Design World July 2018

www.designworldonline.com

July 2018

inside: Motion Control: Brushless dc motors: options

for industrial power tools.

p. 56

Making

Linear Motion: Wider adoption of direct

drives for linear designs.

p. 66

Mechanical: Mastering coupling selection

fundamentals.

p. 86

embedded systems clock steady page 72

JULY 2018 DW COVER_FINAL.indd 1

7/10/18 8:57 AM

Integrated Automation, Motion & Drives USA at HANNOVER MESSE USA See the latest technologies and solutions driving the factory of the future.

September 10–15, 2018 McCormick Place, Chicago, IL hannovermesseusa.com

CO-LOCATED WITH

how Free s ion dmiss a r o o fl ode with c

WTWH A S U HM

HANNOVER MESSE 6-18.indd 75

5/31/18 3:03 PM

www.designworldonline.com

July 2018

inside: Motion Control: Brushless dc motors: options

for industrial power tools.

p. 56

Making

Linear Motion: Wider adoption of direct

drives for linear designs.

p. 66

Mechanical: Mastering coupling selection

fundamentals.

p. 86

embedded systems clock steady page 72

JULY 2018 DW COVER_FINAL.indd 1

7/10/18 8:57 AM

PURCHASE

PRODUCTS

ONLINE

www.thkstore.com Large Inventory

Easy Access

Major Credit Cards Accepted

Grease MSDS

2D/3D CAD & Product Configurator

Available for USA/Canada/ Mexico Customers

Collect Shipping Available

Quotation File

Clear lead times and prices are listed in the store (no RFQ required)

Contributes to quick delivery

Grease MSDS (Material Safety Data Sheets) can be downloaded

Visa, Mastercard, and American Express

We ship to the USA (mainland), Canada, and Mexico

2D/3D models and product configurator available for download in most file formats

Cart contents can be downloaded as quotation

Shipping via customer’s carrier account

Contact Us • If you have any questions, please contact TOSsales@thk.com.

• In addition to items in the store, we accept CUSTOM ORDERS.

Technical Support Available • technicalsupport@thk.com • https://tech.thk.com/

THK America, Inc. 200 E. Commerce Dr. Schaumburg, IL 60173

THK_DW 3-18.indd 1

6/28/18 3:19 PM

What’s in your AC Drive?

Features galore AND a wealth of options ALL at a great price.

DURAPULSE AC DRIVES STARTING AT

$422.00 (GS4-21P0)

DURApulse GS4 Series AC Sensorless Vector Drives Up to 300HP!

The DURApulse GS4 series of Variable Frequency Drives (VFD) includes many of the same standard features as our other GS drives including dynamic braking, PID, removable keypad, plus so much more: • Single-phase input capability on all 230VAC models • V/Hz control or sensorless vector control for improved speed regulation • 100kA Short Circuit Current Rating (SCCR) • 50°C temperature rating plus flange mount capability for industrial environments • STO - Safe Torque Off (TUV certified) • Built-in PLC (up to 10k steps) for drive-related logic and I/O control • Built-in analog, discrete, high-speed and relay I/O with expansion capabilities • Serial MODBUS RTU/ ASCII and BACnet protocols included • Optional Ethernet cards include MODBUS TCP and EtherNet/IP™ protocols • GS4 QuickStart menus simplify configuration • Smart keypad stores up to four sets of drive configurations for back-up and transfer to additional GS4 drives • Fire mode and circulatory control mode • Field upgradeable firmware • Free drive configuration and PLC Programming software

Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2016 AutomationDirect, Cumming, GA USA. All rights reserved.

AutomationDirect 7-18.indd 1

Upgrade I/O capabilities AND communications options

4 Digital Inputs 6 Digital 2 Digital Outputs Inputs

EtherNet/IP™

6 Relay Outputs

Modbus TCP

Research, price, buy at:

www.go2adc.com/GS4

1-800-633-0405

the #1 value in automation

6/28/18 3:24 PM

FREAK © Allied Electronics & Automation, 2018

Allied Electronics 2-18 - spread_DW.indd 2

6/28/18 3:24 PM

Automation & Control Freak?

Same here.

We carry more automation & control brand names than any other distributor in North America.

It’s true – we checked.

Get your A&C fill at Allied Electronics 2-18 - spread_DW.indd 3

alliedelec.com

1.800.433.5700 6/28/18 3:25 PM

NEW!

4 AXIS SERVO from

2.25”

I n s ights

We can use our brains better At the recent AICD annual conference in San Antonio, Holly G. Green of The Human Factor Inc. gave a fascinating talk about our brains, and how we can retrain them to work better on the job. While the world has evolved at amazing speed over the last decade and the last century, our brains really haven’t. There’s an increasing disconnect with our brain versus the increasing pace of the world.

Central to understanding our brain is understanding that it really likes well-worn pathways. But, Green explained, the brain can learn new pathways, even in advanced age.

“There’s that old cliché about how old dogs can’t learn new tricks. We’re not sure about dogs, but for humans, we do know that unless you’re dead or your brain is diseased, you can learn new tricks,” she said. “You can build new pathways. The problem is it requires a little bit of time, and it requires attention. And, at the pace we’re running today we don’t ever feel like we have that.”

- brushed or bldc motors - 5 amps per axis - 16 analog inputs - 16 on/off drivers - home and limit in - live tech support - made in the USA See the

EZQUAD SERVO in action!

WWW.ALLMOTION.COM

(510) 471-4000 30097 Ahern Avenue Union City, CA 94587

Some interesting tidbits from her talk: • Contrary to popular belief, we don’t use a mere 10% of our brains. Our brain does focus on about 10% of the incoming data—light, smell, sounds, etc.—to focus on and make inferences from. To prove her point, she had the attendees close their eyes and think about exactly what was on the walls of the ballroom they were seated in. Eyes opened a few moments later, she pointed out a multitude of objects and details that were clearly observable, but which our brains had chosen to ignore, out of a lack of importance.

• Our brains, which only weigh about three pounds, use up about 25% of our body’s energy. Green said to schedule important work meetings early in the day or close a big deal early in the day, before our brains become more tired. “You definitely have decision fatigue in today’s world.”

• There is no such thing as multitasking in a human. Sometimes, what looks like multitasking is that you’re switching between tasks. You can do multiple rote behaviors at a time, but you can only do one thinking task at a time. “You’re switching back and forth, and each time takes a few seconds … start adding that up and imagine how many times you switch in a day. How much time are you actually wasting, by pretending to do more? It’s a fascinating thing, and something that gives worry to behavior scientists.”

• Green said one answer is to purposefully slow down. Take 30 seconds, at different times each day, to reset your brain. Clear your mind, ponder, wander, explore your thoughts. Ask yourself big questions, like, “What if my customers would like this now? I knew two years ago they didn’t go for it, but what if today is the right time? What if I could join with a competitor on this, and we could offer a better solution that benefits each of us even more? What if?”

• Make sure to constantly consume the big picture. What are the trends in today’s world? How can I take advantage of that? How can I carve out just enough time to visit a thought, to fill my brain with some really interesting stuff? You cannot connect dots if you haven’t gathered any dots first. And in today’s world we’ve stripped out the gathering of dots. Visit trend sites like nowandnext.com, globaltrends.com, trendwatching.com, burrus.com to help you think big picture. DW Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com

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

(408) 460-1345

On Twitter @ DW—Editor

4

July 2018 www.designworldonline.com DESIGN WORLD

Insights 7-18_Vs4.LL.indd 4

6/29/18 4:29 PM

The Secret To Keeping Electronics Cool!

NEMA 12 Cabinet Coolers The NEMA 12 Cabinet Coolers for large heat loads up to 5,600 Btu/hr. are ideal for PLCs, line control cabinets, CCTV cameras, modular control centers, etc.

• Measures 8" (203mm) high • Mounts top, side or bottom • Enclosure remains dust-tight and oil-tight

NEMA 4 and 4X Cabinet Coolers NEMA 4 and 4X Cabinet Coolers for large heat loads up to 5,600 Btu/hr. They are ideal for PLCs and modular controls.

• Enclosure remains dust-tight, oil-tight and splash resistant • Suitable for wet locations where coolant spray or hose down can occur

Type 316 Stainless Steel Cabinet Coolers Type 316 Stainless Steel Cabinet Coolers for NEMA 4X applicat-ions are available for heat loads up to 5,600 Btu/hr.

• Resists harsh environments not suitable for Type 303/304 • Ideal for food and chemical processing, pharmaceutical, foundries, heat treating and other corrosive environments

Mini NEMA 12, 4, and 4X Cabinet Coolers

DON’T DO THIS!

It is an OSHA violation that presents a shock hazard to personnel.

The fan blows hot, humid, dirty air at the electronics.

Refrigerant panel air conditioners cause condensation and moisture.

When condensation is present, electrical components can begin to erode, resulting in severe damage.

A bad choice could cost you thousands!

Look Familiar?

When hot weather causes the electronics inside a control cabinet to fail, there is a panic to get the machinery up and running again. The operator might choose to simply open the panel door and aim a fan at the circuit boards. In reality, the fan ends up blowing a lot of hot, humid, dirty air at the electronics and the cooling effect is minimal. If the machinery starts functioning again, the likelihood of repeated failure is great since the environment is still hot (and threatens permanent damage to the circuit boards). Worse yet, that open panel door is an OSHA violation that presents a shock hazard to personnel.

The Real Solution!

Stop electronic downtime with an EX AIR Cabinet Cooler® System! The complete line of low cost Cabinet Cooler Systems are in stock and can ship now. They mount in minutes through an ordinary electrical knockout and have no moving parts to wear out. Thermostat control to minimize compressed air use is available for all models. All Cabinet Coolers are UL Listed to US and Canadian safety standards.

Watch The Video! https://exair.co/58_ccv_ad The only compressed air powered cooler that is CE compliant!

High Temperature Cabinet Coolers

Non-Hazardous Purge Cabinet Coolers

The mini NEMA 12, 4 and 4X Cabinet Coolers for small heat loads up to 550 Btu/hr. are ideal for control panels, relay boxes, laser housings, electronic scales.

High Temperature Cabinet Coolers for NEMA 12, 4 and 4X applications are available for heat loads in many capacities up to 5,600 Btu/hr.

• Measures 5" (127mm) high • Mounts top, side or bottom • Enclosure remains dust-tight and oil-tight

• Suitable for ambients up to 200°F (93°C) • Ideal for mounting near ovens, furnaces, and other hot locations

“It took us three days to get a replacement computer cabinet and we didn’t want to risk another heat failure. Fans weren’t an option since they would just blow around a lot of hot air. Freon-type air conditioners like those on some of our other machines were a constant maintenance project of their own. We purchased EXAIR’s Model 4330 NEMA 12 Cabinet Cooler Jeff Hauck, Lasercraft Inc. Cincinnati OH System since it was easy to install and requires no maintenance.”

exairSKECad_DW.indd 1 Exair 7-18.indd 5

BE AWARE OF CONDENSATION!

NHP Cabinet Coolers keep a slight positive pressure on the enclosure to keep dirt from entering through small holes or conduits. For use in nonhazardous locations.

• Uses only 1 SCFM in purge mode • For heat loads up to 5,600 Btu/hr.

• NEMA 12, 4 and 4X

If you would like to discuss an application, contact:

11510 Goldcoast Drive Cincinnati, Ohio 45249-1621 (800) 903-9247/fax: (513) 671-3363

https://exair.co/58_440

@exair

6/5/18 4:27 6/28/18 3:25 PM PM

Teschler on Topic Not out of tricks: Why automakers don’t worry about fuel economy mandates A funny thing happened when politicians recently floated the idea of freezing automotive fuel economy standards: Automakers collectively said not to bother. A spokesperson for the Alliance of Automobile Manufacturers, a trade group representing major automakers, told a U.S. House of Representatives panel that, “We support standards that increase year over year that also are consistent with marketplace realities.”

The reason automakers don’t hyperventilate over tighter fuel economy standards was evident at this year’s Society of Automotive Engineers’ world conference. There, it was possible to see one technical presentation after another devoted to squeezing additional mileage out of internal combustion engines, ICEs. And numerous presenters openly scoffed at the idea that ICEs were obsolete technology.

On the floor of the SAE show exhibition area, you could also find a few ICE architectures that took nontraditional approaches to produce inventions that delivered better fuel efficiency. Companies promoting these odd-ball engines universally realized there was no chance their creations could become mainstream powerplants for vehicles. Instead, they pitched their

ICEs as range extenders that could run a generator for recharging the battery on electric vehicles.

Even so, developments at the SAE show seem to indicate nontraditional ICEs will have difficulty earning a role even as EV range extenders. The history of fuel economy leads us to conclude that those dissatisfied with the mileage available from existing ICE technology needn’t resort to Stirling engines or horizontally opposed piston engines to get improvements.

All that’s necessary is to wait awhile – designers of traditional engines aren’t out of ideas for improving fuel economy. And they can do so with engine architectures that have been perfected over the course of more than 100 years of development, rather than resorting to new engine layouts having unknown unknowns.

There’s another reason automakers might not do a lot of hand-wringing over tougher fuel economy standards.

Fuel economy measures, known as CAFÉ standards in the U.S., don’t have the same bite they once did.

An illustration comes from Arik Levinson of Georgetown University, writing for the National Bureau of Economic Research. Levinson’s main thesis is that taxing the use of energy, rather than regulating the fuel economy of cars, would actually be fairer and more equitable for

poor people and be more cost effective to boot. He also points out that CAFE standards cost three to ten times as much as a gasoline tax, per ton of carbon dioxide avoided. So efficiency standards are, ironically, inefficient.

The inefficiencies were made worse by a change in CAFÉ calculations in 2011.

Fuel economy targets originally were simple averages. Each manufacturer could meet those targets by selling more fuelefficient small cars and fewer large gas guzzlers. But 2011 ushered in footprintbased CAFE standards. (Vehicle footprint is the area under its four tires.)

What’s interesting is that these new standards give larger cars a more lenient mileage target. For example, a carmaker selling only small cars in 2016, with footprints of 41 ft² or less, had to meet a target of 41.09 mpg. A carmaker selling large cars with footprints exceeding 56 ft² had to hit just 30.96 mpg. Cars between those two extremes face a sliding scale, with an average of 37.8 mpg based on projected sales.

Levinson points out that under this bizarre rule, Cadillacs meet the efficiency standard, but fuel-efficient Sonics do not. So GM can sell noncompliant Sonics, but their sales must be offset by sales of Cadillacs.

In a system where relatively less fuel-efficient big cars subsidize sales of econocars, it is no wonder carmakers tend to worry less about meeting mileage standards. DW

Leland Teschler • Executive Editor lteschler@wtwhmedia.com On Twitter @ DW—LeeTeschler

6

July 2018 www.designworldonline.com

Lee Teschler Column 7-18_Vs2.LL.indd 6

DESIGN WORLD

6/28/18 3:31 PM

WELCOME to automation24.com Your online shop for automation technology

9 High-quality products 9 Competitive prices –

no minimum order quantity

9 Same day shipping 9 Excellent customer service

& technical support

High-quality products from well-known manufacturers:

We are happy to advise you personally! +1 800-250-6772 (free) +1 610-981-2900

Automation24_7-18.indd 7

mail@automation24.com

LIVECHAT www.automation24.com

...

LIVECHAT

Brandon Hobusch Technical support

6/28/18 3:26 PM

Technology Forward Why use

3D printing?

Of what use is additive manufacturing and 3D printing really? It’s a fair question and one that must be answered before this technology gains wider acceptance among designers, engineers, and executives. Materialise, a noted provider of software and 3D printing services, recently hosted a conference— the Materialise Experience—to offer thought-provoking presentations and industry insights into this technology.

And to promote the use of this technology in a range of fields.

One presentation gave an unexpected reason on why use 3D printing. The reason was because 3D printing can reduce or eliminate fear.

The presentation was for the medical use of 3D printing, specifically in medical simulation. 3D printing is increasingly being used in this area—a market that is expected to reach $2.5B by 2022, a 14.9% rate of growth from now until 2022.

Boston Children’s Hospital is a user of medical simulation and has developed a program around it.

Dr. Peter Weinstock’s presentation addressed the question of why use 3D printing? The answer was because it can eliminate fear.

3D printing allows health care professionals to “practice prior to game time.” It helps the surgery team move past a number of fears—fear of complexity, inefficiency, poor teamwork, incompetency, unpreparedness, lack of sleep, disorganization, and the unexpected. Simulation lets you fail without risk or consequence; a useful benefit in any industry.

3D printing can be used to make life-like, accurate reproductions of a patient’s anatomy enabling the surgical team to practice as often as necessary until they know what to expect and what to do about it. Such practice removes the fear of what could go wrong.

Consider the story of Todd, a child born with what appeared to be his brain outside his skull. Todd’s parents were desperate to help their child. They went to several hospitals and no one really wanted to take on this surgery. Then they approached Boston Children’s Hospital. A surgeon put together a medical team and they used their 3D printing simulation lab to create a replica of Todd’s skull. It wasn’t until hours of practice later that the head surgeon, in the middle of the last simulation, said for the parents to

put their child on a plane to come for surgery. Dr. Weinstock, who was the anesthesiologist for the surgery, thought the surgery would take 14 hours. It took four. He thought the child would be in ICU for a week. It was three days. The ability to practice, to simulate everything helped reduce surgical time, and helped speed recovery.

Simulation through 3D printing also makes reaching treatment consensus faster, which gets patients into surgeries more quickly and moving that much faster into healing.

The ability to simulate also helps patients and their families, giving them confidence in knowing what to expect and in seeing the preparedness of the surgical team.

As Dr. Weinstock noted, “Nothing in life is to be feared, it is to be understood, and 3D printing makes this possible.” DW

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

8

July 2018 www.designworldonline.com

Tech Forward 7-18_Vs2.LL.indd 8

DESIGN WORLD

7/6/18 10:19 AM

LESS

Pressure Valve

Floating Gear

Oil Valve

ALL SPRINGS ARE NOT EQUALÂŽ Reduce spring height by 50% over ordinary coil springs while maintaining the same force and deflection. Standard parts available in stainless and carbon steel. Need custom? No problem.

We’ll provide you with the right spring, in the right material, for your application.

FREE SAMPLES: Call (866) 478-9757, or visit expert.smalley.com/DW/springs

Smalley 7-18 (50% less space).indd 9

7/9/18 11:32 AM

Whether it’s a standard off-the-shelf cylinder or a cutting-edge custom assembly, Bimba is uniquely positioned to help with your motion control application. That means everything from simple, non-repairable products to the latest in precision mechatronics or end-of-arm tooling applications. If you’ve got an engineering challenge, Bimba has the solution. From innovative design to unparalleled customer service, it’s all about getting you the right solution at the right time.

© Copyright 2018 Bimba.

All rights reserved.

www.bimba.com BIM-11339 Bimba10 Resizes 2018_DW_WMTM_050118.indd 1 Bimba 5-18.indd

4/9/18 8:52 6/28/18 3:28 AM PM

Green Engineering • VP, Editorial Director

Should I turn my compressor

off at night?

Often, because compressors are located in a far-off corner of the building, air compressors are left to run all night and on weekends. If there are no production activities during these hours, the air compressor(s) will continue to feed leaks and other miscellaneous loads, such as air consuming equipment left on, or air dryer purge. Depending on how many cubic feet per minute these consume, the compressor operating costs can be significant.

With a facility that has only one production shift that requires the compressor to be on 10 hours per day, 5 days per week … the non-production hours (2,550 hours) represent only about 30% of the total 8,760 hours in a year. And if the facility leakage level is about average, about 30% of total production flow, the annual energy consumption for leaks might be substantial.

Let’s say, for example, about 15 cubic feet per minute for a 25 hp (18 kW) system. This would equate to about 28,000 kWh annually. At $0.10 per kWh this would cost about $2,800 per year in extra energy (larger compressed air systems would cost proportionally more). The extra 6,200 operating hours per year would also add maintenance costs. In systems such as this, the off-hours production usually equates to 40% to 50% of the total annual compressor energy consumption!

| istockphoto.com

Paul J. Heney

Turning off the compressor during nonproductive hours can save these additional costs and help your system last longer.

Here are some tips: • Realize that power during non-productive hours is often less costly than during the daytime, therefore the savings are sometimes not as much as you expect.

• If you have a large storage receiver, the pressurization of the plant can take quite a while. Time can often be saved by allowing the receiver to remain pressurized overnight (simply turn off the valve to the plant and allow the compressor to keep it pressurized during off hours).

• Turning the air dryer off during off hours will save additional power if it is a refrigerated style.

• If you have some critical loads that must be pressurized overnight—like HVAC systems or dry charged fire systems—often times, using a small reciprocating compressor to feed these exclusively can save energy.

• Make sure you keep on top of your leak level; measuring the leakage flow at the end of shift or in early morning is the easiest time. DW

Submitted by Ron Marshall

DESIGN WORLD

Green Engineering 7-18 Vs2.LL.indd 11

www.designworldonline.com

July 2018

11

6/29/18 4:28 PM

Contents 7 • 2018

•

vol 13 no 7

•

designworldonline.com

66 56 _MOTION CONTROL

80 _ELECTRONICS

Brushless DC Motors: Options for industrial power tools

When test flows meet workflows

Software for test instrumentation now

Power tools have operating profiles

has as much to do with the automation

that differ from those of most other

of workflows as with technological

motor-driven applications. That’s

advances for analyzing measured

why motors that go into these tools

parameters.

need specialized designs.

66 _LINEAR MOTION Wider adoption of direct drives for linear motion designs

Some applications are migrating from

rotary mechanics to direct-drive linear.

Simpler mechanics, better linear control,

and faster response are key benefits.

72 _TEST & MEASUREMENT

86 _MECHANICAL Mastering coupling selection fundamentals

Mastering coupling selection begins with

understanding the fundamental

capabilities of several different coupling

types. Here are the pros and cons of three

different couplings and when to

use them for specific applications.

Making embedded systems clock steady

Clocks are the heartbeat of embedded

systems. Modern oscilloscopes offer

a broad set of measurements that

take the mystery out of characterizing

and troubleshooting clock jitter.

12

July 2018 www.designworldonline.com

CONTENTS 7-18_Vs2.LL.indd 12

ON THE COVER Modern digital oscilloscopes are making timing and jitter measurements almost routine. | istockphoto.com

A | S | B | P| E

A | S | B | P| E

A | S | B | P| E

American Society of Business Publication Editors

American Society of Business Publication Editors

American Society of Business Publication Editors

2018 Regional

2018 National

Fostering B2B editorial excellence

Fostering B2B editorial excellence

Fostering B2B editorial excellence

2018 Regional

PR INT

DESIGN

DESIGN

Revenue of over $3 million

Revenue of over $3 million

Revenue of over $3 million

Award Winner

Award Winner

Award Winner

DESIGN WORLD

7/2/18 9:38 AM

180330_CYW_DW_US.indd 1 Digi-Key 5-18.indd 13

3/29/18 6/28/18 1:23 3:30 PM PM

7.18

• contents

departments 04 Insights 06 Teschler on Topic 08 Technology Forward 1 1 Green Engineering 16 Design For Industry 26 Design Notes 36 Internet of Things 46 Sensor Notes

50 CAE Solutions 90 Product World 96 Ad Index

HELUKABEL produces cables and wires required for semiconductor manufacturing that can withstand fast-paced and precise movements without contaminating the cleanroom evironment.

A cleanroom-certified track cable, built to maintain the highest levels of cleanliness in order to consistently perform under tight manufacturing conditions.

E-NEWS

CONTENTS 7-18_second page_Vs1.indd 14

14

July 2018

DESIGN WORLD

7/2/18 9:40 AM

DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

CREATIVE SERVICES

DIGITAL MARKETING

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

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics

Digital Marketing Director Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia

Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting

Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer

Digital Marketing Specialist Anna Casey acasey@wtwhmedia.com @wtwh_anna

Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler

Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison

Webinar Manager Lisa Rosen lrosen@wtwhmedia.com

Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion

Graphic Design Intern Anne West awest@wtwhmedia.com

Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

DIGITAL MEDIA/WEB/ DEVELOPMENT

Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave

Senior Digital Media Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick VIDEO SERVICES

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com FINANCE

Controller Brian Korsberg bkorsberg@wtwhmedia.com

Videographer Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh Videographer Derek Little dlittle@wtwhmedia.com @wtwh_derek

Leadlift Onboarding Specialist Mike Ulanski mulanski@wtwhmedia.com @wtwh_mike EVENTS

Events Manager Jen Kolasky jkolasky@wtwhmedia.com @wtwh_jen Events Marketing Specialist Christina Lograsso clograsso@wtwhmedia.com @wtwh_christina PRODUCTION SERVICES

Customer Service Manager Stephanie Hulett shulett@wtwhmedia.com Customer Service Representative Tracy Powers tpowers@wtwhmedia.com Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com Customer Service Representative Julie Ritchie jritchie@wtwhmedia.com

Accounts Receivable Specialist Jamila Milton jmilton@wtwhmedia.com

Digital Production Manager Reggie Hall rhall@wtwhmedia.com Digital Production Specialist Brian Furda bfurda@wtwhmedia.com

2011 - 2017 2014 Winner

WTWH Media, LLC 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103 Ph: 888.543.2447 | FAX: 888.543.2447

Medical Design & OUTSOURCING

DESIGN WORLD

Staff page 7-18_Vs1.indd 15

www.designworldonline.com

July 2018

15

7/5/18 9:05 AM

Design for Industry Food and Beverage

More capacity for

high-force electric actuator

W

When an application needs the force of a hydraulic cylinder but such a cylinder will not fit for other reasons, an alternative is the RSX080 actuator. This economical actuator delivers forces up to 18,000 lbf (80 kN). Designed and tested for 100% duty cycle, it is roller-screw driven for long, consistent life in demanding environments. Applications include pressing, punching, stamping, riveting, fastening, joining, injection molding, and sawmilling.

In addition to the RSX080, there is the RSX096 linear actuator (30,000 lbf; 130 kN). The heavy-duty construction of both models includes tie rods and Type III hard-coat anodized aluminum or zinc-plated steel. A standard anti-rotate feature prevents the rod from rotating without external guidance.

Rated IP65 with an IP67 option, the actuator resists water from a light washdown and dust from outdoor environments. The RSX actuator is also designed and rated for extreme conditions including cold-weather operation. A food-grade version, designed for volumetric filling and other high-force food-and-beverage applications, is made of 316 stainless steel and food-grade white epoxy to meet USDA specifications. DW

Tolomatic | www.tolomatic.com 16

July 2018 www.designworldonline.com

DFI 7-18 Vs4.indd 16

DESIGN WORLD

7/2/18 10:56 AM

Food and Beverage

Encoders for motor feedback

W

When addition measurements of revolutions is needed in food and beverage applications, the hollow option for these shaft-feedback and direct drives systems may be an answer. They feature industrial HIPERFACE standard interface and multiturn function for additional measuring of revolutions.

The SES/SEM70/90 are motor feedback systems offered in 25 mm and 55 mm diameters that use holistic sensing capacitive technology, which makes them unaffected by external influences such as electromagnetic interference and humidity. The products’ compact design saves space and weight and lowers maintenance costs. In addition, the design gives it high shock and vibration resistance, which makes them more rugged and reliable. The SES/SEM70/90 can be directly mounted onto the shaft without additional mounting tools for quick installation and

makes transmission components, such as timing belts or couplings unnecessary.

In addition, the SES/SEM70/90 have single and multiturn versions available.

The mechanical multiturn function takes additional revolution measurements without the need for additional components such as external batteries and cables. The mechanical aspect eliminates loss of the absolute position due to a dead battery. DW

SICK | www.sick.com

We’re Big on Small Details.

Quality. Service. Care.

UNSURPASSED QUALITY IN PRECISION, CUSTOM ELASTOMER MOLDING FOR RUBBER, PLASTICS AND TPE. With over 40 years experience, superior capabilities

and unmatched service, even the smallest detailed component is no big deal for Da/Pro. Call today for more information. Or visit us online at www.daprorubber.com.

Since 1960

Electronics • Controls • Medical Components • General Applications • Precision Tolerance • Virtually Flash-free Parts • Rubber to Metal • Rubber to Plastic Diaphragms With +/– .0015” Tolerance • Custom Compounding • Prototype Tooling Designed to be Incorporated Into Multi-cavity Production Tooling

Injection - Compression - Transfer - LIM • ISO 9001:2008 • Class 10,000 Cleanroom • ITAR Registered USA 918.258.9386 • Europe 49.251.32266.0 • Singapore 65.6264.1880 • EMail - Sales@DaProRubber.com • ©2009 DaPro Rubber, Inc. All rights reserved.

DESIGN WORLD

DFI 7-18 Vs4.indd 17

www.designworldonline.com

July 2018

17 7/2/18 10:56 AM

Design for Industry Medical

Chip antennas fit tight space needs in medical devices

T

Traditionally, small chip antennas used in RF-enabled medical devices have required a designated ground “keep out”

area to minimize interference from other components and ensure the ideal radiation pattern for wireless signals. In some cases, this reserved space can eat up as much as 15 x 20 mm of the printed circuit board.

However, with the drive to further miniaturize next generation medical biosensors and wearables, new alternatives are entering the market that allow the chip antenna to be mounted directly above metal surfaces. By doing so, as much as 10-20% of the space traditionally reserved for the keep out area is no longer required. The chip antenna is suitable for an array of “smart” devices such as watches, clothing, eye glasses, patches, pills and even adhesive bandages.

To work properly, chip antennas have typically been ground plane dependent, meaning they require an appropriately sized and positioned ground plane to form a complete, resonant circuit.

While the PCB can serve as the ground plane, the antenna itself must typically be placed on the edge of the board in an isolated section that is free from ground and metal components that would distort its radiation. Without the isolation distance, the performance of the antenna is affected.

18

“The ‘keep out area’ is fundamental to ensure the chip antenna can electromagnetically radiate to antenna applications, because everything affects the radiation pattern including the package size, where the antenna is mounted and its proximity to the human body,” says Manuel Carmona of Johanson Technology, a leader in high frequency ceramic components including chip antennas, High Q capacitors and EMI chip filters.

According to Carmona, Johanson Technology has been able to eliminate the requirement for a designated ground keep out area through optimization of materials (ceramics and inks), manufacturing processes and RF circuit design.

The 2.4 GHz antenna can be mounted directly onto the metal ground plane.

The product measures 2 x 5mm and is designed for small coin-cell battery operated IoT, 2.4 BLE, wearable, ISM, ZigBee, and 802.11-standard applications where metal or a battery/display covers the entire length or side of the PCB.

July 2018 www.designworldonline.com

DFI 7-18 Vs4.indd 18

The design of the antenna is also critical to range and performance. For example, with medical devices, radio interference could result in interrupted connectivity.

There can be legal ramifications as well. As with any wireless device, products that use RF technology, including Bluetooth, to collect or transmit information are subject to regulation by the Federal Communications Commission (FCC).

“A chip antenna that can be mounted over a ground plane opens up many applications for products that want to incorporate wireless,” says Carmona. “To date, we have received everything from smart shirt buttons to jewelry and other wearables in various shapes and sizes.”

DW

Johanson Technology | www.johansontechnology.com

DESIGN WORLD

7/2/18 10:57 AM

SE2Lad10FAOL.pdf

1

6/18/18

11:13 AM

C

M

Y

CM

MY

CY

CMY

K

IDEC 7-18.indd 19

7/2/18 8:27 AM

SEAL

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

and

DELIVER

Position sensor for tall cylinders

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

T

The SGH50 uses a clever cable mechanism for absolute measurement of hydraulic

or telescopic cylinders. The sensor makes it possible to measure distances up to 5 m. Target applications are agricultural machinery, construction machines, municipal vehicles, forestry machines, piston accumulators and other industrial applications.

The SGH50 can be integrated into hydraulic and telescopic cylinders and has a durable design. A special plastic developed specifically for the purpose, which is characterized by an extension of fluid temperature resistance from 85°C to 105°C, is responsible for this.

The SGH50 meets the specifications of the most extreme vibration standards and easily copes with shocks 100 times the force of gravity. Unlike rod-based sensors, its flexible cable completely absorbs vibrations. The

hydraulic medium provides additional damping of any vibration.

Analog interfaces, CANopen or SAE J1939 provide the communication between the SGH50 sensor and machine control system. Applications in which maximum functional safety is essential can be supplied with redundant SGH50 versions (CAT3, PLd) in accordance with EN13849. For safety variants, SIKO also offers redundant or analog interfaces, redundant CANopen, redundant SAE J1939 or CANopen-safety. DW

SIKO | www.siko-global.com A Carlyle Johnson Company

centritecseals.com 860-643-1531 20

DFI 7-18 Vs4.indd 20

July 2018

www.designworldonline.com

DESIGN WORLD

7/2/18 11:13 AM

O f f- h i g h w a y

Wind turbine yaw drives yield greater efficiency

U

Using unique roller gear technology, these wind

turbine Yaw Drives have an unparalleled power to weight ratio. With aluminum housings, these yaw drives are up to 50% lighter creating a premium weight to torque ratio.

This power density makes installation and maintenance/ repair easier and faster, especially when working at height

1

1/25/18

DW

Gearing Solutions | www.gearingsolutions.com

in a restricted space environment.

TL Design Worls ad copy.pdf

The lighter weight also allows the Yaw Drive to be more responsive, quickly redirecting alignment so that the turbine blades face the wind, producing the maximum amount of electrical energy at all times. These designs suit turbines ranging in size from 10 kW to 50 kW for agricultural, industrial and home wind turbine markets.

8:28 AM

Same Day Shipping on Thousands of Parts

CALL US TODAY!

FREE SAMPLES

C

M

Y

CM

MY

CY

Test Our Trims and Seals for Fit and Function

FREE CATALOG

Quickly View Our Most Popular Lines of Trims and Seals

CMY

DESIGN ASSISTANCE

K

Let Us Help you Find the Right Trim and Seal

IF YOU HAVE AN EDGE… WE HAVE A TRIM! 800-933-4915 HEADQUARTERS 6855 HERMOSA CIRCLE BUENA PARK, CALIFORNIA 90622

DESIGN WORLD

DFI 7-18 Vs4.indd 21

MIDWEST MANUFACTURING 1642 GATEWAY COURT ELKHART, INDIANA 46514

www.designworldonline.com

LOCAL: 714-562-0500 FAX: 714-562-0600

WWW.TRIMLOK.COM INFO@TRIMLOK.COM

July 2018

21

7/5/18 8:15 AM

Design for Industry Robots

Silicone material enables the

3D printing of soft robotic grippers

S

Soft robotics is a subfield of robotics that uses compliant materials. It mimics living organisms

and adapts to its surroundings. For robots, it increases flexibility and adaptability.

To make grippers for soft robotics, the ACEO team from Wacher Chemie AG chose 3D printing because this technology lets designers customize the grippers into varying sizes, shapes and weights. The elastomer material is made from 100% silicone and can be used in food applications and also offers biocompatibility. It is based on Wacker Chemie AG silicone rubber technology.

Silicone elastomers are inorganic synthetic rubbers with unique combinations of chemical and mechanical properties such as hardness or color variation. Silicone is temperature-stable and media resistant. It comes in a nearly limitless array of color, including transparent and black grades. It can be formulated to conduct electricity

or to insulate. Certified silicones are biocompatible, suitable for healthcare applications.

The ACEO team uses a 3D printing process based on a drop on demand principle. The print head deposits single silicone voxels on a building platform, which flow together smoothly, forming a homogeneous surface. After printing a layer, the curing is activated by a UV light. For designs with complex structures, overhangs and cavities, a support material is printed simultaneously.

The support material is easily removed with water.

Then, the part is post-cured to get its final mechanical properties. DW

Wacker Chemie AG | www.aceo3D.com

22

July 2018 www.designworldonline.com

DFI 7-18 Vs4.indd 22

DESIGN WORLD

7/2/18 11:13 AM

Ready to get things moving.

Highly dynamic drive for robotics and industrial applications.

Our 80 mm ECI brushless DC motor offers a new dimension of power.

– Compact drive with high power density – High dynamics with remarkable overload capacity – Less power loss thanks to high efficiency – Compatible with different gearboxes More information contact sales@us.ebmpapst.com

EBM Papst 7-18.indd 23

7/2/18 8:28 AM

Design f o r I n d u s t r y Packaging

With embedded magnets, compact

WHEEL OF FORTUNE We love to see YOU win!

rutronik.com/18244

gearmotors offer wide speed range

T

The IPMax is a line of efficient, lightweight, compact interior permanent magnet (IPM) gearmotors with a wide synchronous speed range. These gearmotors incorporate magnets embedded within the rotor, as opposed to on the surface. No copper losses are experienced in the rotor, and considerably less copper losses occur in stator winding. The

Electronics

Worldwide

High-Tech Components for Your Innovations

As a leading distributor of electronic components we are able to offer you a wide portfolio of products, expert technical support for product development and design-in, individual logistics and supply chain management solutions as well as comprehensive services.

Semiconductors

Displays & Boards

Passive Components

Storage Technologies

Electromechanical Components

Wireless Technologies

For more information about RUTRONIK: sales-na@rutronik.com | www.rutronik.com

Committed to excellence Consult | Components | Logistics | Quality

DFI 7-18 Vs4.indd 24

gearmotors can operate fanless up to 1 hp, and do not require encoders for sensor control. When stopped, a servo lock feature holds the motor in position.

These gearmotors are 23% smaller than comparable ie3 motors, and run 24% cooler for longer lifespan. They employ brake sequential – which sets motor operations when the mechanical brake is turned on or off – as well as a torque limit solution that protects the mechanical system. Various functions of their programmable I/O terminals may be changed according to external circuits or applications. RS485 is included as standard.

Interior permanent magnet motors are suitable for conveyors, fans, and pumps, and are frequently used for factory automation, material handling, packaging, and food processing.

In addition to reduced size and weight, the IPMax gearmotors offer an ingress protection rating of 65 (IP65), meaning they are protected from total dust ingress as well as from low pressure water jets from any direction. Additionally, compared with a brushless dc gearmotor, the IPMax gearmotors feature simple wiring and are easier to connect.

They also offer similar high efficiency without requiring any extra signal cable. DW

Brother Gearmotors | www.BrotherGearmotors.com 24

July 2018

DESIGN WORLD

7/2/18 11:14 AM

IR RT

HA

TY RI CU SE

RF Memory Protection Device 7-18.indd 25

DATA ENCR YPTION

LA N

W

IR EL ES S

?

ZIG BEE

m e m o ry p r o t e c t i o n d e v i c e s

RA LO

X A M I W

MPD

E V A W O R C I M

M e m o ry p r o t e c t io n d e v ic e s . c o m

7/2/18 8:29 AM

Design Notes

A hole was cut in the bottom of this flatbed just to move the mammoth sheave off the bridge.

How to move a bridge with massive bearings

Edited by Mike Santora • Associate Editor Built in 1964, Cleveland’s Willow Avenue Bridge stretches 350-ft over the Old Cuyahoga River Channel, connecting Whiskey Island peninsula to the downtown area.

Hundreds of trucks cross this vertical-lift bridge each day, many loaded with salt mined from under Lake Erie.

The main span of the bridge—some 310-ft of steel and concrete — can rise vertically while remaining parallel with the deck, allowing river traffic to pass below. Two large sheaves housed in towers at each end of the bridge lift and lower the main span much like an elevator. These plus-sized pulleys stand nearly 15-ft tall and tip the scale at around 20 tons each.

It takes big bearings to move a structure this size. Mounted to each sheave is a housed cylindrical bearing weighing more than a sedan. Torrington, now owned by Timken, designed these massive 3,000-pound units for the bridge more than 50 years

26

July 2018 www.designworldonline.com

Design Notes 7-18_Vs4.LL.indd 26

DESIGN WORLD

7/2/18 11:15 AM

LEMO THE ORIGINAL PUSH-PULL SOLUTION

ago. Each has a unique spherical OD that allows for misalignment of the large shaft, and each uses a unique brass double seal for durability and protection against dirt and debris.

This arrangement also uses a thrust cylindrical bearing that helps to properly locate the large shaft, given the considerable forces acting on the sheave.

Of course, thousands of operational cycles can wear down even the most rugged bearings, so when the northwest sheave assembly started to show its age in 2015, city engineers called the Timken engineering team to build a new bearing just as large and long-lasting.

The engineering team determined the best way to replace the bearing was to remove the sheave from its tower. This required one crane and two weeks of traffic shutdown, making time a crucial factor as deviation from this schedule could result in daily fines of $25,000.

With Torrington’s original designs in hand, engineers began to build the new bearing. Throughout this stage engineers conducted a series of stringent component inspections and CMM measurements, taking special

care to ensure everything would fit flawlessly and that installation would go smoothly for the city, given the critical timing of the repairs.

In fact, the Timken engineering team was on-site in Cleveland for the entire bearing replacement process that was completed over just a few days without issue or delay.

As a result, the Willow Avenue Bridge quickly resumed operations and city officials were pleased with the project’s fast progress. DW

Timken | Timken.com

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

LEMO, a global leader in the design and manufacturing of precision custom connector and cable solutions for your specific design.

• Metal & Plastic Connectors • Push-Pull Self-Latching • Custom design for a variety of applications • Cable assembly services

Each sheave bearing assembly stands nearly three feet tall and weighs about 1.5 tons.

• Reliability where quality and safety are essential • ISO13485 Certified

LEMO USA, Inc

DESIGN WORLD

Design Notes 7-18_Vs4.LL.indd 27

www.designworldonline.com

July 2018

27

800-444-5366 info-us@lemo.com www.lemo.com

7/9/18 11:47 AM

Design Notes

“We chose Rize One due to Rize’s isotropic part strength and ink marking capability,” said Jackie Gerstein, Technology Teacher at UCMHS; Faculty Advisor & Mentor,

3D printed pulley helps students rise to new heights

FRC Team 1257.

Edited by Mike Santora • Associate Editor

FIRST (For Inspiration and Recognition of Science and Technology) is a global, non-profit youth organization founded in 1989 to inspire young people to become science and technology leaders and innovators by engaging them in programs that build science, engineering and technology skills. The organization currently offers four programs, one of which is the FIRST Robotics Competition for children in grades 9-12 that encourages teams of 25 or more students to build and program robots to perform a set of challenging tasks in competitive teams at local, regional and global levels. In one competition, a 3D printed pulley gave the students an edge in the competition.

28

July 2018 www.designworldonline.com

Design Notes 7-18_Vs4.LL.indd 28

DESIGN WORLD

7/2/18 11:18 AM

A Tradition of Innovation

From our proven suite of elastomers and thermoplastics, to our innovative thermoplastic composites and electrical connectors, Greene Tweed is your trusted partner for the most advanced solutions on the market.

Chemraz®

Arlon® & Avalon®

Seal-Connect®

Xycomp®

Greene Tweed 7-18.indd 29

Contact Greene Tweed to learn more: 1.800.220.4733

www.gtweed.com

7/2/18 8:30 AM

Design Notes

The team designed and printed a functional pulley with an integrated sprocket. The pulley/sprocket part was printed in one piece on a Rize One 3D printer to reduce the number of parts and minimize part assembly required.

high torque servo gearheads



Did you mean: DieQua Corporation?

Located in Scotch Plains, New Jersey, on the Union County Vocational Technical School campus, the 298 ninth- to twelfth-grade students at the Union County Magnet High School (UCMHS) learn how to solve problems using technology in a project-based, interdisciplinary educational environment. A highly competitive school, only one-third of students who apply to the school are accepted.

UCVTS’ First Robotics Competition (FRC) Team 1257 is comprised of 40 students from the Union County, New Jersey vocational district. They represent a blend of students in both college preparatory and traditional vocational programs.

Jackie Gerstein, a technology teacher at UCMHS, where most of the FRC Team 1257 students attend, is a faculty advisor and mentor of FRC Team 1257. She also focuses on the team’s design, programing and electronics sub teams, while Jackie’s husband Matt Hagan, 3D Print and Design Specialist at Merck, works with the team’s build sub team.

The search is over!

For quality helical bevel high torque servo gearheads providing unmatched performance, durability, and design flexibility, look no further than DieQua. • 11 sizes, torque capacities up to 20,000 Nm • Ratios from 5:1 to 8,900:1 • Smooth or keyed motor shaft input • Multiple output options • Backlash as low as 5 arc mins To find what you’re looking for, check us out on the web, or give us a call.

diequa.com/dw 800-280-5402

half page ad 2018.indd 2

30

July 2018 www.designworldonline.com

Design Notes 7-18_Vs4.LL.indd 30

2/1/18 4:36 PM

DESIGN WORLD

7/2/18 11:19 AM

Rize | rize3d.com

DESIGN WORLD

I need a plastic molder with custom expertise and a large selection of catalog parts.

And they need to be fast and cost-effective.

For more than 65 years, Caplugs has been the leading technical expert in product protection, masking and molded components.

If one of our 15,000 catalog parts doesn’t fit your requirements, our team of design engineers will create a custom-designed solution for you.

You’ll enjoy peace of mind knowing that Caplugs can produce the parts you need — on time and on budget.

Our molding capabilities: • Injection Molding • Vinyl Dip Molding • Extrusion Molding

• Rubber Molding • Vinyl Coating • Die-Cutting

www.caplugs.com 1.888.CAPLUGS sales@caplugs.com July 2018

31 CAP66341 GeneralIndustrial_TwoThirdsPgAd_DW_mech.indd 1

Design Notes 7-18_Vs4.LL.indd 31

R ca of equ pl al es ug l c t s.c at fre om alo e s /f g p am re a p e- rts le sa a s m t pl es

3D printing a pulley FRC Team 1257 had a new competition, or “game,” to play in this year called FIRST Power Up, which entailed building robots that placed boxes on scales in competitive events.

The team designed and printed a functional pulley with an integrated sprocket. The pulley/ sprocket part was printed in one piece on a Rize One 3D printer to reduce the number of parts and minimize part assembly required. The part is operated with a cable. The chain turns the sprocket that is built into the drum of the pulley. Students wind and unwind the assembly to lift and lower the robot’s elevator that holds the boxes.

“We chose the Rize One 3D printer to print the part due to Rize’s isotropic part strength and ink marking capability,” said Jackie. “Labeling was printed directly onto the end of the sprocket part to indicate which chain the students need to use with that sprocket. This avoided any confusion and potential malfunction.”

Using the Rize 3D printed pulley/sprocket part, FRC Team 1257’s robot successfully collected 4 lb boxes, moved them across a gymnasium field, lifted them to full extension - from 18-in. to 6-ft -6-in.

— in 3 seconds. The robot stacked the boxes in a controlled manner to achieve whatever height the Team desired. Their record was 9 boxes stacked in a single match.

The maximum torque on the motor/gearing combination is approximately 60 ft/lb and it can stall this with no apparent ill effect.

Showing the unique isotropic strength of Rize 3D printed parts, FRC Team 1257 used the same part at 40 official matches, including the District Championship, and during practice sessions.

Nowhere is a completely safe, clean and easy-to-use 3D printer more important than with students. The Rize One desktop industrial 3D printer emits no VOCs and uses only safe and recyclable materials. Each component of Rize’s Rizium One material is FDA USP Class VI Certified.

Since Rize One requires zero post-processing of parts following printing, FRC Team 1257 can get their parts 2X faster than other systems, while eliminating messy and harmful solvents.

Said Jackie, “Although the academic year is coming to a close, our Team never stops innovating.

A Sophomore student is currently designing the next generation pulley/sprocket part that will be printed on the Rize One 3D printer.” DW

4/9/18 2:55 PM

7/2/18 11:20 AM

Design Notes SCARA machines use a parallel-axis joint layout.

This means the robot arms can move on an X-Y axis but is rigid in the Z direction, which is suitable for picking and placing.

Automating the food and drink industry Edited by Mike Santora • Associate Editor

According to a market research report by Association for Packaging and Processing Technologies entitled Trends in Food Processing Operations, half of the companies surveyed will be increasing their level of automation over the next three to five years.

Despite this, many manufacturers admit they don’t know where to start. Here, Nigel Smith, CEO of industrial robot specialist, TM Robotics, explores how automation can benefit your facility.

Many industries have already made the jump to automated processes. However, it’s only been in recent years that the food and beverage industry has begun to explore what automation and robotic technology has to offer.

“The food and beverage sector, in general, is well-known for having some of the most severe manufacturing and control regulations in industry,” said Jonathan Wilkins, marketing director at industrial parts supplier, EU Automation. “This is part of the reason why UK manufacturers have been relatively slow in the uptake in automation.

However, this guarded attitude is slowly starting to change.”

Alongside a willingness to adapt, many manufacturers have experienced an increase in the cost of raw material and energy, as well as pressure from retailers for cheaper, faster production. As a result, installing automation equipment is now considered to be the only way forward, but the return on investment (ROI) must be noticeably worthwhile.

32

July 2018 www.designworldonline.com

Design Notes 7-18_Vs4.LL.indd 32

When selecting the type of machine to introduce to your facility, considering the actual needs of your facility and processes will result in a more cost effective and appropriate machine being installed, boosting your potential ROI. Imagine, for instance, that you are producing a ready-to-cook roast dinner meal. This product requires multiple elements to come together in one aluminum tray, be visually appealing to customers and be consistent in weight and appearance. In a facility making this product, machinery needs to pick up and move a wide range of products, from small carrot batons and broccoli florets to potatoes and meat portions.

Using a machine that can be programmed to pick, move and place items means that you DESIGN WORLD

7/5/18 10:29 AM

TRACO POWER North America, Inc. http://us.tracopower.com salesusa@tracopower.com +1 (408) 916-4570

NEXT-GEN DIN RAIL POWER SUPPLIES

TIB Series DESIGN WITH CONFIDENCE • Efficiency 90-94% typical, model dependent • 150% peak power for 4 seconds • Rugged metal case with optional side-mounting • Back power immunity / short-circuit / overload protection • SEMI F47 compliant for voltage sag immunity • Operating Temp -25°C ~ +70°C (-40°C start-up) • High Reliability: MTBF 1 mill hrs per IEC 61709 • 3 year warranty

Models

Power

Peak Power

TIB 080-124

80 W

120 W

TIB 120-124

120 W

180 W

TIB 240-124

240W

360 W

TIB 480-124

480W

720 W

Output Voltage 24 VDC

23.5~28Vadj

Efficiency (Typical)

3.4A (5.1Apk)

90.0%

5.0A (7.5Apk)

93.5%

10A (15Apk)

94.5%

20A (30Apk)

94.7%

C

SCHEME

IEC 60950-1

Output Current

EN 60950-1 EN 60204-1 EN 50178 EN61558-2-16

UL R

US

UL 508 CSA-C22.2 No 107

UL 60950-1

Contact TRACO POWER NORTH AMERICA for evaluation units and technical support Datasheet, Cert’s, EMC Reports, Installation Manual & 3D Drawings available at

tracopower.us/tib

Available stock from our North American distribution network

TRC ELECTRONICS, INC.

TRACO Power 7-18.indd 33

7/3/18 4:47 PM

Design Notes Aside from selecting the right machine and software, exploring the ancillary options for your chosen machine is vital to maximizing ROI. are less likely to have to discard damaged products, helping to reduce unnecessary expenditure. Selective Compliant Articulated Robot Arm (SCARA) machines, like those from TM Robotics, use a parallel-axis joint layout. This type of design means the robot arms can move on an X-Y axis but is rigid in the Z direction, which is suitable for picking and placing.

Aside from selecting the right machine and software, exploring the ancillary options for your chosen machine is vital to maximizing ROI. While human workers can look at a series of ingredients and establish the best way to pick up items based on their shape, position, and material, fully automating these actions haven’t been possible until recently.

Incorporating 3D vision systems will enable the examination of products as well as allowing the machine to determine the order in which they are picked up and assess the best position to place them in the primary packaging. Going beyond human capabilities, this type of software can also view and ascertain whether product labels are fixed correctly, include the right product information and help you meet industry regulations in the blink of an eye.

Even if you have the right software in place to automate this pick and place action, without the right gripper, your processing line can still damage your profit margins. Using grippers that move or pick up delicate items, like the roast dinner carrot batons, with too much force can result in high volumes of wasted product. In this case, opting for a machine that is capable of adapting the force used to lift a product based on sensor data and software will result in reduced waste and a perfect end product.

As revealed in the 2017 Food and Drink Industry Economic contribution and growth opportunities report, 73% of food and drink manufacturers are engaged in automating manufacturing processes, while 46% are engaged in warehouse and logistics automation.

With significant developments transforming how facilities function and a clear focus on revolutionizing the industry, it’s important not to assume that all robots are made the same and that those with fancy features and a hefty price tag will leave you with a problem-free facility. Sometimes, taking the time to assess what you are looking to achieve from the investment can guide you to a simpler and cheaper solution. DW

Twiflex Complete Hydraulic Brake Packages Twiflex now has new compact hydraulic brake packages. Standard packages are available with three different spring applied, hydraulically released brake models with braking force ratings ranging from 6.8 kN to 119 kN.

Standard Products

ADVANCED BRAKING SOLUTIONS FOR INDUSTRIAL APPLICATIONS Twiflex, founded in 1946, specializes in the design, manufacture and supply of advanced braking technologies for industrial applications. Twiflex offers the largest range of pneumatically-, hydraulically-, and mechanically-applied industrial disc brake calipers in the world, along with a full line of thrusters, disc brake systems, flexible couplings, and shafts clutch couplings.

Innovative Twiflex solutions are found in key markets including metals, mining, energy, elevators & escalators, entertainment and marine on applications such as rolling mills, conveyors, hoists and cranes, grinding mills, wind and tidal turbines, theme park rides and propulsion systems.

Products • Spring Applied Caliper Brakes • Direct Acting Caliper Brakes • Clutch Couplings Key Markets • Mining & Aggregate • Power Generation • Transportation • Metals

• Braking Accessories • Flexible Couplings & Shafts

• • • •

www.twiflex.com/dwb Design Notes 7-18_Vs4.LL.indd 34

TM Robotics | tmrobotics.com

Elevator Material Handling Renewable Energy Marine

34

July 2018

DESIGN WORLD

7/2/18 11:22 AM

Create first impressions that last.

As the first point of interaction on your application, access components have the power to make a big impact on your design. Southco access solutions can help you create a seamless user experience that lasts the lifetime of your product.

FREE CAD Files

FREE Samples

Global Support

Online Store

Southco engineers are ready to help. Contact our experienced sales and service teams today: info@southco.com

southco.com 20180524-DesignWorld-CFITL-AV Arm-9x10.875.indd 1 Southco 7-18.indd 35

5/29/18 7/2/18 7:50 8:32 AM AM

Internet of Things Programming software combines real-time control, HMI and data handling

T

The PAC Project Software Suite R10 supports the groov EPIC

system, adds eight new control commands, and lets users designate individual I/O and variable tags as Public Access for read-only or read-write use in IIoT data communications through MQTT/Sparkplug.

In the past, many automation projects were solely focused on real-time control, but nowadays operator interface and data handling are often just as critical, sometimes more so. Therefore, programming software needs to include a powerful real-time control engine and closely integrated human machine interface (HMI) and data handling functions, all in one integrated development environment.

SNAP PAC programmable automation controllers and now groov EPIC edge programmable industrial controllers—are typically programmed using the PAC Project Software Suite. PAC Project Basic, free for download, includes flowchartbased control programming with optional scripting, a configuration utility and HMI development. PAC Project Professional adds an OPC server, database connectivity, PC-based control configuration and support for legacy Opto 22 I/O units.

The suite’s control programming software, PAC Control, is full-featured and easy

36

July 2018 www.designworldonline.com

Internet of Things_7-18_Vs2.LL.indd 36

to use, with more than 450 commands in plain English, plus graphical PID tuning and debugging.

HMI programing is provided with PAC Display. PAC Display Basic is a userfriendly HMI package for building operator interface applications to communicate with groov EPIC processors, SNAP PAC controllers and Ethernet-based I/O units.

PAC Display offers rich features including alarming, trending, security and a library of over 3,000 industrial automation graphics.

PAC Display Professional adds the capability to use redundant scanners and redundant Ethernet links on groov EPIC processors and SNAP PAC controllers. PAC Display Professional also enables logging

DESIGN WORLD

7/2/18 11:26 AM

HIGH PERFORMANCE. STANDARD. With products including linear guides, ball screws, actuators, robot modules and direct drive motors, NSK employs cutting-edge friction control technology and precision accuracy to ensure optimal movement and positioning.

For high loads and high speeds to special environment and compact design requirements, NSK consistently delivers reliable, smooth, and precise motion and control.

PRECISION PRODUCTS FOR LINEAR MOTION AND CONTROL

www.nskamericas.com

NSK Presicion 5-18.indd 37

7/2/18 8:33 AM

Internet of Things

of SuperTrends, historical logs and runtime operator logging data files to an ODBC database.

The most important new feature with this new release is support for groov EPIC. Its control logic and I/O can be programmed with PAC Control, and customers can use PAC Display to develop a Microsoft Windows-based HMI to run on a separate PC. The groov EPIC’s integrated high-resolution touchscreen is not configured with PAC Display, but is instead configured with groov View software, supplied free with groov EPIC. New commands added to PAC Control include two specifically for groov EPIC: Get I/O Channel Quality and Get I/O Unit Quality. The groov EPIC I/O modules incorporate LEDs that change color based on the health of the module, revealing

Internet of Things_7-18_Vs3.LL.indd 38

data quality to a local technician, and this information can also be configured or retrieved programmatically in control logic using these two new commands.

Another major new feature is full support for MQTT/Sparkplug data communication, provided by Ignition Edge, which is embedded in groov EPIC. MQTT’s publish-subscribe communication architecture is superior to request-response methods, and Sparkplug optimizes MQTT for industrial applications.

Public Access tags are a new PAC Control capability, making it easier and more secure to use MQTT/Sparkplug.

During configuration the developer can use Public Access to designate which tags to expose, and to designate each exposed tag for read only or for read-write.

Tags in PAC Control include I/O channels and program variables, some of which can be represented in the Public Access space in more than one way. For example, an integer can be represented as an integer, a Boolean value or an individual bit within the integer. A table can be represented as a table, one element in the table or even one bit of one element—providing flexibility in how tags are exposed or protected PAC Project Software Suite R10 combines all of the most-needed industrial automation elements, aimed squarely at making it easier for end users to configure control, HMI and communications functionality DW

Opto 22 | www.opto22.com

7/6/18 11:10 AM

YOUR CUSTOM SOLUTIONS ARE CGI STANDARD PRODUCTS

Advanced Products for Robotics and Automation CGI Motion standard products are designed with customization in mind. Our team of experts will work with you on selecting the optimal base product and craft a unique solution to help differentiate your product or application. So when you think customization, think standard CGI assemblies. Connect with us today to explore what CGI Motion can do for you.

800.568.GEAR (4327) • www.cgimotion.com

copyright©2018 cgi inc. all rights reserved. 0516spd

CGI 6-18.indd 39

7/2/18 8:34 AM

Internet of Things Touchless angle sensors with CanBus interface

T

The RFC4800 Series of touchless angle sensors measures angular position up to 360°, revolution counter and speed—with J1939 CANBus interface in addition to CANopen.

Features include programmable zero point offset, measurement averaging and sign of rotational direction.

RFC4800 Series has a resolution of 14-bits across 360°, repeatability of 0.36° and independent linearity of ±0.5% of full scale.

J1939 CANBus provides a different feature set than CANopen. The J1939 protocol has transfer fixed at 250 kbit/s and defines shielded twisted pair for cables. While CANopen has a range if data transfer rates allowed. J1939 has peer-topeer or broadcast signaling and fixed messages rather than configurable. There are other differences too.

40

Other RFC4800 Series output interfaces include analog voltage and current, as well as digital outputs options—IO-Link, SSI, SPI, and incremental.

Single and multi-channel versions of the RFC4800 Series are available. Sensors are sealed up to IP69K and operating temperature range is -40 to +125 °C. Mean time to failure is 76 years. DW

Novotechnik U.S., Inc. | www.novotechnik.com

July 2018 www.designworldonline.com

Internet of Things_7-18_Vs2.LL.indd 40

DESIGN WORLD

7/2/18 11:33 AM

Internet of Things

Rugged line of rack-mount Ethernet products

T

The line of 19 in. rack-mount Ethernet products now includes the EKI-7428G and EKI-2428G. The product line includes managed and unmanaged Ethernet switches with up to 28 ports.

Equipped with optional copper, PoE, and fiber connections, these rack-mount Ethernet switches offer flexibility and can deal with most network management applications.

Models with a wide temperature range (-40° ~ 75°C) and rugged design are for field sites in harsh environments while models that operate in a standard temperature range are for management sites where environment condition is more gentle. The models with

ALL the power.

fiber connection can extend the network over a greater distance and can also be used where there is a high level of electromagnetic interference or EMI. The PoE version provides both data connection and power to end devices like wireless AP and IP camera. The managed series provides the ability to configure, manage, and monitor devices and greater control of how data travels. DW

Advantech Corporation, IIoT iAutomation Group www.advantech.com

HALF the size.

When your application calls for a compact hydraulic solution, you can count on the L20 and L30 from Nason. Same bore, same stroke and 50% smaller than a typical NFPA hydraulic cylinder.

CYLINDERS nasonptc.com

NAS_3097 Trade Ads - HalfPg DESIGN WORLD - DW.indd

Internet of Things_7-18_Vs3.LL.indd 41

1

www.designworldonline.com

July 2018

41

5/15/18 11:07 AM

7/2/18 11:36 AM

Internet of Things

The Right Gripper for Your Part

Software supports OPC UA

T

The Crimson 3.1 software supports the OPC Unified Architecture (OPC UA) communication functionality for industrial automation developed by the OPC Foundation.

For use with Red Lion’s HMIs and data acquisition products, those deploying OPC UA to collect data can do so without the need for additional hardware, software, or special code to populate the data. Customers can take machine data directly to enterprise business systems using a single solution from a single source.

With support of OPC UA, Crimson 3.1 acts as a server to publish data for OPC UA clients, often from the shop floor to the data center.

With the ability to converse with over 300 industrial protocols, Crimson 3.1 can connect to disparate automation devices and deliver that data to enterprise business systems simply and easily without the need for additional hardware or software licenses.

Crimson 3.1’s OPC UA Server works with all Red Lion Graphite HMIs, Graphite Controllers and CR3000 HMIs. Crimson 3.1 software features support for additional Ethernet and serial drivers such as EtherNet/IP, DNP3, Modbus TCP, Modbus RTU and many others.

With an intuitive, drag-and-drop graphical user interface and a variety of hardware offerings each supporting multiple simultaneous conversions, customers can easily integrate new functionality into virtually any PLC or SCADA system. DW

- Robotic end effector solutions - Angular & parallel, many sizes and options available - Unique solutions available - For handling various sized parts

Red Lion Controls | www.redlion.net

- Superior design & delivery

1-800-624-8511 for more information, visit:

phdinc.com/gripad

P.O. Box 9070 • Fort Wayne, IN 46899 USA

42

Internet of Things_7-18_Vs3.LL.indd 42

July 2018

DESIGN WORLD

7/2/18 11:46 AM

THE WAY TO CONNECT

NEW! NOW FOR 10 AWG

221-613 20 - 10 AWG

221-413 24 - 12 AWG

221 Series Compact Splicing Connectors: Now for 10 AWG • Same tool-free operation as the original, but in a slightly larger package to accommodate up to 10 AWG • 2-, 3-, and 5-wire versions, just like the original • 20 - 10 AWG; solid, stranded, flexible, tin-bonded • 30 A / 600 V; 105 °C operating temperature

Request a sample at www.wago.us/221

221 Ad.indd 1

Wago — T&M HB 6-18.indd 43

5/11/18 12:09 PM

7/2/18 8:35 AM

Internet of Things Bringing slip rings into the digital manufacturing age

T

Traditionally used to provide continuous power and data communication to equipment mounted on a rotating assembly, slip rings have been developed to help new and existing machinery enter the Industry 4.0 era with high-speed data connectivity. One company, Conductix-Wampfler, chose CC-Link IE open gigabit Ethernet for connectivity for its range of slip rings.

Conductix-Wampfler is a world leader in the design and manufacture of power, signal and data transmission systems for a range of mobile equipment and machinery.

Applications include container handling, tunneling, mining, bulk material handling and process machinery. Typical machines include cranes, rotating arms and gantries, manipulators, wind turbines and cable reels.

By joining the CC-Link Partner Association (CLPA), the company received access to the technical specifications

MEDICAL MOLDED CABLE ASSEMBLIES

required to develop a compliant product. This was complemented by development and certification support for the product range. As a result, Conductix-Wampfler offers standard and custom connectivity solutions that work with Ethernet up to 1 Gbps. DW

CC-Link Partner Association (CLPA) | Am.cc-link.org

Cables:

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

Cardiac Monitoring Device Generator Interface Cable

46840 LAKEVIEW BOULEVARD, FREMONT, CA 94538

Internet of Things_7-18_Vs3.LL.indd 44

•

510-933-3800

Endoscopy Camera

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

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

•

•

bayinfo@baycable.com

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

7/2/18 11:59 AM

D

kelleramerica.com

oem pressure transmitters

The LC and LD lines of OEM pressure transmitters combine microprocessor-based signal conditioning with proven piezoresistive silicon pressure sensor, all within an environmentally-sealed housing to provide fully-compensated, miniature pressure transmitters with ratiometric analog or I2C digital outputs. For more information, contact Keller America toll-free 877-253-5537 or email sales@kelleramerica.com.

Keller 7-18.indd 45

7/2/18 8:41 AM

Sensor Notes Contributed by Daniel Lehmann • R&D Engineer, Sensirion

Four rules for good humidity sensor design

T

The Internet of Things is on the rise as everything becomes smarter and more connected. Battery-driven devices hold an increasingly important role in this as users demand more mobility and convenience. For engineers the development is challenging: it involves knowledge about connectivity, energy harvesting and management, software and sensor integration.

To take full advantage of the performance and features of environmental sensors, e.g. humidity and temperature sensors, mechanical design rules need to be considered.

Incorrect housing and PCB designs may cause unexpected temperature and humidity deviations and could increase the response time. Simply following four basic rules makes the integration easy and straightforward. From our experience, we recommend taking the mechanical integration of the sensors into account in a project as early as possible. The complexity of the integration will increase the later the housing is designed.

Most importantly, the sensor must be exposed to the ambient air as much as possible and large openings in the housing should be used. This guarantees a fast system response and the influence of the housing can be minimized.

1

2

46

July 2018

Sensor Notes 7-18_Vs3 MG.LL.indd 46

Furthermore, the sensor enclosure should be isolated from the other parts of the device. This will reduce offsets of the integrated system.

www.designworldonline.com

DESIGN WORLD

7/2/18 12:01 PM

GRAYBAR KNOWS INDUSTRIAL “We count on Graybar because they carry a wide range of high-quality brands and their service and support is unrivaled by the competition.”

Dave Rogers | Director of Engineering, Sunnen

1-800-GRAYBAR | graybar.com

Graybar 7-18.indd 47

7/2/18 8:42 AM

Sensor Notes

3

The volume around

the sensor — so-called

dead volume — needs to

be minimized. This will

result in a decreased

response time.

Baumer’s O300 miniature laser sensors

Last but not least, the sensor should be placed in an area without heating sources like microcontrollers and ideally, it should be thermally decoupled. Otherwise, the heating effect of other components gives an offset to the sensor signal. If a mechanical solution is not sufficient to solve the issue, Sensirion also offers software-based compensation for that. DW

4

Sensiron | sensiron.com/new-shtc3

48

July 2018

Sensor Notes 7-18_Vs3 MG.LL.indd 48

www.designworldonline.com

DESIGN WORLD

7/2/18 12:02 PM

Sensor Notes Optical sensors for longer operating distances

W

With its R200 and R201 photoelectric sensor

designs, Pepperl+Fuchs enables applications with longer operating distances. Just like the compact R100, R101, and R103 series, both new products consistently offer all photoelectric functional principles in a design that is now larger and suitable for specific mounting situations.

Usability is intuitive and identical across all series — and the standardized IO-Link connection via the latest Smart Sensor Profiles also enables convenient and reliable integration of the sensors.

This complete range offers maximum flexibility in every application and mounting situation. The new series also includes robust DuraBeam laser technology and high-precision Multi Pixel Technology (MPT) for distance measurement.

The new R200 and R201 series offer all photoelectric functional principles: thru-beam sensors, retroreflective sensors with a polarization filter or for clear object recognition, energetic diffuse mode sensors, sensors with background suppression and foreground suppression, measuring light barriers with two switch points, and distance sensors.

All series have an intuitive and identical look and feel during parameterization. Quick and easy sensor adjustment is guaranteed by a multiturn potentiometer and a push button, which function as a combined operating element with three LEDs for visualizing the configuration, status, and diagnostics. DW

Pepperl+Fuchs GmbH | pepperl-fuchs.com

www.designworldonline.com

Sensor Notes 7-18_Vs3 MG.LL.indd 49

July 2018

49

7/2/18 12:05 PM

CAE Solutions

Compact mouse for CAD users

T

The CadMouse Wireless mouse is for mobile workstations. It has a high precision optical sensor with a resolution of 7,200 dpi and a battery life of two months, enriched by the flexibility of Triple Connectivity.

Its compact, ergonomic design and CAD specific features, such as the dedicated middle mouse button or the smart mouse wheel, support engineers and designers in mobile work. The device comes with a lightweight carry case for an easy and safe transport.

The compact, ergonomic CadMouse Wireless has an adaptive polling rate up to 1000 Hz (through USB connection). Its PTFE-feet allows smooth and fluid mouse movements in a mobile work environment and the middle mouse button encourages a comfortable and natural positioning of the hand. It is no longer necessary to click the mouse wheel to move an object or confirm a command.

The SmartScroll function automatically adapts to the current software environment and switches between precise, click-to-click zooming for CAD applications or speedy scrolling with inertia effects to easily scroll through webpages and long documents. The QuickZoom function allows for zooming deep into details of a sketch or construction and the Gesture Button allows for additional increases to performance. The user opens an application or environment-specific radial menu, which provides gesture access to up to 8 frequently used commands that are visualized on-screen by icons and can be individually customized.

CadMouse Wireless supports the following operating systems: Microsoft Windows from version 7 and macOS from version 10.10. DW 3Dconnexion | www.3dconnexion.com/cmw

50

July 2018 www.designworldonline.com

CAE Solutions 7-18_Vs3.LL.indd 50

DESIGN WORLD

7/2/18 12:11 PM

IGNITING THE SPARK OF IMAGINATION

ADVANCING INNOVATION FOR OVER 100 YEARS

A famous scientist once said “Logic will get you from A to B. Imagination will take you everywhere”.

Through our creative design and development expertise, we help our customers dream beyond today’s technology and achieve the impossible.

NEWENGLANDWIRE.COM

NEW ENGLAND WIRE T E C H N O LO G I E S

603-838-6624 • info@newenglandwire.com

New England Wire 7-18.indd 51

7/2/18 8:43 AM

CAE Solutions

Tools for developing digital twins

T

The latest release of MapleSim, a system-level modeling tool, provides new tools for developing digital twins, in addition to greater connectivity with other modeling tools, and expanded modeling scope.

Identifying the optimal motor size required to drive a mechanism is one of the most important goals of simulation with digital twins, and MapleSim 2018 provides tools that make this task easier. The 1-D Motion Generation App allows engineers to create motion profiles that adhere to defined velocity and acceleration constraints. They can define the desired motion of the joints, and then run the simulation to discover the torques and forces required to create that motion. This information can then be used to correctly size the motors, ensuring optimum performance at minimal cost.

MapleSim can be used for modeling multidomain systems that support the rapid creation and testing of initial concepts.

Engineers can try out more ideas in less time, identify and prevent unexpected interactions between different domains, and generate computationally efficient models.

MapleSim 2018 provides greater toolchain connectivity with the ability to import models from more software tools. Â With the expanded FMI support, engineers can import models

52

defined using FMI 2.0 Fixed-Step Co-Simulation, as well as FMI Model Exchange. Other improvements include enhanced Modelica support for easy access to more third party component libraries inside MapleSim. In addition, the MapleSim Heat Transfer Library from CYBERNET offers improved tools for studying heat transfer effects and preventing overheating, while the MapleSim Hydraulics Library from Modelon and MapleSim Pneumatics Library from Modelon add-ons can both take into account temperature effects during simulations.

MapleSim is available in English, Japanese, and French. DW

Maplesoft | www.maplesoft.com

July 2018 www.designworldonline.com

CAE Solutions 7-18_Vs3.LL.indd 52

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

DESIGN WORLD

7/2/18 12:12 PM

CAE Solutions

Easier 3D CAD model downloads

C

CADENAS GmbH published the latest version of the 3D CAD download portal PARTcommunity. Besides millions of intelligent engineering models of component manufacturers, PARTcommunity Version 8 offers engineers and purchasers innovations and features that make it easier to use and more intuitive. There are millions of 3D CAD models from over 460 product catalogs of well-known component manufacturers available to engineers and purchasers for free download.

• Editable dimensioning in 3D view. PARTcommunity Version 8 enables

users to modify component dimensions directly in the 3D view. With the help of an edit icon in the dimensioning view, the model can be customized according to need. After entering the desired dimensions, the 3D view is updated and the changes are taken over in the table. The adjusting of component dimensions within the table is no longer necessary. In addition, the modifications of the dimensions are visible at once in 3D and can be checked for correctness.

• LIVErendering makes product images possible in a matter of seconds.

High-resolution product images can be displayed quickly and easily in the preview on the 3D CAD download portal PARTcommunity. The LIVErendering function uses Maxwell Renderer software and must be supported by the component manufacturer. DW

communication between component manufacturers as well as engineers and purchasers has been improved in PARTcommunity Version 8, while at the same time complying with the new EU Data Protection Directive.

Manufacturers now have the option to send important information about products and services directly to the Inbox of the PARTcommunity users.

CADENAS www.partcommunity.com

• PARTcommunity Inbox informs about manufacturer news. The

• Suggestions on suitable accessories and display of end-of-life

information. Besides recommended accessories, end-of-life information is provided for the respective configuration of a component. Configuration of components is faster, including matching accessories.

• Interactive component information with hotspot. Component

manufacturers can supply PARTcommunity users more information, in addition to their 3D CAD models, such as videos, instructions, links to website contents or alternative components. The hotspot feature enables engineers to obtain more clarity for choosing and using the respective component, without contacting the manufacturer directly.

Component previews have been optimized and equipped with tabs.

During the configuration of a component, the user is shown a greyed-out 3D and 2D preview with the notice that the preview no longer corresponds to the current component and must be updated with a click. Additionally, 2D derivations of the configured components are provided as previews, which are needed for the production drawings. Users can configure the 2D derivation individually here, according to their needs with regard to line thickness, line color, views, and so on.

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

• Extensive previews simplify product selection and configuration.

DESIGN WORLD

CAE Solutions 7-18_Vs4.LL.indd 53

www.designworldonline.com

July 2018

53

7/5/18 8:19 AM

CAE Solutions Ensuring CAD data integrity as it moves through the digital enterprise

T

The rise of model-based initiatives in manufacturing is increasing the need for model re-use. For many customers, especially those in the aerospace industry, stringent requirements demand a high level of data integrity. Whether for downstream manufacturing re-use or for inspection, there is a greater emphasis on the need to trust the CAD model as it moves through the digital enterprise. CADIQ is a validation solution to identify model-based design (MBD) issues that adversely impact downstream uses and processes.

CADIQ provides critical technical capabilities to establish trust in the model as well as trust in any derivatives of the model.

The most recent updates of CADIQ11 include: • Single page 3D PDF report – A single-page report makes it easier to navigate models with saved views and improves usage and internal sharing by reducing file size.

• Enhanced CADIQ viewer and controller – Updates to the CADIQ interface, including redesigned item and folder icons, make it more user-friendly. Switching between saved views from a single viewer window saves time, while new preferences for overriding native annotation color and circling highlighted areas make the results easier to understand with enhanced visual display.

• Enhanced PMI validation for MBD

models – This update offers new PMI and saved view diagnostics, as well as improvements to existing PMI diagnostics, making the validation of MBD models more intuitive. Enhanced support for complex geometric tolerances, including improved diagnostics to handle advanced modifiers and compound datum references, complies with more recent GD&T standards.

• Improved support for advanced data types – CADIQ 11 provides new capabilities to validate advanced CAD model types. For

Linear Components through

See the full line of Components and all the CAE Solutions 7-18_Vs4.LL.indd 54

7/2/18 12:28 PM

example, now engineers can validate JT assembly models containing PMI. Solidworks users can now analyze any of the named configurations of their part models. The analysis of NX models has also been enhanced by allowing users to filter geometry according to multiple named reference sets.

CADIQ compares CAD models of various formats to identify geometric shape, quality, annotation and PMI saved view differences introduced by engineering changes, translation or manual remodeling. It highlights shape differences in form, mass properties, surface geometry and topology. Quality defects that impede analysis, manufacturing or data exchange processes are clearly identified with no extraneous information. CADIQ analysis uses the native programming interface of each CAD system to maximize accuracy and robustness. Validation results can be provided in an easy-to-use 3D PDF format. All functionality is available in a command line interface for integration into PLM systems. DW

International TechneGroup Inc. www.iti-global.com/cadiq

Mechatronic Solutions

Mechatronics available at pbclinear.com CAE Solutions 7-18_Vs4.LL.indd 55

6402 E. Rockton Road, Roscoe Illinois 61073 USA • +1.800.962.8979

7/2/18 12:28 PM

options for industrial power tools

Thomas Baile | Business Development Manager | Portescap

56

July 2018 www.designworldonline.com

Motion Control (PORTESCAP)_ 7-18_Vs5.LE.LL.indd 56

DESIGN WORLD

7/2/18 12:38 PM

M o t i o n

C o n t r o l

Power tools have operating profiles that differ from those of most other motor-driven applications. That’s why motors that go into these tools need specialized designs.

M

Most electric-motor-driven designs demand torque for the entirety of their motion.

In contrast, power tools for fastening, gripping, and cutting applications have a motion profile consisting of two stages.

Power-tool speed stage: At first (as the tool drives a fastener to thread into place

or the jaws of a cutting or gripping tool approach a workpiece) there’s little resistance.

Power-tool torque stage: Then when the tool performs the more forceful work of tightening, cutting or gripping, there’s a sudden torque demand.

These alternating speed and torque cycles constantly repeat in industrial power-tool applications even while necessitating different speeds and torques for various durations.

That’s why such tools — especially those that are battery-operated so running off low voltage and limited available power — benefit from special motor designs that minimize losses.

As we’ll explore, motors that also operate at faster free-run speeds for the speed stage can trim cycle times to boost productivity … and motors that deliver high peak torque during the torque stage can perform a wider range of tough jobs without excessive heating.

Power tools benefit from Portescap EC slotless motors with efficiency of copper turns to minimize joule losses; compact design; and strong coil integrity. The motors can also deliver a wide range of torque constants.

DESIGN WORLD

Motion Control (PORTESCAP)_ 7-18_Vs5.LE.LL.indd 57

www.designworldonline.com

July 2018

57

7/2/18 12:39 PM

M o t i o n

C o n t r o l

Selecting and optimizing motors for power tools Consider the primary options for handheld industrial power tools — brushed dc motors and brushless dc motors. Battery-powered industrial power tools run on low voltages of 12 to 60 V … so here, brushed dc motors are typically economical but have limited life.

The brushes exhibit modes of wear due to electrical influences (from current related to torque) and mechanical influences (due to the friction associated with speed).

Brushless dc motors are more reliable in power tools, as they’re less susceptible to mechanical wear (no brush friction) and can sustain high peak current (no brushes) during the tightening stage, providing far greater life in the hand tool. Brushless dc motors are better suited than brushed dc motors for industrial power tool applications because they require high speed and high peak current.

Unlike typical motion designs that demand torque output from the motor throughout the motion, industrial power tools (IPTs) for fastening, gripping, and cutting often have a motion profile split into two stages. This cycle continuously repeats.

Brushless dc motors for power tools typically one of two configurations

Conventional inrunner motor configurations include permanent magnets on the rotor with three stator windings around the rotor.

Outrunner (external-rotor) configurations have it reversed — so coils are innermost on the stator and the magnets are on the O.D. In other words, the stator coils form the motor center while the permanent magnets on the rotor’s inner surface spin within an overhanging rotor surrounding that core.

Inrunner motor configurations excel in handheld industrial power tools because they have reduced inertia, lower weight, and lower losses. Their longer length and smaller diameter also complement handheld designs for ergonomics. Plus a lower rotor inertia brings better tightening and gripping control.

Conventional inrunner motors include permanent magnets on the rotor; outrunner (external-rotor) configurations have it reversed. Inrunner motors excel in certain handheld industrial power tools because they have reduced inertia, lower weight, and lower losses — plus their longer length and smaller diameter complement handheld designs for ergonomics.

Pros

e

Cons

Slotted brushless dc motors l Small thermal resistance (Coil/casing) l Maximum speed in excess of 100krpm l Fully customized motors l Hipot capability (to 2,500 V) l Torque l Cogging No standard products

58

Slotless brushless dc motors (Ultra EC) l Smooth operation and no cogging l Little iron losses at high speed … low operating temperature and easier control l Low noise and vibration l Winding flexibility l l

Autoclavable option not available High thermal resistance

July 2018 www.designworldonline.com

Motion Control (PORTESCAP)_ 7-18_Vs5.LE.LL.indd 58

DESIGN WORLD

7/2/18 12:40 PM

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

For slotted motors, magnetic induction in the lamination is high because the airgap between the laminations (stator) and magnet is small. However, the motors are inherently rugged. Slotless motors have independently formed coils.

The diameter is usually optimized for magnetic induction with a given copper volume.

BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

PRECISION NUTS & WASHERS

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

ADAPTER SLEEVE ASSEMBLIES

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

Brushless dc windings can be constructed in different physical configurations:

• Motors with slotted stators: Here, the coils

wind through the slots around the stator. Magnetic induction in the lamination is high because the airgap between the laminations (stator) and magnet is small. So, the motors allow a small magnet diameter. The volume of the copper is limited by the slot space and the difficulty of winding within the slot. Having the coil inside the stator slots is advantageous in that it reduces coil-stator assembly thermal resistance.

Without current, the rotor has preferred magnet positions in front of the lamination. That means the motor is prone to generating a cogging or detent torque. One way to decrease the detent torque is to skew the lamination.

But again, slotted motors are inherently robust because the coil is in the lamination.

DESIGN WORLD

Motion Control (PORTESCAP)_ 7-18_Vs5.LE.LL.indd 59

 

July 2018

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

W

HI

TT

ET

-H

IG

GI

NS US

A

WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly.

• Motor with slotless stators: Slotless motors have coils wound in a dedicated operation. This coil goes into the motor airgap during motor assembly.

Magnetic induction in the coil is lower than in slotted motors because the airgap is larger. So the motor diameter is usually optimized for magnetic induction with a given copper volume.

NUTS & WASHERS

Visit our website–whittet-higgins.com–to peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local

or a good distributor.

59

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

7/2/18 12:41 PM

M o t i o n

C o n t r o l

In fact, induction in slotless motors is usually less than that of a slotted brushless motor. So bigger magnets are typically used to compensate for the loss of induction. One caveat to this solution is that it can increase rotor inertia.

But slotless motor power density is a strength.

R/K² — an expression of the ability to maintain speed under load, with lower values being better — is low in slotless motors because induction for a given copper volume is optimized … as evidenced by a sloped curve.

Without circulating current, the rotor sees a continuous permeance. That means slotless motors don’t exhibit cogging or detent torque. Iron losses at high speed in slotless motors are also far smaller than those of comparable designs.

There is another caveat: Slotted motors can handle higher temperatures than slotless motor designs — even to 200° C compared to 150° C, to give a typical comparison. That in turn allows more torque generation. Even so, in power tools usually the limiting factor is maximum temperature over time — to an average maximum of 47° C — or so — to accommodate

Copper losses and iron losses affect overall torque and speed output.

Custom Features: • Integrated linear position sensors

• Special materials for high strength / weight savings

• Integrated valves for load-holding & counterbalance

Cylinder Manufacturing Capabilities.....

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

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

• Internal Cushioning options for deceleration of motion

• Multi-stage telescopic

Visit us at: www.PrinceHYD.com

Prince Mfg 6-15_5.indd 1

60

July 2018

www.designworldonline.com

Motion Control (PORTESCAP)_ 7-18_Vs5.LE.LL.indd 60

7/30/15 4:12 PM

DESIGN WORLD

7/2/18 12:44 PM

TOMPKINS TEST POINT KITS Made for maximum portability and immediate use, Tompkins Test Point Kits are portable, compact, and durable. Since the fittings are designed to be connected under pressure, you can test quickly and at multiple points while feeling confident that they won't leak under vibration or peak pressure. www.tompkinsind.com

www.tompkinsind.com | 800-255-1008

Tompkins 7-18.indd 61

7/2/18 8:50 AM

M o t i o n

C o n t r o l

High-speed motors in power tools must be of a special design to limit eddy-current heating. To this end, Portescap Ultra EC brushless slotless motors have a patented U-coil technology to reduce copper losses. Unlike slotless motors with skewed windings, Portescap Ultra EC motors have windings parallel with the motor axis to maximize magnetic force and power. Plus Ultra EC motors reduce iron losses at high speed. Straight windings also give the motors shorter rotor lengths compared to those of skewed windings which lowers rotor inertia and reduces iron losses.

what’s comfortable for the typical hand-tool user. Beyond that value, heating can become uncomfortable for the operator holding the tool. Safety regulations also require maximum temperature to be held lower.

Of course, the electrical performance of a motor is defined by the magnetic circuit. The magnet has a fixed value but the second component (the copper winding) can be easily modified. By changing with the wire diameter and number of turns, the motor’s torque constant kt and resistance R can be fine-tuned for torque and speed.

Consider the modes of industrial power-tool operation: During the speed stage, the motor must operate at high rpm with little resistance: ω = (U – R · I ) / kt Where ω = Speed in rad.sec-1 and U = Voltage; R = Resistance in ohms and I = Current in Amps; and kt = Torque constant in Nm/A. Because the torque constant is in the denominator of the calculation, smaller kt values make for higher RPMs. This allows more operations in the same time period which boosts productivity.

Now consider the power tool’s torque stage — when the motor must deliver peak torque at low speeds. Torque is the product of the torque constant and current: C = kt · I Where C = Torque in Nm and I = Current in Amps.

Higher kt values here make for a higher output torque at a given current. So by adjusting a motor winding’s kt design engineers can optimize either the speed or the output torque to balance optimization of torque with that of speed operation to reduce overall working cycle time. There is no one solution: kt has to be chosen as the best compromise for a range of working profiles. Motor design experts can support one in this coil design process based on simulations and experience.

Reviewing thermal losses during operation Consider the losses of a typical industrial power-tool

62

July 2018 www.designworldonline.com

Motion Control (PORTESCAP)_ 7-18_Vs5.LE.LL.indd 62

DESIGN WORLD

7/2/18 12:45 PM

operating cycle. There is a relationship between copper losses and torque. So the design engineer may opt for a motor with a low kt value to increase speed … and then compensate for a low kt with more current (I) to get target output torque. But higher current increases copper losses: Copper losses = R · I2

So with higher current comes faster heating of the motor and power-tool — thus limiting maximum possible torque. That’s why power-tool motors should be designed to draw as low a current as possible … to limit heat dissipation (and keep tool temperature cool enough to handle) and conserve battery life.

Now consider iron losses and how they relate to speed. Eddy-current losses increase with the square of speed to heat the brushless motor even if it’s just rotating under a no-load condition. That’s why highspeed motors need special design features to limit eddy-current heating.

Motors with slotless construction excel in most industrial power tools because they have less induction in their laminations than other motors — which equates to no iron losses. Further Portescap improvements on slotless motor construction include straight turns, inner and outer heads, special outputs to prevent loose wires, and axial and radial forming.

NEMA 4X/IP66 Nonmetallic Enclosures & Accessories for Automation Controls

HMI Cover Kits & Prop Arm NEW! 8" x 8" HMI sizes

• Fiberglass Reinforced Polyester (FRP) or Polycarbonate material • Lightweight • Non-corrosive

12" x 12" AM & AM-R Series

• Non-conductive NEMA 4X Vent Kit

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

Connect with us online!

222 North Union Street • Bryan, Ohio 43506 Ph: 800-722-2679 • Fx: 800-237-7269

© 2018 Allied Moulded Products, Inc.

Motion Control (PORTESCAP)_ 7-18_Vs5.LE.LL.indd 63

Scan to learn more about Allied Moulded and the latest in nonmetallic enclosures & accessories.

www.alliedmoulded.com 7/2/18 12:47 PM

M o t i o n

C o n t r o l

Motors that operate at faster free-run speeds for the speed stage can trim cycle times to boost productivity … and motors that deliver high peak torque during the torque stage can drive tough jobs without excessive heating.

PRECISION METAL ETCHING Delivering the best photo-etched metal components Print-to-prototype part in 1 day!

Custom and COTS part fabrication Over 35 Metals Used, including: Stainless Steel & Titanium Extended Temperature Resistance Parts Forming, Plating, Cleaning, & more Technical Sales team ready to provide a Quote!

Visit www.fotofab.com for our FREE Design Guides!

Fotofab, LLC. 3758 W. Belmont Ave. Chicago, IL 60618

www.fotofab.com (773) 463-6211 sales@fotofab.com

More specifically, some new electronically commutated (EC) brushless motors on the market build on a slotless motor design with specialty coil technology. These reduce copper losses because unlike slotless motors with skewed windings, they have windings parallel to the motor axis to maximize magnetic force and power. Plus they reduce iron losses at high speed. Among other benefits, these motors optimize speed and torque for the most challenging applications — including power tools that take the form of fasteners, grippers, and cutting tools.

Two example applications for EC motors in power tools

Assume for one design we have an average duty cycle including two seconds of moderate free speed — as in a pruning shear, nutrunner, gripper, or stapler. Speed is 20,000 rpm and at 2 seconds torque demand goes to 0.84 Nm. Assume for the other design we have a heavy-duty cycle including three seconds very fast free speed — as in an automotive nutrunner optimized for productivity.

Here, speed is to 40,000 rpm and at 3 seconds torque demand goes to 0.69 Nm.

64

Motion Control (PORTESCAP)_ 7-18_Vs5.LE.LL.indd 64

July 2018

DESIGN WORLD

7/2/18 12:50 PM

For the first design: Brushless motor type · L (mm) Poles

Ultra 64

Skewed winding

Slotted motor

Ultra 90

30 · 64

30 · 64

28.5 · 88.5

30 · 90

4

4

4

4

Here straight-coil EC Ultra motors are more efficient (exhibiting less losses) than skewed-winding or slotted motors.

For the second design: Brushless motor type · L (mm) Poles

Ultra 64 HS

Slotted 90

Slotted 100

Ultra 90 HS

Ultra 64

Ultra Speed 60

Ultra Speed 80

30 · 64

28.5 · 88.5

34 · 99

30 · 90

30 · 64

35 · 60

35 · 80

4

4

4

4

4

2

2

There are higher iron losses than in the standard-duty design because the speed is doubled. Even so, straightcoil EC Ultra motors are still more efficient than skewed-winding or slotted motors. DW

Portescap | www.portescap.com

Questions about encoders and motion control?

We’ve got your answers.

For almost 50 years, EPC has been providing encoder solutions for reliable motion feedback. From industrial equipment to packaging to conveying – almost any kind of machinery – we have the encoder solution you need and the expertise to help you find it.

Call us today.

Expert Technical Support – we can help you find the right encoder for your application Highly-Configurable Encoders to fit almost any application Fast Delivery – 4 to 6 days is our standard lead time, and we offer same-day options on many models

We’ll help you find the motion feedback solution you need.

1-800-366-5412 • www.encoder.com

DESIGN WORLD

Motion Control (PORTESCAP)_ 7-18_Vs5.LE.LL.indd 65

www.designworldonline.com

Configure Your Encoder in 3D Configure & download 3D files of encoders at encoder.com

July 2018

65

7/2/18 12:53 PM

Wider adoption of L i n e a r

M o t i o n

Wider adoption of direct drives for linear designs

Direct drives are a motion-control technology projected to see high rates of adoption in coming years, according to market research by the ARC Advisory Group. That’s due in part to an array of industries driving for higher throughput and more accurate processes.

According to Brian Scott, applications engineer at Nippon Pulse America Inc., linear shaft motors excel industrial manufacturing machines and high-accuracy and high-resolution metrology applications.

“We see from sales and applications that there’s significant effort to move from rotary mechanics to direct-drive linear. High-force-density tubular linear motors are one option here. Simpler mechanics and the desire to reduce components are main market forces; others include better linear control and response, fewer failure modes, and reduced supplier counts. As the industry moves forward, there will be increasing conversion to direct-drive linear motion.”

Battery-powered designs also benefit from direct drives on linear axes. For such systems, Steven Feketa of LinMot USA Inc. predicts that direct-drive motors will continue to evolve to become smaller and more compact — with power characteristics suitable for use in mobile designs. These have often been the domain of fluid-powered systems — but Feketa underscores that electric systems are often less wasteful and better performing.

Lisa Eitel | Senior editor

66

July 2018 www.designworldonline.com

Linear Motion 7-18_Vs4.LE.LL.indd 66

DESIGN WORLD

7/9/18 12:44 PM

L i n e a r

M o t i o n

Aerotech ECO linear stages are suitable for positioning applications requiring high stiffness and dynamic responsiveness. Recirculating linear bearings and noncontact linear encoders allow incremental motion to 10 nm with µm-level repeatability. Optional HALAR calibration raises positioning accuracy to ±1.5 µm. An ironless forcer coil outputs high force with zero cogging or windup and tight position control — key to applications needing smooth velocity profiling or high contour accuracy. | courtesy of Aerotech

DESIGN WORLD

Linear Motion 7-18_Vs4.LE.LL.indd 67

www.designworldonline.com

July 2018

67

7/9/18 12:45 PM

L i n e a r

M o t i o n

Nippon Pulse SLP Linear Shaft Stages integrate a Linear Shaft Motor, encoder, and linear shaft support to replace certain conventional ballscrew systems for servo applications.

A high force-to-volume ratio and smaller deadzone make for design compactness. Variations include Acculine SLP stages and Nanopositioning SCR stages.

“We’ve been involved with direct-drive rotary and linear positioners for more than 30 years and have seen them transition from being a novel drive technology to something that’s ubiquitous in positioning applications,” said Brian O’Connor, director of product and market development at Aerotech Inc. So it’s common now to see direct-drive designs in high-precision applications such as semiconductor and consumer electronics — and even in lowerprecision applications such as labeling and product packaging assembly lines, added O’Connor.

Application-specific design features In some cases, direct-drive options for linear applications can allow for more complete customization to specific applications. Consider how some IP69K linear motors are all laser welded to eliminate seals and entry points — to get long design life.

“Another example is LinMot’s PR02 linear-rotary actuators, which deliver two motion types (to simplify integration) and have integrated load cells for precise torque measurements on capping and threading applications,” added Feketa.

| courtesy of Nipon Pulse

Miniature mSR Series positioners are squarerail linear systems from the Electromechanical & Drives Division of Parker Hannifin that provide sub-micron precision. Square-rail bearings pair with a linear servo motor; selectable levels of linear encoders can be configured to application requirements. The positioners incorporate two linear motor technologies — so the mSR 80 (shown in the cutaway here) is fitted with a miniature ironcore linear motor and the mSR100 comes with an mL-18 ironless linear motor. | courtesy of Parker Hannifin

68

July 2018 www.designworldonline.com

Linear Motion 7-18_Vs4.LE.LL.indd 68

DESIGN WORLD

techno

7/2/18 1:16 PM

IMC-000828-ADV_DC TWIN Ad_9x10.875.indd 1

Phoenix Contact 7-18.indd 69

5/16/2018 3:58:03 PM

7/2/18 8:51 AM

L i n e a r

M o t i o n

Shown here are ironcore linear-motor options. | courtesy of Chieftek Precision USA

Coordinated engineering efforts with the supply chain and design-engineering teams produce such application-specific products, added Feketa. “Another example is the shortening of PR02 series linear-rotary actuators — which we did to make them fit under fume hoods in pharmaceutical applications.”

Tubular linear-rotary motors from LinMot also find use on axes of automated-warehouse equipment — including diverter, reject, and handling axes. Within pick-and-place and position systems for packaging and automated assembly, the actuators work in X-Y,

IMPACT CAN DESTROY AN OBJECT OR A SINGLE ELEMENT OF THAT OBJECT

INNOVATING SHOCK & VIBRATION SOLUTIONS Visit sorbothane.com for Design Guide and Technical Data

MADE IN THE U.S.A.

800.838.3906

sorbothane.com

Some linear motors allow for pre-integration of washdown features to get compact actuators that address specific application needs. LinMot’s stainless-steel linear motors are AISI 316 and IP69K rated; they feature hygienically designed casings to withstand chemical and high-pressure washdowns common in food, pharmaceutical, and packaging industries. Linear forces are 47.2 to 200 lb. | courtesy of LinMot

70 Sorbothane_DesignWorldAd_6-17_r3.indd 1

Linear Motion 7-18_Vs4.LE.LL.indd 70

July 2018

DESIGN WORLD

6/12/17 11:21 AM

7/6/18 11:26 AM

X-Y-theta, X-Y-Z, X-Y-Z-theta, and X-X’-Y-Z setups. On collaborative robots, the linearrotary motors actuate end effectors and other light-load axes.

Bending linear-motion definitions with curved direct drives Curved variations of linear motors are a newer direct-drive variation. “These work best in applications that only need semi-circular motion … or on axes with large diameters … and not needing all the torque that a large motor would provide,” said Brian Zlotorzycki, product specialist at ETEL Motors. “So here, the benefits of direct-drive motors can serve unorthodox configurations with smaller overall footprints that necessitate simpler installation and fewer repairs.”

In the medical field, curved linear motor tracks already find use on C-Arm and CT scanning machines where a torque motor would be unintuitive. DW

ISO 9001:2015/AS9100D CERTIFIED

You’ll Get NO Interference on OUR Part!

TOM CUS ES SLID BLE ILA AVA Introducing

Del-Tron’s Non-Magnetic Ball Slides.

Del-Tron’s new product line of Non-Magnetic ball slides provides the ideal solution for applications where magnetic interference cannot be tolerated. These lightweight Non-Magnetic ball slides are the perfect solution for medical, semiconductor, military and laser applications, just to name a few. Manufactured in the USA, these Ball Slides are constructed using silicon nitride ceramic ball bearings, titanium shafts, aluminum carriages, bases, and end caps, along with brass fasteners, making them the perfect solution for your Non-Magnetic linear motion slide requirement.

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

Other

Precision Linear Motion

Products

Linear Slides Ball & Crossed Roller

Precision Linear Motion Required. Del-Tron Preferred.

• Available in 7 profile sizes with travels ranging from .5” to 12” of travel.

• Mounting surfaces provide straight line accuracy to .0005”/”of travel and positional repeatability of .0002”.

• Factory preload minimizes side play and provides low friction.

DL Linear Actuators Lead Screw/Ball Screw Driven

• Self-cleaning ball bearing design offers long life and requires no lubrication.

• Metric ball slides are also available.

Micrometer Positioning Stages Micrometer Driven Ball & Crossed Roller Stages

Order Today! 800.245.5013 Solid Models Available for all Del-Tron Model Numbers

Solid Models Available for all Del-Tron Model Numbers

DESIGN WORLD

Linear Motion 7-18_Vs4.LE.LL.indd 71

July 2018

www.buydeltron.com Designed & built in the U.S.A.

71

7/2/18 1:21 PM

Scott Davidson | Tektronix

Making

embedded systems

clock steady

Clocks are the heartbeat of embedded systems. Modern oscilloscopes offer a broad set of measurements that take | istockphoto.com

the mystery out of characterizing and troubleshooting clock jitter.

72

July 2018 www.designworldonline.com

Test and Measurement 7-18_Vs2_LL.indd 72

DESIGN WORLD

7/2/18 1:25 PM

T e s t

&

M e a s u r e m e n t

E

Embedded systems have become mainstream, working behind the scenes in everything from medical devices to vending machines and beyond. They represent the integration of electrical and mechanical systems and as a result designers have come into contact with them and worked on them at some level, usually integrating them into larger systems or machines. From the electrical side, the key to a smoothly operating system or machine is clock synchronization. This ensures that all subsystems and functions are properly synchronized and working together.

Clocks are the heartbeat of embedded systems, providing timing references and synchronization between components, subsystems, and entire systems. Excessive jitter in clock signals can significantly degrade system operation.

Fundamentally, jitter is any unwanted deviation in signal edge timing from where it should be. Jitter is a fact of life in the design of embedded systems and communication links. As such, for systems to operate reliably under a broad range of conditions, thorough characterization of jitter is a must.

Understanding all there is to know about jitter is not for the faint of heart. Volumes have been written about jitter, an indication of the complexity associated with timing errors. Fortunately, modern digital oscilloscopes are making timing and jitter measurements almost routine. The following examples will show just how straightforward troubleshooting jitter can be.

DESIGN WORLD

Test and Measurement 7-18_Vs2_LL.indd 73

www.designworldonline.com  

July 2018

73

7/2/18 1:26 PM

T e s t

&

M e a s u r e m e n t

Figure 1. The unusual shape of the histogram for the falling edge of the frequency measurements suggests a potential problem. This measurement was performed with a Tektronix 5 Series MSO 2 GHz mixed signal oscilloscope.

The use of measurement statistics functions, such as minimum and maximum frequency for example, are useful for ensuring that the clock frequency is within tolerance, while standard deviation provides a quantitative measure of frequency stability.

Clock jitter characterization Modern oscilloscopes support a range of measurements that provide a good starting point for jitter analysis and to verify that the clock frequency is meeting specifications. The use of measurement statistics functions, such as minimum and maximum frequency for example, are useful for ensuring that the clock frequency is within tolerance, while standard deviation provides a quantitative measure of frequency stability. However, measurement statistics by themselves give little insight into the manner of frequency variation. That’s where graphical tools such as measurement histograms can give more information about the characteristics of the various measurement variations.

In the example shown in Figure 1, frequency and time interval error (TIE) measurements have been made on the rising and falling edges of every cycle of every acquisition of a 40 MHz clock signal. These timing measurements were

Figure 2. Jitter and its components.

74

July 2018 www.designworldonline.com

Test and Measurement 7-18_Vs2_LL.indd 74

DESIGN WORLD

7/2/18 1:27 PM

Fluke 7-18.indd 75 6010058a_Deisgn_World.indd 1

7/2/18 8:52 5/29/18 2:31 AM PM

T e s t

&

M e a s u r e m e n t

Figure 3. Deeper analysis suggests that the clock shaping circuit may need further analysis and optimization in this example of a 40 MHz clock.

Figure 4. Jitter on this 1.25 MHz clock is not coming from uncorrelated DJ components.

Figure 5. Duty cycle variations are visible on the falling edges of the 1.25 MHz clock.

76

July 2018 www.designworldonline.com

Test and Measurement 7-18_Vs2_LL.indd 76

made relative to the average clock frequency in the acquisition. The statistics in the boxes on the right side of the display and in the results table at the top of the display provide a way to characterize variations. The statistics at the left side of the results table represent the current acquisition, while the statistics at the right side represent the accumulation of all acquisitions made over time.

The two histograms on the left represent the frequency and TIE measurement values on the rising edges of the clock for insight into timing variations. In this case, the distributions appear to be fairly Gaussian, suggesting that the jitter is predominantly random.

However, the two histograms on the right represent frequency and TIE measurement values on the falling edges of the clock. Interestingly, the shape of the histogram of the frequency measurements appears to be significantly different, suggesting a need for further investigation.

Troubleshooting and characterizing jitter requires insight into the type of jitter that could be causing timing variations. As shown in Figure 2, timing jitter can be decomposed into components, providing clues into the potential root cause of problems and in determining if various clocks and circuits in a system are behaving as expected.

The jitter summary measurement result shown in Figure 3 includes an eye diagram of the signal, plots showing the histogram and spectrum of the TIE measurement, and a decomposition of the jitter into its individual components. At first glance, the open eye in the eye diagram suggests that the clock signal has fairly low jitter. Indeed, the Total Jitter (TJ@BER) measurement value of about 554 psec is about 2.2% of the 40 MHz clock period. The jitter decomposition shows that the Random Jitter (RJ) component is a small part of the total jitter.

Therefore, the Deterministic Jitter (DJ) must be the dominant component. The bi-modal nature of the TIE histogram also suggests a strong deterministic jitter component. The DJ is further decomposed into Periodic Jitter (PJ), Data Dependent Jitter (DDJ), and Duty Cycle Distortion (DCD).

The PJ here is about a quarter of the jitter. There are clear spectral components in the TIE Spectrum plot, indicating strong peaks at 7, 17, and 32 MHz, which suggests that the jitter has significant uncorrelated deterministic jitter, perhaps caused by signal crosstalk on the circuit board or within the FPGA. Since this is a clock signal rather than a data signal, the DDJ is zero. The DCD also makes up about a fifth of the total jitter, suggesting that DESIGN WORLD

7/2/18 1:33 PM

the clock shaping circuit deserves further analysis and optimization.

To find out what else could be going on in the system, the next step is to look at another clock in the system, in this case a 1.25 MHz clock. As shown in Figure 4, this signal exhibits some different jitter characteristics. From the open eye in the eye diagram, it’s apparent that the jitter on the clock signal is small, an observation that is verified by the TJ measurement value of about 4.4 nsec which is less than 0.55% of the clock period. The jitter decomposition shows that the RJ component is a small part of the total jitter. The PJ is also relatively small, and there are no clear spectral components in the TIE spectrum plot, indicating that the jitter on the signal is not significantly related to uncorrelated DJ components.

Armed with this clue, Figure 5 shows a persistence display of the clock signal,

high torque servo gearheads

Figure 6. This shows the impact of jitter at the transmitter on self-clocking buses, such as CAN.

where the wide falling edges of the signal clearly show that the duty cycle is varying significantly. If the embedded system uses the rising edge of the clock throughout, this duty cycle variation may not present a problem. However, if some of the circuits depend upon the rising edge and others use



Did you mean: DieQua Corporation?

the falling edge, this jitter may actually cause the system to behave incorrectly or unreliably.

Low-speed serial bus jitter measurements Jitter also affects the performance of serial buses including self-clocking buses. Figure 6 shows an

The search is over!

For quality helical inline high torque servo gearheads providing unmatched performance, durability, and design flexibility, look no further than DieQua. • 14 sizes, torque capacities up to 14,000 Nm • Ratios from 1:1 to 13,500:1 • Smooth or keyed motor shaft input • Multiple output options • Backlash as low as 5 arc mins To find what you’re looking for, check us out on the web, or give us a call.

diequa.com/dw 800-280-5402

half page ad 2018.indd 1

DESIGN WORLD

Test and Measurement 7-18_Vs2_LL.indd 77

2/1/18 4:36 PM

www.designworldonline.com

July 2018

77

7/2/18 1:37 PM

T e s t

&

M e a s u r e m e n t

Figure 7. Jitter analysis of a synchronous logic circuit shows how duty cycle distortion on a clock circuit impacts other circuits in a system.

analysis of a 500 kb/sec differential CAN bus signal at the transmitter. Similar measurement techniques can be used on other serial buses, at the transmitter and the receiver.

The first step in this analysis is to recover a clock signal from the serial data signal. In this case, the oscilloscope is performing a clock recovery using a Phase Locked Loop (PLL) with a narrow loop bandwidth to remain locked between data bursts. This recovered clock is then used as the reference for the jitter analysis.

Jitter decomposition shows that the majority of the total jitter at the transmitter is due to Data Dependent Jitter (DDJ), and the random and duty cycle dependent components are small. There is also a considerable PJ component which appears to be related to the amplitude modulation of the signal at the beginning of each of the data bursts (but not related to the individual data bits), which is visible in the eye diagram and time-domain displays.

Stop corrosion in its tracks.

ew

N

Stainless Hydraulic Check Valves

t! uc

od Pr

NPTF, SAE, BSPP Connections Sizes 1/4" through 2" 316L Stainless Steel Metal to Metal Seat Up to 7250 PSI

Cincinnati - Houston - Edmonton 866.FLANGES (352.6437) | anchorfluidpower.com Test and Measurement 7-18_Vs2_LL.indd 78

7/9/18 1:10 PM

Clocked data jitter measurements The final example of jitter analysis is on a synchronous logic circuit. Unlike the previous example, this circuit has an explicit clock signal, so the jitter measurements are made on the cyan data signal on channel 2 relative to the yellow clock signal on channel 1 as shown in the lower right corner of Figure 7.

The clock rate is just 1.25 MHz and the circuit board traces are short, so the signals are fairly clean, as indicated by the low random jitter and wide eye pattern. Because this circuit is using a separate clock signal, the jitter typically would not be data-dependent.

In this case, the jitter seems to be dominated by duty cycle distortion. Further analysis of the circuit shows that the clock for this circuit was derived from the clock that was shown in Figure 5. Not coincidentally, a significant portion of this circuit’s total jitter is due to the duty cycle distortion of the clock signal. DW

Tektronix, Inc. | www.tek.com

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

WHAT DO YOU THINK?

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

Your Partner moving forward!

Registered and Certified to ISO_9001 and AS9100.

From economy commercial to aerospace approved, we’ve got it all!

R

Aurora Bearing Company 901 Aucutt Road Montgomery IL. 60538

complete library of CAD drawings and 3D models available at:

w w w. a u r o r a b e a r i n g . c o m DESIGN WORLD

Test and Measurement 7-18_Vs2_LL.indd 79

July 2018

79

7/2/18 2:03 PM

E l e c t r o n i c s

When test flows meet

workflows

Software for test

Modern software

instrumentation now

such as the LabVIEW NXG environment lets users visually discover hardware, manage drivers, and configure settings without leaving the program.

has as much to do with the automation of workflows as with technological advances for analyzing measured parameters.

Jonah Paul National Instruments Corp.

80

A few years ago, engineers in several industries were asked to list the most significant challenges they faced in test and measurement. The study in which the question was asked, run by Aspencore, received responses that included these: • Adapting to the fast pace of change in technology to provide testing capability and value to end users.

• Designing ever more complex products with shorter time to market.

• Getting test equipment that can test to the latest up-to-date standards.

• Keeping pace with high-speed communication and networking bandwidth (i.e., 100GE, 400GE, etc.).

• Maintaining the ability to test newest generation products without spending large amounts of money on specialty instrumentation that will soon be obsolete.

July 2018 www.designworldonline.com

Electronics 7-18_Vs4.LT.LL.indd 80

DESIGN WORLD

7/2/18 2:06 PM

Sunstone Circuits 7-18.indd 81

7/2/18 8:54 AM

E l e c t r o n i c s

Engineers can rapidly build and then iterate test and measurement systems using the drag-and-drop design approach of LabVIEW NXG.

Before the advent of the package manager, users would add software by using their browser to search through networks of drivers and tools, then manually install the right package.

One noteworthy aspect of the responses is that they refer as much to difficulties encountered because of workflow as to technological hurdles. Most engineers can probably relate to these hurdles. How much engineering time do you spend searching for manuals, pinouts, the right hardware driver, the right utility, and so on? National Instruments surveyed over 400 engineers across multiple industries and found similar results: One obstacle slowing tests is the amount of time spent connecting and integrating components, a task that often involves instruments from multiple vendors.

Reflecting on such issues, it becomes evident that they represent stumbling blocks in workflow rather than technological dilemmas. Consequently, automation suppliers have increasingly tried to construct products with workflows in mind. In that regard, modern software tools help reduce test system setup and configuration time, minimize the time to setup the next measurement, increase test software collaboration, and put the right test data in front of the right people.

Most engineers polled

by NI said they would use web-based user interfaces for remotely monitoring and accessing data.

82

July 2018 www.designworldonline.com

Electronics 7-18_Vs4.LT.LL.indd 82

DESIGN WORLD

techno

7/2/18 2:06 PM

Your Global Automation Partner

WARNING

Not suitable for repairing flimsy connectors (or your reputation).

An example of web-based interfaces created with the LabVIEW NXG Web Module.

An example is the LabVIEW NXG program which now includes workflows that provide additional context and assistance with finding the right information at the right time. A good illustration is the common task of setting up and verifying a bench-full of instruments. LabVIEW NXG incorporates a single screen view that lets the user quickly discover, visualize, configure, and document the instruments involved. If the appropriate drivers are not installed on the machine, LabVIEW NXG guides the user in finding and installing the drivers without leaving the environment.

With drivers installed, NXG provides the documentation, examples, and NI soft front panels necessary to verify the setup and get initial measurements quickly.

It is also possible to configure a system from a catalog before the hardware is actually in the lab. A visual canvas shows the modular instruments available to build a valid setup that meets requirements. A table view of the system lets users efficiently batchedit configurations across instruments

DESIGN WORLD

Electronics 7-18_Vs4.LT.LL.indd 83

Rugged, reliable industrial

as a way to scale up for handling bigger testing jobs. Each of these new capabilities aims to reduce the time spent on common setup tasks so engineers can spend more quality time on acquiring results.

Time spent setting up the first measurement is usually only the first a fraction of a job’s setup time. New requirements generally force test systems to go through numerous iterations.

Consequently, manufacturers have tried to build-in measures that help minimize the time to setup follow-on tests.

Over the last 30 years, LabVIEW has helped engineers boost their productivity through the abstraction of instrumentation tasks. For example, Lawrence Livermore National Lab engineer Glenn Larkin said by adopting LabVIEW instead of traditional approaches to develop an automated maintenance system, his team of three people “prototyped, developed, and deployed the final version of the application in about 15 months, which is roughly one-third of the estimated time

www.designworldonline.com

July 2018

automation products from Turck are built to perform in the toughest conditions, and our engineered solutions are customized to meet your application challenges. Cheap knockoffs can’t compare. Turck works!

Overmolded Deutsch Connectors Designed for longevity in demanding environments where shock, vibration, cold, moisture and oils can affect performance.

83

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

7/2/18 2:08 PM

E l e c t r o n i c s

LOOKING TO START

IN-HOUSE PROTOTYPING?

You can do it.

!

NE W RIE S M SE BLE LA AVA I

Time is money.

required to develop the application using Java or C++.”

LabVIEW NXG builds on this graphical experience. It provides engineering workflows that help transition from hardware setup, initial measurements, and analysis to an efficient development environment. It does so in a manner that lets engineers retain their engineering insight, configurations, and analysis routines.

Engineers using LabVIEW NXG start at a higher level and build on work already done when the need arises for more advanced analysis, logic, or automation.

Reuse of software modules is a manageable problem for engineers working alone. The challenge comes with scaling to a larger validation engineering team. The additional complexity involved requires a level of standardization and an agreed-upon set of tools, workflow, and foundational

Stop waiting on job shops.

Remote access to test status can also help optimze workflows. Using the web, teams can tap into test data so test results are widely visible quickly.

Take the reigns of your prototyping.

Speed your time to market.

×

Engineered and Supported in the USA

×

770M Redesigned with 50% More hp

×

Small Footprint Fits Almost Anywhere

×

Plug into Standard Single-Phase 120Vac Outlet

×

Free Standard Shipping within the Continental USA

TORMACH.COM 84

Electronics 7-18_Vs4.LT.LL.indd 84

July 2018

DESIGN WORLD

7/2/18 2:12 PM

Your Global Automation Partner

software. With that in mind, LabVIEW NXG and LabVIEW 2017 -- along with an increasing amount of other test and measurement software from NI -- have been built on common, open-standard package technology.

One aspect of LabVIEW NXG that makes workflows more efficient is the NI Package Manager. This is a lightweight desktop client that permits browsing for, installing, removing, and upgrading software. Before the advent of the package manager, users would add software by using their browser to search through networks of drivers and tools, then manually install the right package. Similarly, the package manager works in reverse; it lets the user distribute both NI or third-party software, as well as software they’ve written themselves.

In a recent survey, seven out of ten software developers who used the latest version of LabVIEW NXG said they will probably use it to build scalable libraries and system deployments. Collaboration and reuse relies on efficient distribution of software. Distribution via industry-standard package building and package management technology lets engineers confidently replicate systems.

Remote access to test status can also help optimize workflows. Using the web, teams can tap into test data so test results are widely visible quickly. But test engineers often struggle to integrate web-based data display into their setups because web programming isn’t their forte. Consequently, the LabVIEW NXG Web Module introduces drag-and-drop tools for creating webbased interfaces (WebVIs). The interfaces can be viewed from any modern browser on any device—such as tablets and smartphones—without plug-ins. The tool provides a platform for secure hosting that lets engineers with little web programming expertise rapidly develop and deploy a web interface.

Engineers who have some web programming expertise can use the LabVIEW NXG Web Module to build interfaces based on standard HTML5, CSS, and JavaScript technologies. The resulting interfaces can be customized with code

DESIGN WORLD

Electronics 7-18_Vs4.LT.LL.indd 85

directly in LabVIEW NXG or embedded into an existing web-based solution.

In a nutshell, the question is not whether software helps smooth project workflow but rather how you can best use software to address the exponential pace of change in the engineering world. DW References National Instruments Corp., www.ni.com

WARNING Not suitable for managing complex data

WHAT DO YOU THINK?

(or your reputation).

Connect and discuss this and

other engineering design issues with thousands of professionals online

www.designworldonline.com

Rugged, reliable industrial automation products from Turck are built to perform in the toughest conditions, and our engineered solutions are customized to meet your application challenges.

Cheap knock-offs can’t compare.

Turck works!

TBEN-S-RFID Ultra-Compact I/O Modules Manages complex data, with seamless PLC integration, in RFID environments.

Measures just 1.25 x 5.6 inches.

July 2018

85

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

7/2/18 2:11 PM

M e c h a n i c a l

Mastering

coupling selection fundamentals Mastering coupling selection begins with understanding the fundamental capabilities of several different coupling types. We asked Bobby Watkins of Ruland Manufacturing for his insight on just a few of the most common coupling types. Here, Watkins explains the pros and cons of three different couplings and when to use them for specific applications.

Edited by Mike Santora

Design World: Let’s start with zero backlash jaw couplings. What applications are they best suited for and why?

Bobby Watkins: This type of coupling has valuable characteristics under the right circumstances. There are two types of jaw couplings in the world. There are what we refer to as standard industrial couplings, which have an insert that is often called a spider. With straight jaws on the spider it’s a bit of a loose fit into the hub so you can actually put it in your hands and feel some slop. This situation is acceptable as long as users are not positioning with them. If they’re positioning, they’ll need a zero backlash jaw coupling, which is what we manufacture. There’s a profile to the arm on the spider, and it’s an actual press fit, so there is no clearance between the spider arms and the jaws on the hub.

86

July 2018 www.designworldonline.com

Mechanical 7-18_Vs4.MS.LL.indd 86

In fact, on some of the largest sizes to maintain zero backlash, it’s a heavy press fit to the point where you probably need to put it in a vise or a press to put the coupling together. But again, it’s a zero backlash coupling, there can’t be any extra room, and they can be challenging to put together in the larger sizes. The smaller sizes connect by hand rather easily. The benefits of zero backlash jaw couplings are that the threepiece design allows for a highly customizable coupling. Are you going from inch to metric? No worries. There are multiple

DESIGN WORLD

7/2/18 2:16 PM

Gearbox systems benefit from zerobacklash jaw couplings

spider materials to match application needs. This coupling is designed to handle shock loads. If an engineer has a very aggressive move profile where the coupling is starting and stopping quickly, a rigid coupling, for example, or a coupling that doesn’t have cushioning or dampening characteristics like a zero backlash jaw, there will be problems. The shock of a quick stop/quick start can destroy bearings on the input of the ball screw and also the motor bearing.

Zero backlash jaw couplings are designed to handle shock loads. Most commonly, we’re looking at the shock load of an aggressive move profile where there will be frequent starting and stopping. High throughput is also necessary. Users don’t want to have to ramp down or soften that move profile and slow it down to suit a bellows coupling or a rigid coupling. Again, this coupling serves as efficient protection for the life of a motor or actuator and allows design engineers to do those aggressive move profiles without damaging the components.

Fail-safe design. If the spider is damaged, the arms are torn off, for example, the coupling will go metal to metal and still drive. Consequently, in many applications, it’s essential to have a fail-safe design or a positive drive.

The zero backlash jaw coupling can be used. A typical application where you would want a fail-safe design would be in a vertical, Z-axis where you’re lifting or dropping a load that could be very valuable like a boat of wafers for wafer processing.

DESIGN WORLD

Mechanical 7-18_Vs4.MS.LL.indd 87

Drawbacks: Low misalignment capabilities. These couplings are suitable for high torque, high shock applications, but they are not forgiving regarding misalignment. Engineers will notice they get a little bit of forgiveness, but nothing like a beam coupling or some of the other types. Under misalignment conditions, beyond the couplings capabilities, there is going to be high bearing loads.

You are going to put those hubs in sheer. The spider is going to fight, and you’re throwing a bearing load at that point. Again, it requires precision alignment at installation.

For example, you’re running product, the spider fails, but the system is still running. You’ve gone metal to metal. You haven’t disconnected out of the system.

The potential is there for you to be making bad products until someone discovers that the spider has disintegrated.

Again, once that spider disintegrates, you have a metal to metal situation, there’s positive drive, but there’s error everywhere.

due to their high customizability with designers able to select clamp or set screw hubs with inch, metric, keyed, and keyless bores to combine with one of three spider options.

DW: You mentioned beam couplings earlier. Can you tell us more about those? What are the pros and cons?

BW: Beam couplings are probably the most recognizable type of coupling available. This coupling is typical for encoder applications, so many people are familiar with them. Users can also select these couplings for light-duty power transmission applications, light-duty actuators and so forth. In heavier duty applications, you probably need to look at one of the other types of couplings, which

www.designworldonline.com

July 2018

87

7/2/18 2:18 PM

M e c h a n i c a l

Beam couplings are flexible and accurate making them a common choice for encoders.

Increased Reliability for Industrial Applications New 1.27mm pitch Archer Kontrol connectors in horizontal and vertical layouts with 12-80 pin combinations.

Designed with surface mount solder tabs for additional board retention strength, it can withstand lateral and twisting forces in high vibration environments.

Temperature range of -55°C to +125°C Assists with blind mating Fully shrouded connector system Tested to perform up to 500 operations

would be much more common, and a higher torque application. Beam couplings do have their limitations. However, we’re just going to go through some of the benefits first.

It’s a one-piece design. This design element means there’s no maintenance.

There’s various OD links, patterns, and materials to choose from for different applications. They have considerable misalignment capabilities, and they’re forgiving when compared to most other servo couplings.

Don’t cross the line with this coupling, though. If you ask too much of it, if you exceed the misalignment specifications, they do tend to break relatively quickly.

Installation of this type of coupling with a good straight edge is typically good enough.

These are available in metric, an inch to metric.

Some of the drawbacks: These couplings handle only moderate bearing loads depending on conditions. In other words, under misalignment conditions, all couplings will put a load on your bearings as it’s fighting to straighten out. This coupling gives a moderate bearing load. Often, if you look into the size of beam coupling and the torque rating of the standard aluminum coupling, it isn’t enough for your application. The natural progression for that is to look at a stainless-steel version, which, size for size, has higher torque capability.

DW: Clearly, alignment is critical.

Especially so for bellows couplings. Can you tell us more about that?

www.harwin.com/kontrol

BW: Bellows couplings are for precise movement applications. They’re torsionally stiff, have a high RPM capability (10,000

88

RPM) and precise movement. However, they are not easy to align. They do require precision alignment, and they are going to give you only a small amount of forgiveness.

When you have a little bit of misalignment to deal with, you want accuracy. You want high torsional stiffness. This is the coupling.

Some benefits: Suitable for high torque misalignment applications requiring minimal positioning error. A low inertia coupling, the bellows portion in the middle is thin wall stainless steel. The hubs are aluminum to keep the weight down. You’ve got a low weight coupling? Low inertia.

No maintenance required. There’s nothing to do on this coupling as far as regular maintenance is concerned. Again, these are available in step bore combinations, inch to metric, with keys, without keys.

Some drawbacks: No provision for impact loads. We talked about those high impact loads or shock load applications with aggressive move profiles that the jaw couplings do so well. The bellows coupling does not. High shock loads and aggressive move profiles where there’s some torque involved? This coupling does not like it. It tends to fatigue the bellows and can crack it, and eventually tear it. If you need that precise movement, you’re probably going to have to forgive a little bit or perhaps be less aggressive with the move profile than you would with a jaw coupling.

This coupling needs precision alignment. Additionally, it is not suitable for vacuum applications. Our bellows coupling, in particular, is not suitable for vacuum. It’s epoxied together. The bellows portion in the middle is epoxied to the hubs; the epoxy will out gas in a vacuum application. A couple of interesting things about bellows couplings.

July 2018 www.designworldonline.com

Mechanical 7-18_Vs4.MS.LL.indd 88

DESIGN WORLD

7/2/18 2:25 PM

M e c h a n i c a l

When a bellows coupling is in failure mode, that wall accordion portion in the middle has cracked, and it’s only a matter of time before the coupling is going to fail. It will make a snap, crackle, pop noise as the coupling is rotating. In this situation, order a replacement right away because that’s an indication that it’s going to fail.

The mode of failure with the bellows coupling has pros and cons. The good side of a failure on a bellows coupling is that bellows will tear and you’re now disconnected. You’ve got to tear through it.

It’s in two pieces at this point, and you’re not going to keep going and making that product because you’re not driving anymore so that’s a good mode of failure because you know when you are no longer in zero backlash with the bellows couplings, you’re also disconnected. On a vertical application, as we discussed before, where you want a positive drive, you don’t want to drop that load in a vertical application. A bellows coupling is going to tear and you’re going to disconnect and you’re going to drop, possibly drop that load. The mode of failure can be important as to which type of coupling that you choose. DW

DISC PACK COUPLINGS NEWLY DEFINED 350 - 24,000 NM.

Ruland ruland.com

Stainless steel rigid couplings can be used in applications with unsupported shafts such as mixers in food and chemical processing.

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

RW-AMERICA.COM

DESIGN WORLD

Mechanical 7-18_Vs4.MS.LL.indd 89

July 2018

89

7/2/18 2:25 PM

Product World Right angle bevel planetary gearboxes GAM gamweb.com The EPR and PER Series Right Angle Bevel Planetary Gearboxes provide all the advantages of the EPL and PE inline planetary gearboxes in a right angle configuration.

Featuring a high-performing spiral bevel gear input

to an inline planetary gear output, the EPR and PER are available in ratios of 3:1 to 1000:1 and a range of sizes

typically found in other higher-priced competitive gearboxes and is used

and configurations. The EPR Series features five output

in motion control applications where axial and radial loads are minimized.

options including three different shaft outputs, a hollow

The PER has a metric or NEMA shaft output option. As with all GAM

shaft output and a flange output.

gearboxes, the EPR and PER are available with motor mounting plates to

accommodate most servo motors.

The PER is a value option employing output bearings

LDT with shock and vibration resistance Ametek gemco.ametek.com The GEMCO 958A Compact-Housing LDT, was designed specifically with the hydraulic cylinder market in mind.

The 958A is a rugged, accurate, programmable

zero and span, auto-tuning, non-contact LDT in a compact-housing, rod-style package. Less than 1.2-in.

cause the unit to lose position information or require re-zeroing.

in depth, the transducer can be installed in applications

Its non-contact design allows the device to be used in highly

in which a rod-style transducer typically would not fit

repetitive applications without mechanical wear.

or in applications in which customers want simplified

The GEMCO 958A can operate over a range of power (8 to

installation and serviceability. The transducer is made

30 Vdc at 1.6 watts), and a variety of analog outputs with field

entirely from stainless steel and uses agnetorestrictive

programmable zero and span points are available. The Compact-

technology to give absolute position feedback, accurate

Housing unit has an auto-tuning capability that allows it to sense

to 0.04% of the programmable sensing distance.

a magnet other than the standard ring magnet and adjust its signal

The GEMCO 958A LDT is built to withstand

strength accordingly. Units can be ordered in English or metric span

the most-severe environmental conditions and is

lengths from 2 to 100-in. (50 to 2540 mm) and come standard

completely absolute. That means a power loss will not

with either integral cable assemblies or M12 style connectors.

90

July 2018 www.designworldonline.com

ProductWorld-7-18_Vs4.LL.indd 90

DESIGN WORLD

7/6/18 11:38 AM

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

Emergency stop for safety over IO-Link Balluff balluff.com This E-Stop is easily and inexpensively connected directly to the "Safety Over IO-Link" module or to any safety controller using standard M12 connectors, eliminating terminations and reducing the incidence of mis-wiring. "These devices are used in a variety of industries from automotive to packaging;" said Shishir Rege, Safety Marketing Manager at Balluff Inc. "and E-Stops are a core component of almost every machine design and safety risk assessment."

The E-Stop function is a supplementary protection measure and must always be available for any automated equipment. The E-Stop switch initiates an immediate stop command and can be used for personal protection functions. An available adapter allows

KNOW THE RIGHT TIME TO RETIRE YOUR SPROCKET

this device to easily daisy chain to multiple E-Stop locations on one machine. This connectorized E-Stop switch can "plug & play" with the "Safety Over IO-Link" hub to

WITH TSUBAKI’S NEW SMART TOOTH™ SPROCKETS

create a simple, flexible and modular safety

LOOK FOR THE BLUE and have the ability to identify and predict drive system maintenance before

solution.

critical component failure occurs. Strategic placement of Wear Indicator pins on sprocket teeth provides visual indication that a sprocket is either within the allowable wear tolerance, or that it needs to be replaced. When factoring in the cost of critical drive system components, implementation of Tsubaki patented Wear Indicator technology makes sense for applications that are driven by capital equipment, or where non-scheduled downtime is simply not acceptable. So enjoy some R&R with the assurance that your application is running on Tsubaki SMART TOOTH Sprockets.

®

Total Package

USTSUBAKI.COM

DESIGN WORLD

ProductWorld-7-18_Vs4.LL.indd 91

July 2017

91

7/6/18 11:03 AM

Product World Remote I/O AutomationDirect automationdirect.com BRX Remote I/O controllers allow thousands of additional I/O to be added to the BRX PLC system. Each remote controller unit can be expanded with up to eight I/O expansion modules providing up to 256 I/O points per remote rack.

Six controller versions are available and are designed to work seamlessly with Do-more! systems, DirectLOGIC ERM modules, or any Modbus Client/Master device. Supported protocols include Do-more! Ethernet Remote I/O, HOST Ethernet Remote I/O, Modbus RTU and Modbus TCP. Over 4,000 additional discrete and 1,000 additional analog I/O points can be added using the native protocols (over

Motor Feedback Systems for linear and rotative drives

63,000 additional discrete and 15,000 additional analog points are possible when using Modbus TCP).

All units have a built-in 10/100 Mbps

Ethernet port. Modbus I/O units also have an onboard RS-485 port with removable 3-pin connector. Both 120-240 Vac and 12-24 Vdc powered units are available; the ac powered units include an integral 24 Vdc auxiliary output power supply.

Absolute and incremental magnetic measurement ■ ■ ■ ■ ■

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

SIKO Products Inc., Phone +1 (734) 426-3476, www.siko-global.com

92

July 2018

ProductWorld-7-18_Vs4.LL.indd 92

DESIGN WORLD

7/9/18 1:32 PM

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

Plug-and-play vacuum end-of-arm tooling Bimba bimba.com The Collaborative Robot Vacuum Tool (CRVT) now offers a plug-and-play end effector option for collaborative robots. Developed to meet the versatile nature of collaborative robots, The CRVT comes offthe-shelf as a complete solution - no external valve required. Although designed to support a variety of applications with minimal configuration, ther is a wide array of pump options to enable users to meet the vacuum requirements of their application.

“Collaborative robots are making it easier than

Mil-Spec PMDC motor and planetary gear motors Allied Motion alliedmotion.com The Globe line of mil-spec-qualified fractional horsepower PMDC motors and gear motors are available off-the-shelf or on short lead time.

Modified versions – with specially machined mounting provisions, holding brakes, tachometers and/or encoders — are available within two to three weeks through.

Models range in size from 0.75 to 2.25-in. (19 – 57 mm) in diameter. Rated speed ranges from 2400 to 19200 RPM, with rated power from 3 W to 62 W. Planetary gearhead models are available with output torque rated to as high as 62 Nm (8800 oz-in.).

ever for manufacturers to implement automation. With the CRVT, Bimba is looking to make the end effector as flexible and easy to use as the robot,” says Jeremy King, Product Manager for Bimba. “The CRVT is designed to be controlled using the I/O connection built into the robot. No additional software or controls are required.

That means simply connecting the tool to the robot

Key Bellevilles, Inc. LARGEST MANUFACTURER OF DISC SPRINGS IN THE WORLD Live Load with Belleville Disc Springs LARGEST STOCK OF STAINLESS STEEL AND INCONEL SPRINGS IN THE WORLD

and supplying an air-line to it. Once that’s done, you’re ready to program.”

HIGH TEMPERATURE FLANGE BOLT

FREE ENGINEERING ASSISTANCE FLANGE BOLTING SERIES ON STOCK H-13, STAINLESS, INCONEL, AND TITANIUM

MANUFACTURED TO DIN AND NACE SPECS Metric and English sizes available

OUR PRICES ARE THE BEST ~ BUY DIRECT ~ Made in the U.S.A.

Immediate Delivery!

24-Hour Service 7 Days a Week!

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

Visit our Website: www.keybellevilles.com for a FREE Design CD-ROM

LIVE LOADING VALVE PACKING GLANDS

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

DESIGN WORLD

ProductWorld-7-18_Vs3.LL.indd 93

www.designworldonline.com

July 2018

93

7/2/18 3:09 PM

Product World Digital sensor with analogue heart Endress+Hauser sensors-components.endress.com The capacitive-ceramic pressure sensor Ceracore USC30 combines both output signals in one sensor. Each signal is available for further processing. Amongst others, the digital communication path enables the user to adapt many parameters themselves. This includes “turn down,” the change of the zero point and the measuring span. The sensor can therefore cover several measuring tasks and in consequence reduces storage costs. Since the adjustments are made at the sensor level, this can simplify the design of the main electronics.

The Ceracore USC30 can be used industry-independent and

is suited for challenging environments with aggressive media. The 99.9% pure ceramic makes it highly resistant to corrosive and abrasive media.

The ceramic is long-term stable and free of hysteresis. Together with its vacuum resistance and its — up to 40 times — overload resistance, the USC30 is the ideal dry sensor for high-precision measuring tasks.

Linear encoder upgrade Heidenhain heidenhain.us The updated LIF 400 series encoder has a position noise value of 0.6 nanometers at 1MHz and a low interpolation error down to +/- 12 nanometers. Industries that could take advantage of this encoder are semiconductor, metrology, micromachining, and medical.

One of the major updates is the incorporation of the HEIDENHAIN Signal

Processor (HSP1.0) custom ASIC into the scanning unit. This ASIC helps lower the interpolation error, and also powers through contaminations on the scale as it adjusts the LED intensity every signal period while moving at up to 4 meters per second.

This compensation adjusts the amplitude and phase of the signals so that the control

the older version, which saves space and

sees constant perfect signals even with contaminants such as large fingerprints, dust,

improves accessibility when plugged into

and wafer pieces that may be on the glass scale.

tight spaces. This 15 pin male connector is

27 mm shorter than the previous version.

Another addition is a status LED on the connector that indicates the status of the

Also, the connector is now smaller versus

incremental signals and can also be used as a general mounting indication. It’s a simple red/green display for the signals and blue for a good reference mark signal.

94

July 2018 www.designworldonline.com

ProductWorld-7-18_Vs4.LL.indd 94

DESIGN WORLD

7/6/18 11:40 AM

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

Zinc die-cast flat adjustable tension levers JW Winco jwwinco.com The GN 126 and GN 126.1 Zinc Die-Cast Flat Adjustable Tension Levers are available in Steel and Stainless Steel, with Tapped or Plain Bore Insert or Threaded Stud. The RoHS compliant flat adjustable levers are characterized by their low height. Designed for swiveling in confined spaces or the lever is to be clamped in a particular position, the insert or threaded stud is moveably attached to the handle with serrations. Pulling the lever disengages the serrations, allowing it to be swiveled to the desired clamping position. On

Large girth gear drive lubricant Klüber Lubrication klueber.com/us/en Klüberfluid C-F 3 ULTRA is a lubricant developed specifically for the lubrication of medium-size to large girth gear drives. It is based on synthetic hydrocarbons and mineral oil to provide good adhesion, resistance to high pressure and protection against wear. Klüberfluid C-F 3 ULTRA enables the end user to inspect open gears while in operation and significantly reduce the amount of cleaning time for NDT inspections. Klüberfluids will not clog spray nozzles and will freely flow from gear guards while offering superior protection over traditional asphaltic-based products.

Klüberfluid C-F 3 ULTRA can be used for immersion, paddle wheel,

circulation and spray lubrication of large girth gear drives. Such drives are found in rotary kilns, tube mills, drums and similar machinery used in the cement, lime, gypsum, mining and chemical industries and in power plants.

“releasing” the handle, the serrations re-engage automatically via a spring.

The handle is zinc die-cast, powder coated

in either a black or silver textured finish, while the hub cover is either black or light gray. The countersunk screw is either steel or stainless steel, and either chemically blackened or a plain finish depending on the material type. The steel insert or threaded stud has a blackened finish, while the stainless version is European Standard No. 1.4305 (AISI 303).

DESIGN WORLD

ProductWorld-7-18_Vs4.LL.indd 95

www.designworldonline.com

July 2018

95

7/6/18 11:04 AM

Ad Index

SALES

Aignep USA ..............................................79 Allied Electronics & Automation ........................... Cover,2,3 Allied Moulded Products..................... 63 AllMotion ...................................................... 4 Altra Industrial Motion ..........................34 Anchor Fluid Power ...............................78 Aurora Bearing Company ...................79 Automation24, Inc. ................................... 7 AutomationDirect ...................................... 1 Bay Associates Wire Technologies Corp. ..........................44 Bimba ...........................................................10 Canfield Connector ...............................70 Caplugs .......................................................31 Centritec Seals ........................................20 CGI Motion ............................................... 39 Da/Pro Rubber Inc. .................................. 17 Del-tron ....................................................... 71 DieQua .................................................30,77 Digi-Key ......................................................13 ebm-papst Inc. ........................................23 Encoder Products Company ............. 65 EXAIR Corporation ................................... 5 Fluke ............................................................75 Fotofab ..................................................... 64 Graybar ......................................................47 Greene Tweed & Co. .............................29 Harwin ....................................................... 88 HELUKABEL USA ....................................14 IDEC Corporation .....................................19 igus ............................................................ IBC ITT Enidine ............................................... 38

Keller America ..........................................45 Key Bellevilles Inc. ................................. 93 LEMO USA, INC. .....................................27 Memory Protection Devices ...............25 Nason ..........................................................41 New England Wire Technologies & New England Tubing Technologies ........................................................................51 NSK Precision ..........................................37 OKW USA ....................................................15 PBC Linear ......................................... 54,55 PHD Inc. .....................................................42 Phoenix Contact .................................... 69 Prince Manufacturing Co. .................. 60 R+W America ........................................... 89 Rotor Clip .................................................. 49 Rutronik .....................................................24 SEW Eurodrive ....................................... BC SIKO Products ..........................................92 Smalley Steel Ring ................................... 9 Sorbothane ..............................................70 Southco .....................................................35 Sunstone Circuits ...................................81 THK TOS .................................................. IFC Tompkins Industries, Inc. ......................61 Tormach .................................................... 84 Traco Power .............................................33 Trim Lok .......................................................21 Turck .................................................... 83,85 US Tsubaki .................................................91 Wago USA .................................................43 Whittet-Higgins ...................................... 59

Jim Powers

Mike Caruso

mcaruso@wtwhmedia.com 469.855.7344

Garrett Cona

gcona@wtwhmedia.com 213.219.5663 @wtwh_gcona

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

Courtney Seel

cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

Michael Ference

mference@wtwhmedia.com 408.769.1188 @mrference

Michelle Flando

mflando@wtwhmedia.com 440.670.4772 @mflando

Mike Francesconi

LEADERSHIP TEAM

Publisher Mike Emich

memich@wtwhmedia.com 508.446.1823 @wtwh_memich

mfrancesconi@wtwhmedia.com Managing Director 630.488.9029

Scott McCafferty

David Geltman

dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david

Neel Gleason

ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty

EVP Marshall Matheson

mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

Tom Lazar

tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom

ine.com

nworldonl

www.desig July 2018

inside:

Check out the digital edition!

ol: Motio n Contr Motors: Options DC Brushle ss al Power Tools. for Industri

p. 56

n: Linea r Motio

n of direct Wider adoptio . linear designs drives for

p. 66

Mecha nical:

n coupling selectio Masteri ng fundam entals.

p. 86

Making

So much happens between issues of Design World that even another issue

embedded ms syste ck steady clo

and other significant news to the design engineering community.

designworldonline.com

page 72

PM 7/2/18 3:38

JULY 2018 DW

FOLLOW US ON

would not be enough to keep up. That’s why it makes sense to visit designworldonline.com and stay on Twitter, Google plus, Facebook and Linkedin. It’s updated regularly with relevant technical information

AL.indd 1

COVER_FIN

Follow the whole team on twitter @DesignWorld

DESIGN WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. DESIGN WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care.

DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2018 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

Subscription Rates: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only.

Subscriber Services: To order a subscription or change your address, please email: designworld@omeda.com, or visit our web site at www.designworldonline.com DESIGN WORLD (ISSN 1941-7217) is published monthly by: WTWH Media, LLC; 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103. Periodicals postage paid at Cleveland, OH & additional mailing offices.

POSTMASTER: Send address changes to: Design World, 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

96

July 2018 www.designworldonline.com

AD INDEX_7-18_Vs1.indd 96

DESIGN WORLD

7/5/18 4:01 PM

Unlimited advantages... ...replace metal bearings with plastic

Upgrade your linear system to drylin® drylin® W linear bearings and guides offer lightweight and quiet operation, as well as a range of other advantages, including up to 40% reduction in overall bearings costs.

motion? plastics!

Visit www.igus.com/linear-factcheck to see if drylin is right for your application ®

igus 6-18.indd 1

7/5/18 10:07 AM

Don’t get torqued off.

Get TorqLOC®!

Can’t remove your corroded gear unit from your Assembly

machine shaft? Well, stop fretting about it. Man up and get TorqLOC® from SEW-EURODRIVE. With its stainless steel construction, keyless hollow shaft, and taper bushings, TorqLOC® disassembly is fast and easy. The same bolts used for assembly are used for disassembly.

Disassembly

Not only does TorqLOC® reduce your maintenance headaches, it also eliminates belts, chains, and sprockets to reduce energy costs.

seweurodrive.com / 864-439-7537

SEW Eurodrive 7-18.indd 1

7/2/18 8:49 AM