DESIGN WORLD MARCH 2023

March 2023

MOTION CONTROL: Part one: Scalar and vector VFD control methods

p. 50

ELECTRONICS: Sustainability challenge: Lithium-ion versus sodium-ion batteries

p. 56

Precision

CONNECTORS: Rotary slip ring connectors — what are they used for?

motion stage

has the right stu

LINEAR

LOCAL MANUFACTURING

THK is committed to meeting the worldwide demand for linear motion products. We manufacture, assemble, and ship across North America from our location in Hebron, Ohio. We’ve also ramped up our automating processes at existing facilities, including our U.S. manufacturing plant, where over 70% of THK Robotics Components are manufactured. Automated processes at this state-of-the-art facility enable increased production while maintaining the high standard of precision associated with THK products.

To learn more, call us at 1-800-763-5459 or visit www.thk.com.

See us at ATX West, Anaheim CA, Feb. 7 - 9, Booth #4254

The Assembly Show South, Nashville TN, April 4-6, Booth #557

THK Manufacturing in Hebron, Ohio

1–2 Week Delivery of Select LM Guides and Actuators

QUICK SHIP COMPONENTS

See us at: Promat, Chicago IL, March 20-23, Booth #N9810

As with most industrial control projects, cost is king, but you don’t have to sacrifice quality to keep your budget intact. For over 15 years, the C-more line has served tens of thousands of installations without missing a beat.

C-more HMIs are built to last and provide many advanced capabilities, including object animations, logic and math operations, web server/mobile app access, and data logging, all for a surprisingly low price.

Now with FREE software!

World’s first wear-resistant DLP resin

Rapidly print high resolution components

iglide® i3000: Purchase resin directly or print parts with our online 3D print service

• Withstands long-term temperatures of up to 80°C

• Lasts 30-60x longer than conventional DLP resins

• Dry-running, low-maintenance performance

• Resolution of up to 35µm

• Inner channels possible

• Extremely wear-resistant

A new way of thinking

One of the most valuable pieces of “real estate” in any magazine is the page facing the inside back cover. Over the years, I’ve known many publications — both trade and consumer — with must-read departments or columns in that sacred space. Many times, they’re on the lighthearted or even humorous side. I’ve even subscribed to some publications where the column was such a draw that I’d open the magazine “backwards” to digest that content first. While Design World has never had a dedicated column on that page, it’s something our editorial team has long discussed.

You may have noticed that we’ve finally made a change there; starting with last month’s issue, a new column called Technical Thinking appears facing the inside back cover. We’re so excited about this change, thanks to the always thought-provoking writing of our new columnist, Mark Jones.

Mark is the Creative Director at MJPhD, LLC, an independent consulting firm. He retired after an industrial career of more than 30 years with a Fortune 100 company. During his career, he investigated a wide range of technologies, developed goals for sustainability related to innovation, implemented strategies related to renewable resources, and more. Responsibilities for communications and strategy around R&D filled the last decade of Mark’s career. Technology and e orts to improve sustainability remain fascinations to him. Mark has written for our sister publication, R&D World, and his occasional contributions there have consistently been some of that magazine’s most widely read content.

The main thrust of Design World will, of course, remain the highly engineered componentry and system design news, applications, and technical how-to features that you’ve counted on over the past 17 years. But Mark has a gift for taking real world interactions — reading a restaurant menu, hunting for morels in a forest, observing roads being salted — and delving into the technical steps that led humanity to that moment or wondering what that activity means for the future. I believe that his writing will add something positive to your reading experience each month.

I hope you enjoy Mark’s writing as much as our sta has, and that you soon find yourself opening Design World in a “backwards” fashion first. DW

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

On

Companies get by with a little help from their friends in 2023

It’s March. If you’re like me, by now, your New Year’s resolutions are either collecting dust or just starting to pay dividends. Which scenario we find ourselves in often depends on realizing early that we need to work with others to achieve our goals — those that find the best team tend to find the best results. Going into 2023, PT/MC companies seemed to agree with this logic.

At the beginning of the new year, the Power Transmission Distributor’s Association posted an article about recent mergers and acquisitions on its website. According to the PTDA, companies across the PT/MC marketplace were choosing to work together. Despite 2022’s economic witches brew of interest rate spikes, bond market instability, a pullback in leveraged finance, and more, several companies chose to unite.

“Mergers and acquisitions are on the rise across all industries, and the PT/MC marketplace is no exception. Not even a global pandemic could sideline M&A activity. Economies of scale and scope, increased market share, tapping into new markets and fresh talent — all can bring great rewards.”

The PTDA specifically cited Motion’s blockbuster acquisition of Kaman Distribution Group (KDG) and FICODIS’ acquisition of independent distributors, to name a few. A recent Wall Street Journal piece also explained that we can expect even more companies to follow suit in 2023. If not necessarily in the same ways we’ve seen in the past.

“…many companies adapted, structuring deals to sidestep market volatility and minimize financing costs. In doing so, they provided a glimpse of what’s likely ahead for

deal-making this year, bankers and advisers said. ‘The M&A market is not going to stop. It just doesn’t work that way. What it does is it evolves,” said Christopher Auld, head of leveraged finance at investment firm Stifel Financial Corp.’”

While 2023 is expected to see an uptick in M&A activity, exactly when is not clear. Mergers and acquisitions are still heavily influenced by the kind of stability and predictability that’s been in particularly short supply in the last few years. How does the Federal Reserve plan to pace future rate increases? Are regulatory demands going to increase as they did in 2022? And, of course, there’s a blue ribbon for anyone that can tell you what will happen with inflation. For now, it looks like companies will continue to band together to reach their goals before the next new year and its new resolutions. DW

The PROmax power supplies from Weidmüller are extremely durable and offer high levels of scalability. Their robust construction allow them to withstand brief and continuous overload conditions, ensuring reliable power to critical loads. Additionally, the integrated mounting system allows for easy installation into a preexisting control panel.

Paul J. Heney • VP, Editorial Director

Wiegand energy harvester enables new IoT technologies

UBITO, part of the FRABA family, has announced a development of Wiegand technology as an energy source for smart sensors. After more than two years of e ort at FRABA’s R&D center in Aachen, Germany, a research team has demonstrated a prototype of a wireless sensor powered by Wiegand technology that could support Internet of Things networks. The project involved the development of a new Wiegand Harvester capable of capturing enough energy to power the sensor’s electronics package, including a highe ciency ultra-wide-band radio transmitter. This achievement (a world first) helps to position Wiegand technology (which collects energy from movements of an external magnetic field) beside established energy harvesting techniques such as solar, piezo, or thermo-electrics as an energy source for sensor nodes in the emerging industrial IoT.

“Wiegand sensors have been a core component of our encoder products for over 15 years,” said Tobias Best, global head of the UBITO startup. “While this technology has provided a highly reliable way of detecting and recording rotations in flow meters and multiturn encoders, we have always been looking forward to its wider potential, especially for energy harvesting.”

With this goal in mind, FRABA undertook a development project aimed at improving the energy output from Wiegand devices and demonstrating the possibility of selfpowered sensors that could detect events and transmit data wirelessly to an IoT network. The R&D project was conducted with Aachen’s University for Applied Science, with financial support from the German Ministry of Education and Technology. The project team succeeded in producing a new Wiegand Harvester — a device that could generate more than 50 times the energy of commercial Wiegand sensors.

“This level of output makes it possible to dream of energy selfsu cient sensors that can communicate data wirelessly over a significant distance,” said Best.

The team chose a window sensor system for a practical demonstration of an IoT sensor node powered by Wiegand-harvested energy.

Two Wiegand harvesters and their associated electronics were mounted on the window, with bar magnets mounted on the frame. The harvesters, made up of a 21 mm long pieces of Wiegand wire surrounded by a copper coil, are the size of an AAA battery. Whenever the window is opened or closed, the harvesters pass the magnets, triggering abrupt magnetic polarity changes in the Wiegand wires.

The amount of energy delivered is largely independent of how quickly or slowly the window is moved — a key benefit of Wiegand technology.

The current pulses induced by these polarity reversals generate about 10 microjoules of energy. A key goal had been achieved: the amount of energy captured was su cient to activate a microcontroller and collect a reading from a temperature sensor built into the system. The team added an ultra-wide-band transmitter module that could transmit 134 bytes of data to a receiving station 60 meters away.

“This is a lab demonstration, not a commercial product,” said Best. “However, by showing the capabilities of a system made up of Wiegand devices and o -the-shelf electronic components , we hope to spark interest in the wonderful potential for this technology. With the Industrial IoT projected to grow by a factor of three over the next decade, the future is very exciting.” DW

UBITO www.ubito.com

WHAT DO YOU THINK?

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

42 LINEAR MOTION

High-precision motion stage has the right stu

In-house designed and built motion control components are used to design and build a high-precision motion stage.

50 MOTION CONTROL

Part one: Scalar and vector VFD control methods

AC motors pair with variable frequency drives to satisfy process as well as motion-control applications. Here we compare how the operation of these drives diverge.

56 ELECTRONICS

Sustainability challenge: lithium-ion versus sodium-ion batteries

As electrification increases, rechargeable batteries will contribute significantly to sustainability goals. But determining which battery type is best remains a challenge.

62 TEST & MEASUREMENT

What is a Smith chart and why do I need one?

A Smith chart provides insight into RF/microwave designs. Even if you work primarily with lowspeed analog and mixed-signal designs, you could benefit from familiarity with the Smith chart as wireless products proliferate and as high-speedserial data signals exhibit microwave-like e ects.

66 CONNECTORS

Rotary slip ring connectors — what are they used for?

Rotary slip ring connectors are important components in various applications like multi-axis robots in industry 4.0, wind turbines for sustainable green energy, machine tools, medical systems, and more.

Follow the whole team on twitter @DesignWorld

EDITORIAL

VP, Editorial Director

Paul J. Heney pheney@wtwhmedia.com @wtwh_paulheney

Managing Editor

Mike Santora msantora@wtwhmedia.com @dw_mikesantora

Executive Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel

Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion

Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon

Senior Editor

Rachael Pasini rpasini@wtwhmedia.com @WTWH_Rachael

Associate Editor Heather Hall hhall@wtwhmedia.com @wtwh_heathhall

CREATIVE SERVICES

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

Senior Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer

Senior Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison

Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel

Director,

Bruce

bsprague@wtwhmedia.com

WEB DEV / DIGITAL OPERATIONS

Web Development Manager

B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave

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

Front End Developer Melissa Annand mannand@wtwhmedia.com

Software Engineer David Bozentka dbozentka@wtwhmedia.com

DIGITAL MARKETING

VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia

Digital Marketing Manager

Taylor Meade tmeade@wtwhmedia.com @WTWH_Taylor

Webinar Coordinator Halle Sibly hkirsh@wtwhmedia.com

Webinar Coordinator Kim Dorsey kdorsey@wtwhmedia.com

EVENTS

Events Manager Jen Osborne josborne@wtwhmedia.com @wtwh_jen

Events Manager Brittany Belko bbelko@wtwhmedia.com

Event Marketing Specialist Olivia Zemanek ozemanek@wtwhmedia.com

VIDEO SERVICES

Videographer

Garrett McCafferty gmccafferty@wtwhmedia.com

Videographer

Kara Singleton ksingleton@wtwhmedia.com

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

Renee Massey-Linston renee@wtwhmedia.com

Customer Service Representative

Trinidy Longgood tlonggood@wtwhmedia.com

Digital Production Manager

Reggie Hall rhall@wtwhmedia.com

Digital Production Specialist

Nicole Johnson njohnson@wtwhmedia.com

Digital Design Manager Samantha King sking@wtwhmedia.com

Marketing Graphic Designer

Hannah Bragg hbragg@wtwhmedia.com

Digital Production Specialist

Elise Ondak eondak@wtwhmedia.com

FINANCE

Controller

Brian Korsberg bkorsberg@wtwhmedia.com

Accounts Receivable Specialist

Jamila Milton jmilton@wtwhmedia.com

Design for Industry

Flexible gaging for inspection

When an aerospace or medical application calls for high-speed comparative gaging for inspection, the Renishaw Equator system may fit the bill. It’s a lightweight, fast, and highly repeatable gage that operates with “push-button” simplicity. It can also be used by firearms manufacturers for production of handgun barrels, frames, and slides, and some lower and upper AR (Armalite Rifle) components.

The Equator system takes a simple concept of using a master (known) part and couples it with a highly repeatable and versatile structure for fast, flexible gaging on the factory floor. Along with IPC (Intelligent Process Control) feedback, the Equator system allows the gaging to update the machining process for immediate feedback without a need for manual o set adjustments.

Based on an easily scalable and adaptable “parallel kinematic” structure, the Equator system allows high speed scanning and rapid moves between features, while retaining sti ness that delivers point-to-point repeatability, critical for accurate gaging. The Equator system o ers the flexibility to scale appropriately without too much in the way of dedicated fixturing.

Installation of an Equator system takes minutes, and an operator can switch between gaging of di erent parts in seconds. Re-configuration of the gaging system to accommodate part design changes, or to measure new parts, is possible in a fraction of the time needed for conventional custom gaging, using industry standard DMIS programming.

Equator systems are available with two levels of software; a programmable version for production engineers to create DMIS programs and, at a lower price, a shop floor system which allows those programs to be executed but prevents operators from making modifications. Both software levels include easy-to-use MODUS Organizer operator front-end software. In the programmable version, MODUS Equator programming software allows engineers to rapidly create gaging routines for any part – simple or complex, prismatic or free-form. DW

Triaxial variable

capacitance accelerometer handles

harsh environments

When you need to take precise measurements in harsh environments, the Model 3743F provides accurate readings over a wide operating temperature range. It is for testing aircraft flight/flutter, in-flight vibration, low frequency aircraft/ airframe vibration measurements, space launch vehicle vibration, automotive ride quality, road load data acquisition (RLDA), and structural dynamics.

As part of the “F” series of MEMS DC response sensors, which also includes 3711F, 3713F, and 3741F, the Model 3743F uses variable capacitance MEMS technology for stable and accurate measurement in a wide input voltage range from 5 to 32 Vdc. It simultaneously measures acceleration and lowfrequency vibration in three mutually-orthogonal axes (X, Y, Z).

The triaxial di erential output accelerometer features:

• Stable and accurate measurements using MEMS technology

• Ability to measure low frequencies and long duration events

• Excellent linearity (0.3%) and low noise

• Exceptional Thermal Performance (+/- 1% from -54 to 121 C)

• Available in six measurement ranges: ± 2, ± 10, ± 30, ± 50, ± 100 and ± 200 g’s

The titanium package is stud mounted and has an integral hermetic 9-pin receptacle that mates with our 037Gxx / 037ENxxxNU detachable shielded cable assembly, sold separately. The 3743F is currently shipping in 6-8 weeks. DW PCB

Magnetics handle the harsh environments of space

Fiber optics collect the light om the celestial bodies. The extremely precise alignment of each of the fibers is performed by 500 small robots, which are driven by FAULHABER motors.

The CCM (Chameleon Concept Magnetics) family of products withstand the harsh environments of aerospace and particularly of space applications. CCM technology is a response to the growing interest of electronic engineers for inductors and transformers with multiple outputs, high power density, and reduced footprints. These ‘chameleon-like’ products can be either an inductor or a transformer depending on the inductor ranges and complement the existing SESI and TT product families.

The CCM product family currently consists of five sizes, CCM4/5/6 and CCM20/25, allowing optimized component design in a pick-and-place surface mount (SMD) package. Through-hole (TH) packages are also available upon request. The maximum transferable power in the CCM25 is about 200 W, depending on the operating conditions of the transformer. The CCM30 is currently under development and this model would approach 350 W. The CCM series is flexible with a number of pin options available, from 2×6 pins for the smallest package, up to 2×10. Qualified for aeronautic and space applications, the CCM product line is robust. The monolithic design provides high mechanical performance, proven by the successfully testing in accordance with MIL-STD-202 (methods 213 and 204).

CCM transformers and inductors can operate over a wide temperature range with a minimal operating temperature of -55°C. The standard thermal grade of the technology is 140°C. Thanks to the technology design, the thermal resistance is 30% lower than standard industrial components. The epoxy molding that protects the winding ensures a lower temperature gradient and a better heat dissipation.

Each unit is thoroughly tested with a dielectric withstanding strength of 1,500 VAC. Component materials meet UL 94-V0 rating. Thermal resistance data is available for each package size. The CMM products are manufactured to MIL-STD-981.

Features and benefits:

• Designed to withstand severe environment as space, avionics

• Bobbin winding Technology using standard profiles (RM, EQ, etc.)

• Epoxy Transfer molding technology

• SMD package

• Multiple pins

• Ferrite withstand high shocks and vibration (MIL STD 202 Method 213 & 204)

• Good repeatability of electrical characteristics, allows good regulation of multiple outputs power supply

• Higher power density up to + 30% compared to standard package

• Easy to pick and place

• Flexibility of use

• No stress on the Ferritecore External assembly

Applications:

• Aeronautics & Space

• Common mode chokes

• PFC chokes

• Gate Drive transformers

• SMD filtering chokes

• Current transformers

• Flyback transformers

• Forward transformers

• Push-Pull transformers

DW

Exxelia Magnetics

Exxelia.com

CNC for smart production processes

Machine controls continue to o er a greater range of features. One example is the SINUMERIK ONE CNC, which o ers new technological functions and a redesigned user interface. It o ers 95% operational compatibility with Sinumerik 840 D sl, as well as optimized machining speed, contouring accuracy, and machining quality.

A universal and flexible CNC system, it is compliant with the applicable IT security standards. The extended option package, included as standard with SINUMERIK ONE, includes the following options:

• Execution from external storage (EES)

• Shopturn/Mill upgrade package

• CAD reader for the Sinumerik

• Sinumerik & EMCONNECT, your digital process assistant

EMCONNECT is included in the standard machine. All it takes to switch between the EMCONNECT apps and the control is one click. What is more, all production-relevant data can be displayed in full screen or in sidebar view.

The SINUMERIK ONE was developed for smart production processes.

• The digital twin for production planning is an integral part of the CNC. The virtual and physical controls merge and complete each other

• Run MyVirtual Machine replaces Sinutrain

• Significant reduction of the product development and launch times thanks to the ‘digital first’ strategy

• Improved networking and data communication capabilities

• The virtual preparation of the start-up reduces the actual commissioning time

• Significantly increased CNC performance

• Significantly reduced non-productive times and full integration into the TIA portal thanks to the integrated SIMATIC S7-1500F PLC

Positioning stage offers four motor choices

Flexibility in machining components enhances the design process. For example, the XYZR Series of Four-axes Stages are the integration of a: 15 mm, 30 mm, 50 mm, 75 mm, or 100 mm linear stages (in any combination) for the X, Y, and Z axes, and a 60 mm or 100 mm diameter rotary stage capable of 360° of continuous rotation. These stages suit applications such as: Laser scanning, drilling, and machining, reverse engineering, inspection, assembly, measurements, tracking, and positioning.

This series of four axes stages feature four motor options. The -01 option is Stepper Motor driven, the -02 option is Three PhaseServo Motor driven with a Quadrature Optical Encoder, the -03 is DC Servo Motor Driven with a Quadrature Optical Encoder, and the -04 option is Stepper Motor Driven with Quadrature Optical Encoders for position verification.

Each axis of these black anodized aluminum alloy stages features high precision crossed roller bearings. The 15 mm, 30 mm, 50 mm, 75 mm linear axes feature high precision 1 mm per turn lead screws and the 100 mm linear travel stage has a 4 mm per turn lead screw. Typical repeatability and positional accuracy of a stepper motor driven stage is 10 microns. For higher resolutions and greater travel speeds select one of the closed loop servo motor options.

The rotary axis is equipped with a HOME switch to signal the motion controller the ZERO position. Each rotary axis has a pattern of precision mounting holes for mounting tooling and the 100 mm diameter stage has a thru hole. The linear axes are equipped with limit switches to signal the motion controller that end of travel is reached.

Each of these stages can be ordered with a fully plug-andplay compatible multi-axis motion controller for any motor combination. DW

Compact linear motion system for small spaces

When you need to implement complex applications in small spaces, this family of compact linear systems can make design easier. Designers needing thrust and bearing support in a single, compact unit now have the flexibility to build such applications with these versatile components.

As demand for smaller-scale applications grows, so does the challenge of packing high functionality into a smaller footprint. In building a compact linear system, a designer can configure a unit or combination of units from a variety of components based on their specific application details. Components include, but are not limited to:

• Integrated stepper motors

• Lead screws

• Profile rail linear guides

• 60 Case LinearRace shafting

• Linear Ball Bushing bearings

• End blocks

Many features can be customized, including screw diameters and leads, mounting holes and mounting configurations.

To take maximum advantage of such flexibility, engineers can refer to an innovative 3D modeling tool that optimizes their solution by revealing design tradeo s in real time. The tool guides the designer in tailoring motor size, stroke length, and other variables to function most e ectively within given load and space parameters.

The resulting design information is used to produce a prototype, which is sent back to the engineer for testing. Because of such close user involvement during the design process, the number of design iterations is reduced, which, in turn, decreases the likelihood of mistakes being made.

These compact linear systems are appropriate for applications requiring high-accuracy linear axes in confined spaces, such as 3D printers, microscope stage managers, medical pipetting systems, and semiconductor manufacturing. They are available with NEMA motor sizes between 14 and 23; stroke lengths of up to 40-in. (1000 mm); and load capacities up to 2091 ls (9300 N). DW Thomson

CLEAN EATING

UNCOMPROMISING PURITY IN FOOD PRODUCTION THANKS TO EFFICIENT SEALS

Seals used in the food industry have to meet very high requirements. That‘s because hygiene and the appropriate certifications are critical for the safety of processes and end products. Yet extreme temperature fluctuations, aggressive media such as cleaning agents and grease, and abrasive additives like nuts or pieces of fruit

present a huge challenge. Freudenberg Sealing Technologies has developed special seals made of innovative materials that can withstand these extreme conditions permanently and uncompromisingly – for the clean production of all kinds of food. foodandbeverage.fst.com

for Industry

Stepper drive for fixed-load, lowspeed, point-to-point applications

The P80630-SDN stepper drive o ers features such as smoothness, precision and torque across the full speed range in a more compact package that enables smaller, lighter, more versatile machines.

The stepper drive powers and controls stepper motors operating on 24 to 75 VDC with up to 5.5 Arms current per phase (7.8 Arms peak). It suits labelers, indexing tables, CNC machines, packaging systems, pumps and other single-or multi-axis systems requiring low-speed, point-to-point motion control for fixed loads.

The drive delivers improved positional accuracy as demonstrated in laboratory tests using PMX series stepper motors. This compact, powerful new drive achieves 10% greater output current in a 60% smaller package that is up to 34 mm shorter in height than the 6410, depending on the model. Moreover, it reduces setup time by delivering smooth, precise performance at all speeds without the need for electronic damping control switches.

The P80630-SDN stepper drive supports conventional single-ended or di erential step and direction interfaces (user-provided pulse train required) or CW/CCW command inputs. Dip-switch selectable settings include motor phase current, idle current reduction and step resolution up to 1/128 microstep, all with no programming required. Dedicated enable input and fault output provide control of the drive’s power stage and error monitoring. Additional models with new features are scheduled for release in the coming months. Selected drives will also include widely used fieldbus protocols for integration with industry-standard motion controllers. All drives in the series are CE, RoHS, and REACH certified. DW

Kollmorgen

www.kollmorgen.com/en-us/products/drives/ stepper/p8000

Hollow sha gears offer high

torque outputs

HPF series of hollow shaft gear units provide exceptional torque density and positional accuracy, making them suitable for a range of industrial applications including robotics, packaging, and material handling. They feature a high torque output, with maximum continuous torque ratings up to 1000 Nm and maximum peak torque ratings up to 1500 Nm.

The hollow shaft design allows for easy integration and installation in tight spaces, while also allowing for the passage of cables, hoses and other mechanical parts through the gear unit. Additionally, the hollow shaft design provides a high torsional rigidity, making it suitable for high-speed applications.

Built with state-of-the-art manufacturing processes and materials, the HPF series gear units are durable and reliable even in the most demanding environments. They also feature low backlash and low noise operation for applications where precision and quiet operation are a must. DW

Features include:

• Hollow Shaft: 25 to 32 mm

• Available in 2 Frame Sizes

• Peak Torque: 100 to 200 Nm

• Ratio: 11:1

• Backlash <3 arc-min

• Extra-large Cross Roller Output Bearing

Harmonic Drive

electromate.harmonicdrivegearhead.com/products/harmonic-planetary-gear-units/hpf

Manufacturing an all-new Italian SUV

Edited by Mike Santora • Managing Editor

Comau has designed and deployed a flexible Body-In-White (BIW) manufacturing solution for Alfa Romeo’s all-new Tonale, the first Alfa SUV of the new generation, meeting customer production targets, quality goals, and time-to-market objectives.

The new and enhanced 20 lines are designed to allow the automaker to assemble its mid-size Tonale in a random mix of up to 4 di erent versions while maintaining the desired throughput. Fully scalable, the solution lets the automaker produce multiple brands on the same line while allowing them to further expand production in the future.

Tasked with building five completely new lines and retooling 15 existing lines to accommodate the new vehicle, the Comau team deployed the production lines in record time despite multiple challenges. The SUV chassis is significantly larger than the compact car for which the line was originally designed, and the team was asked to make the necessary changes without sacrificing the production of either vehicle. Through simultaneous engineering, the team designed a transformation strategy that allowed the retooling operation to be executed in parallel with the existing activities, according to its “Zero Loss Launch” philosophy. Comau also worked on the lines during the plant’s natural downtime, thus minimizing any impact on production.

As part of the engineering team’s lean manufacturing approach, the automated and semi-automated production solution is based on the proprietary ComauFlex technology, nicknamed Butterfly, due to its agility and use of suspended robots. This setup allows Alfa Romeo to change or modify a specific vehicle model by adjusting the robot tooling, not the arrangement of the robots themselves. In addition to protecting the scalability of the customer’s initial investment, the solution is designed to enable the introduction of new models in the future for a fraction of the initial expenditure.

Indeed, the entire system features 468 welding robots, 148 of which are entirely new and 320 taken from existing lines. The engineering team used advanced simulation tools during the development period, guaranteeing the best quality product and throughput.

In addition to allowing Alfa Romeo to perform the complex body shop processes with precision, the solution fully assembles the entire BIW from start to finish. With the aid of three di erent vision systems to aid the automated picking and positioning of pieces, the robots weld, fasten and perform other activities, including spreading the semi-structural adhesive on the parts and plasma cutting during the end-of-line activities. All said, the process involves the insertion of roughly 2,800 welding spots for each model.

With significant net output, Alfa Romeo can bank on substantial savings in terms of time, long-term costs, and production e ciencies. Moreover, because the solution is a fully modular system built around standard products combined within an expandable design framework, the automaker can quickly expand its manufacturing environment with limited impact on existing production.

“To join forces with a prestigious brand such as Alfa Romeo is an

The entire system features 468 welding robots, 148 of which are entirely new and 320 taken from existing lines. The engineering team used advanced simulation tools during the development period, guaranteeing the best quality product and throughput. In addition to allowing Alfa Romeo to perform the complex body shop processes with precision, the solution fully assembles the entire BIW from start to finish.

incredible opportunity to develop cuttingedge technologies. We are proud to see the tangible results of Comau’s field-proven expertise within the collaboration between two Italian examples of excellence,” explained Pietro Gorlier, Comau CEO. “Our commitment to unwavering quality is seen within the processes and products used to make the Tonale and allow us to ensure maximum value for the customer.”

“In supporting the Alfa Romeo brand in their product expansion, Comau has fully leveraged its longstanding experience in automation and smart manufacturing to deliver an unprecedented level of flexibility,” added Andrew Lloyd, Comau’s Chief of Engineering. “This innovative approach to implementing new technologies and retooling existing lines and equipment is a direct result of our commitment to o ering increasingly scalable and sustainable solutions, helping our customers better meet their objectives today and tomorrow.” DW Comau | comau.com

Plate heat exchangers vs. shell and tube designs

Edited by Mike Santora • Managing Editor

For simple non-viscous fluids, the choice of heat exchanger typically comes down to a choice between plate heat exchangers (PHEs) and shell and tube designs. The proponents and manufacturers of both types of heat exchangers make strong cases for the use of each technology and the suitability of each type of heat exchanger, but ultimately the heat transfer situation will determine the best heat exchanger for the role.

There are also several considerations less frequently addressed when evaluating the advantages of shell and tube and plate heat exchangers. It is first important to understand the di erence between the two designs, as this will make it easier to understand the di erences in costs, operational e ciency, and maintenance.

One aspect of plate heat exchanges often not considered is the cost of gasket replacement.

As the name suggests, a plate heat exchanger consists of a series of pressed metal plates separated by gaskets. The service fluid (which provides the heating or cooling e ect) and the product (the material to be heated or cooled) flow through the gaps between alternate plates. In contrast, a shell and tube design features a tube (or series of tubes) running through a shell. The product flows through the tube, and the service fluid through the gap between the tube and the shell.

The advantages of plate heat exchangers include their simplicity and high-heat exchange performance (when used with simple fluids). However, the

In a plate heat exchanger, the service fluid and product flow through the gaps between alternate plates.

Design Notes

Shell and Tube heat exchangers contain fewer gaskets, normally simple O-rings.

capital costs of the two technologies are not always clear-cut. Neither are the di erences in pressure drop created by the two designs, but tubular heat exchangers are generally capable of operating at higher temperatures.

While PHEs often require less space than tubular units, the exact size di erence depends on the design of the tubular unit being compared. Heat exchangers which use corrugated tube technology (like HRS tubular heat exchangers) to increase thermal e ciency can provide equivalent heat exchanger performance in a smaller package than traditional smooth-tube designs.

Many PHE manufacturers claim their designs will operate for years without the need for maintenance but will also admit that cleaning (which often involves similar levels of disassembly to servicing) depends on the viscosity, fouling, and scaling potential of the product. In other words, admitting that real-world performance is much less impressive than the theory. In contrast, corrugated shell and tube heat exchangers are specifically designed to reduce fouling, meaning that their performance parameters are based on real-world operational situations.

Total cost of ownership (a combination of the capital cost and operational costs over the working life of the unit) is a major factor when considering which type of heat exchanger to invest in. Cost of ownership depends heavily on maintenance. And one of the biggest maintenance costs is gasket replacement.

The gaskets between each plate are an inherent design feature of PHEs but are prone to failure, particularly when operating at high temperatures. This is particularly true where operation involves many repeated heating and cooling cycles, which stress the gasket material, and the metal plates, which are often just 0.5-0.6 mm thick.

Even when they do not fail, regular gasket replacement is often part of the standard service requirement. This means that the price of gaskets must be considered in the overall cost of ownership, along with the downtime and direct servicing costs. Because most shell and tube designs are of welded construction, there are no internal gaskets to fail or replace. Where removable tubes are used, O-ring gaskets are the norm, making them much easier and less expensive to replace than the bespoke gasket designs required for plate heat exchangers. DW

HRS | hrs-heatexchangers.com

In a shell and tube heat exchanger, the product flows through the tube/s, while the service fluid flows through the gap between the tube and the shell.

OVER 25 YEARS’ EXPERIENCE WITH MANUFACTURING AND SOURCING OF MATERIAL, SUB-ASSEMBLIES AND FULL TURNKEY PRODUCTS.

• PRODUCTS: We offer component manufacturing, engineering, sourcing, custom component manufacturing. Kingway offers components and subassemblies all the way to full box builds.

• LOGISTICS: Kingway can help develop a custom Logistics plan to meet your needs including Expedited Air Freight, Sea Freight and Domestic Warehousing.

• VISION STATEMENT: Kingway Electronics offers Direct Sourcing and Customized Logistics Management by utilizing our 25 plus years of relationships and experience to deliver better Pricing, Shorter Lead Times with the Goal of Maximizing our customers profitability.

Where the rubber meets the road for component design and manufacturing

Edited by Mike Santora • Managing Editor

Optimizing the development of a custom rubber seal can be challenging. Relying on industry specialists and considering potential manufacturing methods and production volumes will enable you to navigate the innovation process. Custom rubber seal manufacturing experts o er a great understanding of how production volumes, methods, materials, and design, interrelate and impact costs and a ect performance and time to market. They also contribute diverse skillsets.

One powerful skill is prototyping production-intent custom elastomer components. Prototyping is advantageous, as it allows testing on the live part before committing significant budget and resources to any aspect of component design, giving design engineers the opportunity to adjust and consider the potential production outcomes. By bringing the prototype

design, materials, and methods as close to the production equivalent as possible, you will yield accurate component performance results and the highest quality production.

The earlier you involve your custom rubber manufacturer in your product development process, the better. Relying on elastomer manufacturing specialists can help you prevent design and performance issues while achieving budgetary constraints.

Your rubber component is the final piece of the product design puzzle, and it must fit your

product — there is no room for deviation. Failure to recognize the importance of the rubber component design can negatively impact your costs and product performance.

In short, the earlier you talk to your rubber component manufacturing specialist about your project and objectives, the easier you will arrive at the best process and material solution.

When it comes to manufacturing custom elastomer components, there are three common molding techniques:

Injection molding

Injection molding injects heated elastomer material into the mold under high pressure. The compound flows from the heating chamber to a series of runners and sprues, which direct the rubber into the tool at multiple points. Some materials are better suited for injection molding than others. Elastomers with better flow rates will move through the machine more favorably than highly viscous materials. Injection molding is suitable for highvolume production and can yield better results for components with generally lower geometric complexities. Injection molding is typically an automated process, making operator costs null.

Transfer molding

Transfer molding is most like injection molding. A sheet of rubber material is placed into a pot, located above the top plate, that features gates through which the compound flows into the mold below. Above the pot, a plunger lowers and compresses the material and, while also applying heat and pressure, forces the compound to flow through the top plate gates and fill the entire mold cavity.

During this process, the compound fills the contours of the pot and forms a pad of elastomer that doesn’t fill the mold. This pad is disposed of as waste, making transfer molding ideal for lower-cost materials.

Compression molding

Compression molding is suitable for low-volume production. A pre-form of rubber compound is placed into one side of the tool cavity. One half of the tool is closed against the other, and heat and pressure are applied to enable the material to flow and fill the cavity.

Compression molding is suitable for more malleable materials, with medium-hard elastomers working best. This method is often better suited for simple designs, as the pre-form compound is initially very flexible and di cult to insert into complex molds. Additionally, compression molding can have a very high cavity count, which helps to o set labor costs.

Unlike injection molding, compression molding machines require an operator, making the process subject to labor availability and more human error. Applications for compression molded components range from simple O-rings to complex diaphragms with diameters exceeding 10-in.

Relative Tooling Costs

How to choose the right tool for the job Tooling, or the mold that forms the elastomer, typically consists of two or more custom-machined cavities and steel plates. In most elastomer molding processes, the tooling plates undergo heat and pressure to force the rubber compound

This chart shows relative costs when setting minimum compression tooling costs equal to 1. The bars show the range from minimum to maximum price. Compression tooling is generally the most coste ective, and injection has the widest price range.

Design Notes

into the tool. It’s important for all parts of the mold to have consistent dimensions, close tolerances, and proper surface finishes to ensure high-quality finished components.

Tool construction begins with CNC machines hollowing out a solid steel block that is divided into multiple plates according to the component’s design. If a design requires interior contours, a steel core pin is inserted into the tool to shape the internal features of the finished component.

Consider your production volumes

Production volume impacts molding machine selection and cost-e ectiveness and is typically the first factor to consider when deciding which molding process to use. For example, at high production volumes, some manufacturing methods cannot keep up with the cycle times necessary, ultimately a ecting the end-product’s time to market.

The industry rule of thumb is to use injection molding when producing a million components or more per year, while low-to-medium volume production is the sweet spot for compression and transfer molding.

Finding the right material

To decide which rubber compounds to use, it’s critical to understand the function of the finished component. For example, if the objective is to seal a fluid, you should know whether it needs to seal against many di erent fluids or one specific fluid.

Some common factors to consider include

• Providing structural support.

• Energy transmission or absorption.

• Pressure and temperature conditions.

Whether you need a variable-speed AC, a high starting-torque PMDC, or a zero-maintenance brushless DC gearmotor, we’ll help you find the right solution for your application.

EXPERIENCE.

If you’ve got questions, we’ve got you covered.

• Wet or dry environments.

Failure to consider the critical requirements and functions may result in failures. Trelleborg

Sealing Solutions has an extensive compound portfolio, and it commonly formulates new materials to meet application-specific requirements for custom-tailored components.

Design features that influence product development

Molded rubber components vary in design complexity and can range from simple ring seals

to complex subcomponents that must be overmolded together. The design will naturally push engineers toward di erent materials or processes. Here are some of the most common design features that will have an impact on your choice:

Corners. Sharp corners are generally di cult to manufacture and increase the likelihood of component defects. Although costly, high-quality tooling can mitigate potential defects and impact the success of the end-product.

Undercuts. An undercut is a feature that projects back into the main body of a component. The closer an undercut comes to the axial center, the deeper the undercut. Deep undercuts provide their own set of challenges, as they make the component di cult to remove from the mold. Orientation also contributes to removal di culties. For example, if a deep cut is perpendicular to the mold opening, it can be impossible to remove the component from the mold.

Sharp edges. Components with thin edges, often referred to as “knife edges” or “feather edges,” usually tear as they are removed from the mold. Post-cure deflashing steps can further chip the edge, creating additional imperfections. If possible, it’s best to avoid incorporating knife edges in designs unless absolutely necessary. If your component does require a thin edge, squaring o the edge with a flat minimum of 0.010-in. will significantly reduce the likelihood of damage.

bonding to occur, special adhesives must be applied to the insert before molding. This bond will keep an overmolded component as one object without relying on the component or insert shape.

Incorporating inserts into component designs usually requires secondary preand post-mold tasks, such as insert surface etching, masking, unmasking, applying adhesive, and deflashing.

Flash. The excess rubber that escapes in small amounts from the mold while undergoing heating and pressure is called flash. Usually, this small amount of rubber is forced through the parting lines, or seams, between the tooling plates. It is common to remove flash as part of the post-molding process via manual tear trimming, cryogenic processing, tumbling, or precision grinding.

Overmolding. Sometimes elastomer components must be paired with subcomponents of other materials like steel, brass, aluminum, or plastic. Typically, the rubber compound is overmolded over the non-rubber subcomponent. When designing rubber overmolded components, there are a few design principles to keep in mind to maximize the strength of the bond between the elastomer and insert.

Gates. Transfer and injection molded components usually employ gates to ensure the compound uniformly flows into the tool. You can place gates at various locations on the cavity. Gate marks, the small, raised spots or depressions where the gate interacts with the cavity, are left behind after the molding process is complete and can sometimes impact seal functionality and appearance.

Holes. If your rubber component requires holes, a pin must be placed inside the mold cavity. This core pin is responsible for forming the internal contours of the finished component. The molding process uses high pressures with the potential to deflect the core pin and produce a hole with inconsistent dimensions. Designing core pins with diameters as large as possible, particularly at the pin base, will minimize the risk that the pin will bend or break during the molding procedure. Other guidelines to keep in mind:

• The hole height should not be more than twice the diameter.

• The minimum hole diameter should be 0.050-in.

• Cover as much of the insert’s surface as possible with rubber, maintaining a minimum thickness of 0.020-in.

• Avoid shutting o the flow while the compound travels along a vertical surface.

• Provide proper lands (steps).

Building the prototype

There are two types of bonding methods used when overmolding rubber to a subcomponent material:

• Mechanical bonds require the insert to feature holes, projections, or depressions on its surface. For chemical

When operations are running at maximum capacity, unforeseen issues can impact uptime significantly, leading to missed deadlines. Prototyping provides opportunities to refine designs and manufacturing processes before production and is essential to ensure full-scale production goes o without a hitch. During the prototyping phase, especially with complicated designs, it’s best to manufacture and test under conditions as close to the operational manufacturing environment as possible. DW

In 1980, Great Britain’s National Trust recommissioned Gondola, an 1859 steam-powered vessel for 86 passengers styled after a Venetian gondola, on Coniston Water in Cumbria, England.

How to bring a 164-year-old gondola back to life

Edited by Mike Santora • Managing Editor

In 1980, Great Britain’s National Trust recommissioned Gondola, an 1859 steam-powered vessel for 86 passengers styled after a Venetian gondola, on Coniston Water in Cumbria, England. The 86-ft. long vessel is powered by a twin-cylinder, “V-90” configured double-acting steam engine that generates a maximum torque of 8,000 Nm (5,900 lb.ft.) with a service speed of approx. 8 knots.

To bring the boat back to life, a Bibby Resilient Series grid coupling was installed between the steam engine crankshaft and the propeller shaft. The coupling was a smart choice for the propulsion drivetrain since torsional flexibility and alignment damping were primary concerns for steam engines, which have high torque and significant expansion/ contraction characteristics.

Bibby Turboflex grid coupling.

Over four decades later, in 2022, operators noticed a knocking noise at higher RPMs and shortly after a change of speed. The grid coupling was suspected to be a possible source of the noise. The boat’s manager sent photos of the coupling to Bibby for help in determining whether he needed to replace the coupling.

Upon viewing the photos, a Bibby engineer identified the coupling as a Type C and Size 212. While the coupling’s hubs and cover remained in good condition, the gridmember was corroded and worn. It has since been found that the coupling was not the source of the knock, but the gridmember was replaced as a precaution regardless.

Fortunately for Gondola, Bibby still manufactures a standard issue RC212 coupling and was able to quickly ship a replacement gridmember. Bibby was also able to confirm the availability of parts and support for the future. DW

Bibby Turboflex bibbyturboflex.com

eSIM makes it easier to change carriers

eSIM frees up space in IoT devices and can be programmed remotely, making connecting devices and changing carriers easier.

By Steve Taranovich Subscriber Identity Module (SIM) cards

add cost, take up valuable space inside devices, and can be troublesome to handle. eSIM devices eliminate such cards. For IoT devices, users can switch carriers without sending a person to a remote site to swap a card. How did eSIM evolve from SIM cards, and why? Let’s explore.

What is a SIM card?

A removable SIM card is a small chip contained in nearly all cell phones and cellular-connected IoT devices. The SIM card’s function is to store information that enables a cell phone to communicate with its carrier’s cell towers. If the SIM card is removed from a phone, the ability to text, call, or access information on the internet would not be possible.

| Pixabay

Enter eSIM

An eSIM takes the chip out of its card. It’s usually soldered directly to a device’s PC board. That saves precious space, enabling such things as increasing battery sizes. The eSIM can be programmed and re-programmed remotely through software when a user wants to change carriers for phone numbers.

One example of SIM use is an Apple eSIM on the iPhone 14, which lets users activate any cellular plan, provided the eSIM isn’t locked on a single network. Users can program eight or more eSIMs on an iPhone and switch between two phone numbers at the same time.

GSMA and eSIM

eSIM is a global specification issued by the Groupe Speciale Mobile Association (GSMA) that enables remote SIM provisioning of any mobile device. The GSMA announced the first eSIM Security Certification on July 19, 2022. Moving from removable SIM to eSIM provides many benefits:

• eSIM has the same level of security as the removable SIM.

• Device end users benefit from easy management of subscriptions and connections. There is no longer a need to manage multiple SIM cards.

• eSIM allows remote management of subscriptions for organizations.

• Distributors now have simplified logistics and reduced customization for regional areas and specific operators.

• Operators can now simplify the expansion of their businesses in emerging markets, such as consumer electronics, wearables, and automotive.

• Manufacturers of devices can benefit from the reduced space in their product designs, leading to smaller devices. Devices can also now be made airtight to resist dampness, vibration, and temperature.

The IoT was one of the reasons that the eSIM card was ushered into existence. The eSIM was small and did not need a slot in devices because it is an embedded chip, hence the name “eSIM.” Thales, an eSIM solution provider, reports that by 2025, approximately 4 to 5 billion smartphone connections will be using eSIM cards from the M2M/B2B IoT and consumer markets.

eSIM applications Mobile phones

The newest iPhone, iPad, Samsung, Oppo, and Pixel smartphones are just a few examples of devices with eSIM capability. eSIMs have many benefits, including highly e cient subscription management and seamless remote connectivity over a product’s lifecycle. This greatly benefits fastgrowing product sectors in large IoT deployments, such as smart meters. eSIM benefits include easier changing of service providers without swapping phones or SIM cards because they can be reprogrammed through the phone. International travel with a smartphone with an eSIM no longer requires replacing the eSIM as the original SIM devices did.

IoT

The IoT is continuing a digital transformation that is enabling more device connectivity. This is leading to the job of interfacing with many Connectivity Service Providers (CSPs) who need roaming agreements to connect their devices in a multitude of countries. Such businesses need

SIM card sizes have shrunk, and that trend continues with eSIM.

LOW VISCOSITY COATING features SUPERIOR ACID

Tested

Part

an easy, secure method to connect devices, especially with the benefits of using only one SKU, which can eliminate extra supply chain costs.

Transportation and mobility

A dynamic eSIM environment provides the necessary flexibility to automatically and dynamically enable devices that can connect virtually to any cellular network without that device having to travel across a city, country, or border.

Service providers

eSIM technology service providers can now simplify device activation while saving time and cost. Here is how.

• Remote management: Technicians will no longer need to travel to sites to update SIM cards and devices when the Mobile Network Operator (MNO) contracts expire.

• Simplification of the manufacturing process and logistics: eSIM enables devices installed via a service provider to connect to any MNO. This eliminates the need to manufacture multiple product variations that can support various networks.

• Streamlining installations: Devices with an eSIM will automatically choose the best MNO for each deployment site. This eliminates technicians traveling many travel hours to various sites to test devices for their connectivity needs.

Moving eSIM forward eSIM and its successor, integrated SIM (iSIM), have positioned themselves as part of the range of capabilities that designers need to consider when planning a cellular-based IoT product. Moving away from a plastic removable SIM has led to a requirement for Remote SIM Provisioning (RSP) that manages the profiles on the device.

Benefits to the consumer will be a much easier device setup because there is no longer a need to insert or replace a SIM card. Plus, there is a range of new mobile-connected devices from which the consumer can choose, and devices will be able to operate independently of a smartphone. DW

References

Using eSIM and iSIM will save money for IoT deployments, Quectel

IoT Connectivity – Understanding the role of SIM and eSIM in IoT, Thales

How eSIM can help you with your connectivity needs, Thales Thales adaptive connect, Thales

Solving permanent roaming challenges through eSIM and localization, Kaleido Intelligence

What is an eSIM card? How will it impact you?, US Mobile

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 di erentiate 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.

On-device learning AI chip targets edge IoT apps

Rohm Semiconductor has developed an on-device learning AI chip (SoC with on-device learning AI accelerator) for edge computer endpoints in the IoT field. The new AI chip uses artificial intelligence to predict failures (predictive failure detection) in electronic devices equipped with motors and sensors in real time with ultra-low power consumption.

Generally, AI chips perform learning and inferences to achieve artificial intelligence functions, as learning requires a large amount of data to be captured, compiled into a database, and updated as needed. So, the AI chip that performs learning requires substantial computing power and consumes a large amount of power. Until now, it has been di cult to develop AI chips for edge computers and endpoints that can learn in the field and consume low power to build an e cient IoT ecosystem.

Based on an “on-device learning algorithm” developed by Professor Matsutani of Keio University, Rohm’s newly developed AI chip mainly consists of an AI accelerator (AI-dedicated hardware circuit) and Rohm’s high-e ciency 8-bit CPU “tinyMicon MatisseCORE.” Combining the 20,000-gate ultra-compact AI accelerator with a high-performance CPU enables learning and inference with an ultra-low

power consumption of just a few tens of milliwatts (1000 times smaller than conventional AI chips capable of learning). This allows real-time failure prediction in a wide range of applications since “anomaly detection results” (anomaly score) can be output numerically for unknown input data at the site where equipment is installed without involving a cloud server.

Going forward, Rohm plans to incorporate the AI accelerator used in this AI chip into various IC products for motors and sensors. Commercialization is scheduled to start in 2023, with mass production planned for 2024. DW

Rohm | rohm.com

The new AI chips for edge devices and endpoints consume low power to support an efficient IoT ecosystem.

| courtesy of Rohm

motion stage

High-precision has the right stu

In-house designed and built motion control components are used to fabricate a new high-precision motion stage.

Edited by Miles Budimir

The Proton Motion Stage from Prodrive Technologies is built entirely from in-house off-the-shelf components, ensuring maximal integration and compatibility.

In many specialized manufacturing operations, precision is non-negotiable. Yet, at the same time, many system designers and integrators are also being challenged to increase performance and reduce costs.

To meet the dual demands to increase performance and lower costs, Prodrive Technologies has developed a portfolio of high-precision motion components that are othe-shelf. This new line of products is specifically designed with advanced technologies to help meet the demands of high-performance motion applications. It’s also designed to keep costs under control and make it possible to easily select and combine the right products for the specific application’s requirements.

As an example, the company recently developed a high-precision stage known as the Proton Motion Stage. The stage combines a range of o -the-shelf components, designed and manufactured in-house, to meet the requirements of high-precision and reliable measurement inspection applications, such as those involving scanning electron microscopes or wafer inspection.

One thing that makes the new stage stand out compared to other motion stages is the modular and scalable approach to the design, which also simplifies the process of bringing solutions to market. “In the past, businesses would create a motion stage by sourcing the di erent elements from various suppliers and attempting to combine them for their requirements,” explains Milan van den Muyzenberg, Technical Director for Prodrive Technologies Motion & Mechatronics program. “Our solution has been designed to provide a ‘one-stop shop’ instead, helping to speed up the time to market.”

Because all of the components are manufactured by one source, they are designed to be easily integrated and work seamlessly together. For example, every drive is optimally designed to work with the actuators and every part of the stage can communicate accurately with the master controller. What’s more, these components can also be e ectively combined with products from other manufacturers, if and where required.

Tried and true building blocks

Each application has di erent system requirements, from velocity, stroke, and accuracy, to throughput. A fully configurable system, where one can develop a motion solution by picking and choosing the specific products required, has clear benefi ts.

The Proton Motion Stage is scaled to specific requirements using othe-shelf components as its building blocks. It can even provide a highaccuracy option for those specifying systems for vacuum compatibility, where in the past there has been far less choice compared to stages suitable for atmospheric operation. With conventional motion stages that apply cross roller bearings and appropriate pre-loading, interference can be an issue as a result of temperature changes which can cause variations and negative e ects on friction. The new stage is uniquely built with statically determined preloaded mechanisms to ensure that interference has a limited e ect on motion performance. A number of othe-shelf components were used in its construction, including linear actuators, servo drives, motion controllers and more, including a motion software platform with real-time performance and tooling. Below is a look at how each of these components contributes to the overall design of the motion stage.

The Gryphon family of ironless motors are suitable for applications requiring long stroke motion and a high peak force without force ripple and attraction forces in vacuum conditions. The motors also use flat wire technology to maximize the heat transfer from the coil to the housing.

Highly efficient motion without contamination

A bad actuator in a motion stage has the potential to result in bad yield, poor accuracy, low performance, and reduced throughput. In vacuum stages, it’s also critical that particles from the actuator do not ‘leak’ or cause out-gassing into the environment. In other words, clean operation is vital. Another challenge is that there is no air to dissipate heat within the vacuum environment, meaning that heat must therefore be transferred di erently.

The company’s Gryphon linear actuator series features ironless linear motors that were designed to manage thermal challenges by transferring heat via the metal part of the coil unit. This increases reliability, preventing system failures. In precision applications, such as semiconductor inspection, failure of a part such as a linear motor can have a big impact on operations.

“If a motor phase were to stop working, the whole stage could potentially need to be disassembled and reassembled by a skilled worker, taking valuable time,” says Bart Gysen, Motors Product Line Manager for Prodrive Technologies. That’s why the company has invested in the design and testing of the Gryphon linear actuators specifically to reduce the chances of these sorts of issues arising on site.

The new motion stage is uniquely built with statically determined pre-loaded mechanisms to ensure that interference from temperature changes has a limited effect on motion performance.

Vibration isolation for high positioning accuracy

The company’s Iris actuator is another vacuum-compatible component available o -the-shelf. Six of these limited stroke voice coil actuators are included in the Proton Motion Stage, providing active vibration isolation. This eliminates the disturbances that could disrupt high positioning accuracy. These could include external disturbances and the forces created by the components of the motion stage itself.

With an understanding of each of the components that comprise the motion stage, the company has been able to accurately identify the forces caused by other parts of the machine and reduce the amount of vibrations accordingly, which is also easily adjustable via the control software.

What’s more, the design of the stage takes into account the potential disturbances that the machine could also cause to its own environment and has been designed to eliminate these vibrations as much as possible.

Drives that reduce drift

Drives drift over time. So, when a setpoint is being requested, it will eventually deviate, taking longer to correct, and negatively a ecting performance. In a metrology application, this can be problematic, as accuracy, repeatability, and speed are all needed when moving between positions.

The new stage is designed with drives such as the company’s Apogee and Kepler series drives. These feature low drift components and specially designed voltage reference and custom current sensors, which compensate for drift issues.

Most drives are built with a focus on automation applications, rather than the high-performance environments found in semiconductor applications. However, because every part of the Proton Motion Stage is

Fabco-Made NFPA

Versatile, rugged cylinders—when you need them A

Our NFPA interchangeable pneumatic cylinders take the guesswork out of cylinder selection.

We design and manufacture our NFPA cylinders in Gainesville, Florida—so expect fast delivery, supply chain resilience and local support no matter your application. Built tough, our NFPA actuators feature anodized aluminum heads and barrels and stainless steel hardware for corrosion resistance. They also incorporate high-strength composite rod bearings and PTFE piston wear bands for superior load handling and long service life. Choose from 19 standard mounting options and hundreds of standard configurable options to meet the requirements of almost any application. Standard catalog not enough? Tell us about your application and let us design a custom solution optimized for your environment.

• Standard bore sizes: 1.5–6 inches

• Standard strokes to 99 inches

• Pressure rating: 250 PSI

• Temperature range: -10° to +165°F

• Conforms to NFPA dimensional specifications

• Lead time for standard configurations: 7–10 days

MADE IN GAINESVILLE, FLORIDA

Linear Motion

The motion controller features multiple EtherCAT buses which help to reduce the delay between the motion controller and the servo drives. Combined with the controller’s multicore x86 processor, this shortens the amount of time needed to collect sensor values, calculate new setpoints, and communicate these back to the drives. The faster this process, the more it can help improve the overall performance of the motion stage.

Iris actuators are rectangular voice coil motors designed for applications requiring short stroke motion with a low stiffness and high bandwidth.

produced in-house, there is much more control over all of the variables involved. With a greater focus on components that reduce drift and deliver high linearity, the drive can enable high dynamic performance within a motion stage.

What’s more, these drives also feature low noise, ensuring no additional disturbances are introduced into the system. This eliminates jitter, which could cause inaccuracy, and enables applications to move at specific velocities without being impacted by noise and disturbances. This is essential in scanning applications, for instance.

The drives also feature a high switching frequency which provides high bandwidth and good attenuation for external disturbances. Internal filtering also limits disturbances to other systems like external sensors which can be extremely sensitive to noise in high-precision applications.

Real-world motion control

Another integral part of the Proton Motion Stage is the motion controller. The Poseidon motion controller works with the Prodrive Motion Platform (PMP) to collect sensor data and then communicate seamlessly with the servo drives to determine new position setpoints.

The PMP motion control software, with real-time performance and tooling, runs the algorithms required for motion control. However, it also provides extensive simulation capabilities. The PMP integration in Simulink lets engineers generate ready-to-load binaries, which can be loaded into the system easily, without requiring a specialist software engineer.

The big benefi t of simulation is that the stage’s processes can be tested even without the hardware in place to verify that it’s working. Optimization of the hardware or control of the system, and the impact of any changes to them, can then be captured at this early stage, making it quicker when the time comes to complete testing with the hardware.

However, this approach is also beneficial for saving businesses

PMP motion software provides real-time performance and tooling. The Matlab and Simulink interfaces allow the combination of simulation code with an existing motion system, providing more opportunities for control loop optimization and tuning.

NCC Subminiature

The new small one with 16 mm diameter

Not Connected Closed

Socket parts IP54 not mated

IP67 in mated condition

Bayonet locking with 5 contacts

Socket parts with solder and dip solder contacts

Ø 16

Ø 19.9

www.binder-usa.com

development time and money. There is no need for a dedicated software engineer to code the algorithms, as there are customizable examples that users can simply adapt, and then test and re-test as needed. The PMP can implement a control algorithm code, generated from Matlab/Simulink, and run it with each EtherCAT cycle.

The next step in customizing motion stages

In the future, it will also be possible for motion applications to specify an othe-shelf Pinpoint laser interferometer. This provides a high accuracy, vacuumcompatible solution which enables position measurement directly, or closely to, the point of interest.

Just like most interferometers, Pinpoint delivers on high resolution

and reliability. However, it has a unique design featuring a distributed feedback laser which extends its lifetime. Instead of requiring replacement every few years, Pinpoint will last for more than ten years, usually outliving the lifetime of the system itself. This reduces maintenance requirements, as well as replacement and service costs.

Pinpoint also excels with absolute position measurement. This technique is used instead of the homing process and takes as little as 20 seconds to complete. The result is that from that point, the interferometer will always precisely measure the exact same location, reducing manual interventions needed. Even if the machine is turned o and on again or moved, these settings are easily and quickly recovered, saving time. DW

Prodrive Technologies

www.prodrive-technologies.com

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

industry information site

Bonded

316 Stainless Steel Shaft

316 Stainless Steel Bearing

Part one:

Scalar and vector

VFD control methods

AC motors pair with variable frequency drives to satisfy process and motion applications. Here, we compare how these operations diverge.

Lisa Eitel | Executive editor

AC motors are often used in equipment that runs at constant speed regardless of load, such as fans, pumps, and conveyors. But for designs needing speed control, AC motors pair with variable frequency drives (VFDs) that regulate the motor’s speed via one of two control methods — scalar control or vector control — to vary the frequency of the supplied voltage.

A scalar is a quantity that has only magnitude, such as mass or temperature. A vector is a quantity that has both magnitude and direction, such as acceleration or force.

Scalar VFD control methods

Scalar methods for VFD control work by optimizing the motor flux and keeping the strength of the magnetic field constant, which ensures constant torque production. Often called V/Hz or V/f control, scalar methods vary both the voltage (V) and frequency (f) of power to the motor to maintain a fixed, constant ratio between the two, so the strength of the magnetic field is constant, regardless of motor speed.

The appropriate V/Hz ratio is equal to the motor’s rated voltage divided by its rated frequency. V/Hz control is typically implemented without feedback (i.e. open-loop), although closed-loop V/Hz control — incorporating motor feedback — is possible.

V/Hz control is simple and low-cost, although it should be noted that the closed-loop implementation increases cost and complexity. Control tuning is not required but can improve system performance.

AC drives are essential to the efficient control of conveyors. Dreamstime | Hrishchenko Oleksandr

Motion Control

In a VFD, AC power is converted to DC through the rectifier. The rectified power is then filtered and stored in the DC bus (link). The inverter converts it back to AC power with the proper frequency and voltage. Servodrives are sometimes called servo inverters (for their most significant subsection).

Speed regulation with scalar control is only in the range of 2 to 3% of rated motor frequency, so these methods aren’t suitable for applications where precise speed control is required. Openloop V/Hz control is unique in its ability to allow one VFD to control multiple motors and is arguably the mostcommonly implemented VFD control method.

Vector VFD control methods

Vector control — also called fieldoriented control (FOC) — controls the speed or torque of an AC motor by controlling the stator current space vectors, in manner similar to (but more complicated than) DC control methods. Field oriented control uses complex mathematics to transform a three-phase system that depends on time and speed to a two-coordinate (d and q) timeinvariant system.

The stator current in an AC motor is made up of two components: the magnetizing component (d) of the current and the torque-producing component q. With FOC, these two current components are controlled independently … each with its own PI controller. This allows the torqueproducing component, q, to be kept orthogonal to the rotor flux for maximum torque production, and therefore, optimum speed control.

Like scalar methods, vector VFD control methods can be open-loop or closed-loop. Open-loop vector control (also called sensorless vector control) uses a mathematic model of the motor operating parameters, rather than using a physical feedback device. The controller monitors voltage and current from the motor and compares them to the mathematical model. It then corrects any errors by adjusting the current supplied to the motor, which adjusts the motor’s torque production accordingly. With senseless vector control, it’s

VFD-driven cooling-tower motors

DC BUS RECTIFIER INVERTER

Leung Cho Pan

important to have a very accurate mathematical model of the motor, and the controller must be tuned for proper operation.

Closed-loop vector control uses an encoder to provide shaft position feedback, and this information is sent to the controller, which adjusts the supplied voltage to increase or decrease torque. This is the only method that allows direct torque control in all four quadrants of motor operation for dynamic braking or regeneration.

Vector control methods are more complex than scalar VFD control methods, but they o er significant benefits over scalar methods in some applications. For example, open-loop vector control enables the motor to produce high torque at low speeds, and closed-loop vector control allows a motor to produce up to 200% of its rated torque at zero speed, useful for holding loads at standstill. Closed-loop vector control also provides very accurate torque and speed control for industrial applications.

More on how V/Hz control works

As mentioned, the most common type of VFD control is a scalar method called volts per hertz (V/Hz) or volts per frequency (V/f).

AC motors are designed for a magnetic field or flux of constant strength. The magnetic field strength is proportional to the ratio of voltage V to frequency Hz — or V/Hz. But a VFD controls the motor speed by varying the frequency of the applied voltage, according to the synchronous speed equation:

N = 120 · f / P

Where N = Motor speed (RPM)

f = Input voltage frequency

P = Number of motor poles

Varying the voltage frequency a ects both the motor speed and the strength of the magnetic field. When the frequency is lowered (for slower motor speed), the magnetic field increases, and excessive heat is generated. When

V/Hz control maintains a constant ratio between voltage (V) and frequency (Hz). The V/Hz control method allows one VFD to control whole motor arrays, which is especially useful in process-type applications.

AutomationDirect

the frequency is increased (for higher motor speed) the magnetic field decreases, and lower torque is produced. To keep the magnetic flux constant, the V/Hz ratio must remain constant. This keeps torque production stable, regardless of frequency.

V/Hz control of a VFD drive avoids this variation in the magnetic field strength by varying the voltage along with the frequency to maintain a constant V/Hz ratio. The appropriate V/Hz ratio is given by the motor’s rated voltage and frequency.

For example, a motor rated for 230 V and 60 Hz will always operate best at a V/Hz ratio of 3.83 (230/60 = 3.83).

Traditional V/Hz control does not use feedback and only changes the voltage and frequency to the motor based on an external speed command. For closedloop V/Hz control, encoder feedback can be added to measure the motor’s actual speed. An error signal is generated based on the di erence between actual speed and commanded speed, and the controller generates a new frequency command to compensate for the error.

While it improves speed regulation, closed-loop V/ Hz control isn’t common due to the added cost and complexity of the encoder and feedback hardware.

Performance and benefits of V/Hz control

V/Hz control is a simple low-cost method of operating variable frequency drives and is generally regarded as the most common VFD control scheme. It is suitable for both constant torque and variable-torque applications

Shown here is a VFD installed to control local conveyor functions. Conveyor motion controls are just one suitable application for VFDs with logic capabilities — to eliminate the need for an additional PLC.

and can provide up to 150% of the rated torque at zero speed for startup and peak loads. Speed regulation is in the range of 2 to 3% of the maximum rated frequency, so this method isn’t suitable for applications where precise speed control is critical. The most common use for V/Hz control is to drive industrial equipment such as fans and blowers.

One unique benefit of V/Hz control over other methods is that it allows more than one motor to be operated by a single VFD. All the motors will start and stop at the same time, and they will all run at the same speed — which is beneficial in some process applications such as heating and cooling.

Final note on terminology

Note that the terms variable frequency drive and variable speed drive are often used interchangeably, but there is

a distinction between the two. A VSD is any drive that can control motor speed — including both AC and DC motors. In fact, VSDs can even operate via mechanical, hydraulic, or electrical means. In contrast, a VFD is equipment used to control the speed of an AC motor … and it does so by varying the frequency of the supply voltage to the motor. DW

Look for the second part of this article series in the May issue of Design World.

Motion Control Tips | motioncontroltips.com

EE Classroom on Silicon Carbide

Silicon Carbide (SiC) has made its mark in bringing faster, a smaller, and more reliable components than its fellow semiconductors to market. While SiC components have been around for a couple of decades, there is still a lot to learn and a lot to consider when choosing the most suitable WBG semiconductor for your device.

LET US HELP with tutorials, from looking at how WBG semis stack up in power conversion efficiency to an overview of SiC FETs and MOSFETs.

Check out our EE Classroom to learn more: www.eeworldonline.com/silicon-carbide-classroom

Lithium-ion versus

challenge: sodium-ion batteries

Which is more sustainable: Li-ion or Na-ion batteries? That’s a complex and dynamic question without a simple answer. The electrification of everything is expected to lead to post-lithium-ion battery (LIB) technologies, such as potassium-ion batteries (PIBs), sodium-ion batteries (SIBs), and possibly more exotic chemistries. In the near term, the dominance of LIBs will be almost unassailable. The key word is “almost.”

By

Among the keys to replacing LIBs will be the ability of the contenders to o er improved sustainability in addition to matching the performance capabilities of LIBs. There is no single agreed-upon international definition of sustainability. That makes any discussion or analysis of sustainability problematic. Sustainability is often described in three dimensions related to environmental, economic, and social factors. E ective recycling can be an important environmental consideration related to sustainability. For example, the materials in lead-acid batteries (PbAs) are about 96% recycled, making them a highly sustainable technology. Looking at challengers to LIBs’ dominance, SIBs are already being commercialized, while PIBs are mostly a work in progress.

Rechargeable batteries are a key technology supporting sustainable systems such as electric vehicles and grid-scale energy storage. LIBs will continue to improve. But they are a mature technology, and it’s expected that the improvement rate for competitive chemistries, such as SIBs, will be faster and eventually close the gap with LIBs. It’s not clear how rapidly any

As electrification increases, rechargeable batteries will contribute significantly to sustainability goals. But determining which battery type is best remains a challenge.

Jeff Shepard

transition away from LIBs will occur. If it occurs, sustainability must compete with economic and technical performance considerations.

Japan is one of the leaders in maximizing the sustainability of LIBs and has developed multiple streams for using old LIBs, especially LIB battery packs in EVs. Even when EV battery packs no longer deliver the needed range, they can still have significant

capacity. Sometimes, the battery packs can be refurbished for less demanding transportation applications, used in di erent applications such as stationary energy storage, or recycled.

Recycling is well-established for PbAs but is not generally available for LIBs. Materials such as plastic cases and metals are first separated when batteries are commercially recycled. With LIBs, the next step is to separate

Battery recycling is a four-step process that can help increase the sustainability of rechargeable batteries.

| courtesy of EPRI Journal

the cathode materials, such as lithium and cobalt — both are in very limited supply. Today’s challenge is that the cost of separating lithium and cobalt is too high compared to the cost of new materials. That’s one factor that makes it uneconomic to recycle LIBs.

Standardized and simplified

Among the challenges to effectively recycling LIBs are the wide variety of package styles and chemistries. PbAs have a much more limited range of package sizes and are mostly packaged in specific types of plastics. In addition, the lead grids are relatively easy to melt down and recycle. In contrast, many sizes and package materials are used for LIBs and a range of LIB chemistries, which significantly complicates any recycling processes. While there is also a wide range of SIB chemistries, including sodium manganese magnesium oxide (NaMMO), sodium nickel manganese magnesium titanate (NaNMMT), sodium and ironbased Prussian blue analogs (NaPBA), and others, SIBs are generally easier to recycle compared with LIBs. But the materials’ low economic value limits the commercial recycling prospects.

SIBs are an emerging technology, and there’s an opportunity for the SIB industry to develop a limited range of package styles modeled after PbAs, reducing the cost of recycling SIBs and improving the economic equation of recyclability. The performance of NaPBAs is getting close to or even better than that of their LIB counterparts. As SIB performance rivals that of LIBs, sustainability may take a more central role in choosing between the technologies. Battery recycling can be envisioned as a four-step process:

• Collection

• Disassembly

• Material recovery

• Material reuse

In Japan, used LIBs can be reused or recycled to maximize sustainability. Image courtesy of Murata.

Batteries must be designed appropriately to maximize the benefits of recycling. Image courtesy of CIC energiGUNE.

LCA for rechargeable batteries includes the production of the batteries, their integration into systems such as EVs, and the impact of their lifetime use and recycling. | courtesy of Advanced Energy Materials.

E ective LIB and SIB battery recycling technologies are still a work in progress. They will need to process “secondary” materials, such as graphite, polymers, electrolytes, solvents, and salts, and recover any higher-value materials. Several options are available, including removing organics and electrolytes using thermal processes and recovering other elements using pyrometallurgical or hydrometallurgical processes. Work under the European Battery Directive has identified hydrometallurgical processes as the most promising for recovering battery materials with the quality levels needed to support battery

production and a circular battery economy.

Battery recycling processes must also be developed with sustainability and minimizing environmental impacts as key considerations. It does not necessarily increase sustainability if the recycling process results in large amounts of environmental damage. A comprehensive strategy for battery recycling requires that both the batteries and recycling processes be simultaneously optimized. This process is called “design for recycling,” which extends from the physical design and assembly of batteries to simplify

& Where You Need Them

Free up more shelving space and purchasing power with blanket and scheduled ordering: Lock in your price, and have your North American and international cord sets delivered on your schedule throughout a calendar year. Our cord sets and accessory power systems ship straight from the factory. Want the cords hanked, coiled, tied, bagged and boxed? Need 1-D or QR barcodes for easier warehousing? Customize cord lengths and colors for countryspecific cords configured and ready to use right out of the box!

SIBs are an emerging technology, and there’s an opportunity for the SIB industry to develop a limited range of package styles modeled after PbAs, reducing the cost of recycling SIBs and improving the economic equation of recyclability.

High Performance Incremental Encoders

recycling and increase yields and materials optimization to support cost-e ective battery recycling processes.

Alternatively, if economic recovery of key materials is not possible, battery recycling e orts should focus on minimizing the environmental impacts of battery disposal at end-of-life. That could require using di erent materials capture technologies and being supported with di erent battery designs. One study has found that recycling SIBs such as NaMMO and NaPBA or the LIB LiFP with low material values may result in only limited environmental benefit. Of course, it’s not that simple, and the same study observed that with similar recycling rates, the toxic impact and resource depletion resulting from NaMMO, NaPBA, and NaNMMT SIBs use could be lower than most LIBs. Economics also matter. For example, today, the cost to capture lithium and cobalt from recycling LIBs is significantly higher than the costs of the mined raw materials.

Social sustainability

Quantum Devices’ QM35 and QM22 are bearingless, modular encoders ideal for high volume OEM applications and competitively priced for all sizes of motion control projects. Both models offer versatile electrical configurations allowing for customization and can be used with our QC201 Commutation Indicator for fast, accurate motor encoder alignment.

Let our engineers assist in your sensor design. Utilizing our own silicon foundry, we fabricate our own photodiodes. Then we build from the ground up, with design and manufacturing on-site providing for application-specific products.

While di cult to quantify or place an economic value on, social sustainability can be an important consideration in the overall sustainability of products such as rechargeable batteries. According to the United Nations Global Compact, “social sustainability is about identifying and managing positive and negative business impacts on people. The quality of a company’s relationships and engagement with its stakeholders is critical. Directly or indirectly, companies a ect what happens to employees, workers in the value chain, customers, and local communities, and it is important to manage impacts proactively.”

For example, the high level of PbA recycling came about partly due to the realization of the harm that lead causes to society if it gets into the environment, especially into the water supply. In the case of LIBs versus SIBs, SIBs currently appear to o er better social sustainability. Compared with obtaining sodium and the other elements for SIBs, mining lithium and cobalt for LIBs is fraught with negative environmental impacts and has been linked to alleged human rights abuses.

Design for sustainability

Designing for sustainability is the ultimate goal, but it can be challenging since the total environmental cost of producing and using rechargeable batteries is not assigned just to the design and manufacturing processes. There are multiple direct and indirect environmental impacts from rechargeable battery production, including high energy needed to produce the cells that result in greenhouse gas (GHG) emissions, resource depletion, and environmental impacts of mining the various materials and acidification of the local environment if the production process is not properly managed.

A life cycle assessment (LCA) can provide a starting point for systematically analyzing the impacts of rechargeable batteries throughout their entire life cycle. For example, an LCA for EV batteries includes the entire battery production process, how the batteries fit into the EV production process, environmental impacts from recharging the batteries over their useful lives, and the factors related to repurposing or recycling spent EV batteries. It’s a complex process. For example, lighter weight batteries need less energy to be carried as part of an EV, batteries with longer cycle lives can reduce the impact of repurposing or recycling the cells, batteries with higher charge cycle e ciencies can reduce the production of GHGs from recharging, and so on.

The bottom line

So, are LIBs or SIBs more sustainable? The answer is still unfolding and will be impacted by numerous factors, including the changing costs of the materials used in both types of batteries, how cost-e ectively the batteries can be repurposed or recycled, the social sustainability of each technology, and the total life cycle environmental impacts of LIBs versus SIBs. In any case, rechargeable batteries, especially post-lithium rechargeables, are expected to

be major contributors to a more sustainable society. DW

References

Environmental Aspects of Grid-Scale Battery Deployment, Electric Power Research Institute

How do lithium-ion batteries contribute to the realization of a sustainable society?, Murata

Longer Lasting Sodium-Ion Batteries on the Horizon, Pacific Northwest National Laboratory

On the environmental competitiveness of sodium-ion batteries under a full life cycle perspective – a cell-chemistry specific modeling approach, Royal Society of Chemistry

Recycling of Lithium-ion Batteries: The Way for a Sustainable Energy Transition, CIC energiGUNE

Social Sustainability, United Nations Global Compact Sustainable Electric Vehicle Batteries for a Sustainable World, Advanced Energy Materials

Reduce Inventory with

Scheduled Ordering

Blanket orders allow customers to lock in a price and have their North American and international cord sets shipped whenever they need them during a calendar year. Scheduled orders allow customers to set predetermined schedules, e.g., order 1,000 and have 250 delivered quarterly, monthly—whenever you need them. Your cord sets delivered on your schedule throughout the year. Our cord sets ship straight from the factory. Want the cords hanked, coiled, tied, bagged and boxed? Need 1-D or QR barcodes for easier warehousing? Customize lengths and colors for country-specific cords.

Smith chart and What is a

why do I need one?

A Smith chart provides insight into RF/microwave designs. Even if you work primarily with low-speed analog and mixed-signal designs, you could benefit from familiarity with the Smith chart as wireless products proliferate and as high-speed-serial data signals exhibit microwave-like effects.

By Rick Nelson

hen a signal’s wavelength (λ) approaches the lengths of the conductors carrying it, you can no longer rely on the lumpedelement impedance model represented in Figure 1, in which perfect conductors carry currents traveling at infinite speeds.

With RF signals, think instead of a transmission line consisting of an infinite series of distributed impedances (Figure 2). The Smith chart simplifies calculations involving complex numbers in the form of x + jy, which come up frequently in RF/microwave designs that involve transmission lines and require impedance matching.

Why do impedance matching?

Two reasons. First, given a source with a fixed impedance (50 Ω in Figure 1), the maximum power transfer theorem states that the maximum amount of power transfers to a load if the load impedance matches the source impedance. Figure 3 plots load power (red curve) vs. various load impedances (horizontal axis), showing that the load absorbs maximum power when it matches the source’s impedance. You are probably familiar with this theorem. The values shown in Figure 1 approximate what you might find working with a receiving antenna, but the theorem applies to DC and low-frequency

Figure 1. With a lumped-element impedance model, perfect conductors carry currents at infinite speeds.

Test & Measurement

designs at high voltages as well. (Note that an antenna signal level would generally be expressed in dBm, not µV, but the voltage value helps show how the theorem works.)

Yes, but something doesn’t sound right — if the impedances match, how could e ciencies ever be higher than 50%?

Note that the theorem says nothing about designing source impedance to match a given load impedance — for DC designs, you should minimize

source impedance regardless of load impedance. The black trace in Figure 3 plots e ciency, which indeed is 50% at the 50-Ω point, but e ciency continues to climb as the load impedance increases, although overall power falls. The theorem applies when you have a fixed, unalterable source impedance. If, as in Figure 2, you are using a halfwavelength dipole antenna to receive a signal, the antenna presents a source impedance of (73 + j45) Ω, which you must consider when choosing a

Figure 2: Use a distributed-impedance model when a signal’s wavelength approaches the length of the conductor carrying it.

Figure 3. Maximum power transfer occurs when load impedance equals source impedance, but for low-frequency circuits efficiency continues to increase as load impedance increases.

The Smith chart simplifi es calculations involving complex numbers in the form of x + jy, which come up frequently in RF/ microwave designs that involve transmission lines and require impedance matching.

transmission line, low-noise amplifier (LNA), or other components.

So, I should match impedances when receiving a signal but minimize source impedance when transmitting?

No! I mentioned there are two reasons for impedance matching at RF frequencies. The second is to minimize reflections that impedance mismatches cause, calculated using the reflection coefficient Γ:

This equation shows that if ZS = 50 Ω and ZL = 150 Ω, half the incident power will reflect back from the load to the source. The reflected power never reaches your antenna and is dissipated as heat, possibly damaging your transmission line and power amplifier.

OK, I’m sold on impedance matching. How does the Smith chart help me?

The Smith chart includes a plot of $Gamma; and overlays it with circles and arcs representing impedance to allow you to relate G to source, line, and load impedances. In Figure 4, Γ equals 0 at the origin, and its magnitude is 1 along the outer black circle. Each blue circle and red arc represent a locus of points of constant resistance and reactance, respectively. DW

Figure 4. The Smith chart includes a plot of G and overlays it with circles and arcs representing impedance.

Rotary

slip ring connectors —

what are they used for?

Rotary slip ring connectors are important components in various applications like multiaxis robots in industry 4.0, wind turbines for sustainable green energy, machine tools, medical systems, and more.

Shepard

Jeff

This FAQ considers how slip ring connectors differ from commutators and how mercury-wetted, pancake, and wireless slip ring connectors work. Their capabilities and reviews applications where they are used to transfer power, control circuits, transmit analog or digital signals, or liquids and gases.

Slip rings, split rings, and commutators

Slip and split rings are designed to maintain electric circuit continuity between fixed and rotary sections in a mechanical system. The difference is that a slip ring can transmit signals and or power between the sections, while a split ring is used to reverse the direction of current flow as the rotary section spins.

A split ring is literally split into at least two pieces; in some designs, there are multiple splits in the ring. When split into two and used in a commutator, the split ring is alternately connected to the poles of a motor reversing polarity as the motor spins. The split ring is connected to the motor poles with brushes. The combination of the split ring and brushes is called a commutator.

Slip rings are also called rotary joints, rotary electrical interfaces, rotating connectors, collectors, and swivels. They are available in various geometries and constructions, like a pancake and through bore designs (Figure 1).

Slip ring construction

The most common slip ring constructions are based on mechanical connections with brushes on a stator that slide against conducting rings on a rotor. The brushes can be made from various conductive materials, and the selection of material is based on several factors, including signal bandwidth, the amount of power to be transmitted, quality of the signal or power to be transmitted, speed of rotation, environmental factors, and reliability requirements. The moving mechanical contacts often require monitoring and frequent maintenance. Environmental factors are often the most limiting factor in the performance of mechanical slip rings. In addition, the sliding contacts can generate vibrations and electrical noise that can reduce the quality of the transmitted signals. That can be especially troublesome in applications requiring real-time control, like robotics. Several other slip ring designs are available to meet the demands of specific applications.

Figure 1: Pancake (left) and through bore (right) are two common designs for slip rings.

| Wikipedia

Connectors

Mercury-wetted slip rings

Mercury-wetted slip rings replace the sliding brush contacts with a pool of liquid mercury bonded to the contacts. The mercury maintains a low friction and e cient electrical connection between the two sides of the slip ring. Mercury solidifies at about -40°C, which can limit the use of this design. In addition, mercury is a toxic substance and poses safety challenges.

Wireless slip rings

Wireless slip rings transmit signals and power using magnetic coils on either side of the slip ring and produce contactless and frictionless transfers. These designs are more suited for harsh environments requiring less maintenance than conventional moving mechanical contacts. Wireless slip rings can transmit higher frequency signals with higher quality and less interference, but they are limited in the amount of power they can transmit. If power coupling is essential, a traditional moving contact slip ring can usually transmit several orders of magnitude more power in the same size solution.

Fiber optic slip rings

Fiber optic rotary joint (FORJ) is a type of contactless slip ring designed for data transmission only. FORJs are particularly useful in high EMI environments and typically use 850 or 1550 nm infrared transmission of analog or digital signals and can data rates of 50 Gbps or higher. FORJs can be challenging to implement and su er from high signal attenuation if not precisely aligned in angular and axial directions. Misalignments can also result in rotational signal fluctuations. Because of their sensitivity, using FORJs in industrial environments can be especially challenging and demand high levels of protection, increasing installed costs.

Inductive and capacitive slip rings

Near-field coupling using electric or magnetic fields can also implement noncontact slip rings. In these designs, nonradiating capacitive and inductive circuit elements transmit data or power. Capacitive slip rings use electric fields to transmit data. These solutions are robust, low-cost, and lightweight.

They also have excellent performance even when misaligned and can support data transmission speeds of several Gbps in harsh environments independent of rotational speed. Because of their robust and high-speed performance, capacitive slip rings are used in time-sensitive industrial applications like robotics and are complimentary with the Ethernet fieldbuses.

Inductive slip rings use electromagnetic induction and are suited to di erent applications. Like capacitive slip rings, inductive designs are suited for industrial applications with high rotation speeds. In contrast with capacitive slip rings, inductive slip rings are better suited for power transmission rather than data transmission. The blade pitch control systems in wind turbines commonly use inductive slip rings. As shown, there are a variety of common slip ring technologies, each with a particular set of performance tradeo s (Table 1).

Wind turbines and slip rings

Three types of slip rings are commonly used in wind turbines.

• Hub slip rings, as noted above, are usually inductive designs used in large utility-grade turbines.

• Yaw slip rings enable the turbine head on small privately owned turbines to rotate as needed by the wind direction. These are often a type of contact slip ring.

• Generator slip rings are used to carry power in utility-grade turbines.

Table 1: There are a variety of contact and contactless slip ring designs with a range of performance

tradeoffs.

| Table: Analog Devices

Robots and slip rings

The slip rings used in multi-axis robots are more varied and can include over 200 circuits in complex designs. In addition, slip rings in industrial robots can be used to link coolant or other fluids between the fixed and rotating parts of the machine.

Hydraulic or pneumatic slip rings are often referred to as rotary unions. In addition to transmitting electric signals and power, these slip rings support the flow of coolant, gases, water, or steam. Some designs include pressure regulation or sensors to monitor environmental parameters and the operating condition of the slip ring. Large hydraulic slip rings are also commonly used in heavy construction equipment like excavators.

Fastener Engineering

This area has long been one of the most read and sought after by our engineering audience! From screws to bolts and adhesives to springs, these critical but often overlooked components are the key to every successful design.

FastenerEngineering.com will serve readers in the mechanical design engineering space, providing news, product developments, application stories, technical how-to articles, and analysis of engineering trends. This site will focus on key issues facing the engineering markets around fastener technology, along with technical background on selected components.

ADDITIONAL RESOURCES:

• Special print section in select issues of Design World

• Fastener Engineering monthly newsletter

Figure 2: This SiGe transceiver can support 60 GHz wireless slip ring designs. | Analog Devices

Connectors

60 GHz wireless data slip ring

A millimeter wave data interface slip ring has been suggested using frequencies from 57 to 64 GHz for industrial applications. The silicon-germanium (SiGe) transceiver was developed for small-cell backhaul systems but can also support industrial slip ring designs (Figure 3). Using an integrated synthesizer, the SiGe chipset can be tuned in discrete frequency steps of 250, 500, or 540 MHz from 57 to 64 GHz. An external signal can also be used to control the modulation, coherency, and phase noise needs of specific applications.

The transceiver includes support for modulation schemes like on-o keying (OOK), quadrature amplitude modulation (QAM), frequency shift keying (FSK), and minimum shift keying (MSK). It has a maximum output power of 15 dBm and a maximum modulation bandwidth of 1.8 GHz and can be monitored using an integrated detector. The chipset features adjustable low-pass and high-pass baseband filters, a low noise figure, and flexible digital or analog IF/RF gain control.

The receiver signal chain includes an integrated amplitude modulation (AM) detector that simplifies the demodulation of signals like OOK that use amplitude modulation. While the transceiver supports several modulation schemes, OOK is especially suited for control applications like slip rings since it can be implemented without high-speed data converters, which can add to cost and power consumption. In addition, OOK does not require complicated modulation and demodulation stages and can support the low latency needed for real-time industrial control applications.

Summary

Slip rings are important components in various industrial, green energy, and medical applications. Many contact and contactless slip ring technologies include mercury wetted, wireless, inductive, capacitive, and FORJ. In addition to transmitting electric data and power in rotating machines, slip rings send gases and liquids between the rotating sections. DW

WE INNOVATE.

Leighton Lee II was an innovator. He founded our company on that spirit, and it’s how we solve tough problems today. Every product you see here—from miniature check and relief valves to shuttle valves, flow controls, precision orifices and plugs—was developed to solve a customer’s fluid control challenge. Since 1948, we’ve been delivering engineered solutions for a wide variety of demanding applications. We have the experience, product breadth, and technical know-how to provide engineered performance, with zero risk. Don’t let an imitator ruin your day—or your design. Contact us today to put our knowledge to work for you.

Learn more at theleeco.com/innovate

Product World

Ethernet

Acromag acromag.com

remote I/O modules

Acromag has released two new Ethernet Remote Input/Output (I/O) modules, the NT2510 and NT2530, as part of its Busworks NT Series. These modules are designed to be a cost-e ective solution for monitoring and controlling analog and discrete signals in industrial applications. Eight models have bidirectional discrete I/O, voltage or current analog inputs, and optional analog current outputs. NTE modules have dual RJ45 ports and a web server with field-selectable Modbus TCP/IP or EtherNet/IP communication. They also have an integrated DIN rail bus that allows up to three NTX expansion I/O modules to be connected, and a spacesaving design that requires only 25 mm of DIN rail per module. The modules are suitable for harsh environments with hazardous location approvals, high noise immunity, and a temperature range of -40 to 70° C. They can function as a network client or use Acromag’s i2o peer-to-peer communication technology to transfer data directly between modules without the need for a host or server. The modules also have multicast capability and support conditional logic.

Each module will support multiple protocols which are selectable using any web browser to configure the network settings and I/O operation. The modules typically function as a network client, but also o er Acromag’s i2o peer-to-peer communication technology to transfer data between modules directly without a host or server in between. Multicast capability and conditional logic are included.

E-chain with extender crossbars

igus igus.com

Igus has developed an extender crossbar design for its E4Q modular energy chain series to guide large hoses safely.

With the help of an adapter system, the e-chain can be individually adapted to the hose diameter. The tool-free E4Q opening mechanism ensures easy energy supply installation and filling.

In 2019, igus launched a new series of e-chain cable carrier systems named E4Q, which has already proven itself in applications worldwide, from machine tools to linear robots. It is particularly popular because of its modularity. The E4Q scores points with long unsupported lengths and long travels. In addition, the user can save 40% assembly time and 10% weight compared to the standard E4.1 series.

The extender crossbar can be mounted on the energy chain with an adapter system. For inserting hoses, those used in the wood industry, igus relies on the E4Q crossbars. These can be opened and closed without tools and are available in 15 widths. This o ers users a high level of variability when configuring their energy supply.

YOUROPTIMIZEDESIGN

We make it easy to take your design further with a custom ring or spring.

• Economical Prototyping (No-Tooling-Charges™)

• Quick Lead Time

• Diameters from .118” to 120” in 40+ Materials

• Industry-Specialized Design Support

Custom Retaining Rings and Wave Springs

Product World

DC-to-DC converters

AutomationDirect

automationdirect.com

AutomationDirect has added new RHINO Pro DC-toDC converters that are designed for harsh industrial environments and provide high EMC immunity, shock/ vibration resistance, and thermal shock resistance.

This line o ers models with 150 W outputs at 12, 15, 24, or 48 Vdc, and ultra-wide input voltage ranges of Vdc or 18-75 Vdc. They provide protection against overload, short circuit, reverse input, overvoltage, and input under-voltage lock-out, and deliver a constant current output at 100% load, making them suitable for battery charging applications.

The new RHINO Pro DC-to-DC converters o er a 3-year warranty, are ULrecognized, CE-marked, and RoHS compliant.

Cleanroom-rated static eliminator

Exair

exair.com

The new Intellistat Ion Air Nozzle is the latest solution for static elimination in sensitive processes. Like the Intellistat Ion Air Gun, this new Nozzle provides a lightweight solution rated Class 5 for clean rooms and controlled environments per ISO 14644-1. The Ion Air Nozzle comes equipped with a mounting bracket to assist with remote mounting or benchtop assembly for hands-free use. It will reduce 1000 volts to less than 100 in 0.6 seconds and up to 24-in. away. The Intellistat Ion Air Nozzle is a comprehensive solution for neutralizing static in sensitive processes like scientific and electronic testing, cleaning medical or pharmaceutical products and packaging, or removing debris from sensitive electronics.

The compact stainless-steel adjustable bracket can be installed into a customer’s process. Operations requiring both hands to package, test, or assemble parts now remain static-free. The nozzle is equipped with an LED indicator to assure proper functionality while employing EXAIR-engineered air nozzles to maximize e ciency and meet OSHA requirements for sound level and dead-end pressure. Made from durable static dissipative polycarbonate and featuring a non-marring nozzle, the Intellistat assures its usefulness in applications such as PCB or electronics manufacturing.

The EXAIR line of Intellistat products is UL-listed and CE compliant along with the rest of EXAIR’s full line of static eliminators.

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

Gigabit ethernet switches

Red Lion redlion.com

The N-Tron Series NT5000 Gigabit Managed Layer 2 Ethernet switches and their gigabit speed are designed to improve network security and reliability for industrial organizations of all sizes and environments. The NT5000 maximizes operating performance and system uptime through seamless integration, advanced management, and diagnostic capabilities, network redundancy, and layered security, and helps organizations meet information technology and operational technology needs for dependable communication.

Designed and assembled in the United States, NT5000 switches are available in 6, 8, 10, 16, and 18 port configurations in all copper or a mix of copper and fiber options that can meet specific installation requirements. With a durable, metal enclosure and wide temperature range, the NT5000 is a compact solution for reliable operation in harsh, industrial environments, including factory automation, robotics, food and beverage, oil, and gas, marine, and rail.

The NT5000 is engineered for fast and easy deployment right out of the box. Its modern, graphical user interface includes a configuration wizard that walks users through the initial setup. It also has password encryption, multilevel user access, MAC security, IEEE 802.1X with RADIUS remote authentication, and more. Administrators can view the event and syslog to clearly see the state of the network in real-time and receive notifications about access attempts or configuration changes. The switch can be set to automatically disable user or port credentials after failed access attempts.

Mini small-diameter cable glands

Lapp North America

e.lapp.com

The extended SKINTOP MINI range includes 2 to 7-mm diameter glands, allowing system designers to obtain protective, secure seals for their small-diameter cables while reducing cable density in their networked devices.

Features and benefits include:

• Low height for high-density packing.

• Robust, nickel-plated brass construction.

• Temperature range of -60° to +200° C.

• IP68 protection for harsh environmental conditions.

LAPP’s SKINTOP MINI cable glands are suitable for the medical device, pharmaceutical, and automotive manufacturing industries.

Product World

Linear encoder for industrial applications

SICK sick.com

SICK launched the new DAX linear encoder product family for highprecision detection of piston positions in hydraulic cylinders and monitoring linear movements in machines, providing flexibility for countless industrial applications. The product family o ers three designs to suit these applications, all with industry-appropriate measuring ranges. An Online Configurator provides step-by-step assistance to users in selecting a suitable DAX. For applications with special requirements, the smart and flexible system architecture of the product family allows for tailored and e cient customization.

The detection of a linear position is contactless — and therefore wear and maintenance-free — based on magnetostriction. This absolute measurement principle ensures the highest level of machine availability with no reference runs required. In addition, DAX linear encoders o er comprehensive diagnostic functions. This opens the possibility of using the sensors for condition monitoring and integration into digital transformation environments.

The DAX linear encoder is suitable for measuring positions in many applications, including injection molding machines, presses, automotive machinery, printing and packaging machines, wind, hydro, and solar plants, wood processing, or medical technology.

With the DAX product family, SICK has expanded its portfolio of magnetostrictive linear encoders for industrial applications. Since the device uses an absolute measurement principle, no reference run is required. Three housing variants are available for the market launch of the DAX: a design for integration into industrial hydraulic cylinders, a flat type with block magnets for mounting in tight installation situations, and a version with a slide profile that guides the position magnet, thereby ensuring a very precise and repeatable position measurement. The available measuring range is between 50 and 2,500 mm and is individually configurable in 1-mm increments.

Drive calculator

FAULHABER

faulhaber.com

The FAULHABER Drive Calculator is the perfect tool for developers to find a suitable drive system for a specific application in record time. It is easy to use and functional: the modern, clear user interface was designed with optimal usability in mind, and helpful tool tips provide valuable detailed information. For faster calculation, the program uses global presets with common average values. Of course, the default settings can be adjusted to individual needs, such as considering the ambient temperature, supply voltage, or available space.

The suitable solutions are then shown to the user in a clear list of results, which he or she can further narrow down as needed using powerful filters. The FDC currently enables the calculation of seven drive types and two operating modes. A detail page for each drive system shows the calculated thermal values and performance diagrams as well as other important information and data. What makes this unique is that the user can change the values on the fly and have them recalculated and displayed immediately. In addition to the calculation, optimal controls are also displayed to complete the drive system. In the end, the user can download the selected solutions as a PDF or request them directly online.

President, Urology Boston Scientific

Chief Strategy Officer Moon Surgical

JEFFERY ALVAREZ

MEGHAN SCANLON CEO, Chairman, President Becton Dickinson

TOM POLEN CEO, Chairman Boston Scientific

MIKE MAHONEY Senior Vice President, Sales Boston Scientific

KRISTIN LAROCCA

President, Digital, Robotics, and Enabling Technologies Stryker

ROBERT COHEN

Global Head of Robotics R&D Johnson & Johnson MedTech

MARTIN BUEHLER CEO OssoVR

JUSTIN BARAD

Product World

Machine visualization solution

Emerson emerson.com

Machine builders in any industrial application can now use Emerson’s PACSystems RXi HMI, a next-generation machine visualization solution designed to help set their systems apart for customers. The new system easily helps users overcome the limitations of lower budgets, fewer people, and higher productivity demands. This highly intuitive human-machine interface (HMI) addresses the needs of today’s industrial workforce with easy-touse, smartphone-like graphical displays without sacrificing rugged, industrial performance.

Unlike traditional resistive displays, PACSystems RXi HMI is designed with projective capacitive touchscreen technology that allows users to interact with the visual display with 10-point multitouch capabilities like swipe, pinch, or zoom to move to the next screen or expand a chart, enabling easy operation by a wide range of personnel with varying levels of training and experience.

PACSystems RXi HMI comes pre-loaded and pre-licensed with the advanced Movicon WebHMI software, so the device is conveniently ready to operate out of the box, saving the customer time.

PACSystems RXi HMI is HTML5-ready which allows users to collaborate from anywhere, so that the operations, management, and maintenance teams can all view the same screen at the same time, no matter the distance. This immediate sharing of information and access to expertise reduces maintenance costs and improves productivity.

Rotary Latch line

Southco Southco.com

Two new options have been added to the heavy-duty R4 Rotary Latch line: an anti-vibration feature and an integrated cable mounting bracket solution. Southco’s new R4-30 Rotary Latch additions dampen noise from vibration and simplify cable mounting for applications requiring remote latching. The R4-30 Rotary Latch with Integrated Bumper — available with any of the R4-30 configurations — holds the latch striker between the cam and bumper, eliminating the potential for unwanted noise and vibration for applications in motion. The R4-30 with Cable Mounting Bracket is available for bottom lever solutions and enables cables to be easily configured and incorporated into the rotary system, without needing to buy and install a separate cable bracket.

The R4-30 Rotary Latch with Integrated Bumper and Cable Mounting Bracket is available with high-strength steel and corrosion-resistant stainless-steel construction. The R4-30 has either single-stage or two-stage engagement which supports increased operator safety by eliminating false latching conditions in heavy-duty equipment applications. The latch systems provide a robust solution to secure panels with push-to-close convenience, o ering concealed latching at one or more points of the application. When combined with Southco AC Actuators and Cables, R4 Rotary Latches create a complete Rotary Latching System, providing secure, reliable, remote latching for interior and exterior applications.

SALES

Ryan Ashdown rashdown@wtwhmedia.com 216.316.6691

Jami Brownlee jbrownlee@wtwhmedia.com 224.760.1055

Mary Ann Cooke mcooke@wtwhmedia.com 781.710.4659

Jim Dempsey jdempsey@wtwhmedia.com 216.387.1916

Mike Francesconi mfrancesconi@wtwhmedia.com 630.488.9029

Jim Powers jpowers@wtwhmedia.com 312.925.7793

@jpowers_media

Courtney Nagle cseel@wtwhmedia.com 440.523.1685

@wtwh_CSeel

LEADERSHIP TEAM

Publisher Mike Emich memich@wtwhmedia.com 508.446.1823

@wtwh_memich

CEO

Scott McCafferty smccafferty@wtwhmedia.com 310.279.3844

@SMMcCafferty

EVP

Marshall Matheson mmatheson@wtwhmedia.com 805.895.3609

@mmatheson

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© 2023 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. Nonqualified 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; 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Periodicals postage paid at Cleveland, OH & additional mailing offices.

POSTMASTER: Send address changes to: Design World, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114

By Mark Jones

Time saved on energy consumed

On the second pull, there was a cloud of white smoke and the engine sputtered to life. My 20-year-old snowblower was ready to tackle the fresh snow. The 2-cycle fumes hitting my face come with twinges of guilt. I don’t need to use the snowblower. My trusty snow shovel o ers a fumeless, fossil fuel free option.

The snowblower has been mostly idle recently. Snowfall is well below average this winter and, now retired, I have been shoveling. It is better for the environment. It gives me some exercise, too. I’ve done testing and I’ve done some math. Shoveling takes four times longer than snowblowing when the snow is less than an inch or so. More snow doesn’t change the time required to blow by much — but it increases shoveling time significantly. The four inches on the drive today would require five times longer to shovel.

Creating a new unit is almost the height of arrogance. Thinking I’ve come up with something so profound it requires a new unit is a big leap. I am about to do it, wishing my last name was more interesting, something more akin to Volta or Kelvin, and didn’t share the same first letter as Joule. Jones is sure to be a tough sell as the name for a new unit.

My snowblower saves me time by converting energy to useful work. Time Saved per Energy Consumed, TSEC, is my new unit. Seconds saved per megajoule expended in the SI implementation. Today’s snowblowing took me about 36 minutes and 0.2 gallons of gasoline, 26 megajoules. Shoveling would have taken 3.25 hours. I saved 363 seconds per megajoule. That’s 363 Joneses.

Not all energy is used to replace labor, but much is. Ads may lead us to think we drive and fly for the thrill, but we do it to save time. Snowblowing is a nice case since there is such an obvious manual comparison.

A TSEC of 363 Joneses is higher than most other activities. Compared to walking to my local grocery store, driving saves only about 175 seconds per megajoule consumed. Flying to visit my son rather than driving, a 600-mile trip, is a relatively low 30 Joneses.

Time is money. Both time and energy are easily converted to dollars, further justifying my use of the snowblower. Energy cost for the snowblower is $3.12/gallon today. Time doesn’t trade so transparently. Using $15/hour as the cost of time, 363 Joneses means every dollar spent on gasoline avoids $64 of labor. Return increases with higher wages, with higher value time. Parity for 363 Joneses is easily calculated. $200/gal of gasoline is where energy cost and labor cost at $15/hour are equal, at least in my driveway, in the snow.

Gaining time at 363 Joneses, a pint and a half of gasoline, 62 cents worth, processed through my snowblower, freed up two and a half hours of time. The megajoules were well-spent. I am skeptical, but hopeful, Jones will stick as the unit of TSEC. Only time will tell. DW