFIX 6.5, part of the Proficy family from GE Digital, leverages the latest technology to help deliver faster time to insight and greater efficiency for operations while speeding time-to-value for system integrators. iFIX 6.5 offers capabilities to decrease development and deployment time and increase engineering, system integrator, and operator productivity. These enhancements provide new object orientation in a unified and central Proficy Web-based configuration environment for Rapid Application Development, a modern Web-based database manager, high-performance HMI sample applications to jumpstart development, new high-performance HMI Dynamos, performance, and security improvements. iFIX suits process industries like water/wastewater, life sciences, food & beverage, consumer goods, and specialty chemical industries.

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SWITCHES & SENSORS

In the category of Switches & Sensors, this year’s LEAP Award winners are…

GOLD

Texas Instruments ti.com

Product: TMCS1100 and TMCS1101 Hall-effect current sensors The TMCS1100 and TMCS1101 from Texas Instruments (TI) are the industry’s first zero-drift, Hall-effect current sensors. The devices provide the lowest drift and highest accuracy over time and temperature while providing reliable 3-kVrms isolation, which is important for AC or DC highvoltage systems such as industrial motor drives, solar inverters, energy storage equipment, and power supplies. Combining 600-V lifetime working voltages with low sensitivity and offset drift enables the TMCS1100 and TMCS1101 devices to deliver significantly higher performance in a simplified implementation.

The devices provide a total sensitivity drift over the temperature of 0.45% maximum, which is one-third of other magnetic current sensors, and a maximum full-scale offset drift of <0.1%. This translates into high measurement accuracy and reliability across a wide current range.

The devices also offer a 0.5% lifetime sensitivity drift. This low lifetime sensitivity drift further reduces the performance degradation associated with system aging over time. The accuracy at 1% max for the TMCS1100 and 1.5% max for TMCS1101 eliminates the need for device calibration and the typical linearity of 0.05%, reduces signal distortion, and helps maintain accuracy across the extended industrial temperature range of -40°C to 125°C.

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WINNERS SILVER

Ashcroft Inc. ashcroft.com

Product: Ashcroft sealed E2X & E2F industrial pressure transducers The Ashcroft sealed E2X and E2F industrial pressure transducers for hazardous locations can be calibrated in the field. Offset and span adjustments are incorporated within the housing and can be externally adjusted with magnet. Each is equipped with accurate and reliable sensing technology, with pressure ranges from vacuum to 20,000 psi and absolute ranges up to 500 psia. Models E2F (explosion-proof) and E2X (explosion-proof /intrinsically safe) carry FM, ATEX, and IECEx approvals as well as an IP66 or 67, NEMA 4X rated enclosure to protect against water and humidity.

a

Features: • Uses Ashcroft’s CVD thin film technology • +/-0.25%, +/- 0.50%, or +/-1.0% of span accuracy available • Standard ranges from vacuum to 20,000 psi and 0 to 500 psia (custom ranges available) • Rugged 316 stainless steel Housing • Diaphragm available in 17-4 PH, 316L stainless steel or A286

SILVER

Infineon Technologies AG infineon.com

Product: XENSIV PAS CO2 Sensor Based on the photoacoustic spectroscopy principle, light heats the target gas molecules, vibrating. The vibration can be “heard” by a MEMS acoustic detector and used to determine the concentration of the target gas in a sample. Precise engineering optimizes the detector for low frequency, and the gas absorption/sampling chamber is acoustically isolated from external noise.

Full integration of the detector on a 14 X 13.8 X 7.5 mm PCB results in a device that is 75% more compact and 2X lighter than today’s commercially available CO2 sensors.

The sensor directly reads actual CO2 concentration, not a correlation, and is sensitive to ±30 ppm ±3% of reading between 400 – 5000 ppm. High configurability (sampling rate, baseline calibration) and multi-interface options (*UART, I2C, PWM) provide ease of use with the required flexibility.

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HONORABLE MENTION

Banner Engineering bannerengineering.com

Product: Q5X Jam Detection Mounted on the side of the conveyor, the Q5X Jam Detection sensor extends the functionality of Banner’s existing dual-mode technology to look for a change in signal strength and distance between the face for the sensor and the packages. Since it does not rely on gaps, it can detect jams faster and more accurately than conventional jam photo eyes.

HONORABLE MENTION

GMN

gmnameplate.com Product: Custom membrane switch panel for LogiLube’s SmartOil-M series SmartOil-MTM Series integrates off-the-shelf IIoT sensors to provide real-time condition monitoring of in-service operating fluids by measuring fluid attributes such as viscosity, water-in-oil contamination, oil cleanliness, wear debris, particle count, and dielectric constant.

HONORABLE MENTION

Omron Electronics Components omron.com

Product: B5W-DB Diffuse Reflective Sensor The B5W-DB light convergent optical sensor is a long-distance LED object detection sensor that works at distances over 500mm and up to 1000mm in some instances. This sensor has a small package design allowing it to be mounted in smaller spaces and from four possible directions.

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2021 WINNERS TEST & MEASUREMENT In the category of Test & Measurement, this year’s LEAP Award winners are…

GOLD

Keysight Technologies keysite.com/us

Product: N9042B UXA X-Series Signal Analyzer Keysight Technologies launched its N9042B UXA X-Series signal analyzer to provide the industry’s widest analysis bandwidth and deepest dynamic range to help users solve their difficult mmWave challenges — tight design margins and timelines, complex modulation, and stringent standards.

At mmWave frequencies, signal quality is more susceptible to impairments such as modulation errors, phase noise, and distortion.

Keysight’s N9042B UXA X-Series signal analyzer and the frequency extender set a new level of performance for high-frequency measurements, including up to 110 GHz to cover the current 5GNR FR1 and FR2 bands, as well as most radar, EW, and satellite bands.

A completely new front end provides low noise performance and high dynamic range, addressing applications in Tx test, such as EVM and other modulation quality tests — while also excelling at measurements of lowlevel and unknown signals.

The N9042B supports the X-series family of multi-touch applications and the 89600 VSA software. A new CPU performs compute-intensive measurements, such as demodulation and EVM, up to 40% faster than prior analyzers.

Key product specifications for the N9042B UXA X-Series signal analyzer include: • 2 Hz to 110 GHz unbanded, preselected frequency range • 11 GHz wide analysis bandwidth • 4 GHz of corrected analysis bandwidth to test wideband, high-throughput communications designs • Industry’s best error vector magnitude (EVM) • The industry’s best swept displayed average noise level (DANL) of - 174 dBm at 1 GHz

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Notes of Raw material table : SCr415 (including corresponding materials of SCr415) is defined as equivalent material of SCM415.

In case of carburizing (case hardening), SCM415 is normally used.

In case of requirements for harder material, SNCM220 and/or SNCM420 is normally used.

Values of hardness is determined by production condition.

Actual expected hardness value is informed in a quotation of gears.

Notes of Gear precision grade table : Above mentioned equivalent grades are for reference only.

Not all grades completely match each other.

Largest selection of

Stock Metric GEARS in North America

15/05/21

14:20:18

259 Elm Place, Mineola, NY 11501 Phone: 516.248.3850 | Fax: 516.248.4385 Email: info@khkgears.us

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2021 WINNERS TEST & MEASUREMENT

SILVER

ITECH Electronic Co. itech.sh/en

Product: IT7900 Regenerative Grid Simulator T7900 Regenerative grid simulator is a programmable, four-quadrant, AC/DC power source. It has high power density, 15 kVA in 3U height.

The range of power output from 5 kVA to 960 kVA enables it to fulfill various test requirements. IT7900 is also a four-quadrant power amplifier, which can be applied to P-HiL test and the test of many different pieces of grid-connected equipment.

Besides single-phase and three-phase output, it has a reverse phase as well. Under the reverse phase mode, it can reach double voltage output. It has a working mode of CC, CV, and CP. With the unique islanding mode (RLC settable), just a single unit of IT7900 can realize the anti-islanding protection test. The typical applications of for IT7900 include the power test of PCS, energy storage systems, microgrid, BOBC (V2X), and PHiL.

BRONZE

Rohde & Schwarz rohde-schwarz.com

Product: R&S SMM100A The R&S SMM100A vector signal generator provides ecxellent RF characteristics across the entire frequency range from 100 kHz to 44 GHz. The instrument covers the bands below 6 GHz used by existing wireless standards, plus the newly defined bands for 5G NR FR1 and Wi-Fi 6E up to 7.125 GHz and the 5G NR FR2 bands up to 44 GHz. The internal baseband generator in the R&SSMM100A supports a maximum RF modulation bandwidth of 1 GHz. Digitally modulated broadband signals can thus be generated as required by wireless standards.

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GEARBOXES | COUPLINGS | RACK & PINION FOR PRECISION MOTION CONTROL & ROBOTIC APPLICATIONS Articulated Robot Joints and 7th Axis

Zero-Backlash Robotic Flange Gearboxes and Helical Rack and Pinion Systems, customized to your application

Cartesian System Build your own with Linear Mount Products

designed to simplify the process of designing and building a cartesian system. Everything Between the Motor and the Actuator Hollow Output Gearboxes

GCL Cycloidal withstands shock loads of 5x nominal torque

Inline or Right Angle, include custom adapter to mount to any linear actuator

PMK Space-saving Parallel Mount Kit

GCL Cycloidal with integrated pre-stage

GSL Strain Wave

Distance Coupling

with harmonic gearing for precise motion

Connect actuators without additional external bearings

GSL Strain Wave Theta/Wrist Axis

Trunnion Headstock Drive

Zero-backlash gearboxes provide precision positioning

GCL Cycloidal

Precise point-to-point motion

7th Axis/Robot Transfer: Dyna Series + Helical Rack & Pinion Designed for optimal system performance

GPL Planetary

Vibration-free, continuous coordinated motion between trunnion & robot

From zero-backlash gearboxes to rack & pinion, GAM has the flexibility and broad product range for all your motion control and robotic applications As a U.S. manufacturer with broad product offerings in the gearbox industry, as well as the in-house engineering design experts and manufacturing capabilities to develop customized solutions, we can help with your application.

www.gamweb.com | info@gamweb.com | 888.GAM.7117 GAM Enterprises, Inc. | 801 E. Business Center Dr. | Mount Prospect IL 60056

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© 2022 GAM. ALL RIGHTS RESERVED

1/16/22 1:00 PM

Product World Coupling for large ball screw applications Miki Pulley mikipulley-us.com The SFF Coupling offers exceptional torsional stiffness and strength. These couplings have rugged steel hubs with a black oxide finish. This coupling design ensures accurate machining center shaft rotation with precise control. The coupling’s flexible element gap dampens conductive heat transfer from motor to output shaft. The coupling provides limited shaft misalignment to alleviate premature system bearing wear.

The coupling’s aerodynamic profile decreases noise while optimizing performance at high speeds. Simple yet reliable, SFF couplings are available in single and double element configurations. Bores can be arranged with clamp, taper-lock, or keyed styles for specific application requirements.

Basic SFF specifications:

• Maximum RPM: 18,000 • Maximum allowable torque: 221.27 ft-lb (800 Nm) • Backlash: Zero • Ambient operating temperature: -40 - 120 C (-40 - 248 F)

Conveyor system configurator mk North America, Inc. mkCAD360.com CAD360! has enhanced design tools and better access to equipment models. The tool makes it faster and easier than ever to design and share custom conveyor systems from the manufacturer.

The CAD360! conveyor configurator allows for 2D and 3D models to be downloaded for easier sharing across departments and provides engineers with expanded file options for their layout and design needs. There’s also the ability to download SAT files in addition to the other popular download options (STEP, DWG, and PDF).

Users input their target values for length, width, and height, select drive location and target options, and a model is generated on demand. Live measuring, improved view control, and several other interactive modeling tools allow the user to investigate model details right within CAD360! Software.

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All products available directly on

from

WHAT’S NEW RULAND

RULAND.COM

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TOOL-LESS ADJUSTMENT COMPONENTS • Adjustable handles and knobs replace standard hardware and can be used to torque components without tools.

• Levers can be used with Ruland shaft collars for quick installation and adjustment.

Adjustable Handle

Star Knob

Shaft Collar with Lever

SLIT AND CONTROLFLEX COUPLINGS

Ruland Manufacturing is proud to support the FIRST Robotics Competition as a Gold Supplier of precision shaft collars & couplings.

• Slit couplings are available in short and long styles giving designers a variety of body sizes to choose from to fit application envelope and performance requirements.

• Controlflex is a highly flexible encoder coupling designed for applications with high speed, low torque, and wide differences in shaft sizes (up to a 4:1 small to large ratio).

• Slit couplings are available in bore sizes from 1.5mm to 12mm (1/8” to 1/2”) and controlflex couplings are available in sizes from 6mm to 40mm (1/4” to 1-1/2”).

Slit Coupling

Controlflex Coupling

MOUNTABLE SHAFT COLLARS • Available with OD flats and holes for direct mounting of the collar to other components.

• Proprietary manufacturing processes ensure superior fit, finish, and holding power.

MODULAR MOUNTING SYSTEMS • Assortment of components that allow users to build small assemblies for mounting sensors, conveyor rails, machine guards, and more.

• Optional pre-designed kits make it easier to select the right system for your application.

• Manufactured in a variety of sizes, styles, and materials.

QUICK CLAMPING COLLARS

UNIVERSAL JOINTS

• Hand operated: no tools required to install, remove, & adjust.

• Widest selection in the industry: over 3000 standard single and double universal joints to start your next design with.

• Available from Ruland in 2 weeks or less for the shortest lead times in the industry.

• Best suited for systems that require frequent adjustments.application.

• Yokes, pins, and blocks are precision machined, ground, and selectively heat treated for smooth operation at high operating angles.

www.ruland.com | sales@ruland.com 1/18/22 1:12 PM

Product World Steel disc couplings with updated design Ringfeder ringfeder.com Using in-depth finite element analysis (FEA), RINGFEDER has optimized the redesign of its TND Series, which now includes two coupling types: High Deflection (HD), which offers excellent shaft misalignment compensation, and High Torque (HT), which incorporates a higher power density.

With their high material quality, compact design, and tight tolerances, TND Series couplings have superior concentricity, maximum operational reliability, smooth operation, and low vibration levels — even in the presence of fast rotational speeds or irregular rotational forces. They also avoid wear, don’t require cleaning or lubrication, and offer a long service life when properly installed.

Features:

• Modular design for maximum flexibility.

• Bore diameters from 25 to 215 millimeters.

• Nominal torques up to 130,000 Newton-meters.

Stepper motor I/O terminal Beckhoff beckhoff.com The EL7062 dual-channel EtherCAT Terminal enables the direct connection of two stepper motors in the medium power range of up to 3 A and for a voltage range of 8–48 V. With flexible parameterization and minimized channel costs, the flexible motion interface is suitable as a low-cost drive for a range of stepper motor applications.

In a compact form factor, the 24-mm-wide EL7062 EtherCAT Terminal contains two stepper motor output stages, two digital inputs for limit switches, and one encoder interface per channel for a wide range of 5 V encoders. Via parameterization, the EL7062 flexibly adapts to the connected stepper motor and its corresponding application requirements. Regarding the input encoder signal, the module supports the entire spectrum of TTL encoders (5 V differential, single-ended/open collector). High-resolution microstepping ensures smooth and precise motor operation.

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As EV market grows, so does push for higher efficiency ‘The electric car has no future.’

That’s what some said in 1908 when Henry Ford introduced his cheap Model T. Despite his new assembly line manufacturing concept, that single statement rendered electric vehicles (EVs) obsolete.

EVs had been around since the 1830s and by 1900 were 38% of the U.S. market for ‘horseless’ carriages. The market then dwindled to virtually nothing for the larger part of the 20th century.

The resurgence of the EV market is following a similar but opposite exponential change, with the global passenger car stock at over 10 million in 2020. Despite a pause due to the pandemic, the market is set to rise at a compound annual growth rate of 17.4% in 2021 to close to the $1 trillion mark by 2027.

Such dramatic growth naturally spawns many approaches to the implementation of the EV solutions in motor, battery, charger and electric drive technologies.

Market drivers Government targets for emissions reduction are driving the EV sales increase along with subsidies for buyers as well as for vehicle and charging infrastructure manufacturing.

These benefits offset the still-higher price tag of the EV compared with a gas-powered vehicle. The buyer’s choice will eventually come down to availability, as ICE-only vehicles are no longer offered.

There are other factors at play.

For example, EVs are potentially components of sustainable energy -generation microgrids, with the EV battery providing local and grid storage to help further reduce dependence on utility power generation and associated emissions. Still, drivers are unlikely to use that scenario as a rationale for buying an EV. Perhaps a stronger consumer incentive is the aspirational side of owning what has become a mobile data center, with the perceived benefits of extra safety, autonomous driving and continuous communication between vehicles and roadside infrastructure.

These features are to an extent available in ICE cars now, but they are bundled into an EV on the back of the already-considerable processing power necessary to get the best efficiency out of the electric drivetrain.

designs, ensuring there is always backup. The space shuttle had five.

Make of that what you will, and design for safety remains a major topic in EV electronics.

Power conversion efficiency is key While batteries are more energy-dense, cars have gotten heavier.

Ancillary loads such as air conditioning, heating and power-assised everything have also increased substantially. All this adds to the increased expectation of on-road performance. This has curiously resulted in EVs that over several years improved dramatically in battery and drive technology but still only reach a few hundred miles range, even less with the family, the dog and their accessories.

A focus for automotive engineers is to extend battery life by minimizing drive inverter and motor losses and to return energy to the battery while braking or coasting. It’s also a virtuous circle to an extent; lower loss means lighter heatsinks and less traction demand on the battery. If losses are lower, currents are lower, and cables and connectors also get smaller and lighter.

Efficiency also enables faster charging When the car is safely connected to utility AC or DC power, range anxiety might subside, but stress levels rise again as time ticks by.

Efficiency and speed of the charging process are therefore also important. The power electronics in the EV drive, on-board charger and the roadside or home charger are comparable. They all convert AC/DC or vice versa with some DC/DC thrown in, using switchedmode power supplies. The semiconductor switch is key. Its losses when on and during switching transitions dominate the whole power conversion process.

Engineers have choices in the topology of power conversion stages, power bus voltage levels and semiconductor switch technology, with consequent trade-offs.

WEBINARS: Avnet suppliers guide you to the best resources. Learn more

Of course, the manufacturer must carefully manage the perceived and real dangers of catastrophic failure modes of the electronics and hacking. Manufacturers tout their dual-redundant automotive

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Empowering Automation

Product World Touch probe Heidenhain heidenhain.us/about-us

A gripper inspired by the motion of a human finger ADAPTIVE DESIGN Finger modules flex multiple joints to conform and adapt to various workpieces, offering an unmatched

The TS 760 touch probe is designed for a contouring TNC and other major CNC controls. This device is distinguished by its 3-D accuracy making it especially useful during 5-axis machining and more.

The new TS 760 probe offers high accuracy (±1 µm) and homogeneous switching behavior over 360°. For 3-D measurement, the feed rate/ probing speed of 1 m/min is four times faster than other commercially available products that offer the same repeatability of (2σ ≤ 0.25 µm).

The TS 760 also offers a low trigger force of (≈ 0.2 N; axial: ≈ 1.5 N), eliminating form and surface damage. If desired, the probing point can be cleaned with the integrated flusher feature using compressed air and a cooling lubricant of up to 60 bars.

level of versatility and application potential.

CONFIGURABLE SYSTEM Modules can be assembled in radial or parallel hub arrays with one to five fingers in each position.

WIDE RANGE OF USE Suitable for both industrial and collaborative robots.

Visit phdinc.com/flexion to see FLEXION in action.

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Why Choose Us? n

Access millions of electronics products from 600+ world class suppliers

n

Global resources with operations in 35 different countries Personalized customer service and technical

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support from a team of industry experts Value added services such as: stockroom solutions, custom components and enclosures,

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kitting, and more Market-leading online community with over 600,000 engineers Call us for a quote on large or small orders, or email quote@newark.com

SHOP THE WAY YOU PREFER

EPROCUREMENT SYSTEMS

Website: newark.com Email: order@newark.com / quote@newark.com Phone: 1 800 463 9275 M-F 7:00 a.m. – 8:00 p.m. (EST) Fax: 1 480 308 1687 Technical Support: Go online for live technical support or call 1 877 736 4835

We can link with any eProcurement system, and our dedicated e-team will facilitate your implementation.

Community: element14.com

NO MINIMUM ORDER FEES

Email: eproc@newark.com

SHIPPING Domestic: Order M-F by 9:30 p.m. (EST) Export: Order M-F by 6:00 p.m. (EST)

YOU CAN FIND US AT…

In-stock products normally ship the same day

GLOBAL REACH, LOCAL RESOURCES

newark.com • 1 800 463 9275

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Millions of products, 800,000 in stock

n n

Supporting 48 websites in 35 languages Authorized distributor for 3000+ brands globally

1/16/22 1:03 PM

Spring Applied Brakes

Product World Contactless monitoring of cables in e-chains igus igus.com

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

SEE HOW IT WORKS!

100 Randolph Road • Somerset, NJ 08873 Phone: 732-271-7361 • Fax: 732-271-7580 https://ogura-clutch.com/spring • info@ogura-clutch.com

igus has introduced the latest generation of monitoring sensors that check the electrical condition of chainflex cables in e-chain systems without contact or intervention in the existing harnessing.

The company’s i.Sense CF.D monitoring sensors allow real-time monitoring without extra cores and, in combination with the new i.Cee: plus II evaluation module, allows even more efficient predictive maintenance for protection against expensive system failures.

The latest CF.D generation facilitates the predictive maintenance of chainflex bus and data cables in igus e-chain systems. The smart system consists of two sensor units clipped onto the cable before and after the chainflex cable to be monitored. They are small enough to fit into the distribution box on the moving end side and the control cabinet on the fixed end side. During operation, the sensors continuously check the cables’ transmission properties.

POWER TRANSMISSION-PART CONVEYING

PYRATHANE® BELTS Lifetime Warranty Against Manufacturing Defects

LINE SHAFT CONVEYOR BELTS Original Equipment and Connectable

CUSTOM MADE IN INCH, METRIC & O-RING SIZES • Round, Flat and Connectable Polyurethane Belts • Very Clean Operation • Eliminates Tensioning Devices • Exceptional Abrasion Resistancexxxxxxxxxxxxxx AN ISO 9001 CERTIFIED COMPANY

641.792.2405 sales@pyramidbelts.com

pyramidbelts.com

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Motion Controls for any project … simple to complex, Single-axis Single-axis to Multi-axis Single Multi axis MultiOMS has gained the confidence of designers for more than 40 years, not only through the clever use of their patented technology in their products, but also by being a great business partner to their customers. Let OMS help identify

the best solution for your project success.

Control Motion and I/O Many applications require multiple points of control through a given process. This often leads to fragmented controls and undesirable process behavior. A multi-axis controller from OMS Motion can bring the complete process together into a fluid predictable and controlled process.

Visit us at: http://www.OMSmotion.com sales@OMSmotion.com 800.707.8111 /OMSMotion

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Product World M12 connector with multiposition, lockable A-coding binder USA binder-usa.com This two-pieceM12 circular connector offers versatility with several special features including, square-flange housing for easy assembly, multi-position, and lockable A-coding that supports variable cable installation. The new connectors simplify secure sensor and actuator connections in factory automation and robotics applications.

The connector’s two-part design enables user-friendly, safe assembly. The square-flange variants of binder’s 763 series consist of the metal flange housing and a contact carrier equipped with a lockable coding nose, which can rotate in 45° increments. Additionally, the housing of the M12 single-wire model has the same drilling scheme as the M16 form factor, allowing users to switch between design sizes without adapting existing houses for field devices such as sensor/actuator boxes.

Pallet conveyor with ISO Standard Class 4 rating Dorner dornerconveyors.com The ERT150 is suitable for small and light-load assembly automation and medical and medical-device assembly applications. It is the only pallet conveyor of its kind available with an ISO Standard Class 4 rating for cleanroom applications. Earning the ISO Standard 14644-1 Class 4 rating means the ERT150 will conform and not contribute to the contamination of cleanrooms to those standards.

As implied by its name, the ERT150 uses rollers to move pallet conveyors smoothly with no friction (a byproduct often seen in belt-driven platforms). The conveyor’s open design eliminates concerns of small parts or screws dropping into rollers and causing conveyor damage or jamming.

The ERT150 is well-suited to operate in cleanroom environments requiring a pallet handling conveyor capable of zoning for no or lowback pressure accumulation and automation assembly applications within industries including medical, electronics, and consumer goods.

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Power supplies with integrated UPS AutomationDirect automationdirect.com AutomationDirect has added open frame and panel mount power supplies, with integrated UPS functionality, to its RHINO SELECT series of power supplies. The integrated UPS feature provides seamless battery switchover to keep critical operations running when there is an unexpected loss of power.

These industrial power supplies support a wide operating temperature range and provide TTL status outputs for external monitoring systems. RHINO SELECT power supplies are UL 60950-1 and UL 62368-1 recognized, CE marked, and RoHS compliant.

Also, the PSB24-240-1 has been added to the RHINO DIN Rail mount series. This power supply ensures reliable startups using its “Power Boost Technology” — shortterm power used to support high inrush current. This power supply is UL 508 listed, UL 60950 recognized, CSA certified, CE marked, and RoHS compliant.

Smallest industrial camera with housing and C-mount IDS Imaging Development Systems ids-imaging.us The XCP camera family of the uEye+ product series combines industrial quality, a favorable system price, and fills a gap in the market as the smallest camera with housing and C-mount. The models measure 29 x 29 x 17 mm and have a completely closed zinc die-cast housing with a screwable USB Micro-B connector. With costoptimized electronics and compatibility with standard lenses, they are well-suited to price-sensitive applications.

With the market launch of the camera family, IDS shows that cost-effective industrial cameras with C-mount can also be offered in the industry’s smallest standard format.

They are aimed at customers who value budget-friendly, extremely compact, and lightweight camera models in industrial quality over extraordinary camera features.

They are used for analysis tasks in the laboratory, as eyes in autonomously navigating vehicles in production, or for visual support of robots in automation.

Initially, the industrial cameras will go into series production with the 2.3 MP global shutter sensor AR0234 and the 5 MP rolling shutter sensor AR0521 from ON Semiconductor. Other sensors will follow.

DESIGN WORLD

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Product World E1-rated inductive proximity sensors

FOR FASTER OVERLOAD PROTECTION

Carlo Gavazzi GavazziOnline.com The ICS Series E1-Rated Inductive Proximity Sensors are designed for challenging applications on mobile equipment. These sensors focus on reliable detection and reduced downtime.

E1-approved inductive sensors ensure accurate and reliable detection of actuating parts such as hydraulic pistons, gear speed, crane position, and movement on refuse vehicles, mobile cranes, concrete mixers, tractors, fire trucks, harvesting equipment, buses, forklifts, and more.

These mobile platforms are typically exposed to high levels of shock and vibration from the terrain, exposure to salt and debris from the road and vehicle engine refuse gases, extreme voltage peaks if a battery is disconnected from the alternator, wide operating temperature ranges, and electromagnetic interferences generated by radio transmitters.

TORQUE LIMITER 9 Immediate disengagement 9 Compact and backlash free 9 Field adjustable

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Motion Components

to Automate any Industry

Servo Gearheads for Linear Actuators

800-349-0245

diequa.com/dw

Diequa 207 full page1-22.indd print ad august.indd 1

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Product World Small, rigid, crossed roller bearings IKO ikont.com The CRBT105A is a small, thin unit designed to provide strong rigidity for space-constrained automated machine designs.

The CRBT105A has a 10 millimeter bore diameter, 21 millimeter outside diameter, and a width of 5 millimeters. The CRBT105A offers rigidity up to four times greater than double-row angular contact ball-type bearings. This size and high rigidity make the CRBT105A suitable for robots with articulating arms and compact surveillance cameras.

With rollers alternately crossed at right angles to each other between inner and outer rings, the CRBT105A produces a greater contact surface to allow the bearing to handle heavy or complex loads from any direction simultaneously. This orthogonal roller arrangement results in a bearing that occupies half the sectional area of rear-mounted, 45° contact angle single-row roller or ball-type bearings.

Disc couplings for test, measurement, and inspection systems Ruland ruland.com These disc couplings are zero-backlash, have high torque and torsional stiffness, and can accommodate all forms of misalignment, making them well-suited to the requirements of test, measurement, and inspection systems. Single- and double-disc styles allow the designer to tailor coupling performance to application requirements.

Disc couplings comprise two anodized aluminum hubs and multiple thin flat stainless steel disc springs.

Single-style disc couplings mate the hubs directly with the disc springs. Their short length makes them ideal for applications with space constraints, but they cannot accommodate any parallel misalignment. Designers must ensure that misalignment can be tightly controlled to use a single disc coupling. Double styles are manufactured with a center spacer made from anodized aluminum for high torque or acetal for electric isolation. This design allows the two sets of disc springs to operate independently from each other to accomodate all forms of misalignment.

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Product World Drive systems for packaging applications NORD DRIVESYSTEMS nord.com The combination of NORD’s modular gear units, motors, and variable frequency drives provides intelligent solutions for the special requirements of the packaging industry. These drive systems can power many types of equipment, including roller conveyors, belt conveyors, chain conveyors, stacker cranes, palletizers, case packers, and sealer wrappers. A team of dedicated engineers works with users one-on-one to configure a drive solution that is highly specialized, Industry 4.0 ready, and an exact fit for their needs.

With over 20,000,000 possible configurations from their standard product line, the team can frequently accomplish this without the need for costly custom components. These electronic control products work with their gear units and motors for easy integration and industrial networking capabilities. These modular products also allow for versatility and are designed for quick installation and execution of precise operations such as speed and timing for conveyors.

Robust seal for mounted tapered roller bearing SKF skf.com This new mounted, tapered roller bearing has been paired with a superior seal. The mounted tapered roller bearing, also known as a Type E bearing, incorporates the CR Seal. This extends service life by virtually eliminating the ingress of contamination, even under harsh conditions.

The mounted tapered roller bearing is used when an increased thrust load is needed with limited axial movement. This makes it appropriate for demanding industries such as mining, aggregates, and cement.

Potential applications include material handling equipment, such as belt feeders and screw conveyors, and process machinery, including grinders, shredders, and mixers.

These units typically break down for one reason: seal failure. By improving seal performance, they can be designed to last much longer — extending uptime and increasing reliability.

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

Open aperture voice coil stages Moticont moticont.com The HCDS-051-064 Series of Open Aperture Voice Coil Stages are linear DC motor (also called voice coil) driven stages. Designed for closed-loop servo operation, an integral quadrature optical encoder with differential outputs is standard. The stages are clean, quiet, and efficient, with low inertia, high acceleration, and high speed.

Each stage has a built-in home switch for accurate initialization upon power-up. These compact open aperture stages have a footprint of just 11.500-in. (292.1 mm) long x 4.000 (101.6 mm) wide x 3.755-in. (95.4 mm) high. They are suitable for laser drilling and milling, optical focusing, testing, laser steering, mirror positioning, scanning, oscillation, switching, sorting, pick-and-place, and the pass-through of fiber optics, electrical, and air lines.

Each HCDS-051-064 Series stage has precision threaded mounting holes for tooling or fixtures. It has a linear travel of 1.20-in. (30.5 mm), plug-and-play wired connectors, and convenient mounting holes for easy integration into new or existing applications. These stages are available with a resolution of 29.5 microns and 25.4 microns

Modular machine tending application cells ABB abb.com

HIGHLY COMPACT SMARTMOTOR™ SERVO SOLUTIONS FOR AUTONOMOUS VEHICLES.

ABB has launched a new family of modular machine tending application cells for the metals industry to maximize flexibility and machine utilization while minimizing lost productivity caused by unforeseen production stoppages.

Featuring six different versions, the FlexLoader M family offers a variety of ways of loading and unloading machines based on the size, shapes, and amount of the workpieces being handled, making it suitable for applications such as foundries and die casting operations producing multiple types of products in varying quantities.

DESIGN WORLD

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January 2022

RELIABLE MOTION SOLUTIONS.

• Fully integrated designs • Most compact, power-dense solution on the market • Complete servo system

Learn how our easily deployable programming language gets your machine to market faster at animatics.com

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1/16/22 1:07 PM

Ad Index Able Electropolishing ........................................ 64 Accumold .............................................................. 128 Ace Controls .........................................................67 Actuonix Motion Devices ................................ 99 Aerotech ................................................................ 90 Allied Moulded Products ................................ 139 AllMotion ................................................................... 4 Altech Corporation .....................................11,13,15 Automation Direct .................................................. 1 Automation24, Inc. ................................................9 AVNET ...................................................................199 Bailey Hydraulics .................................................37 Bay Associates Wire Technologies, Inc. ......................................... 29 Beckhoff Automation ....................................... 98 Beswick Engineering ......................................... 44 binder USA ........................................................... 45 Bird Precision ....................................................... 99 Bishop Wisecarver ............................................. 85 Bodine Electric Company ..................................12 Boker’s, Inc. ........................................................... 49 C-Flex Bearing Co .............................................. 103 Cadence .................................................................53 Canfield Connector ............................................ 49 Canon U.S.A., Inc. .............................................. 155 Carlo Gavazzi ........................................................73 CGI Inc. .....................................................................71 Chieftek Precision ................................................91 Clippard ..................................................................... 3 CMT ......................................................................... 55 Coilcraft ................................................................. 123 Components Corporation ............................... 54 COMSOL .................................................................75 Cornell Dubilier Electronics, Inc. .....................79 CS Hyde Company ............................................ 136 Del-tron .................................................................. 80 Diequa .................................................................. 207 Digi-Key Electronics .............................................17 Dodge Industrial ...........................................Cover Dorner ..................................................................... 118 Eagle Stainless Tube & Fabrication, Inc. ............................................. 65 Encoder Products Company .......................... 62 Exair Corp ................................................................. 5 Fabco-Air, Inc. ........................................................61 FAULHABER Micromo ...................................... 147 FESTO ..................................................................... 83 Fischer Connectors .............................................14 GAM ........................................................................195 Harmonic Drive .................................................... 112 Harwin .....................................................................23 HAWE Hydraulic .....................................................81 HELUKABEL USA .................................................41 Hunger Hydraulics .............................................. 111 IDS Imaging Development Systems GmbH ............................................149 igus ......................................................................... 153 Intech ..................................................................... 126 Interpower ......................................................19, 129 ITT Enidine ...........................................................166 J.W. Winco, Inc. .................................................... 36 Keystone Electronics Corp .......................7, 209 KHK USA Inc. ....................................................... 193 KNF Neuberger .................................................. 179 KOA Speer Electronics ....................................140 Koford Engineering .............................................52 Kollmorgen ...........................................................105

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Kyocera AVX ..........................................................57 Lenze Americas ................................................. 167 Lin Engineering .................................................. 157 Main Mfg ............................................................... 142 Master Bond.......................................................... 36 maxon ..................................................................... 151 METCASE .............................................................. 131 Miki Pulley U.S. .................................................... 48 Misumi USA, Inc. .................................................BC mk North America, Inc. ..................................... 43 Moog Animatics .................................................. 211 Murrelektronik, Inc. ..............................................70 Nason ..................................................................... 40 NB Corp .................................................................. 89 ND Industries ....................................................... 63 New England Wire & Tubing Technologies .................................................. 181 Newark, An Avnet Company ......................... 201 Nitto Kohki USA .................................................. 95 NSK ......................................................................... 152 Ogura Industrial Corp. .................................... 202 OKW Enclosures, Inc. .........................................33 OMS Motion, Inc. ...............................................203 Opto 22 ...................................................................25 Oriental Motor USA Corp ................................ 143 Parvalux ................................................................ 173 PBC Linear ............................................................ 96 Permco .................................................................. 212 Phd Inc. ................................................................200 PI (Physik Instrumente) LP ...............................24 PM B.V. ................................................................... 113 PMD ........................................................................ IBC Pyramid ................................................................ 202 R+W America ......................................................206 ROLEC Enclosures, Inc. .................................... 69 Rota Engineering ............................................... 110 Ruland Manufacturing Co., Inc. .................... 197 Schmersal ............................................................ 130 SCHURTER Inc. ................................................... 103 SIKO ......................................................................... 58 Smalley Steel Ring ...............................................31 Smart Products ....................................................97 SMC Corporation of America ........................ 137 Sorbothane ......................................................... 142 Stock Drive Products/ Sterling Instrument .......................................52 Super Swivels ........................................................18 Tadiran Batteries ................................................ 119 The Lee Company .............................................. 28 THK America, Inc ................................................ IFC TRACO POWER North America, Inc. ............ 141 Trim-Lok ..................................................................35 Veljan Hydrair ...................................................... 191 WAGO Corporation ............................................ 117 Weidmuller ...........................................................109 Weintek USA ....................................................... 163 Whittet-Higgins ....................................................27 WON ST US .......................................................... 125 Würth Industry North America ...................... 59 Yaskawa Electric America .................................51 Yates ...................................................................20,21 Zero-Max, Inc. ......................................................... 2

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

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Leadership in Engineering

Abaco Systems Inc .............. 214 Able Electropolishing .......... 215 Accumold ................................. 216 ACE Controls .......................... 217 Actuonix Motion Devices ............................... 218 Aerotech ................................. 220 ALA Industries ....................... 221 Allied Moulded Products .. 223 AllMotion ................................. 222 Altech Corporation ............. 225 AMETEK Programmable Power ................................. 226 Automation24, Inc. .............. 227 AutomationDirect ................. 219 Avnet ....................................... 228 Bailey Hydraulics ................. 229 Banner Engineering ...........230 Bay Associates Wire Technologies, Inc. ........... 231 Beckhoff Automation ........ 232 Beswick Engineering .......... 233 binder USA ............................ 234 Bird Precision ........................ 235 Bishop Wisecarver ..............236 Bodine Electric Company .......................... 237 Boker’s Inc. .............................238 C-Flex Bearing Co. Inc ........239 Cadence ................................. 240 Canfield Connector .............. 241 Canon U.S.A. Inc .................. 242 Carlo Gavazzi ........................ 243 CC-LINK PARTNER ASSOCIATION ................. 244 CGI Inc. .................................... 245 Chieftek Precision Co., Ltd. ............................. 246 CIT Relay & Switch .............. 247 Clippard ................................... 248 CMT .......................................... 249 Coilcraft ...................................250 Components Corporation ....................... 251 COMSOL ................................. 252 Control Techniques Americas ........................... 253 Cornell Dubilier Electronics, Inc. .............. 254 CS Hyde Company .............. 255

Del-tron Precision, Inc. .......256 DieQua ..................................... 257 Digi-Key Electronics ............258 Dodge Industrial ..................259 Dorner ......................................260 Dynatect Manufacturing, Inc ......................................... 261 Eagle Stainless Tube ......... 262 ElectroCraft, Inc. ..................263 Encoder Products Company ..........................264 EXAIR Corporation ..............266 Fabco-Air, Inc. ....................... 267 FAULHABER MICROMO .........................268 FESTO ......................................269 Fischer Connectors ............ 270 FluiDyne Fluid Power .......... 271 GAM .......................................... 272 GE Digital ................................ 273 GoEngineer ........................... 274 Harmonic Drive LLC ............ 275 Harwin ..................................... 276 HAWE Hydraulik ................... 277 HEIDENHAIN CORPORATION ............... 278 HELUKABEL USA ................ 279 Hunger Hydraulics ..............280 IDS Imaging Development Systems, Inc. .................... 281 igus ........................................... 282 Intech .......................................283 Interpower ..............................284 ITT Enidine .............................265 J.W. Winco, Inc. .....................285 Keller America Inc. ...............286 Keystone Electronics Corp. ................................... 287 KHK USA Inc. .........................288 KNF Neuberger ....................289 KOA Speer Electronics ......290 Koford Engineering .............. 291 Kollmorgen ............................. 292 Kuebler ....................................293 Kuriyama of America ..........294 Kyocera AVX ..........................295 Lenze Americas ...................296 Lin Engineering .................... 297 LinMot USA Inc. ....................298 Main Manufacturing ...........299

Master Bond .........................300 maxon ....................................... 301 METCASE ...............................302 Midwest Motion Products, Inc. ..................303 Miki Pulley U.S. .....................304 Misumi USA ...........................305 Mitsubishi Electric Automation ......................306 mk North America, Inc. ...... 307 MOCAP ....................................308 Moog Animatics ...................309 Murrelektronik, Inc. ............... 310 Nason ........................................ 311 NB Corp .................................... 312 ND Industries ......................... 313 New England Tubing Technologies .................... 314 New England Wire Technologies .................... 315 Newark, An Avnet Company ........................... 316 Nitto Kohki USA .................... 317 NORD DRIVESYSTEMS ....... 318 Novotechnik ........................... 319 NSK Precision .......................320 Ogura Industrial Corp. ........ 321 OKW Enclosures, Inc. ......... 322 OMRON Automation ........... 323 OMS Motion, Inc. .................. 324 OPC Foundation .................. 325 Opto 22 ...................................326 Oriental Motor ...................... 327 Parvalux ..................................328 PBC Linear .............................329 Permco ....................................330 phd Inc. .................................... 331 PI (Physik Instrumente) LP ........................................ 332 Pilz Automation Safety L.P. ....................................... 333 Pivot Point Inc. ..................... 334 PM B.V. .................................... 335 PMD ..........................................336 PTC ........................................... 337 Pyramid Incorporated ........338 R+W America .........................339 RAM Industries .....................340 Regal Rexnord ....................... 341 ROLEC Enclosures, Inc. ..... 342

Rota Engineering ................ 343 Rotor Clip ................................344 Ruland Manufacturing .......345 Sager Electronics ................346 Schmersal .............................. 347 SCHURTER Inc. .....................348 SDP/SI-Stock Drive Product ..............................349 SEW-Eurodrive .....................350 SICK, Inc ................................... 351 SIKO Products ....................... 352 Smalley Steel Ring .............. 353 Smart Products USA ..........354 SMC Corporation of America .............................355 Solidworks ..............................356 Sorbothane ........................... 357 Stratus Technologies ........358 Super Swivels .......................359 Tadiran Batteries .................360 Technosoft .............................. 361 Temposonics .........................362 The Lee Company ...............363 THK ...........................................364 TLX Technologies ................365 Tolomatic ................................366 TRACO POWER North America, Inc. ........ 367 Trelleborg Industrial Div .......................................368 Trim-Lok, Inc. .........................369 Turck ........................................ 370 Veljan Hydrair ........................ 371 WAGO Corporation ............. 372 Watlow ..................................... 373 Weidmueller ........................... 374 Weintek USA, Inc. ................ 375 Whittet-Higgins .................... 376 WON ST USA ......................... 377 Würth Industry North America ................. 378 Xometry .................................. 379 Yaskawa Electric America .............................380 Yates ......................................... 381 Zero-Max, Inc. .......................382

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