DESIGN WORLD MAY 2021

www.designworldonline.com

May 2021

inside: LINEAR MOTION: Getting straight on roller screws

p. 82

MEDICAL: Choosing silicones for medical device lubrication

p. 86

THE ROBOT REPORT:

Evolution of

Boston Dynamics’ box-moving robots

p. 54

HMIs

with controls— then and now page 76

MAY 2021 DW COVER_FINAL.indd 1

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Disrupting the aerospace industry I hope you’ve been enjoying our monthly Future of Design Engineering Series of webinars as much as I have. Last month, we had an engaging talk by Charlie Light, Program Manager for the Space Based Nuclear Detonation Detection Program at Los Alamos National Laboratory.

Light’s discussion of the aerospace/defense sector was fascinating. Once dominated by large companies like Lockheed Martin, Boeing, and Northrop Grumman, this sector is beginning to open up to more players. The traditional manufacturers were deep-pocketed customers that had an eye towards maximizing performance in a way that other industries weren’t willing to — and they weren’t willing to take certain risks.

It used to be a fight to get in the proverbial door; it was always big incumbent versus potential disruptor. But that’s changing today. Light said that the barrier to entry has come down, as innovation has allowed certain capabilities to be developed — sometimes with at least a demonstration at a lower price — than they have before. In some fields, the opportunity space for disruptors is as good now as it’s been in a long while.

Where the disruptor can succeed is with a big idea or a significant incremental improvement for a known need. 3D printing of rocket engine parts is a great example of that. In fact, Light thinks that 3D printing across the board is potentially very, very disruptive for a lot of different industries. That’s partly because some aspects of additive manufacturing are new, and some 3D printing abilities are dramatically different than what had been available before.

What’s more, there’s not a good understanding yet of what the capabilities and limitations are.

Light said that disruptors can get into the door by saying, “I know there’s an existing need — and I’m going to approach it om a different angle that’s going to give you a fundamentally different cost point or capability.”

For component manufacturers who haven’t worked with aerospace customers before, Light said that the jump is probably smaller than they think. He noted that the aerospace industry for a long time has started with commercial solutions as proof of principle points, and then looked at those to ask, “Is there some degree of assessment I can do to see where this commercial component breaks down?”

He suggested looking at your existing product line and compare it to what’s being delivered to aerospace applications by competitors.

“There’s more cost tolerance in order to get a performance against one of those figures of merit — maybe it’s mass, maybe it’s power consumption, maybe it’s reliability. Aerospace is not monolithic; it has many different applications and a ton of different needs.” DW

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

(408) 460-1345

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

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Teschler on Topic STEM classes don’t teach engineers how to think It’s no secret that the media eagerly report potential technical breakthroughs with hyperventilating headlines. The most recent example is the buzz surrounding battery technology for electric vehicles. We might wonder why EVs don’t all have a 1,000-mile range given the number of news reports about spectacular advances coming out of battery research labs.

But the reason EVs still need to charge up after a few hundred miles is that the media often fails to clearly indicate the preliminary nature of the findings they trumpet. Even worse, they seldom report when the studies they hyped previously fail to pan out.

Researcher Estelle Dumas-Mallet of France’s University of Bordeaux tried to estimate the depth of this bias in news reporting. Dumas-Mallet and her colleagues examined 156 studies on disease risk that were written up in the popular press. All the studies getting this attention reported positive results.

Thirty-five of these papers (covered in 234 news articles) were eventually proven invalid. Yet only four news articles were published pointing out the original stories were incorrect.

It seems that many journalists don’t understand the phrase “preliminary results” when it comes to science. This

lack of comprehension adds to the sea of nonsense and half truths now making up our news feeds. But it is only one aspect of why we seem to live in a never-ending stream of misinformation.

Often, information is presented in ways that are either purposely or accidentally misleading.

You might think STEM grads would be better equipped to spot such shenanigans. Many of the engineers I’ve worked with have had a high opinion of their own mental faculties, particularly compared to the reasoning abilities of liberal arts majors. If your engineering courses were like mine, they focused heavily on problem solving. But the problems we were taught how to solve were mainly those that fell to physical principles and mathematical analysis rather than sniffing out prevaricators.

Researchers studing misinformation say STEM grads are no better at detecting it than those with liberal arts degrees. In fact, STEM grads may be worse at ferriting out half-truths because STEM has an orientation toward problems with neat solutions.

“We generally do a good job teaching mechanics: students learn how to manipulate matrices, transfect cells, run genomic scans, and implement machine learning algorithms,” says University of Washington professors Carl Bergstrom

and Jevin West. “But this focus on facts and skills comes at the expense of training and practice in the art of critical thinking.”

The UW professors say the problem with a single-minded focus on facts and skills is that it leaves STEM students unprepared to detect deceptive arguments and nonsense. Bergstrom and West, whose fields are biology and information technology, claim students in humanities get more practice in these areas than do those in STEM. “In the humanities and the social sciences, students are taught to smash conflicting ideas up against one another and grapple with discordant arguments. In STEM fields, students seldom are given paradoxes that they need to resolve, conflicting forms of evidence that they must reconcile, or fallacious claims that they need to critique,” the two say.

One problem the two see is that STEM grads tend to believe arguments backed up by numbers. But “Numbers are ideal vehicles for promulgating BS,” they say. “Numbers feel objective but are easily manipulated to tell whatever story one desires....We are told that ‘the data never lie.’ But this perspective can be dangerous.”

Perhaps a reason for some humility the next time you’re ready to believe breathtaking data from a battery lab. DW

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

6

May 2021 www.designworldonline.com

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Technology Forward

Signs of maturity In year’s past, the big news of additive manufacturing (AM) usually involved new ways to make parts one layer at a time, or an improvement that made making a part faster. Since the pandemic, the focus of AM has changed a bit. Instead of new technology, the recent news focuses on business developments. It began, for example, when Desktop Metal went with a Special Purpose Acquisition Company (SPAC) to go public.

Then, Stratasys bought Origin, a company that developed a softwarecentric additive manufacturing solution based on digital light processing for production-oriented polymer applications.

Then, Desktop Metal acquired EnvisionTEC and Stratasys added stereolithography to its lineup of 3D printers with the UK-based RP Support Ltd. (RPS) Next, VELO3D Inc. plans to work with an SPAC to go public and raise capital. This transaction is expected to be completed in the second half of this year.

Carbon3D is pursuing partnerships to expand in Europe.

Materialise acquired the option to buy Link3D Inc., an additive workflow and manufacturing execution systems (MES) company and recently opened a

new facility in Germany.

And Nano Dimension Ltd. announced it has signed a definitive agreement to acquire DeepCube Ltd. (“DeepCube”), a leader in Machine Learning/Deep Learning (ML/DL) technology.

According to some reports, $11 billion from Special Purpose Acquisition Companies (SPACs) has been invested in the 3D printing industry recently. SPACs are a way to go public through mergers rather than Initial Public Offerings (IPOs).

As many industry analysts are claiming, the pandemic has highlighted the usefulness of AM. This technology is viewed now as helping to manage the unexpected.

Thus, these SPACs see the potential for strong future growth in AM. So, are we on the Gartner Hype Cycle slope of enlightenment?

Perhaps.

The involvement by SPACs indicates confidence in this technology’s growing costcompetitiveness and advances.

There’s a lot of buzz around the potential for AM to facilitate digitization. Many industry watchers see AM as an “interface technology” between digital designs and real products.

But it should be remembered that additive manufacturing is a long-term growth industry. It will take its place as both a prototyping

technology and a manufacturing technology. It may not, however, deliver the short-term results many inventors look for. The AM industry has been down that road before when it was overhyped and stocks rose based on that hype. Then, the crash came.

The pandemic, though, has highlighted an arena that AM users have long thought was a key application—the supply chain.

Finally, many executives see the value of being able to design anywhere and build those designs anywhere. The nimble supply chain that can also enable local manufacturing is now the new corporate goal for manufacturing.

For now, investor interest is a sign of a maturing industry. Hopefully, this technology will continue along the slope of enlightenment and onto the plateau of productivity. DW

Leslie Langnau llangnau@wtwhmedia.com On Twitter @ DW_3Dprinting

8

May 2021 www.designworldonline.com

Tech.Forward 5-21_Vs2.LL.indd 8

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Green Engineering Paul J. Heney

• VP, Editorial Director

Packaging machines designed to use shrink film made of 100% recyclate

When it comes to sustainability, plastics have a bad reputation among many consumers.

“The problem here lies less in the explicit use thereof, for plastic has a number of positive material properties. It’s not just unbreakable and flexible, for instance, but also effectively protects the packaged item om various damaging factors,” said Martin Thyssen, packaging expert for cardboard, paper and shrink film at KHS. “Consumers, retailers and the food and beverage industries are thus increasingly calling for environmentally- iendly packaging systems that aren’t merely recyclable but also made of recycled materials.”

With the option of now processing shrink film made of 100% recyclate, the KHS Group is meeting this demand and adds a further sustainable alternative to its packaging portfolio. The use of film made entirely of recyclate is possible on all KHS shrink packers in the TSP, WSP, SP and PSP series. Thanks to their modular design, existing machines can be easily adapted. Fully recycled film is suitable for use with both PET and glass bottles as well as beverage cans.

Using recycled film is to the operator’s advantage in several respects.

“On the one hand, compared to new material it reduces the carbon footprint by up to 65%, according to market information supplied by various film manufacturers, and this thus helps to significantly save on resources,” said Thyssen. On the other, bottlers would then be prepared for the planned changes to 10

May 2021

Green.Engineering.5-21.Vs2.LL.indd 10

legislation in some countries regarding fixed quotas. In Great Britain, for example, by April 2022 plastic packaging must be made up of at least 30% recyclate. France is already one step further: as of January 1, 2021, plastic packaging must contain at least 50% post-consumer recycled materials. In both countries, companies face increased taxes should they undershoot these quotas.

It cannot be denied that the use of film made of recycled material is more expensive than conventional new film. Experience shows that up to 10% in additional costs are incurred for 50% rPE, with this surcharge rising to a maximum of 15% for 100% rPE. However, Thyssen is convinced that the benefit of acting sustainably by using recycled film overrides the increase in expenditure — especially when failing to meet statutory thresholds means paying environmental taxes in the future.

Besides continuing to be easy to process, the sustainable packaging system also carries a valuable message.

“In facilitating the handling of film made completely of recycled material, we’re taking a clear stand for the protection of the environment,” said Thyssen. In doing so, KHS is specifically endeavoring to further establish eco iendly systems on the market and promote the circular economy. DW

KHS | khs.com/en/

www.designworldonline.com

DESIGN WORLD

4/29/21 9:34 AM

Our solution for the servo drive system SIMATIC MICRO-DRIVE from Siemens.

The drive solutions from ebm-papst for SIMATIC drive controllers from Siemens combine network capability with functional safety. For you, this means an additional plus in simplicity and reliability. SIMATIC MICRO-DRIVE is the new servo drive system for the safety extra-low voltage range. This system is composed of the PDC (Profidrive Control) servo controller, flexible motors and connection cables.

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4/29/21 9:30 AM

Contents 5 • 2021

•

vol 16 no 5

•

designworldonline.com

86 76 _MOTION CONTROL

92 _FASTENER

HMIs with controls—then and now

How advances in adhesives are leading to greater freedom of design

Recent years have brought staggering advancements in HMI control and IIoT functionalities. While previously only modest applications could rely solely on HMIs with so -PLC or PC functions for controls, today’s HMI technologies can o en satis the same requirements for more demanding installations.

82 _LINEAR MOTION Getting straight on roller screws

A Supplement to Design World - May 2021 www.therobotreport.com

Advances in adhesive formulations are providing design engineers with more options.

Here’s a look at your options.

Evolution of Boston Dynamics’ box-moving robots page 54

98 _ELECTRONICS Fast current sensors for advanced applications

The high switching speeds of modern power electronics call for sensors able to keep up with the megahertz-level equencies involved.

Anisotropic magneto-resistive technology fits the bill.

INSIDE: • WTWH Media acquires Mobile Robot Guide .......................................................53 • Designing an omnidirectional mobile manipulator with 7 DoF ...................................62 • 5 critical sensor integration challenges for AMRs ............................................................68

ROBOT_REPORT_COVER_5-21_Vs1.indd 51

4/30/21 3:25 PM

51-75

Knowing the differences between the several kinds of roller screws can help determine the best fit for an application.

86 _MEDICAL Choosing silicones for medical device lubrication

The right silicone can enhance the design of medical devices. Here are tips on choosing the right one.

12

May 2021

CONTENTS.5-21_Vs2.LL.indd 12

ON THE COVER

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

The latest human-machine interfaces are capable enough to execute an array of tasks for control, | Dreamstime.com networking and IIoT functions.

www.designworldonline.com

DESIGN WORLD

4/30/21 3:47 PM

Digi-Key 2-21.indd 13 210108_AMNP_DW_US.indd 1

4/29/21 1/7/21 9:31 1:58 AM PM

Connect Your Power 8 Ways

5.21

• contents departments

Interpower® 1-Week Lead-Times and Same Day Shipping on in-stock North American cords and cord sets help untie today’s logistical Gordian knots. Our U.S.A.made cords navigate past troubled waters and ports stacked with shipping containers. Our power cords are customizable—lengths, colors, labels, packaging—to your specifications. All Interpower cords are tested in both design and production phases.

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Same Day Shipping on in-stock products

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No minimum order requirements

06

Teschler on Topic

08

Technology Forward

16

power connection make the direction of the cord critical, an angled plug minimizes the space between connectors reducing the strain on both plug and cord. Different plug angles allow choices on how a cord can be plugged into a power source.

1-Week U.S. Lead-times on Interpower products

Insights

10 Green Engineering

Whether ordering 1 cord or 5,000, Interpower offers eight Interpower ®provides customized different ofIowa, the NEMA solutions.angles Made in Interpower 5-15 plug.

When limited space remains unaffected by logistical between equipment and the lockdowns and slowdowns.

•

04

Design For Industry

26

Design Notes

38

CAE Solutions

42

Internet of Things

48

Connector Notes

104

Product World

112

Ad Index

®

®

Toll-Free Phone: (800) 662-2290 E-mail: info@interpower.com Business Hours: 7 a.m.–6 p.m. Central Time

Order Online!

www.interpower.com

CONTENTS 5-21_second.page_Vs2.LL.indd 14

14

May 2021

DESIGN WORLD

4/29/21 3:58 PM

DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

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

VIDEO SERVICES

WEB DEV / DIGITAL OPERATIONS

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

Videographer Garrett McCafferty gmccafferty@wtwhmedia.com

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

PRODUCTION SERVICES

Front End Developer Melissa Annand mannand@wtwhmedia.com

Customer Service Manager Stephanie Hulett shulett@wtwhmedia.com

Software Engineer David Bozentka dbozentka@wtwhmedia.com

Customer Service Representative Tracy Powers tpowers@wtwhmedia.com

DIGITAL MARKETING

VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia Digital Account Supervisor Taylor Meade tmeade@wtwhmedia.com @Taylor Meade

CREATIVE SERVICES

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

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Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com Customer Service Representative Renee Massey-Linston renee@wtwhmedia.com Digital Production Manager Reggie Hall rhall@wtwhmedia.com Digital Production Marketing Designer Samantha King sking@wtwhmedia.com Digital Production Specialist Elise Ondak eondak@wtwhmedia.com

Webinar Coordinator Kim Dorsey kdorsey@wtwhmedia.com

FINANCE

EVENTS

Controller Brian Korsberg bkorsberg@wtwhmedia.com

Events Manager Jen Osborne jkolasky@wtwhmedia.com @wtwh_jen

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Event Marketing Specialist Olivia Zemanek ozemanek@wtwhmedia.com

WTWH Media, LLC 1111 Superior Ave., 26th Floor, Cleveland, OH 44114 Ph: 888.543.2447

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Medical Design & OUTSOURCING DESIGN WORLD

TEAM page 5-21_Vs1.indd 15

www.designworldonline.com

May 2021

15

4/29/21 9:41 AM

Design for Industry Material handling/conveying

Complete distributed drive system For horizontal conveyor applications, the Sinamics G115D is a compact drive system. The drive comprises the motor, drive and gearbox in one unit and is offered in two versions — wall-mounted and motor-mounted.

The drive offers IP protection class (up to IP66 / UL Type 4X) and is suitable for use in harsh environments.

Its compact dimensions fit confined areas. The drive system can also be operated reliably over a temperature range of -30 to 55 degrees Celsius (-22 to 131 degrees Fahrenheit).

The drive is suitable for applications in intra-logistics and airports, as well as in the automotive and food and beverage industries. Its power ranges om 0.37 to 7.5 kilowatts (1/2 to 10 hp) for wall-mount applications and 0.37 to 4 kilowatts (1/2 to 5 hp) for motormounted applications. The drive system can be put into operation quickly and easily with comprehensive integration into the Totally Integrated Automation (TIA) portal including Startdrive commissioning so ware or the Sinamics Smart Access Module (SAM) web-server for Wi-Fi setup and diagnostics.

16

May 2021

DFI.5-21_Vs2.LL.indd 16

www.designworldonline.com

For digital transformation and cloud-based analysis, Sinamics G115D is integrated into the entire MindConnect portfolio and is compatible with MindSphere applications such as Analyze MyDrives.

With Profisafe, the Sinamics G115D has Safety Integrated in the form of STO (Safe Torque Off ) SIL2, which standardizes and facilitates the certification process. For flexibility in terms of installation, service and maintenance, the solution is equipped with a plug-in connector and flexible connection possibilities. The device is suitable for interaction with Simatic controllers such as the Simatic S7-1200 or Simatic ET200 for motion control. DW

Siemens usa.siemens.com

DESIGN WORLD

5/4/21 7:32 AM

A Superior Line HIGH QUALITY DIN Rail Terminal Blocks Complete Line

Easier setup of

material handling systems

Many Styles & Configurations

CP Series

Getting a machine up and running fast for better productivity is easier if the settings to run applications are already in place. The Danfoss VLT AutomationDrive EZ FC 321 provides variable speed control of all asynchronous and permanent magnet motors, on any industrial machine or production line. It offers standard features right off the shelf with no special configuration or customization required. As an intelligent variable equency drive, it can help save energy and improve flexibility in a range of processes.

The drive performs in all industrial environments and grid voltages, including 690V. Enclosures are available up to NEMA 4X (depending on model), and integrated dc chokes and RFI filters in all models protect installations by minimizing harmonic distortion and electromagnetic interferences.

All drives are tested at full load before leaving the factory.

With a flexible modular design, the AutomationDrive EZ FC 321 offers standard features that can be expanded with plug-and-play options with additional features and fieldbuses. Safe Torque-Off is a standard safety feature that can be applied through hardwired safety.

Drives up to 100 HP come standard with class 3C2 coating (acc.

IEC 60721-3-3). Drives 125 HP and above come standard with 3C3 coating.

The drive is easy to set up and operate via the user- iendly graphical control panel and requires minimal maintenance.

It includes groups for several of the most common applications, including conveyors, pumps and fans, and setup with mechanical brake. DW

with Push-in TECHNOLOGY Highlights • Tool-less wiring for easy connection • Direct connection of solid wires and flexible wires with ferrules • Stainless steel push-in spring • No special tool required for pushbutton release • Wide range of blocks for many design options • Sensor & Actuator terminal blocks

Thinnest 3.5 mm wide terminal block in the industry

Universal Push-In Jumper Technology

Supply voltages and power range: 3 x 200 – 240 V...................... 0.33 HP – 100 HP 3 x 380 – 480/500 V............. 0.5 HP – 200 HP 3 x 525 – 600 V..................... 1 HP – 100 HP 3 x 575 – 690 V..................... 125 HP – 200 HP

Danfoss www.danfoss.com

DESIGN WORLD

DFI.5-21_Vs2.LL.indd 17

Contact info@altechcorp.com May 2021

17

908.806.9400 AltechCorp.com

4/29/21 10:03 AM

Design for Industry Material handling/conveying

Guided container and tray identification made easy

Conveyor lines o en have small spaces that complicate the installation of add-on equipment like bar code readers. The BCL200i is a stationary bar code reader that supports guided container and tray identification and fits many tight spaces on the conveyor line.

The BCL 200i is a 1D bar code reader with integrated industrial interfaces and simple PROFINET configuration. The device can be configured directly in the control via the GSDML file. The compact design fits tight spaces on or between conveyor lines, and features a side cable outlet as well as its dovetail connection.

The reader detects 1D codes in guided container reading, regardless of whether the bar code is printed vertically or horizontally on the label. The same is true for guided tray identification when moving trays are horizontally marked with 1D codes. The web-based configuration tool enables remote diagnostics om anywhere in the world.

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DESIGN WORLD

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A Superior Line

The integrated code reconstruction technology (CRT) enables the bar code reader to read bar codes with small line heights as well as damaged or smudged labels. With the aid of the CRT decoder, bar codes can also be read at a large twist angle.

The reader can be initiated without an additional sensor system through automatic reflector activation (autoReflAct). This feature operates by directing the scanner with reduced scanning beam towards a reflector mounted behind the conveyor path.

As long as the scanner is targeted at the reflector, the reading gate remains closed. If the reflector is covered by an object such as a container with a bar code label, the scanner activates the read procedure. The label on the container is then read. The read procedure is completed as soon as the scanner has a clear line of sight to the reflector again. DW

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Design for Industry Material handling/conveying

Warehouse robots deliver flexibility Warehouse robots are a good option for manufacturers and distributors of all sizes who need to transfer loads within their facilities quickly but without reconfiguring production lines or factory footprints.

They can be deployed wherever and whenever needed, interfacing with existing conveyor systems and providing flexibility as volumes change.

Autonomous Mobile Robot (AMR) technology—also known as warehouse robots—is now within the reach of mid-size companies. These robots provide more flexible material handling when used in conjunction with Motor-Driven Roller (MDR) and other conveyor systems.

New technologies are making it easier and more affordable to deploy autonomous robots in companies of all sizes as a complement to other types of material handling equipment.

These AMRs consist of Nord-Modules robotic top modules for the warehouse robots. These units offer speed, space, and flexibility and can be fitted to various AMR designs.

The Nord-Module’s Quick Mover 180, for example, uses an autonomous robot base with a flexible top module that performs multiple material handling tasks and handles a plethora of materials—gates, half pallets, plastic boxes, carton boxes, carts and cobot solutions. Without

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changing top modules, manufacturers have the ability to integrate the Quick Mover with MDRs to:

• • •

Transport multiple types of containers om point A to B to C. Pick up goods om gates and deliver to a dropoff point.

Precisely re-position goods to another automation area (e.g., a CNC machine).

The unit is controlled by a provided smartphone and can carry up to 485 pounds. Set-up and installation take approximately 30 minutes. Sensors help the Quick Mover 180 navigate quickly and safely around people, stationary objects and other obstacles.

Other Nord-Modules for AMRs include the Pallet Mover style motorized roller conveyor modules, which can carry over 3,000 pounds. DW

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robotic innovations to packaging systems The so MC compact microcontroller enables any major OEM programmable logic controller (PLC) to seamlessly control any motion control component, including robots, drives, and motors to add innovation and modularity to packaging systems.

The so MC motion controller provides packaging equipment suppliers the flexibility and controls they need to innovate and optimize customer solutions at the cost of an industry-standard network gateway.

The microcontrollers lets packaging machine-builders interface with Rockwell Automation PLCs and EtherNet/IP networks to add multi-axis motion control to any existing system. The controller delivers Industry 4.0 machine-to-machine communication while simpli ing and reducing the overall cost of motion control system design and configuration. At the same time, so MC increases the flexibility and efficiency of automated packaging lines and expands OEMS’s capabilities to innovate.

A centralized method for designing and integrating additional motion axes and/or robotics capabilities lets machine builders design and use standard robot models such as delta, SCARA, and cartesian/ gantry robots. The controller provides advanced motion control of the motors, robots, or robotic controllers while handling all communication between the material handling systems and the AllenBradley PLC. A decentralized method allows machine builders to customize a system using motors and drives om the STXI Motion product portfolio, which are optimized and ready for use with the so MC. DW

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Design for Industry

also cutting ng

Semiconductor

These chips meet networking needs The LCCI Series of ultraminiature multilayer ceramic chip inductors are for high- equency RF applications. These inductors are available in three standard EIA chip sizes — 0201, 0402, and 0603 — with tight-tolerance physical dimensions almost exclusively in the submillimeter range and tinplated surface-mount terminations, enabling compatibility with high-density PCBs and reflow soldering in space- and weight-constrained applications within the telecommunications and networking markets, as well as with lead ee and RoHS directives.

The inductors are reliable and offer performance om 100 MHz to 2.4 GHz, exhibiting high Q, high signal efficiencies, low DC resistance (DCR), tight inductance tolerances down to ±0.1nH, and guaranteed self-resonant equencies (SRF) up to 10 GHz. Applications include mobile communications and computer networking systems, wireless large-area networks (WLAN), radio- equency identification (RFID) systems, personal handheld systems (PHS) ranging om smartphones and tablets to media players and gaming devices, and EMI countermeasures in high- equency circuits.

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DESIGN WORLD

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The LCCI Series are rated for use in operating temperatures spanning -40°C to +85°C and are available with three standard inductance values: 3.9nH, 39nH, and 390nH and seven standard inductance tolerances: 2%, 3%, 5%, 10%, 0.1nH, 0.2nH, 0.3nH. Inductance values for 0201 parts extend om 0.3nH to 39nH with inductance tolerances ranging om ±0.1nH to ±5% and minimum SRF values spanning 1,500 MHz to 10,000 MHz. Inductance values for 0402 parts extend om 0.3nH to 150nH with inductance tolerances ranging om ±0.1nH to ±5% and minimum SRF values spanning 550 MHz to 10,000 MHz. Inductance values for 0603 parts extend om 1.0nH to 470nH with inductance tolerances ranging om ±0.3nH to ±5% and minimum SRF values spanning 300 MHz to 10,000 MHz. DW

The inductors are reliable and offer performance from 100 MHz to 2.4 GHz, exhibiting high Q, high signal efficiencies, low DC resistance (DCR), tight inductance tolerances down to ±0.1nH, and guaranteed self-resonant frequencies (SRF) up to 10 GHz.

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Design for Industry Semiconductor

Integrated motor control ICs improve

motor efficiency by 35%

Two system-in-package (SiP) solutions simpli brushless DC (BLDC) motor control design for a range of cordless battery-powered applications such as power tools, drones, water pumps, vacuums, cleaning robots, fans, and other systems. Combining multiple functions into an SiP solution, the RAJ306001 and RAJ306010 motor drive ICs deliver improved low-speed or high-speed rotation and high torque control while minimizing required board space and reducing solution cost. This results in a turnkey design for easy, efficient, and safe BLDC motor control.

The RAJ306001 and RAJ306010 are single-package motor control ICs that control three-phase BLDC motors used in a range of battery-powered devices. The ICs integrate an RL78/G1F microcontroller (MCU) and pre-driver into an 8x8 mm QFN package. The highly integrated SiP form factor eliminates as many as 30 external components shrinking the solution area by up to 50% with lower control system costs.

Designed with heat management in mind, the ICs feature self-aligned dead time (SADT) to prevent the shoot through and offer adjustable pre-driver output current capacity – up to 500 mA – to drive large-capacity MOSFETs, which makes heat dissipation design easier . This allows the ICs to drive MOSFETs at the optimum switching timing – reducing FET switching margin times to approximately 1/10 the time compared with conventional systems and enabling highly efficient motor drive control with reduced heat generation.

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POWER TRANSMISSION

RETAINING DEVICES & The RAJ306001 or RAJ306010 ICs can be combined with complementary analog and power offerings to create comprehensive solutions for a variety of motor control applications. These combinations showcase the capabilities of the motor control ICs for applications such as the 24V Cordless Blender and Portable Power Tools. Winning combinations using the RAJ306001 and RAJ306010 will help customers further optimize their solution in terms cost and space critical for these applications.

Key features of the RAJ306001 and RAJ306010 motor control ICs • Renesas MCU and pre-driver integrated into a single 8x8 mm QFN package, including a charge pump, linear regulators, current detection, programmable slew rate control and BEMF detect circuitry for sensor-less operation

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High integration optimizes board space and reduces control system BOM costs

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Design Notes

How to ampli your conveyor system with robotics Stacy Johnson

Dorner’s 2200 Series conveyor and related accessories can be controlled with Universal Robot’s software plug-in to aid in setup, configuration, and control.

The integration between conveyors and robotics has brought a much higher level of automation to various packaging applications in recent years.

The two components work hand-in-hand to deliver a streamlined, efficient operation with more accuracy and a strong return-on-investment.

In 2021 and beyond, this joint effort will only get stronger within industries like packaging as conveyors become more advanced in their integration capabilities with robotics. Take a look in any modern-day processing or packaging facility, and you’ll see automation is the prime driver behind the way products are being produced.

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BRAAS works closely with several automation manufacturers, such as Universal Robots, in designing custom solutions that seamlessly integrate conveyors and robotics for the packaging industry.

Just as technology is playing a larger role in the expansion of conveyor capabilities, the same can be said for robotics. New to the scene are smaller, more agile collaborative robots or cobots, designed to safely share a workspace with people. This opens up new applications within packaging, assembly, and other industries that previously did not involve any robotic interaction.

“Where we see a greater increase in collaborative robots is in smaller operations, meaning less than 1,000 employees where the automation work is being done in-house. That’s where we see the most growth,” said Dan Toynton, Product Specialist at BRAAS Company, a distributor/reseller of products and related services for industrial automation and control. BRAAS works closely with several automation manufacturers, such as Universal Robots, in designing custom solutions that seamlessly integrate conveyors and robotics for the packaging industry.

He said good examples of robotics being deployed in smaller operations are in end-of-line applications where palletizing is required for lighter parts.

Robots can remove employees om the monotonous, repetitive action of loading and unloading pallets all day long, which, in the long run, saves organizations money in time and labor while reducing the risk of injury.

“There is clearly a field acceptance we’re seeing with collaborative robots that they’re proving themselves to be

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Design-Notes-5-21-Vs4.LL.indd 27

reliable and more universally accepted,” Toynton said. “They’re safer to work around, and cobots are quite easy to set up and work with.”

The Conveyor/Cobot Relationship Robotic manufacturers have gone to great lengths to remove the guesswork and fear of the unknown o en associated with programming these systems. They are also making the integration with conveyor systems a much easier endeavor. This, in part, is driving many traditional conveyor applications to consider adding robotics.

“We’re seeing more and more integration of cobots with our conveyors,” said Scott Grahl, Engineering Manager, New Product Development, Dorner.

The process to streamline the conveyor/ cobot merger begins with robotic manufacturers, some of whom have created their own so ware to make installation and programming fast and easy. Universal Robots offers a so ware package that allows OEMs to piggyback off their system.

For example, Dorner’s 2200 Series conveyor and related accessories can be controlled with Universal Robot’s so ware plug-in to aid in setup, configuration, and control. Once the program is installed, users can add conveyors to

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The 2200 Series can be controlled with UR’s software plugin to aid in setup, configuration and control. Once the program is installed, the conveyors can be added to the cobot control program, and the user can set the inputs and outputs needed for starting, stopping, speed reference, and monitor status information.

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Design Notes the cobot control program and set the inputs and outputs needed for starting, stopping, speed reference, and monitor status information. This integration acts as a handshake between the conveyor and cobot, where an operator can run multiple conveyors off the controller at one time, and observe overall line performance.

Just as technology in robotics continues to evolve, conveyors are keeping pace as well. Robotic applications o en require product to be in an exact location, in the exact position, and at the exact time on the conveyor.

But to do that successfully requires a conveyor system that’s efficient, reliable, and engineered to work in conjunction with robotics. Not every conveyor can do that.

Servo-driven precision-move conveyors deliver accurate alignment of time and distance that provide indexing repeatability of +/- .040-in., all at a rate of 100 indexes per minute. Additionally, pallet system conveyors have become a popular choice for many automationfocused applications that require exact movements and positioning of parts, as they can be setup or programmed to start and stop at specific intervals to sync up with robotic interaction or other processes. These types of conveyors dominate in automotive component manufacturing, and other industries, including packaging, medical devices, electrical and electronics, and product testing and inspection that call for automated and manual assembly or handling of products.

Pallet system conveyors are available in multiple styles, such as dual belt configurations powered by common drives and flexible plastic chain belt designs. These conveyors come with li ing modules and can interface with robots, change product orientation, or rotate product 90° or 180°.

Some application designs dictate product to be moved in and around equipment and machinery. To accommodate this need, conveyors need to be flexible and make tight turns — which is best for flexible chain conveyors.

Ideal uses for flexible chain conveyors are processing and packaging, industrial, medical, life sciences, and the health and beauty industries.

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Many conveyors are engineered for robotic integration within automationtype applications, but the key is to select the right one for your needs. Conveyors today are built to user specifications to improve the efficiency and output of the production line.

Conveyors have become integral components in all phases of the automation, assembly, and industrial markets. But when they are synced up with robotics, their role takes on even greater importance. Merging the two components successfully takes forethought and expertise om a reputable conveyor OEM to provide the best return on investment.

Here are things to consider when adding robotics to your conveyor system: • Ensure the environment around the conveyors and robotics is dry, clean, and ee om dust. Contaminants, even small foreign particles, can hinder performance.

• Ensure an adequate source of power for both components, and room for mounting controls for conveyors and robotics.

• Robotics have long reach and will be swinging between the conveyor and related equipment. Ensure there is enough space for it to perform its operation without placing staff or other machinery in danger.

• Speaking of reach, how far do you need your cobot to reach to perform its function? Cobots come in various sizes, om small tabletop models that reach about 20-in. to larger units that reach more than 50-in.

• The base of a robotic system needs to be securely mounted to a level concrete floor. The base of even a smaller cobot can still be several square feet in dimension; be sure you have enough room to accommodate the size.

The best path forward is to work with conveyor and robotic suppliers to design a work cell that best integrates conveyors and robotics. These suppliers will be looking at not only your goals and objectives for the cell, but factors such as how product is arriving to the cell; height, weight, and shape of the products being moved; available space or employee interaction. DW

Dorner www.dornerconveyors.com

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Design Notes

Automated reject system helps in

cheese production application

Vepo Cheese outlined high performance, futureproofing, and an independent reject system on each line, as key criteria for its Oudewater factory in The Netherlands.

Edited by Mike Santora • Associate Editor

The North American cheese sector, valued at $56,976 million last year, is expected to grow annually by 2.1% CAGR between 2020-2023. Dutch imports of the dairy product make up a significant chunk of the market share, with statistics reporting a value of nearly $88 million last year.

For Vepo Cheese, which serves both national and international markets, the company recently chose Fortress Technology to upgrade its inspection process and introduce a more fail-safe solution for its growing production demands. The company outlined high performance, future-proofing, and an independent reject system on each line as key criteria for its Oudewater factory in The Netherlands.

Approaching Dutch manufacturer Jansen Control Systems to design the compact incline inspection lines, each integrated with a vertical packaging machine, Vepo first examined Fortress’ Stealth system. However, the company soon realized the increased sensitivity of the Fortress Interceptor metal detector and the advantages it could bring for cheese applications.

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Cheese comes in many forms and has high conductivity, so it is one of the most challenging products for metal detection. Explaining the issue, Fortress Regional Sales Manager Eric Garr comments, “Inspecting wet products has for many years presented cheesemakers with several challenges. Due to the high moisture content, combined with minerals and salt, cheese, like metal, can be very conductive — resulting in a high level of product effect. Also, in many cases, the product effect of cheese may lack a specific phase point as it moves through DESIGN WORLD

4/29/21 10:48 AM

The Interceptor overcomes the propensity of “wet” product effects that can drown out the signal, particularly signals caused by a stainless-steel contaminant. Software algorithms make this possible by distinguishing between indicators specific to the product and those that flag anomalies.

the aperture of a metal detector, adding to the challenge of overcoming the product effect.”

The Interceptor overcomes the propensity of “wet” product effects that can drown out the signal, particularly signals caused by a stainless-steel contaminant. So ware algorithms make this possible by distinguishing between

indicators specific to the product and those that flag anomalies. By singling out low equency signals, the Interceptor leaves the alert om stainless steel more readily identifiable in the higher- equency range.

The result of separating these two readings is that any genuine contamination om metal is not swamped by product effect.

The ability to isolate rejected packs without interrupting the production flow was also crucial to Vepo. On previous inspection lines, the company did not have an automated reject system. If a contaminated pack were identified, the belt would stop, and an operative would have to intervene, remove the pack, and restart the inspection process.

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Design Notes Reaffirming the importance of automation efficiency, Technical Operations Manager at Vepo, Hugo van Put said, “The automated reject system gives us 100% control over production.

There’s less human involvement, therefore less risk of human error. This also lowers the risk of a metal contaminant slipping through the safety net. From an efficiency perspective, continuous production is one of the main benefits.”

Noting that the one-day installation went smoothly with clear training support, Hugo adds that false-positive rejects have also fallen since the systems were implemented. “Fortress metal detectors are really sensitive. This helps us feel confident that the risks of contaminants are minimal, with less chance of a food safety issue. Having the double readings within the Interceptor system also lowers

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The ability to isolate rejected packs without interrupting the production flow was also crucial to Vepo. On previous inspection lines, the company did not have an automated reject system. If a contaminated pack were identified, the belt would stop, and an operative would have to intervene.

the risk of false-positive rejects, which saves on food waste.”

Processing transparency is another advantage of the fully integrated packing system. Each metal detector has Contact Reporter so ware. Data om each packaging line is collated in a universal collection system, enabling quality assurance and production leaders to monitor processing and inspection performance om a centralized location.

This automated record keeper developed

by Fortress also helps the factory to keep

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track of and record data for rejects, tests, and process settings. Therefore, the cost of maintenance and spare parts is lower.

Commenting on the installation, which went live in August 2019, Hugo concluded, “Efficiency is integral to our production process. And the two teams understand exactly where we are coming om in terms of balancing product quality and enhancing operational productivity.” DW

Fortress Technology fortresstechnology.com

DESIGN WORLD

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Design Notes

How to upgrade your HMI for semi-outdoor environments Edited by Mike Santora • Associate Editor

When a non-temperaturecontrolled recycling facility had issues with a 5-yr-old existing display panel, its team had to look for a replacement. A semi-outdoor location, the recycling facility regularly faced temperatures below eezing, and visibility was challenging with all the natural light. The cold temperatures

A semi-outdoor location, the recycling facility regularly faced temperatures below freezing, and visibility was challenging with all the natural light.

Automation integrator Robert Springer suggested to facility management that they try the Pro-face Extreme.

created a sluggish response om the display. Additionally, the nontempered glass of the existing display scratched easily. Automation integrator Robert Springer suggested to facility management that they try the Pro-face Extreme. The specs were better than some other options, and he could replace and develop the new screen at the same cost as a direct replacement of their existing system.

Management took the opportunity, and Springer replaced the screen and redeveloped the HMI. “We went om a PanelView Plus 6 to a 12.1in. Pro-face Extreme HMI with the screen’s redevelopment, reducing the screens om 6 to 3-in. due to the additional real estate for the same cost.

Also, because the size was larger, it allowed for easy upgrades, as it is easier to make a hole bigger than smaller. We also gained better temperature specs and visibility specs (-30 to 70°C ) as opposed to 0-55 °C,” said Springer.

He notes that other stainless screens are now available on the market, but the cost can be prohibitive. Pro-face was the economical solution because the total cost included Display, Box Module, and Programming with a bonus of increased specs including vibration specs, UV resistance, and a screen resolution slightly higher than a 720p TV.

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DESIGN WORLD

4/29/21 10:50 AM

ISO 9001 • ISO 13485

EAGLE STAINLESS Tube & Fabrication, Inc. This was also an interesting application as the new equipment was talking to an Allen Bradley micro1500, over Ethernet, through an Ewon gateway, to DF1. There were many technologies employed in this application.

Spriger’s specific issue when converting DF1 to EIP was that the packets were not the same. Most converters like Moxa Gateways convert om DF1 to an Ethernet encapsulated packet. EIP is slightly different in that there is a handshake somewhere in there — Springer could not simply encapsulate the DF1 RS232 packet with an Ethernet header and send it down the line, that is PPP. Anyone that tries that with the Moxa unit notices that an interesting issue arises. When logging in through RSLinx and RS500 to the Micrologix, it will talk every time. But if you do not connect with RS500 (Over Ethernet in RSLinx), then the screen will not talk.

“Protocol converters can be a real pain, and they are expensive. This would have been a great application for Pro-face Connect, but it had not launched yet. Either way, this older Ewon 141 did the conversion well, and the screen allowed it to talk right through,” said Springer.

The real challenge for Springer was that he did know the previous system. He had… a user manual. Spinger had to figure out the comm configurations and the addresses. Integrators that

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Design Notes have dealt with micrologix all know that the tags are not stored in the PLC. Therefore, there was the standard challenge of backtracking tags om the IO drawing applied. Device communication was further complicated because the Allen Bradley Screen had already failed, and the development file was locked. Locked is not encrypted; it is a lack of information, so it cannot be rebuilt.

Springer started the integration by breaking into the ewon to decipher the settings. He then connected with RS500. Then he tried the screen. It worked the first time, but the screen was flickering. He found that when the PLC Comm settings were set, it defaulted the text table selection address to another address that was rolling; the screen was changing languages every scan of the PLC. Somewhere in that development, the language became compromised and made the screen go malfunction. Initially, this made Springer think he had a significant comm issue. But a er a quick call to Pro-face, the tech support team resolved the issue.

Springer also said he regularly updates Proface screens remotely.

“It really is easy. You have to manually address the screen since the way the VPN is set up, it usually won’t auto-scan them. This one is no different, the connection was weak on the site, so I had to use PASV on the settings, which is a more passive setup that works better on slow connections. This one has been updated remotely as well.” DW

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

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CAE Solutions

Easily upload, share and manage projects in the cloud

The digital transformation of engineering continues to advance. As part of its cloud services, EPLAN is presenting a service for cross-project collaboration – EPLAN eManage – which lets users upload EPLAN Platform projects into the cloud environment to share and work on them there. Uploads go into the secure ePulse cloud environment. The ee version was launched mid-March – and an expanded, paid version will follow in August 2021.

The EPLAN Platform systems in connection with this cloud service will network control cabinet manufacturers and panel builders, OEMs and system integrators as well as machine and plant system operators. They all work together on a central project that can be synchronized on the EPLAN Platform via eManage in roundtrip engineering. Clear access rights and role assignments ensure data security and provide flexibility for project access.

Users only need one click to publish their project data directly in EPLAN eView. This allows defined users the opportunity to look and comment on entire projects. It further enables cross-company review processes to be

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digitally implemented. eManage supports project participants in quickly searching for specific content.

EPLAN Projects are synchronized for all project participants and stakeholders. Changes in the project are visible to all participants and the project documentation is always current – across the entire project life cycle and even into operations and service scenarios. DW

EPLAN www.EPLAN-so ware.com/emanage

DESIGN WORLD

4/29/21 10:58 AM

NEW GENERATION

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High Flow, Low Power, Low Leakage Across an Extensive Cycle Life The Lee Company is excited to announce a new generation of versatile and innovative 3-port solenoid valves. In a miniature 10mm package, the genvi® solenoid valve platform features high flow capacity, low leakage and ultra-low power consumption. Designed using innovative manufacturing techniques, this new valve offers not only unmatched reliability, but also an economical price point suitable for molecular diagnostics, respiratory therapy, compression therapy, environmental analyzers, breath analysis and other applications where performance and reliability are paramount.

When designing portable or stationary instruments, OEMs are often challenged with meeting aggressive size, power, and weight limitations, all without sacrificing the remaining elements of system-level performance.

Each subcomponent is therefore pushed to offer improved performance within a smaller footprint.

Featuring high flow and low power consumption, genvi solenoid valves are the solution. An extremely tight leakage rating reduces compressor demand and further underscores the valve’s ability to provide consistent long-term operation across an extensive cycle life.

Custom valve solutions, supported by The Lee Company’s engineering experience in microfluidics, are also available to meet specific application requirements.

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CAE Solutions

NVIDIA launches Omniverse Design Collaboration and Simulation Platform

NVIDIA announced the coming general availability of NVIDIA Omniverse Enterprise, a technology platform that enables global 3D design teams working across multiple so ware suites to collaborate in real time in a shared virtual space.

NVIDIA Omniverse Enterprise makes it possible for 3D production teams, which are o en geographically dispersed, to work seamlessly together on complex projects. Rather than requiring in-person meetings or exchanging and iterating on massive files, designers, artists and reviewers can work simultaneously in a virtual world om anywhere, on any device.

NVIDIA Omniverse Enterprise has been in early evaluations with design teams at companies like BMW Group, Foster + Partners, and WPP. It follows the launch three months ago of an open beta for individuals.

Said Jensen Huang, founder and CEO of NVIDIA, “Building on NVIDIA’s entire body of work, Omniverse lets us create and simulate shared virtual 3D worlds that obey the laws of physics.

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DESIGN WORLD

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The immediate applications of Omniverse include connecting design teams for remote collaboration to simulating digital twins of factories and robots.”

Omniverse Enterprise includes the NVIDIA Omniverse Nucleus server, which manages the database shared among clients, and NVIDIA Omniverse Connectors, which are plug-ins to industry-leading design applications. It also includes two end-user applications: NVIDIA Omniverse Create , which accelerates scene composition and allows users in real time to interactively assemble, light, simulate, and render scenes, and NVIDIA Omniverse View, which powers seamless collaborative design and visualization of architectural and engineering projects with photorealistic rendering. NVIDIA RTX Virtual Workstation (vWS) so ware, also part of the platform, gives collaborators the eedom to run their graphics- intensive 3D applications om anywhere.

Omniverse Enterprise is tested and optimized for professionals to run on NVIDIA RTX laptops and desktops, and NVIDIA-Certified Systems on the NVIDIA EGX platform. This makes it possible to deploy the tool across organizations of any scale, om small workgroups using local desktops and laptops, to globally distributed teams accessing the data center using various devices.

NVIDIA Omniverse Enterprise so ware is available on a subscription basis and includes NVIDIA’s Enterprise support services.

NVIDIA’s partner network of leading computer makers -- including ASUS, BOXX Technologies, Cisco, Dell Technologies, HP, Lenovo and Supermicro -- are supporting NVIDIA Omniverse Enterprise. DW

NVIDIA www.nvidia.com

DESIGN WORLD

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Internet of Things

Digital twins are key to virtual production environments Keith Higgins • VP of Digital Transformation • Rockwell Automation

To help identi design issues earlier in the machine build cycle, machine designers look to virtually commission new production lines using digital twin technology. This technology can simulate nearly every aspect of machine operation without needing access to a single piece of physical equipment. It allows customers to optimize their manufacturing design in a virtual environment prior to investing in the physical world.

Although the virtual commissioning concept has been around for a few years – many organizations are still figuring out how to get the most out of their virtual production processes. For example, understanding how and why to connect the digital twin to the real operational logic of its control system.

What is virtual commissioning?

As consumers demand new products and more variety, companies race against the clock to stay ahead and deliver. One tried and true solution is to find new motors, hydraulics and other components that can withstand more demanding requirements to improve machine performance, which are integrated into existing machines with minimal disruption.

However, controls testing on a new or updated machine occurs at the very end of the project when the start-up deadline is approaching. A variety of issues can still occur at this stage, for example a functionality problem such as an unexpected stoppage or a misplaced sensor, or a last-minute customer concern, like the HMI’s sequence or layout. Industrial companies report that fixing a machine issue during commissioning can be 100x more costly than fixing it in the design phase.

These are the reasons behind the move to virtual commissioning, a process that uses a digital model and simulation of a machine to perform controls testing before the machine is built. The goal is to identi design issues as early in the build cycle as possible.

Once tests on a virtual machine are completed, it o en takes less than two days of machine downtime to implement optimizations to existing machine operation.

Virtual commissioning enables the creation of a virtual environment that uses real operational logic and connects to a control system. Designers and engineers can test, debug, and veri performance before customers bolt the machine into the floor of their plant.

Virtual commissioning is enabled by so ware that creates a digital twin of a machine design. An effective digital twin is not just a 3D visual model. Physics can be applied to test operation and interactions with people or other machines. An interactive digital twin of both the machine design and the real operational logic of the control system can veri and demonstrate the operation of the machine

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and the controller before it goes into production.

Creating a digital twin of a machine using simulation so ware involves three primary steps: first, bring in the machine’s CAD. Then, mockup the machine’s movements and devices like sensors on the CAD. Finally, connect the CAD to the controller and its tags. And with that, designers have an open sandbox where they can test a machine and its logic digitally. This helps organizations take control testing off the critical path and avoid making changes at the 11th hour.

How to optimize virtual environments The value of digital engineering doesn’t stop a er machines are commissioned.

There are many different use cases where these virtual environments can improve how workers do their jobs and make decisions. Once production starts, digital twins can mimic processes, machines and controls to help plant personnel learn about operations and experiment with changes. Operators can make mistakes without consequence. And, they can be trained in normal scenarios as well as exceptional ones.

They can also be required to demonstrate procedures, awareness and effectiveness before they start working in a real production environment.

Virtual training also reduces costs, since trainees do not have to travel to a training location or rely on equipment being available. Instead, they can access everything digitally.

DESIGN WORLD

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A digital twin can change how organizations see, run and manage production. For example, manufacturers can use real-time 3D simulations to do a trial run on how to run products, machines and facilities at maximum throughput. Running a digital twin in parallel with a real machine also helps organizations identi issues as the machine’s performance dri s om the model.

Additionally, technicians can use a digital twin to reduce downtime or even get ahead of it. Technicians can use a digital twin of a machine within an augmented reality (AR) environment to troubleshoot issues before shutting it down. They can use the AR technology to digitally overlay work instructions on the physical machine to expedite repair.

Creating predictive models with a digital twin also helps technicians get ahead of failures. Then, the required maintenance can be scheduled during a planned shutdown.

Gartner estimates that businesses will save US$1 trillion each year in asset maintenance by using IoT through digital twins. What’s more, 30% of Global 2000 companies will be using data om digital twins of IoT connected products and assets to improve product innovation success rates and organizational productivity, achieving gains of up to 25%.

In junction with digital twins, a digital thread is a strategic amework that aims to optimize the product, asset, system, or process lifecycle by interconnecting critical functions across an organization.

This includes the digital trail of data created by a digital twin across an asset’s lifecycle. Connecting ERP, EMS, MES, and MOM systems via a digital thread allows information to flow between systems to inform and optimize businessdriving processes om design, to supply chain, to production. A digital thread-

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Creating a digital twin of a machine using simulation software involves three primary steps: first, bring in the machine’s CAD. Then, mockup the machine’s movements and devices like sensors on the CAD. Finally, connect the CAD to the controller and its tags. powered strategy provides the entire value chain with access to unified digital data captured during design, virtual simulation, and physical operations.

By harnessing the digital thread, organizations can enable coherent data flow throughout the organization, om design to maintenance, which leads to improvements and benefits throughout the entire operation. DW

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F O K C SI

?

S G N I R P S L I O C

Internet of Things

Continued growth forecast for industrial networks despite pandemic Every year, HMS Networks carries out a study of the industrial network market to analyze the distribution of new connected nodes in factory automation. This year’s study shows that, despite the COVID pandemic, the industrial network market

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is expected to grow by 6% in 2021.

Industrial Ethernet is growing steadily. Growing by 8%, Industrial Ethernet continues to take market share. Industrial Ethernet now makes up for 65% of the global market of new installed nodes in Factory Automation (compared to 64% last year). EtherNet/IP and PROFINET are fighting for first place, but this year PROFINET passes EtherNet/IP at the top of the network rankings with 18% market share compared to 17%. EtherCAT continues to perform well globally and now matches the leading fieldbus PROFIBUS at 8% market share. Modbus TCP is next at 5% market share and together with fieldbus brother Modbus RTU, these Modbus technologies now account for 10% of the market, confirming their continued importance in factory installations globally.

Fieldbus decline halted. The ongoing fieldbus decline reported

by HMS in recent years is almost halted with a fieldbus decrease of only -1% in 2021, as factories tend to stick to existing technologies to a higher degree in uncertain times, such as during the pandemic. Fieldbuses are now at 28% market share of the total amount of new installed nodes (30% last year). PROFIBUS is still the clear fieldbus leader at 8% followed by Modbus-RTU at 5% share and CC-Link at 4%.

Wireless is here to stay. Wireless continues to grow rapidly at a rate of 24%. Wireless now has 7% market share but the market still awaits the full impact of 5G in factories. With ongoing global activities about wireless cellular technologies as enablers for next level smart manufacturing, HMS expects that market demand will increase for wirelessly connected devices and machines to be included in the less cabled and flexible automation architectures of the future.

Smart and sustainable manufacturing requires networking.

“Industrial network connectivity for devices and machines is key to obtain smart and sustainable manufacturing, and this is the

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Industrial Ethernet is growing steadily. Growing by 8%, Industrial Ethernet continues to take market share. Industrial Ethernet now makes up for 65% of the global market of new installed nodes in Factory Automation (compared to 64% last year).

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main driver for the growth we see in the industrial networking market,” says Anders Hansson, Chief Marketing Officer at HMS Networks. “Factories are constantly working to optimize productivity, sustainability, quality, flexibility and security. Solid industrial networking is key to achieving these objectives.”

Regional network variations. EtherNet/IP and PROFINET are leading in Europe and the Middle East with PROFIBUS and EtherCAT as runners up. Other popular networks are Modbus (RTU/ TCP) and Ethernet POWERLINK. The U.S. market is dominated by EtherNet/IP with EtherCAT gaining some market share. PROFINET and EtherNet/ IP lead a agmented Asian market, followed by strong contenders CC-Link/CC-Link IE Field, PROFIBUS, EtherCAT and Modbus (RTU/TCP). DW

HMS Networks www.anybus.com

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Internet of Things

ODVA enhances EtherNet/IP To address issues of cost, size, and power that have been a hindrance to EtherNet/IP pushing out to the edge of the network, ODVA announced that CIP Security, the cybersecurity network extension for EtherNet/IP, has added support for resource-constrained EtherNet/IP devices. CIP Security will provide device authentication, a broad trust domain, device identity via PreShared Keys (PSKs), device integrity, and data confidentiality for resourceconstrained devices such as contactors and push-buttons. Additionally, a narrow trust domain, user authentication, and policy enforcement via a gateway or a proxy are available options.

The new CIP Security specification adds a Resource-Constrained CIP Security Profile in addition to the EtherNet/IP Confidentiality and the CIPTM User Authentication Profiles.

The Resource-Constrained CIP Security

Profile is similar to the EtherNet/IP Confidentiality Profile, but is streamlined for resource-constrained devices. The same basic security aspects of endpoint authentication, data confidentiality, and data authenticity remain. Access policy information is also included to allow a more capable device, such as a gateway, to be used as a proxy for user authentication and authorization of the resource constrained device.

Implementation of CIP Security for resource-constrained devices requires only DTLS (Datagram Transport Layer Security) support instead of DTLS and TLS (Transport Layer Security), as it is used only with low-overhead UDP communication.

The protections offered by CIP Security are now available for EtherNet/ IP networks via a resource-constrained version of CIP Security that includes fewer mandatory features.

ODVA also announced that The EtherNet/IP Specification has been enhanced to allow vendors to bring the network to resource-constrained devices in-cabinet, including push buttons and contactors. The continued decrease in the cost of semiconductor chips has enabled increased connectivity of simple devices, as evidenced by the rapid expansion of the Industrial Internet of Things (IIoT). The sustained, strong growth of EtherNet/IP combined with accelerating IT/OT convergence has made it possible to deploy EtherNet/IP within cabinets on lower-level automation devices such as contactors and push buttons.

The inclusion of resource-constrained devices within cabinets on an EtherNet/IP network is enabled by recently published enhancements to The EtherNet/IP Specification including the physical layer In-Cabinet Profile for EtherNet/IP along

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with low overhead UDP-only resourceconstrained EtherNet/IP communication.

Resource requirements have been reduced via enhancements such as an IT friendly LLDP node topology discovery mechanism, auto-commissioning support, and auto-device replacement support. Additionally, a specification for a new select line circuit facilitates the efficient delivery of system wide sequential commands.

The EtherNet/IP in-cabinet bus solution reduces interface components through use of single pair Ethernet (IEEE Std 802.3cg-2019 10BASE-T1S) and reduces node cost via multidrop cabling that spans a single cabinet with one interface per device and one switch port that supports many devices. Cost is further reduced via cables that use

composite network and control power to eliminate separate parallel runs.

The select line for topology eliminates configuration switches by enabling discovery based on relative position and allows for direct connection with programming tools during assembly for parameterization. Assembly time is lowered by eliminating most wire or cable preparation with insulation displacement (piercing) connectors.

Nodes will also be able to be replaced with compatible nodes of the same type during normal system operation without any engineering tools in a plug and play manner.

Lastly, ODVA announced the April 2021 publication of the DeviceNet and ControlNet Specifications, which have replaced the usage of the words “master”

and “slave” within ODVA references.

Developers of devices for ODVA networks will now use the words “client and server” (EtherNet/IP, including the integration of Modbus devices), “controller and device” (DeviceNet), and “system time supervisor or active keeper” (ControlNet) to describe these functions. DW

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ODVA | www.odva.org

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Connector Notes

Field-ready connectors withstand military and defense environments

Fischer Ultimate 80

Fischer Ultimate Series in size 15

Fischer Connectors has extended its series of ultra-rugged and harsh-environment connectors with two new products: the Fischer UltiMate 80, a field-ready NATO STANAG 4695-compatible connector offering unparalleled functionality and ruggedness in comparison with similar harsh-environment quick-release connectors; and the standard Fischer UltiMate connector now available in size 15 with various pin layouts of up to 27 signal and power contacts.

Intermateable with other NATO STANAG 4695 connectors, the UltiMate 80 connector comes in two layouts featuring 6 or 7 signal and power contacts (size 08) with up to AWG 22. Engineered in Switzerland, it offers an ultra-rugged, lightweight and IP68-sealed connectivity solution for any harsh environment, especially for defense and security applications and soldier modernization programs. It is compliant with MIL-STD-810 and MIL-STD-202, providing environmental and mechanical performance and endurance that outperform by far other suppliers’ similar connectors: • Ruggedness: high resistance to corrosion (500h salt mist), up to 10,000 mating cycles for the plug / 5,000 for the receptacle, random vibration 7.7 Grms, shock resistant (100 G), cable bending resistance (±90° for 5000 cycles), temperature (-55 ° to 135 °C), triple key coding • Light weight: housing material in aluminum: 2,7 g • Environmental sealing: connector Ingress Protection mated and unmated: IP68 sealing 2m/24h.

It comes as a pre-cabled plug, and a pre-cabled and/or panel receptacle.

As for the new Fischer UltiMate connector in size 15, it meets special power and high-speed datarequirements for further design and technology developments with various contact layouts (2, 4, 8, 4+12 or 27 signal and power contacts).

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All Fischer UltiMate series connectors are designed for field operations in extreme environments. Environmentally sealed to resist extreme shocks and vibrations, these durable and reliable connectors interconnect devices, equipment, hubs and embedded electronic systems where weight matters, for example in defense security, industrial, instrumentation, marine and underwater, as well as robotics and unmanned vehicles.

Their resin-sealed contact block offers extreme sealing (up to IP68 / IP69 even unmated, gastight, CBRN decontamination), high shock and vibration resistance, as well as superior cable resistance in terms of traction. DW

Fischer Connectors US fischerconnectors.com

DESIGN WORLD

4/29/21 12:45 PM

A D V E R T O R I A L

Taking PCB Connector Technology to the

next level

How WAGO continues to set new standards

Often, it’s the small components that make a big difference and this is particularly true for electronic devices. Take PCB connectors, for example, which connect wires to a printed circuit board. These are simple components but their reliability is critical.

“The importance of this connection is too often glossed over. If that connection goes awry, the entire device is rendered non-functional,” shares Cory Thiel, Product Manager – PCB Interconnect with WAGO Corporation. “A reliable connection is fundamental to a trustworthy application. Fortunately, WAGO has always been about trouble-free connections.”

WAGO pioneered spring-pressure connection technology back in 1951 — known today as CAGE CLAMP® technology. In fact, WAGO introduced the world’s first PUSH WIRE® connector for junction boxes in 1968, allowing for simple yet secure connections.

Lever actuation continues that innovation.

“At that time, our founders had sought to provide a better method for connecting wires — one without screws or crimps, or any unnecessary extras. The CAGE CLAMP® spring-pressure connection technology became the universal connection system that’s still leading the industry today,” says Thiel.

“As it relates to field-wired connections, it boils down to installer convenience and reliability,” he explains. “The challenge for the device design engineer has been to incorporate a field connection that delivers both. Often, their default bias is toward the familiar.

And, historically, that’s the ubiquitous screw terminal…because everyone knows, or at least believes they know, what to do with a screwdriver.”

The problem here is twofold. Every screw terminal has a torque value that ensures its reliability, but no one can predict the skill level of the technician in the field.

“At the point of wiring, how many in the field routinely use a torque screwdriver? Likely, not many,” Thiel points out. “So, we could argue that few connections are done correctly in the field when using screw terminals.”

Imagine, however, if field connections could be made reliably without the use of any tools and regardless of operator skill. That’s what WAGO’s latest family of PCB Terminal Blocks and Connectors for Power Electronics brings to the table: fail-proof lever operation.

“The lever means it offers a 100% tool-free ability to install wires correctly every time, regardless of a technician’s skill level in the field,” he says. “Once again, WAGO continues to offer trouble-free connections to the PCB, whether that’s in the form of a terminal block or a pluggable connector.”

DESIGN WORLD

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PCB Terminal Blocks & Pluggable Connectors for Power Electronics www.wago.us/powerelectronics

Features include: • A completely tool-free and intuitive lever operation • Flexible wiring angles to a PCB (0°, 90°, or 180°) • Maximized current and voltage ratings (up to 85 A/1000 V) with minimum space consumption • Full protection against mismating, with coding and locking options available “As an added capability, the terminal blocks can be provided with individually color-coded poles for another layer of errorproofing due to their modular design. This same modularity allows for the addition of spacers where necessary for even higher voltage ratings,” says Thiel.

“The goal has never changed,” he adds. “WAGO continues to set the standard by providing secure, trouble-free, and toolfree connection technology. And now that’s offered with even greater power capabilities and for smaller spaces.”

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A Supplement to Design World - May 2021 www.therobotreport.com

Evolution of Boston Dynamics’ box-moving robots page 54

INSIDE: • WTWH Media acquires Mobile Robot Guide .......................................................53 • Designing an omnidirectional mobile manipulator with 7 DoF ...................................62 • 5 critical sensor integration challenges for AMRs ............................................................68

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The Robot Report

WTWH Media

acquires Mobile Robot Guide Acquisition of industry-leading mobile robotics website strengthens WTWH Media’s robotics brand and serves as a catalyst for future growth.

The Robot Report Staff

Business-to-business publisher WTWH Media, parent company of Design World and The Robot Report, acquired Mobile Robot Guide (MRG), the leading online resource for news and information about mobile robots, the applications they enable, and industries they support. Mobile Robot Guide will become incorporated into WTWH Media’s existing network of robotics websites, magazines, newsletters, events, and research.

Mike Oitzman, founder of Mobile Robot Guide, will continue as editor of MRG, as well as assist in the development and execution of new robotics media initiatives and lines of business. See mobilerobotguide.com for more information.

According to Dan Kara, Vice President, Robotics at WTWH Media, “We are delighted to announce the acquisition of Mobile Robot Guide, and to have someone as high caliber as Mike Oitzman join the WTWH robotics and intelligent systems team. Mike is highly regarded as a leading robotics industry expert and an authority on mobile robots, and the Mobile Robot Guide website he created is recognized as the world’s foremost resource for mobile robotics news and information. I look forward to working with Mike to build and expand WTWH Media’s robotics media offerings, and in doing so, supporting both users and suppliers of robotics and intelligent systems products and services, as well as the robotics sector as a whole.”

Scott McCafferty, Co-founder & Managing Director of WTWH Media, notes, “The addition of Mike Oitzman to WTWH Media’s Robotics Group, coupled with the acquisition of Mobile Robot Guide, will further strengthen WTWH Media’s robotics portfolio, allowing us to better serve the entire robotics value chain of end-users, engineers and OEMs, researchers, investors and more. Mike launched Mobile Robot Guide, and as such he is perfectly positioned to integrate this high value asset into

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WTWH Media’s existing robotics and intelligent systems business lines.”

Mike Oitzman remarked on the acquisition, “I am excited to see Mobile Robot Guide evolve and grow with the resources and reach of WTWH Media.

Dan Kara and Steve Crowe are well respected within the robotics community and I look forward to joining the editorial team for the Robotics Group, and I am also anxious to help WTWH deliver world class events again in the coming years.”

WTWH Media’s robotics network now includes The Robot Report, Collaborative Robotics Trends, Mobile Robot Guide and Robotics Business Review, online technical, business and investment news and information portals focused on robotics and intelligent systems. WTWH Media also produces leading robotics conferences including the Robotics Summit & Expo, RoboBusiness Conference & Exposition and the Healthcare Robotics Engineering Forum. RR May 2021

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The Robot Report

Evolution The company’s newest robot, Stretch, is a mobile manipulator designed to move boxes out of trucks and build pallets inside warehouses.

Steve Crowe Editorial Director The Robot Report

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of Boston Dynamics’ box-moving robots Using robots to unload eight on receiving docks isn’t a novel idea. A quick YouTube search will return a slew of results. But many of these previous approaches have been stifled by high costs and the inability to handle a growing variety of packages.

Of course, robotics companies are still working on the problem, which is one of the major issues for warehouse operators. Dextrous Robotics, a Memphis-based robotics startup, is developing its Chopstick system it hopes can unload eight with more success and at a action of the cost of previous solutions. Co-founder Evan Drumwright discussed the approach in the RoboBusiness Direct session “Advances in Robotic Picking, Grasping and Manipulation.” www.therobotreport.com

THE ROBOT REPORT

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Truck unloading is one application Stretch is targeting. Stretch can lift up to 50 lb, pick 800 cases per hour, and reach boxes up to 10 feet high. | Boston Dynamics

Next-gen Handle Stretch is the next generation of Handle, a robot Boston Dynamics introduced in 2017 that combined wheels

and legs. Stretch doesn’t have legs, but it does have an omnidirection mobile base with four independently controlled wheels, a custom 7-DoF industrial robot arm that can li up to 50 pounds, a custom suction gripper and much more. The air system for the gripper is onboard the mobile base. Stretch comes with an 8-hour battery life, but there will be a 16-hour battery option and the ability to plug Stretch in for continuous power.

Stretch uses the Pick vision system, which Boston Dynamics acquired when it bought Kinema Systems in April 2019. Pick uses high-resolution 2D and 3D vision and machine learning algorithms for robotic depalletizing. Kevin Blankespoor, Boston Dynamics’ VP of product engineering, said Stretch can pick up

THE ROBOT REPORT

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Now Boston Dynamics is throwing its innovative hat into the ring. It revealed its newest robot, Stretch, a mobile manipulator designed to move boxes out of trucks and around warehouses. When it goes on sale in 2022, for a yet to be named price, Stretch will initially focus on truck unloading and later add palletizing to its repertoire.

Stretch is currently being tested by a few partners. Boston Dynamics is seeking customers to pilot Stretch with truck unloading tasks.

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Building pallets will be a future application for Stretch. Boston Dynamics envisions more autonomy in that task, saying Stretch will be navigating the aisles of the warehouse by itself. | Boston Dynamics

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to 800 cases per hour. Its arm has a sevenfoot reach and can reach boxes up to 10 feet high. Stretch weighs 2,650 lbs.

Stretch is semi-autonomous, Blankespoor said, and the level of autonomy depends on the application. When it comes to unloading a truck, for example, a person still needs to open the truck door, verify the content and move the Stretch robot into position by driving it inside the truck with a joystick. “At that point you hit ‘Go’ and Stretch will fully autonomously do the rest of the job unloading the boxes,” Blankespoor said.

Building pallets will be the second application for Stretch, and Blankespoor envisions more autonomy in that task. “Stretch will be navigating the aisles of the warehouse.

It’ll be going to different pallets that are singleSKU pallets and grabbing a few boxes building up an outgoing pallet. For that task, Stretch will take on more of the kind of localization and navigation you see in some other AMRs [autonomous mobile robots] that navigate through the warehouse and have more autonomy.”

Blankespoor said collaborative robot arms lack the speed and strength to lift the number of heavy cases per hour that Boston Dynamics targeted. So it built a custom industrial robot arm. For safety, Stretch uses speed and separation monitoring. “As people get closer to the robot, it will slow down,” he said. “If they get closer still, it will stop. And that way we can allow the arm to move heavy boxes fast without risk of hurting anyone.”

www.therobotreport.com

Handling variety the key As you might notice in videos of Stretch, all the boxes inside the truck and on the pallet look identical and are perfectly stacked. Most, if not all, trucks that need to be unloaded in the real world won’t look like that. So Stretch’s success, like other attempted solutions before it, could be determined by its ability to handle a variety of packages.

“That’s an astute observation,” said Blankespoor. “It’s pretty easy to detect a box sitting by itself. But detecting a box when they’re packed tightly together or when there’s a big variety, is a much harder task. But that’s where our Pick box detection software comes in. And that’s one of the things you’ll see next with Stretch. We’re starting off with more straightforward trucks, but we’re going to get into more complex types of boxes, different types of boxes over the coming year.”

FedEx’s Aaron Prather discussed during his recent RoboBusiness Direct keynote that the biggest challenge in solving the truck offload issue is the high level of package diversity a solution would need to be able to handle. Prather started his FedEx career offloading trucks while still in college.

“When unloading a bulk loaded truck, you may start with boxes of a certain size, then you hit a layer of bigger or smaller boxes, then a layer of rugs (because people buy rugs online now), and then back to the same size boxes you started with. This is why it is so hard to automate this process.”

Stretch robot just the beginning?

Boston Dynamics in 2020 acquired a boatload of warehouse automation patents from X Development, LLC, an R&D organization founded by Google.

Boston Dynamics was owned by Google from 2013-2017. Certainly some of the IP helped with Stretch, but it likely points to a broader interest in the logistics automation space.

Industrial Perception, a company acquired by Google in 2013, partnered with Wynright on truck unloading research.

“Well, we’ve definitely had interest in the warehouse space since Atlas. That’s when we figured out what a big market

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Stretch lifts Boston Dynamics popular Spot quadruped. | Boston Dynamics

Stretch features an omni-directional mobile base, four independently controlled wheels, a custom 7-DoF industrial robot arm, a custom suction gripper and a proprietary vision system. | Boston Dynamics

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The Robot Report this is, and how much potential there is for mobile robots in the warehouse space.

I don’t want to say too much about the patents, but we have a warehouse robotics team that is growing rapidly, which I’m heading up. And that includes development of the Stretch robot, we have our Pick vision system, we have a fleet management software system that can pull together different robots into doing coordinated activities. So it really just fits into the kind of broader picture that Boston Dynamics is going hard into the warehouse space.”

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Learning from Spot Boston Dynamics introduced in February 2021 Spot Arm, a robotic arm for the Spot quadruped that offers a max lift capacity of 24.3 lbs. While Spot Arm looks vastly different from Stretch’s industrial robot arm, Blankespoor said the core technological building blocks are the same.

“If you look at the wrist joint of Stretch, it’s actually the same as the hip joint on Spot. So it uses the same electric motors and the same gearboxes, same sensing even the same software,” he said. “We use the same cameras and depth sensors across our different platforms. More importantly, we use the same software underneath to actually understand what those sensors are seeing – everything from box detection to obstacle detection. So even though it looks really different from Atlas or Spot, Stretch is built from most of the same technologies.

And that enabled us to get a prototype built really fast.”

Atlas remains an R&D platform, while Boston Dynamics has sold more than 400 Spot robots since the quadruped first went on sale last year. Boston Dynamics won a 2020 RBR50 Innovation Award for Spot as it jump-started the commercial quadruped market.

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Fleet management, WMS integration Boston Dynamics and OTTO Motors released a video in March 2020 that demoed their vision of the future of logistics automation.

In the video, Boston Dynamics’ Handle robot picked boxes and built pallets on top of the OTTO 1500 heavy-duty AMR. Blankespoor said the two companies continue to collaborate, and it’s played an important role in the development of a fleet manager for Stretch.

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The Robot Report “Part of the important piece of that demo with OTTO Motors was to get heterogeneous robots working together.

There’s a lot of AMR companies that control their own robots, and they might have a fleet manager to do that. But there’s not a whole lot of fleet managers that can control a variety of different types of robots, coordinated to do different tasks. One of the reasons we’re working with OTTO is to coordinate the pallet movement and the case movement with different robots.”

Blankespoor also said integration with warehouse management systems is on Boston Dynamics’ roadmap. But he said it’s more crucial later on when Boston Dynamics starts to tackle order building.

“Truck unloading is nice because it’s a little more isolated in terms of the integration tasks. Once the robot is in front of the truck and you say ‘Go,’ our box detection system will tell Stretch where all the boxes are, what size they are, we actually even weigh the boxes as we’re first lifting them up, so we can move them as quickly as possible. This means we don’t necessarily have to do as much integration work.”

“The second task that we’re going to bite off is order building. And for that you do need warehouse management system integration, but it should be akin to what you do with people, right?

Here’s an order, go build me a pallet with five of this box and four of this box, and stack it all up. We’ll need to convey that information to our robots so they can go do those tasks.”

Evolution of a box-moving robot You might think a logistics robot is out of left field for Boston Dynamics, but it’s shown interest in the space for a while. In 2016, one of its first videos of the next-gen Atlas robot showed the humanoid bend down, pick up a box, and place it onto a cart. Then in 2017, Boston Dynamics introduced Handle, a hybrid robot that combined wheels and legs.

Stretch is the next generation of Handle.

“We got a lot of interest [for Atlas] from warehouses,” Blankespoor said. “We knew we could design a simpler robot, and that’s where Handle really came from. Handle was an offshoot of Atlas.

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“We branched off and designed Handle for a couple of reasons. One was that we wanted to do something more purpose-built for the warehouse.

And another reason was that we always wanted to combine wheels and legs.

Handle was an opportunity to explore both of those things. So we built a couple versions of Handle and started doing warehouse tasks.”

“First we were doing pallet building, and that was working pretty well. Then we started doing truck unloading with Handle. And at that point, it was an eye-opening experience – Handle could do the job. It could grasp the boxes and move them, but it took too long.

And to make a cost-efficient robot for customers, you need to move cases pretty fast. Stretch can move cases about five times faster than Handle, so that’s one of the reasons we made the next jump.”

Hyundai an early customer?

Hyundai Motor acquired a majority stake in Boston Dynamics from Softbank in December 2020 for about $880 million.

A Softbank affiliate retained the other 20%. Spot Arm was an important announcement since it effectively turned Spot into a mobile manipulator, not just a data collection platform. But the introduction of Stretch is the biggest announcement from Boston Dynamics since the acquisition. So will Hyundai be an early test customer for Stretch?

“They absolutely could be,” said Blankespoor. “We’re excited to work with Hyundai. Obviously they’re a worldclass manufacturer. Hyundai has its own logistics companies in Korea, and they definitely could be a customer for us in the future.” RR

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The Robot Report

Designing

an omnidirectional mobile manipulator with 7 DoF ROS integration, reduced power consumption, ease of use, and flexibility are key to new mobile manipulator.

Steve Crowe | Editorial Director, The Robot Report

Over the past few years, mobile manipulation has often been mentioned as a robotics trend to watch. Perhaps advances being made in a variety of enabling technologies – sensors, controls, power – are finally making mobile manipulation a reality. There have been at least three mobile manipulators introduced within the past couple of months. Boston Dynamics certainly had the most interesting take with its Stretch robot, while Desmasa launched a more traditional mobile manipulator with its MCR+.

The third on that list is a new collaborative mobile manipulator from Waypoint Robotics and Productive Robotics, a Calif-based developer of cobot arms. The system integrates Productive’s OB7 cobots onto Waypoint’s Vector omnidirectional autonomous mobile robot.

I visited Waypoint to get a sneak peek at the system. The prototype I saw featured a Vector 3DHD and the basic OB7 cobot, but the mobile manipulator can also integrate Productive’s other 7 degree-of-freedom cobot arms – OB7-Stretch, OB7-Max 8, or OB7-Max 12 – depending on the application. The system uses Productive’s standard teach pendant.

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“If you have a machine shop that has a bunch of CNC machines with a relatively high cycle time that don’t need to be tended very often, it’s really hard to justify putting an arm at every station,” said Waypoint Robotics CEO and co-founder Jason Walker. “If you’ve got one device that can serve multiple stations, then that makes sense.”

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The Robot Report Productive Robotics OB7 Cobot Lineup Cobot

Payload (kg)

Horizontal Reach (mm)

Repeatability (mm)

DOF

OB7

5

1000

0.1

7

OB7-Max8

8

1700

0.1

7

OB7-Max12

12

1300

0.1

7

OB7-Stretch

4

1250

0.1

7

A standard product offering Waypoint Robotics, a spinout of Stanley Innovation, has sold mobile manipulators for years. But they’ve been one-off projects. This mobile manipulator will become part of the product portfolio for both Productive and Waypoint.

“There’s a difference between us saying we have a mobile manipulator as a standard product compared to we have an option to have a mobile manipulator,” said Waypoint Robotics CEO and cofounder Jason Walker. “The mobile manipulator [with Productive Robotics] is something we’re integrating a lot more extensively and tightly.”

Walker and Productive Robotics president Zac Bogart first met at ATX West 2019. Both companies will be selling the mobile manipulator. Walker said this will benefit customers and integrators who are accustomed to working in particular environments.

“If they already know the language of the OB7, they can add a coding block to the teach pendant that tells the Vector to drive to a certain location and do whatever it’s supposed to do,” said Walker. “It’s a control paradigm that lives in the OB7. People who are familiar with that ecosystem don’t have to go learn a whole new ecosystem. It can also work the other way around, too, for those who are familiar with Waypoint and the Dispatcher software.”

Workers can use this mobile manipulator for a variety of tasks, including machine tending, quality assurance sampling, material replenishment, and many others.

ROS integration key Walker talked at length about how Productive’s 7-DoF arms and Vector’s omnidirectional capabilities will enable the mobile manipulator to work in tight spaces and make unique movements.

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| Waypoint Robotics

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While demoing the system, Walker set up separate waypoints for Vector in its software and the OB7 by using its onboard buttons and moving it through space. However, Walker said there’s no reason why one button can’t make both waypoints, highlighting another way ROS can help take interoperability to the next level.

Productive’s 7-DoF arms and Vector’s omnidirectional capabilities will enable the mobile manipulator to work in tight spaces and make unique movements. | Waypoint Robotics

But there are plenty of other 7-DoF cobot arms. So why did Walker choose to partner with Productive?

“We’ve integrated a bunch of different arms, but the OB7 is energy efficient, it’s ROS-native, it’s made in the USA. [Productive] is a scrappy startup about the same age as us,” said Walker. “And it’s a company capable of understanding the opportunity and the unique benefits of mobile manipulation.”

The mobile manipulator doesn’t rely heavily on ROS at the moment, but

Walker said it offers a great path forward for even tighter integration.

“We can combine setup tasks for each device into one task. That will lower the effort required for somebody to set it up or reconfigure it or move it around from one location to another to do a different job,” he said. “The system also has two computers – one for the arm and one for the mobile robot. The more we can get the two things merging closer together, we can remove one of the computers to further reduce cost.”

Reducing power consumption Walker said one of the biggest problems with mobile manipulators is power and energy consumption. He said nearly all the mobile manipulators he’s built as one-offs in the past required a spare battery and additional integrated battery kit.

“Since most of the robots we were building were bespoke robots going into R&D Labs, it was tolerable to plug in the mobile robot into one cord and plug in the batteries for the arm into another cord,” he said. “But for a commercial product, that’s never acceptable.”

Walker said Waypoint approached the power problem from a number of angles. One of them is by using Waypoint’s EnZone wireless charging system. The mobile manipulator is capable of supporting two EnZone receivers, meaning double the energy can be delivered. He also said that while OB7 operates at 48 volts, it can be re-tuned to operate at 24 volts – the same as Vector.

Walker said his mobile manipulator can get at least six hours of run time.

Waypoint built this older, one-off mobile manipulator for the Verizon 5G Challenge in 2019. | Steve Crowe

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The Robot Report “We’re committed to, over time, cost reducing this thing,” said Walker, who isn’t ready to share the price tag. “A big part of that is taking out all of the extra power conversion stuff, and doing a version of it that’s natively 24 volts.

Instead of going through converters, we’ll feed battery power straight into the arm.

And that’s going to significantly reduce the cost and size.”

Walker claimed Productive’s cobot arms are also more energy-efficient than the competition. “When we do a UR5 integration, we usually use a 1000 watt inverter. We leave the AC-to-DC converter that’s built into the box and then add an inverter so that you can use either DC power from the robot or AC power from the wall. [In this new mobile manipulator], we’re doing it with a 400 watt inverter. The fact that it can be done with that small amount of power is huge. We’re lucky to get 4 hours out of UR5 mobile manipulator, so it’s just more efficient.”

is moving. For example, if there are a bunch of parts that need to go into a CNC machine, they can be sorted or oriented a specific way while the mobile manipulator is in transit. “This is also where the seventh axis is helpful,” Walker said. “The arm can spin around and operate safely within the footprint of the robot.”

Are customers ready for mobile manipulation?

I’ve seen many mobile manipulators at trade shows that combine a mobile base from Mobile Industrial Robots (MiR) and a cobot arm from Universal Robots. Of course, both companies are owned by Teradyne. I recently asked Greg Smith, president of Teradyne’s industrial automation group, if we’d see an official mobile manipulator from the group in the near future.

“There’s an interesting economic challenge around arms on mobile bases.

When people look at doing automation,

“If they already know the language of the OB7, they can add a coding block to the teach pendant that tells the Vector to drive to a certain location and do whatever it’s supposed to do,” said Walker.

manipulation and shared a story about one of the first companies interested in this new mobile manipulator.

“If you have a machine shop that has a bunch of CNC machines with a relatively high cycle time that don’t need to be tended very often, it’s really hard to justify putting an arm at every station,” he said. “If you’ve got one device that can serve multiple stations, then that makes sense.”

He added, “the things that have held customers back in the past has been how easy it is to set up, how much it costs and what it can do.”

“The reason we’re doing this product now is because we’ve helped solve the cost problem by having an arm and a robot that, over time, can get less and less expensive. We can integrate the systems more, we’ve massively lowered the entry price because we don’t have to have additional batteries.”

“This is an omnidirectional AMR with a 7-DoF arm, so you get something that’s actually better than the other solutions out there. Most of the other solutions are differential drive and a 6-DoF arm. So for me those are the key things – the energy and power, the degrees of freedom, the overall footprint capabilities, ROS integration, and ease of use. If this isn’t easy for everybody to use, then it’s a non-starter. Everything else falls apart.”

RR

Dragging items like Spot Workers can use this mobile manipulator for a variety of tasks, including machine tending, quality assurance sampling, material replenishment, and many others. We recently saw Boston Dynamics’ Spot quadruped grab and drag a concrete block. Walker said they’re currently working on similar functionality.

“An immediate use would be the ability to drag a tote off of something and onto the robot,” he said. “One of our targets are companies that don’t want to revise their environment, or want to as little as possible. If this robot can drive up to a counter and pull a tote off onto it, that’s less work than setting up a conveyor or a pickup and drop off station.”

They’re also working on the ability to perform tasks while the Vector robot

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they look at it from an ROI perspective.

How long is payback going to take? How much utilization does the automation get? If you take a cobot arm and stick it on top of a mobile robot, then you’re in a situation where when you’re using the arm, the base isn’t adding any value. And when you’re using the base, the arm isn’t adding any value.”

“It has to be a much higher value application to justify the spend because you’re only using half the robot at any moment. There’s some challenges in terms of getting the right price point to be able to do that. But we also see some interesting niches where even with today’s technology, It makes a whole ton of sense to do.”

Walker brought up these comments during my visit, saying he disagreed.

He said there’s a thirst for mobile

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5 The Robot Report

critical sensor integration challenges for AMRs

Sensor integration challenges can lengthen product development roadmaps and create unexpected downtime during deployments.

Adam Rodnitzky | COO & Co-Founder, Tangram Vision

Sensing arrays on autonomous mobile robots (AMRs) are robust and redundant by design; beyond their critical role in operational safety, they build the data foundation for differentiating features like machine learning capabilities and high-speed operation.

Yet engineering teams are o en unaware of how difficult it can be to quickly integrate and reliably operate the multi-sensor arrays upon which AMRs rely.

These sensing systems are subject to internal constraints (resource-limited hosts, for instance) and external constraints (hazard-filled operating environments) that present unique engineering challenges that must be addressed for safe, reliable operation.

Here are five of the most critical engineering tasks to solve when integrating multiple modes of sensing on an AMR platform.

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The impact of too much data can be serious for an AMR. While the most likely outcome is excessive latency, the worst outcome is data blackouts.

|Tangram Vision

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The Robot Report

When attaching a sensor to an AMR, pay attention to fastener torque. Over torquing one or more fasteners can twist a sensor’s chassis.

|Tangram Vision

1 2 Time synchronization Let’s start with one of the most important: time synchronization between sensors and the host. Your host has a clock.

Your sensors have clocks. But do they agree? Without intervention, they won’t — and that is a problem. When a sensor sends data with a different timestamp than the host, the host interprets that data according to its own clock, not the sensor’s. The host may then reach the conclusion the sensor is miscalibrated, and send the AMR into a failure mode.

Worse yet, the host may believe it is interpreting the data correctly, and continue to operate with faulty sensor data. That can lead to an unsafe robot, as its actions will be out of sync with what it observes.

To prevent this failure, all sensor clocks need to be time synchronized. This is a process that must be done on a continual basis, as minor differences in clock speeds can add up to big differences over time.

Doing this constant correction requires knowledge of the sensors and host om a hardware perspective to understand how the clock is integrated into the hardware.

Typically, sensor clock correction isn’t addressed in sensor SDKs or documentation. In fact, sensors om most manufacturers rarely consider or even offer solutions to the problem of understanding the clock offsets and how they might interact in a larger system.

A er all, why should a LiDAR provider care about every possible IMU on the market, and try to accommodate a finite but large list of clocks and different methodologies

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for getting timestamps? This is le up to the developer to figure out, whether they know how to or not.

Sensor calibration Most vision sensors used by AMRs leave the factory pre-calibrated. This factory calibration creates a so warereadable model of a set of key physical ccharacteristics haracteristics of the sensor. This iincludes ncludes where the optical elements are a re in three-dimensional physical space in relation to the sensor chassis.

It also includes a lens distortion model to account for manufacturing defects that are an unavoidable part of sensor production.

By using this data, a perception engineer can tune an individual sensor to achieve the greatest precision and accuracy. But these intrinsic calibrations aren’t permanent. Physical impacts to an AMR (very common in busy environments like warehouses) can throw off these precise sensor calibration settings, requiring recalibration.

Sensor Tip: When attaching a sensor to an AMR, pay attention to fastener torque.

Over torquing one or more fasteners can twist a sensor’s chassis. Even small torsional twists can severely throw off factory calibration.

The current standard for in-field recalibration is the checkerboard process.

With this process, a checkerboard (or similar) pattern is placed in different locations and orientations in ont of www.therobotreport.com

the sensor, and a so ware process is run to interpret the sensor’s new spatial coordinates and distortions based on measurements it constructs om the pattern.

The most popular checkerboard process comes om OpenCV. However, more advanced processes have arrived more recently, including Kalibr om the ETH-Zurich computer vision lab, and Vicalib om the University of Colorado Boulder. Both are better suited to multisensor calibration processes, and both promise a more rigorous calibration process that produces better results in terms of accuracy and precision of the final intrinsics.

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Spatial registration When an AMR is equipped with multiple sensors, each sensor must understand not just where it is in three-dimensional space, but where every other sensor is in three-dimensional space. Along with clock synchronization, spatial registration is critical to ensure that sensor fusion can be accomplished for an AMR. Sensor Tip: What is sensor fusion? This is taking data streams om two or more sensors and combining them in both space and time. This can help achieve much higher accuracy than what is possible with a single sensor, and can also unlock capabilities (3D reconstruction, for instance) that aren’t possible (or easily possible) with a single sensor.

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Much like single sensor calibration, spatial registration can degrade when sensors or the AMRs they are attached to move due to physical impacts. Even tiny, unexpected shi s will require that all sensors undergo extrinsic recalibration.

Similar to a single sensor intrinsic recalibration process, multi-sensor extrinsic calibration is currently achieved with the same hand-eye process using a checkerboard pattern. Unfortunately, this process can take up to 45 minutes or more for multi-sensor arrays. Tangram Vision is working on sensor autocalibration so ware to automate this process on a continual basis while an AMR is in operation.

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Real-time data streaming A single sensor can generate hostcrushing amounts of data. Multiple sensors? This requires carefully designed data structures and data management.

The impact of too much data can be serious for an AMR. While the most likely outcome is excessive latency, the worst outcome is data blackouts, where entire packets are dropped. Imagine a fastmoving robot that suddenly receives late data or no data. Depending on what is in the path of that robot, the result can be disastrous.

Connection reliability “USB is the worst.” While there is some truth to this statement, the reality is that all connection types have inherent weaknesses that can stop an AMR in its tracks. USB is singled out more o en because it is ubiquitous, and because it is capable of performing many tasks simultaneously (for instance, both data and power delivery).

Sensor Tip: Many USB connection issues are the result of using a poorly designed hub or the incorrect cable. Make sure that your hub and cable choices support the data rates your platform will need for operation. Keep cable runs as short as possible to minimize the possibility of data and power interruptions.

Ethernet can provide more reliable data transfer, but it requires a separate power connection, which can then introduce an additional point of failure. No matter what connection type is specified, it pays to understand the different standards that connector and cable manufacturers can use, and to find cables and connectors that meet a standard that supports your use case.

Sensor Tip: High dynamic range (HDR) cameras are becoming more widely used for robots that work in environments with very dark or very bright lighting conditions. However, HDR cameras can take up huge amounts of bandwidth and host compute because of the sheer amount of data they generate.

Depending on the host, they may consume an entire core just to process their datastream. When speci ing an HDR camera, consider your host’s processing capacity and ensure it can handle the added strain.

DevOps for Perception The team at Tangram Vision previously built the popular Structure Sensor & SDK depth sensing platform. We saw firsthand all of these sensor struggles and more as we worked with robotics companies to integrate both the Structure Sensor and other perception sensors onto their platforms. These so ware and sensor challenges typically added a year or more of additional engineering time to product development roadmaps, and created equent, unexpected downtime during deployments.

We launched Tangram Vision to eliminate these development and deployment challenges with a continually evolving, best-in-class sensor management platform. The Tangram Vision SDK automatically manages time synchronization, sensor calibration, spatial registration and data management for multi-modal, multisensor platforms like AMRs and other robots. It also provides early notification of sensor faults, including connection errors, and can assist with automated restarts when connections temporarily fail.

The Tangram Vision SDK is launching in public beta in Summer 2021. Early access to our private Alpha is available by request. RR

This Vicalib sensor calibration pattern was developed by the Autonomous Robots and Perception Group at University of Colorado Boulder.

|Tangram Vision

To prevent data blackouts and latency, your data model needs to consider a concurrent approach that does not block the host om continuing to consume new data as it comes in. This approach not only ensures that just enough sensor data is always available for safe operation, but also preserves host compute for other critical AMR tasks.

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M o t i o n

C o n t r o l

HMIs

with controls—

then and now

Recent years have brought staggering advancements in HMI control and IIoT functionalities. While previously only modest applications could rely solely on HMIs with soft-PLC or PC functions for controls, today’s HMI technologies can often satisfy the same requirements for more demanding installations.

Pre-integration of related components by suppliers is a trend seen across the automation industry — in housings that integrate their own bearings and seals, cable carriers that integrate their own connectorized cables, motors that integrate their own drives, belt pulleys that integrate their own locking devices, conveyors that integrate their own sensors, and actuators and stages that integrate … well, everything related to imparting motion to an axis. No doubt industry can expect to see suppliers assuming more component and system integration in coming years — especially as design engineers are encouraged to focus on core competencies outside motion systems.

HMIs are no exception to this integration trend … and industry has seen many new offerings on the market (sometimes billed controller HMIs) that can handle the traditional HMI functions of data collection, batch processing, displaying 76

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HMI+PC have become standard components over the last 20 or so years.

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| Dreamstime.com

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M o t i o n

C o n t r o l

HMIs for standalone installations assume PLC functions and connect to PC, PAC, or motion controllers for advanced tasks.

information … as well as various control functions.

Some HMIs today take the form of low-maintenance embedded HMIs run on an embedded OS to consume minimal memory and processing power. That’s because the software of embedded HMIs are specifically optimized for HMI computational processes and nothing more.

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The benefits of such integration include: • Fewer parts and less cabling • A compact design that takes up less space on a machine • Centralized control and interface • Shorter development time thanks in part to a single development environment First a history lesson to put this in perspective: Early precursors to modern HMIs for automation were based on cathode ray tube (CRT) information displays complemented by other programming-terminal peripheral devices such as keyboards.

The latter were especially important in applications needing frequent program changes or text inputs — such as machining based on CNC, for example.

Those unfamiliar with CRTs should check out a few Wikipedia articles and Google images detailing how CRTs work. It’s an interesting part of industrial-control history. Basically, CRTs use high-voltage power supplies to generate and steer electron beams at phosphor dots on glass tubes’ interiors.

Of course, such CRT technology required bulky and expensive

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transformers and coils … and generated magnetic fields. That’s why earlygeneration programming terminals for initial or occasional writing of controlsystem software (as well as downloading and debugging user code) would wherever possible employ temporary connections to display screens. These let programmers see what they were doing but avoided the drawbacks of permanent CRT connections.

In fact, yet another approach that was (and in some cases remains) common for relay-based control systems was to simply rely on traditional tactilecontrol user-input components such as pushbuttons and status outputs such as pilot lights for a low-cost machine I/O arrangement.

Fast forward to today: Since the advent of low-cost flatscreen displays, the cost of packaging modern HMIs into control systems has plummeted. A concurrent drop in prices for other control-panel technologies means that today, even OITs come with modest one or two-line displays that are digitally programmable.

But touchscreen functionalities complemented with the ability to display text, images, and even videos have made HMIs the most powerful and cost effective operator interface for a lot of machinery.

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Industrial PCs with HMI functionality A common HMI variation now taken for granted are those built around industrial PCs. In fact, it’s astounding how many design engineers today would define HMIs to be self-contained PCs or equivalent fanless electronics based on a single circuitboard running Linux or other operating system (OS).

Such HMI+PC components are more complicated and costlier than some alternatives due to their inclusion of more electronics and software resources. Nevertheless, they’ve become standard components over the last 20 or so years — executing (in

traditional setups) the HMI and PCbased machine controls on a common microprocessor. The last few years have even seen new HMI+PC iterations with dual and even quad-core processors (1 and 1.6-GHz) for the benefits of an integrated system but segregation of HMI and control functions for realtime handling of advanced motion and automation tasks.

No matter the exact PC electronics, HMIs built into PC-based systems are part of a multi-function design. In many cases, that makes it possible to expand system functions as needed. In fact, some such HMI systems often deliver capabilities beyond machine control —

Some controller HMIs with multiple processors can run a realtime OS on one CPU core and general-purpose logic on another. Such arrangements leverage what’s called asymmetric multi-processing (AMP) architecture — an arrangement that can outperform traditional symmetric multiprocessing (SMP) architectures running one OS across processors.

SAFETY COMMUNICATIONS

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CONFIGURATION MENU

including digital and analog I/O-based integration into automated factory and enterprise-level systems.

The assumption of control functions is a natural progression of HMI technology, as traditional PCs are all based on a centralized processor hosting an OS that manages attached resources — including memory, external communications, and (most significantly to this topic) visual display.

That means employing a PC already in the system to manage an industrial screen incurs no additional cost.

When suppliers manufacture the PC components to fit into a flat format, this imparts yet another benefit … namely, a

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SoC • CONTROLLER Asymmetric multi-processing (AMP) architecture segregates realtime control logic from HMI logic for batch processing, data collection, and display tasks.

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streamlined and economical amalgam component with a single housing and mount. Increasingly the latter takes the form of bracket hardware adhering to geometrical standards of the Video Electronics Standards Association for VESA mounting of consumer as well as industrial flat-panel screens.

HMI+PC products also facilitate efficient fault and diagnostic messaging, adjustments of machine functions for maintenance and repair tasks, and network communications.

Note there is one important caveat to using HMIs capable of controls: Design engineers accustomed to traditional design approaches might be inclined to specify a control system and then a suitable HMI later in the design process.

Specifying HMI+PC components or really any format of HMI that assumes control functions necessitates a more holistic design approach to leverage all components’ interoperabilities.

Other HMI+control combinations and where they excel Some HMIs today take the form of low-maintenance cost-effective embedded HMIs — run on an embedded OS to consume minimal memory and processing power. That’s because the software of embedded HMIs are specifically optimized for HMI computational processes and nothing more. In contrast with the HMI+PCs covered earlier (which require engineers to purchase and install software on their own) most such embedded HMIs are prepackaged and preinstalled with OS and application software. Make no mistake, though: Embedded HMIs are often quite sophisticated … especially when installed in networked arrays.

Many HMI permutations can even execute tasks typically associated with PLCs. These are sometimes billed as including soft PLC functions — utilities that have long been machine-control industry standard.

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written in a licensed copy of IEC 61131-3 Controller Development System (CODESYS). There’s also deterministic and realtime control over critical operations.

Of course, many automated installations coordinating arrays of advanced operations still require standalone controllers such as PACs. Complicating the taxonomy is that there are in fact PACs that integrate virtual embedded HMIs — executing operator-console tasks much like some screenless HMIs. DW Motion Control Tips motioncontroltips.com

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| Dreamstime.com

Recall that standalone PLC formats range from the simplest of controllers (capable of executing only basic ladderlogic instruction sets) to sophisticated multi-function components commanding multiple control modes — over processes and even motion-control applications in some cases. The range of HMI PLC capabilities is equally diverse.

That said, most HMIs powerful enough to assume PLC functions (thanks to processing and memory sufficient for running software as well as Ethernet, I/O, COM, or other connectivity) can execute the HMI tasks of data logging, plotting, and graphing along with alarm setting and trend monitoring — as well as PLC tasks including I/O data processing and handling ... execution of all PLC ladder-logic ... instructions and PID control over discrete motion tasks ... and execution any other programming

Shown here is an HMI example from the machine-tool industry.

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M o t i o n

Getting straight on roller screws Knowing the differences between the several kinds of roller screws can help determine the best fit for an application.

Michael Boudreau, P.Eng. Application Engineering Manager Rollvis S.A.

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Planetary roller screws – also referred to as satellite roller screws – have long been the primary choice for applications that involve heavier loads and higher forces than traditional ball screws can withstand, or that require better speed and positioning accuracy than hydraulic cylinders can provide. But some roller screw designs – specifically, recirculating roller screws – are also well-suited for high-precision applications, where resolution and positioning accuracy are of utmost importance.

Knowing the differences between traditional planetary roller screws and recirculating roller screws – which are a special variation of the planetary design – and looking at some examples of best-fit applications for each can help determine the right one for your application.

Planetary roller screws Planetary, or satellite, roller screws are the most familiar design, consisting of a screw, nut, and satellite rollers, all of which have triangular threads with matching helix angles. The screw and nut have multiple-start threads, while the rollers have a single-start thread.

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The nut has a roller ring and a geared wheel at each end, and the ends of each roller have cylindrical pivots and gear teeth.

The pivots of the rollers are mounted in the holes of the roller ring, ensuring the rollers remain equidistant. The gear teeth on the ends of the rollers engage with the gear wheels at each end of the nut, which guide the rollers parallel to the axis of the screw.

Note that in this design, there is no axial movement between the rollers and the nut, so the rollers don’t need to be recirculated.

The curvature of the rollers gives them much larger contact areas than that of the balls in a ball screw, and roller screws typically have more contact points than ball screws. Together, these features allow planetary roller screws to withstand much higher loads than ball screws. This higher load-carrying capacity is often cited as their main advantage, but having larger contact areas also gives roller screws better rigidity and less deflection than similarly sized ball screws, making planetary roller screws ideal for grinding applications. And despite this large contact area, the crowned profile of the rollers means that efficiency is nearly the same as that of a ball screw.

Rollvis RV type planetary roller screws and RVR type recirculating roller screws are manufactured with the same grinding accuracy and, therefore, have the same preload capabilities and the same axial play and repeatability specifications. The RVR recirculating type has higher accuracy due specifically to its operating principle, rather than to any differences in manufacturing.

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M o t i o n

Thrust Forces Rigidity Speed Low input torque Efficiency Small Leads Compact Nut Dimensions

Ball Screw

Planetary Roller Screw RV

Recirculating Roller Screw RVR

+ ++ ++ + +++ ++ +++

+++ +++ +++ ++ +++ + ++

++ +++ ++ +++ ++ +++ +++

Planetary roller screws are used wherever extremely high loads and high regidity are required, such as pressing and welding applications.

Recirculating roller screws Recirculating roller screws are a special variant of the standard planetary design, with the same primary components; a screw, nut, and rollers.

Like the planetary design, the screw and nut have threads with a helix angle, but for recirculating designs, the screw and nut have only a single- or doublestart thread. And instead of threads, the rollers have circular grooves perpendicular to the axis of the screw, so they need to be “recirculated” after each turn around the shaft.

In the recirculating design, the rollers are held in a cage, with each slot in the cage being slightly longer than the roller length. Because the rollers are grooved rather than threaded, when the screw shaft turns the rollers are axially displaced in the nut along the length of the slotted cage.

Once a roller makes a complete revolution around the screw, cams at each end of the nut disengage the roller

from the screw shaft and return it to its initial position, but advanced axially by the amount of the screw lead.

Performance and applications With rollers as the load-bearing elements, both traditional planetary roller screws and recirculating roller screws provide high load capacities and excellent rigidity. The key difference is that recirculating designs – because they require only a singleor double-start screw thread – can be manufactured with fine leads, even with large screw diameters. Some recirculating designs even have fractional-millimeter leads (0.25 mm, for example). And with a fine lead, the required input torque is minimized. The trade off, however, is that recirculating roller screws have lower speed and acceleration capabilities than traditional planetary designs.

Planetary roller screws are used wherever extremely high loads and high rigidity are required, such as pressing and welding applications. And machine builders are more frequently choosing planetary roller screws over hydraulic systems, to reduce system complexity and maintenance costs.

Recirculating roller screws are commonly used where micronlevel positioning is required, such as in semiconductor manufacturing equipment. And they’re often the best choice for applications that combine the need for micron-level positioning

Planetary vs. Satellite The term “planetary” roller screw comes from the fact that when the screw shaft turns, the rollers spin on their axes as they orbit around the nut, much like planets orbiting around their sun.

The first patent for a roller screw was issued in France in the 1940s, and in French, the word “satellite” is used to describe the movement of the rollers around the screw. This is why planetary roller screws are sometimes referred to as “satellite” roller screws.

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with high stiffness and rigidity, such as in grinding equipment or for fine-tuning the focus on telescope lenses.

Planetary roller screws – whether standard, recirculating, or other special variants – are known as problem-solvers in challenging motion applications. They excel in applications that require highly dynamic operation – high speeds combined with high load capacities and good positioning accuracy – performance criteria that traditional ball screws and hydraulic cylinders have difficulty meeting. DW Rollvis S.A. rollvis.com

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In both standard and recirculating roller screws, the

flanks of the screw and nut thread profiles are purely triangular, with flat surfaces. But the flanks of the roller threads (planetary designs) or grooves (recirculating designs) are crowned.

This is an important design feature because it allows the rollers to experience rolling – rather than sliding – contact. This rolling contact gives both traditional and recirculating roller screw designs high efficiencies, despite the large number of contact points on the rollers.

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As an inorganic polymer, silicone lubricants are chemically inert and stable over extended periods of time.

The molecular backbone of silicone fluids is much stronger than the carbon-tocarbon chain in hydrocarbon polymers.

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M e d i c a l

Choosing

silicones

for medical device lubrication The right silicone can enhance the design of medical devices. Here are tips on choosing the right one.

John Freedman • Director of Biomaterials, and Alex Santayana • Applications Engineer Avantor’s NuSil brand

From needles to syringes and cannulas to guidewires, the design of certain medical devices requires consideration of friction. A biocompatible silicone lubricant can reduce insertion, drag and break-loose forces at the interfaces between surfaces to improve performance and protect components. It can also reduce friction between a device and human tissue, creating a more positive patient experience.

Medical-grade silicones, including lubricants, have long been used in medical devices. To ensure a lubricious silicone’s properties deliver the expected results — both for the manufacturing process and end use — consider these key factors:

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Is the silicone biocompatible?

Lubricious silicones used in medical components and devices must be biocompatible and typically conform to ISO 10993 standards. Most will advise designers to select a high-purity, medicalgrade silicone lubricant that is supported

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As an inorganic polymer, silicone lubricants are chemically inert and stable over extended periods of time. The molecular backbone of silicone fluids is much stronger than the carbonto-carbon chain in hydrocarbon polymers. As a result, silicone lubricants better resist oxidation, chemical attack, extreme temperatures and shear stresses.

Will the silicone lubricant be compatible with the manufacturing process?

A silicone lubricant must work with the manufacturing process of a component or device. Application methods include dipping, dispensing, spraying or wiping. Silicone fluids may be diluted using a compatible solvent carrier to apply a thin film. Dimethyl silicone polymers can be dispersed in nonpolar organic solvents and, to a lesser extent, in aromatic hydrocarbons, mineral spirits and isopropyl alcohol. Fluorosilicone polymers (and copolymers) can be dispersed in chlorinated hydrocarbons and ketones. For convenience, some medical device manufacturers offer select polymers pre-dispersed to a specified solids content for ease of use. An alternative to fluids, a non-slumping grease is recommended for applications that require a lubricant that will not migrate.

Is the lubricious silicone suitable for the substrate?

Whether the component or device is made from silicone, metal, glass or plastic, each substrate has different characteristics that can pose unique lubrication requirements. Understanding the nature of the substrates being lubricated can help identify why a specific type of lubricant would be the best choice in the design of a device.

Silicone substrate A cured silicone elastomer’s surface can often exhibit a high coefficient of friction (COF). The surface can be inherently tacky, which can affect the performance of molded or extruded parts that move or slide. Additionally, silicone elastomers tend to block or stick to each other due to chemical affinity. For example, in slit valves the opening can self-heal and no longer open.

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A biocompatible silicone lubricant can significantly reduce insertion forces to improve performance, protect components and create a more positive patient experience.

When working with a silicone substrate: Consider a lubricant with a low chemical affinity to the elastomer. It’s critical for a lubricious silicone to have a low chemical affinity with the molded elastomer part. If the lubricant is chemically too similar to the component, the lubricant may absorb into the component, causing the component to swell. If this occurs, the fluid is depleted from the surface, which will reduce or eliminate the lubricating effect. Most silicone components are produced using a dimethyl silicone elastomer, so choosing a fluorosilicone lubricant, which has minimal chemical affinity to the dimethyl silicone, will minimize absorption and maintain lubricity.

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Consider a higher-viscosity fluid for longer lubrication periods.

As a silicone lubricant’s viscosity increases, the chance of migration (diffusion) decreases. Due to less migration, the fluid with a higher viscosity may lubricate a silicone surface for a longer period of time than a lower-viscosity fluid.

Consider alternative technologies to eliminate the need for a traditional lubricant. Innovations offer medical device designers alternatives to conventional lubricious silicones. For example, a curable, nonmigrating coating can reduce the COF when applied to a silicone substrate’s surface. When cured, these coatings not only chemically bond with the underlying silicone substrate, they also have minimal impact to its mechanical properties. This creates a flexible — and durable — coating that significantly lowers COF on parts that move, slide or rub.

Specific formulations are available for elastomeric substrates that incorporate either platinum-cured or tin-cured systems to meet individual processing needs.

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M e d i c a l

Reduce processing time with selflubricating silicone elastomers. This type of technology helps reduce the number of processing steps during manufacturing. With the self-lubricating silicone elastomer, the lubricant is formulated into the elastomer and elutes over time, creating a lubricious surface on the final molded component.

These elastomers eliminate the need for the additional processing steps, where a lubricant is applied to the surface of a component or device. Additionally, this type of elastomer can be specially formulated with the specific lubrication level and physical properties needed for the application.

should occur in a moisture-controlled environment.

Metal substrate Hypodermic and suture needles, scalpels or other cutting edges with metal surfaces have an inherently high surface friction. This friction causes discomfort for the patient as the metal penetrates tissue. Component design can help counteract penetration and drag forces. For example, hypodermic needles are tri-beveled with an elliptical opening, followed by an elongated tube, to make penetration easier and prevent coring effects.

However, the metal substrate still exhibits surface friction. Silicone lubricants can be applied to lower the COF of the metal surface to minimize the effects of surface friction, without compromising penetration or cutting efficacy.

Consider ambient humidity. With some lubricious silicones, curing may be initiated when exposed to ambient humidity. If adjustments are needed to optimize viscosity or solids content, they

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When working with a metal substrate: Consider penetration frequency and lubricant longevity. For applications involving repeated use, the lubricant must be robust and will typically use a cross-linked silicone system, often supplied as a silicone dispersion.

Inert polydimethylsiloxane (PDMS) fluids function as great all-purpose lubricants for various penetration and cutting surfaces. Although they improve lubricity, they are best suited for one-time use.

Consider dispersion and bonding behavior. A dispersed silicone formulation that provides some bonding capability to the metal it coats makes it a good choice for needle lubrication. Lubrication can be further enhanced by adding PDMS fluid to the dispersed silicone

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formulation. For applications that will undergo multiple usages, a dispersed high-viscosity silicone is often the best choice.

Glass substrate Quartz, sand and glass have a silicon-oxygen chemical structure similar to silicone fluids, allowing the fluids to bond well with glass.

When working with glass: Consider a hydrophobic lubricant. Hydrophobic coatings, such as PDMS silicone oil, are recommended for syringe barrels to promote container drainability. Coating the interior of glass pre-filled syringes with a PDMS silicone oil can also help reduce drag.

Consider high-temperature heating to activate cross-linking. It’s important to understand that PDMS fluid by itself is nonfunctional and doesn’t cure. However, this can be addressed by exposing the syringe to extremely high temperatures to activate some polymer cross-linking to enhance bonding to the glass substrate. The result is a functional interaction between the siliconized glass barrel and plunger to make the system operate efficiently.

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Plastic substrate From valves to stopcocks, a variety of plastics are used in medical devices. Silicone lubricants can ease friction in these applications.

When working with a plastic substrate: Consider a PDMS fluid. Silicone fluids are primarily used in the majority of applications containing plastic to plastic or plastic to metal contact points to reduce friction between the components.

Higher viscosity PDMS oils tend to have better performance with break-loose force, for example in a stopcock. Lower viscosity fluids perform well when used in applications requiring smooth gliding and/or rapid movement.

Consider a silicone grease. Where controlling migration of the lubricant is critical, a silicone grease would be a good option due to its consistency. Greases are especially useful for applications that have parts with vertical movement. Similar to a fluid, they can reduce the break-loose force in applications such as stopcocks or stoppers.

Finally, consider working with a medical-grade silicone supplier early in the design process. An experienced supplier can help guide the selection of a formulation that matches a device’s friction reduction and material requirements while supporting commercialization with a lubricious silicone that meets regulatory guidelines, so patients can have a more comfortable and effective experience. DW Avantor Sciences www.avantorsciences.com/nusil

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How advances

in adhesives are leading to greater freedom of design

Michelle Froese • Editor, Fastener Engineering

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F A S T E N E R S

To reliably join two structures, design engineers are typically bound to a few options: mechanical fasteners, welding, or adhesives. Adhesives are often the preferred choice when: • The weight of an application matters • The speed of assembly is critical • Different types of materials require joining • Assembly tools (such as screwdrivers or drills) are inconvenient or add to the project costs • An aesthetic appeal is important Of course, each structure must be assessed individually to determine the ideal fastening method. If adhesives are chosen, the next step is to decide on the best formula based on the assembly requirements. To this end, advances in adhesive formulations are providing design engineers with more options.

Considering PSAs Conventional pressure-sensitive adhesives, or PSAs, are one type of substance that offers unique characteristics. PSAs are non-reactive and easily bond two components together. These bonds are formed by applying pressure to the adhesive film and surface or substrate of the application, which is advantageous as activation is not reliant on heat, light, water, or solvents.

“Pressure-sensitive adhesives are commonly used in consumer electronics or industrial applications,” explains Dr. Karl Bitzer, head of product management at DELO, a global manufacturer of industrial adhesives. “And, typically in the form of an adhesive tape.”

Such tapes may offer benefits, depending on the application.

They can bond dissimilar materials, reduce assembly time, and

A liquid PSA can be dispensed on the smallest of parts, such as during the assembly of smartphone speakers.

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Table: A comparison of selected features of conventional tapes with liquid pressure-sensitive adhesives or PSAs. CONVENTIONAL TAPE

LIQUID PSA

Freedom of design

Difficulty with corners or 3D applications

All geometries are possible

Miniaturization

Narrow features are challenging

Tiny features are possible

Immediate

Immediate

No additional processing

Additional irradiation required

Pre-conditioning required, with exact positioning

Within seconds

Semi-automated

Automated

High

Low

FEATURES:

Initial strength Ease-of-use Cycle time Automation CO2 footprint

eliminate the need for mechanical fasteners. Overall, adhesive tapes simplify the assembly and manufacturing processes as they reduce additional steps, such as drilling holes in a structure (for screws) or applying heat (to set certain properties).

However, these tapes also have limitations. “In terms of small and complex geometries, they’re often challenging to apply because of their lack of stiffness and tack-related characteristic,” says Bitzer. Tack is a common term when referring to PSAs (in other words, how “sticky” it is). “For example, tape can be difficult to apply to extremely small structures or those with curves or three-dimensional shapes.”

In such cases, this makes tape applications nearly impossible to automate, increasing the assembly time and efforts. Also, as smaller and more

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complex structures trend forward — particularly in the electronics sector — such limitations are becoming major drawbacks. Fortunately, there is an alternative solution. The answer lies somewhere between conventional adhesives and PSAs. “With conventional types of adhesives, a curing mechanism or set temperature is required. Plus, the components are unable to bond by only pressing them together,” he says. “On the other hand, with pressure-sensitive adhesives, a sheet or roll of tape with a liner is provided — and this ‘either/ or’ decision can present drawbacks, depending on the application.”

The alternative: “A liquid pressuresensitive formulation offers an inbetween or middle ground, so to speak.

It can be applied as a conventional adhesive via a dispensing needle but also has an immediate fixation strength — similar to a conventional PSA. So, it’s really a combination of these two options.”

As their name suggests, liquid pressure-sensitive adhesives offer the advantage of dispensing as a liquid and can be applied directly onto a component. Next, they require irradiation via UV light. This creates a tacky surface, much like tape.

“Since the adhesive reaches its initial

Compared to conventional pressuresensitive adhesive tapes, liquid PSAs offer an automated dispensing process and are unlimited by a structure’s shape or geometry. strength immediately after the second component is pressed on, the bonded assembly can be processed directly and without any fixing devices. This is a great advantage over many standard liquid adhesives,” says Bitzer.

Liquid options A variety of dispensing options are also available for liquid pressure-sensitive adhesives, including needle dispensing or jetting for small beads or droplets, as well as stencil or screen printing, or slotdie coating for larger structures (view images of the “processing steps” on the next page). This means automation of the dispensing process is possible, even on an industrial level.

Light irradiation (typically 360 or 400 nm) transfers the liquid adhesive into the tape phase within seconds.

“The tape phase is marked by a significant increase in viscosity,

preventing any ‘flowing’ of the dispensed pattern, which can happen with conventional adhesives, especially on those complex structures,” explains Bitzer.

Since heat is not required for the final curing, the process is also suited for applications where thermal stress must be kept at a minimum. What’s more: after the irradiation is complete, structures cure at room temperature without additional processing.

“Freedom of design is what we’re talking about here,” he shares. “A liquid adhesive has significant advantages over a tape for those structures with complex shapes or sharp corners.

The application process can also be interrupted, infinitely. But for tape, such interruptions technically require placing a new piece of tape down every single time the liner has been removed. I mean this would be a manual process…

The processing steps of liquid pressuresensitive adhesives.

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and just imagine the assembly time here if there are multiple products.”

Of course, each application should be evaluated to determine the ideal method of assembly. There are cases when a conventional tape may be preferable, such as for large, flat surfaces.

“We first focus heavily on what the problem or requirement is, rather than promoting one product or another. This is because the solution has to best address a structure’s material, shape, and other such features — it’s customized. Liquid PSA simply offers one more choice,” says Bitzer. “Again, this goes back to the freedom of design.”

Sustainability in action Liquid pressure-sensitive adhesives can be used in several applications.

“Housing bonding of electrical components is one common example, of an ideal application. However, there are many others. Think of the speaker area on your smartphone or for a smart-home device,” says Bitzer.

“Sensors are a major component where liquid PSAs are useful. In the automotive industry, sensors are used in several parts for electric vehicles or even autonomous driving, including for radar or LiDAR,” he says.

Another example is the ultrasonic sensors found in parking-aid systems. The sensor consists of a piezo element that’s bonded into a complex geometry Using liquid tape, in this case, can make the processes easier.

Another major plus: sustainability. Liquid pressuresensitive adhesives offer environmental benefits, at least compared to tapes.

For one, you’re saving the waste produced by a tape’s mandatory protective liner. Additionally, liquid PSA’s are produced with much lower levels of CO2. This is because the complex and energy-consuming process of applying the adhesive layer to the tape-carrier material via solvents is unnecessary. So, they’re solvent-free.

“If reducing one’s carbon footprint is a goal, which is important in today’s world, liquid pressure-sensitive adhesives offer a ‘cleaner’ choice,” says Bitzer. “Plus, there are different chemical bases with different properties available, further strengthening the freedom of design for engineers.” DW

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Fast current sensors

for advanced applications The high switching speeds of modern power electronics call for sensors able to keep up with the megahertz-level frequencies involved. Anisotropic magneto-resistive technology fits the bill.

In automation, use of precision current-sensing is

Khagendra Thapa • Aceinna Inc.

Inside an AMR current sensor IC

VOC GND GND Vref Vout GND VCC

FAULTB

IP+

of growing importance. Material handling equipment often uses position and velocity feedback that frequently involves measurement of motor or other actuator current. Similarly, advanced current sensing is also necessary to implement numerous energy efficiency measures, as well as for monitoring equipment safety and reliability. In automotive systems, current-sensing helps manage the motor and powertrain.

The migration from passive systems to those using intelligent feedback and control has yielded impressive results. But in discussions of feedback, people often conflate accuracy and precision. They are similar but different things. A good analogy is to think of shooting a bow and arrow, or even just throwing darts. Precision is how closely all of your shots are grouped together.

Accuracy is how close that shot group is to the target.

You can have an industrial machine capable of drilling a

An internal view of an Aceinna AMR current sensor chip shows the U-shaped conductor carrying the current of interest over the AMR sensor material. In this chip, four pins provide connections for current input, and

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another four pins provide connections for the output current.

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E l e c t r o n i c s

BLOCK DIAGRAM VCC

IP-

GAIN AND OFFSET ADJUST AMR SENSOR

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Vref

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Visible on the block diagram of an AMR current sensor (MCA1101)

OCD

FACTORY CALIBRATION

half-millimeter hole in the “o” in a coin, but unless you have the accuracy to put that force in the right place, its precision is wasted.

Overall, power system and motordrive open-loop current-sense accuracy has been an already-impressive ~5% over full temperature range in recent years. Recent Industry 4.0 approaches have moved the goal post towards below 3% at temperatures as high as 105°C. In the area of advanced solar inverters, systems are beginning to realize 2% max accuracy over temperature. High-performance CNC motors will typically look for greater than 1% accuracy over temperature.

Similarly, applications needing extremely wide dynamic range, with good accuracy and precision, will need better than 1% accuracy over temperature. For better control and protection, typical power factor control (PFC) and mainstream power supplies also want better than1% at room temperature and better than 3% over their operating range. Some highperformance power systems optimize accuracy, thermal management, and

May 2021

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AMP

TEMP SENSOR

100

OUT

VOC

from Aceinna are AMR-

FAULTB

based sensors making up

GND TST1 TST2

the Wheatstone bridge sensing circuit.

OSCILLATOR

overall system performance demand for 1% over temperature.

Thermal issues One axiom in embedded engineering is that power management is thermal management. Power efficiency and thermal performance go hand in hand.

A reduction in temperature makes electronics work better and more reliably. Conversely, electronics that operates more efficiently generates less waste heat and has fewer thermalmanagement issues. Optimizing both power and thermal management will significantly improve productivity and cost.

Inverter, motor drive, power supply, UPS, and external charging stations can operate at an ambient temperature range from -40 to 85°C, often up to 105°C. Even some inverter designs where the internal maximum temperature is kept below 70°C are specified for 85°C operation to ensure operational headroom without derating.

Automotive onboard chargers can be specified for 85 to 125°C, while motor drive requirements can be 105 to 150°C,

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depending on the location.

For systems with potentially rapidly changing temperature, it may be easier to measure the system current than to measure temperature as a way to manage thermal performance. Current level can be a leading indicator of several out-of-range events.

Bandwidth is an important consideration in modern power systems. In PFC stages, for example, the output ripple must be filtered to avoid current distortion, and the loop frequency is related to the system bandwidth. Consider the PFC stage as a system delivering power under an input rms voltage and a control signal. Even if the system control-loop bandwidth is lower, cycle-by-cycle inductor switching currents are measured.

Ideally, a power system should have a bandwidth that is a high multiple of the switching frequency to realize a flat gain response and low phase margins at the switching frequency.

A low frequency can work, with some compromise on gain and phase delays at switching frequency. Although overall control-loop bandwidth may be much

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lower than the switching frequency, current measurements should take place at the switching frequency for cycle-bycycle control.

Consider a totem-pole PFC. As a quick review, this topology uses four transistor switches that serve to eliminate the need for a rectifying diode bridge.

Two switches run at high switching frequency and serve as the boost switch and rectifier switch. The other two switches run at line frequency and serve as the line rectifier. Most totem-pole PFCs switch at ~65 kHz to 150 kHz, requiring a bandwidth of at least 300 kHz but ideally 650 kHz to 1.5 MHz. Some advanced designs push this switching frequency to 300 kHz and will require a bandwidth of 1.5 MHz but more often about 3 MHz. Power conversion stages handling high current (>100 A) will nominally switch at at least 1 kHz up to 20 kHz and typically use IGBTs and silicon MOSFETs. Wideband SiC/GaN power switches will boost switching speeds to around the 40-50 kHz range. Further advances in SiC/GaN power stages will possibly move this high-current switching up to 100 kHz in a few years. This operating range will require bandwidth of up to 500 kHz up to 1 MHz. Advanced feedback These kinds of advanced power supplies have been made possible not only by wide-bandgap semiconductors, but also by accurate and precise current sensors.

An example is ACEINNA’s Anisotropic Magneto-Resistive (AMR) isolated current sensors. These highly accurate, wide bandwidth sensors provide best-in-class performance on bandwidth, output step response and accuracy in a single-chip solution.

AMR current sensors can be contrasted with the well-known Hall effect current sensors. The Hall effect refers to the fact that when current moves through a conductor it creates a magnetic field. If this conductor is positioned within another magnetic field, the magnetic field produced by the

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Typical application circuit

VCC R1

IP+ IP+ Primary Current IP+ Input

GND Vref

IP

IP IP

R2

GND

IP+ IP

33K

VOC

Vout

GND

Primary Current

VCC

Output

FAULTB

VCC VCC

Optional circuitry for overcurrent detection

To ADC pin on MCU or A/D input To ADC pin on MCU or A/D input

100nF

10K

application circuit for an AMR current sensor includes overcurrent

R3 C1

A typical

Interrupt to MCU

detection and a means of alerting an MCU (FAULTB pin) if that happens.

electrons moving through the conductor will interact with the outside magnetic field causing the electrons to move to one side of the conductor. This creates a voltage on the conductor that is proportional to the amount of current and can be measured.

In contrast, AMR sensors use a magneto-resistive material that sits near the current of interest and changes resistance proportionally depending on the amount of magnetic field, due to current through a conductor, seen by the AMR sensors, . Unlike Hall-effect sensors, AMR technology can handle a 1.5-MHz signal bandwidth--useful for the higher switching frequencies of advanced power supplies--and has a lower offset and noise, which leads to better accuracy and lower phase shift.

Specifically, the AMR sensor measures the magnitude of a magnetic field parallel to its sensing direction. The usual way of configuring the sensor so it can measure the magnetic field is to use a U-shaped conductor positioned over the AMR material. The conductor carries the current of interest having a magnetic field around it. The AMR sensors sit on top of opposite current carrying conductors with equal distance from a symmetry axis of the sensors.

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The magnitude of the magnetic field parallel to the sensing direction of the AMR sensor gives the output signal.

One big advantage of measuring the field difference between the two opposite primary current flows is the immunity against external stray fields.

Stray fields are likely homogenous over the area of the sensor chip due to the small distance between the resistors, so there is no field gradient to cause an imbalance. And because the AMR sensor has a high sensitivity, there’s no need for a fluxconcentrating magnet as is the case with Hall sensors.

The fully integrated, bi-directional AMR current sensors offer much higher dc accuracy and dynamic range compared with alternatives.

For example, the ±20 A version has a typical accuracy of ±0.6% and has a guaranteed accuracy of ±2.0% (max) at 85°C. The family of products include ±5 A, ±20 A and ±50 A parts. These devices come in an SOIC-16 package with a low-impedance (0.9 mΩ for ±50 A) current path and are certified by UL/ IEC/EN for isolated applications.

These new current sensors also guarantee an offset of ±60 mA, or ±0.3% of FSR (max) over temperature,

May 2021 www.designworldonline.com

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allowing high accuracy over a roughly 10:1 range of currents, a significant improvement in dynamic range vs. Hallsensor-based devices. These devices also exhibit an output step response of 300 nsec and 4.8kV isolation, making them good candidates for current sensing in fast control loops and highperformance power supplies, inverters and motor control applications. DW References Aceinna Inc., current sensing, https:// www.aceinna.com/current-sensors,

DESIGN WORLD

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Product World Solenoid valves reduce power consumption in smaller footprint Emerson Automation Solutions Emerson.com This range of two-way and three-way solenoid valves supports original equipment manufacturers’ need to develop more compact machines and equipment without compromising on fluid control performance. The optimized body design and internal flow path of the ASCO series 256/356 provides a smaller footprint and reduced power consumption, and increased pressure ratings critical in industrial and commercial applications.

The reduced overall footprint of the series 256/356 helps OEMs optimize the internal layout of their equipment, enabling more high-performance fluid control options to be integrated into a smaller and sleeker final product. This is especially important for manufacturers of coffee machines and other beverage dispensers; heating, ventilation, and air conditioning; pumps and compressors; welding equipment; and analytical and medical devices.

Achieving comparative pressure ratings in a smaller valve typically results in increased power consumption, but the series 256/356 reduces energy use by as much as 40%. This enables OEMs to apply a smaller valve while matching or improving the fluid control performance of the previous version and make significant energy savings.

HMI with intuitive user guidance Bosch Rexroth apps.boschrexroth.com The ctrlX HMI offers machine manufacturers optimum freedom when implementing the user experience with intuitive user guidance. The portfolio includes small operating panels, tablets, panel PCs, or large stationary displays with a screen diagonal of up to 24-in. Anti-glare and chemically hardened front glass make display and operating panels suitable for harsh everyday production environments. The 16:9 screen size supports multi-touch operation with ten fingers.

The web-based software solution adapts every representation automatically to different display sizes and prepares important information clearly at all times.

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Congratulates

Mitsubishi Electric was established in 1921 as a spinoff of the Mitsubishi Shipbuilding Company’s electric factory. For the past 100 years, the Mitsubishi Electric Group has contributed to a vibrant and sustainable society by providing a wide range of products and services infused with high technology and creativity in fields ranging from homes to outer space.

About Mitsubishi Electric’s 100th Anniversary Logo The logo symbolizing the company’s centennial anniversary expresses the idea of transformation over the next 100 years. At a glance, the logo appears to be a simple pattern of slanted red and white lines, but by adjusting one’s gaze the number “100” can be seen, even when the logo is turned upside down. By encouraging people to look at things from different perspectives, the logo expresses the Mitsubishi Electric Group’s strong will to create new value and transform itself over the next 100 years, aiming to provide integrated solutions to address diversifying social challenges uniting all the capabilities inside and outside of the Group.

us.mitsubishielectric.com/fa/en • 847.478.2100

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Product World Variable ratio transmission for seeding and fertilizing applications Zero-Max zero-max.com The VRT Variable Ratio Transmissions has an efficient and cost-effective design that ensures accurate and consistent application rates for agricultural seeding and fertilizing equipment.

The VRT is designed to meet the performance requirements for today’s agricultural equipment. The VRT can provide a critical link between the control system and the mechanical seed and fertilizer distribution mechanism. This seeding system, often ground-driven from the wheels of the implement, maintains seed and fertilizer placement accuracy even when the ground speed of the equipment changes.

Features: • Infinitely adjustable to obtain the exact desired ratio.

• Ratio can be adjusted when idle or when running.

• Easily, quickly, and precisely make speed adjustments.

• Variable ratio or fixed ratio operation.

• Speed and torque capabilities are expandable by use of chain and sprocket ratios at the VRT shafts.

Improved HMI software platform ADISRA adisra.com SmartView is a complete human machine interface (HMI) and supervisory control and data acquisition (SCADA) package, designed specifically for machine builder OEMs and discrete part manufacturers to develop effective interfaces for monitoring and analyzing machine operation and overall status. SP1 adds a host of development and usability features, making it even easier for users to create applications with greater flexibility.

SmartView already delivers a comprehensive and easy-touse development environment. New development enhancements include templating functionality supporting re-use of advanced graphic objects and screens across multiple applications and the added flexibility of using tags to dynamically adjust the file and pathnames for recipes and reports. The display resolution of an application is now easily changed to match any target deployment.

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Product World Non-muting light curtains AutomationDirect automationdirect.com Safegate non-muting Type 4 access control barrier safety light curtains are designed to protect a range of industrial applications that do not require muting functionality. Sender/receiver or active/ passive pair versions are available with 24 VDC input, 300 or 400mm resolution, and 0-8m or 0-12m operating distances. ReeR Safegate non-muting light curtains are IP65/IP67 rated. Mirrors and protective columns are available to complete the installation.

Inductive washdown sensors

Real-time monitoring of solid state relays

Balluff balluff.com

Carlo Gavazzi GavazziOnline.com

These inductive sensors provide wear-resistant, non-contact position,

The NRG Series of EtherNet/IP, PROFINET, Modbus Controllers,

detection of metallic objects. Features include condition monitoring,

and multifunction Solid State Relays is designed for real-time

which reports the sensor’s internal temperature, relative humidity, and

communication with a controller, allowing machine builders to

inclination, plus vibration monitoring in real-time via IO-Link. The sensor’s

make informed decisions, solve urgent problems on short notice,

operating hours and more functions are also available using IO-Link.

and aid in the design of autonomous machines.

Also, LEDs on the sensor can show the sensor’s signal quality, blink

By interfacing with machine controllers and PLCs across

when sent a ping via IO-Link to help you locate it, or perform other

EtherNet/IP, PROFINET, and Modbus networks, the NRGC-EIP,

useful functions. Lastly, they are IP68 and IP69K-rated and have Ecolab

NRGC-PN, and NRGC Controllers seamlessly exchange data to

approval. In addition, they have passed what Balluff calls Washdown Plus

achieve industrial digitalization. The NRG Series provides an all-

testing, which simulates over 1,000 washdown cycles — triple the typical

in-one solution for fast switching, accurate monitoring, and high-

number of cycles for IP69K testing.

speed communication — all of which are critical to predicting equipment failures, reducing unplanned stoppages, and optimizing overall performance.

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Stainless steel slide way ends slippage NB nbcorporation.com

In all stainless steel, the NB STUDROLLER is suitable for special environments that are highly corrosive, high temperature, or vacuums. This crossed-roller linear bearing is for motion control applications with fast acceleration and deceleration (at dimensions ranging from 30-600mm lengths, 1-12 mm rollers, endurance is 150 million cycles), the NV type STUDROLLER, with stainless steel Anti-Creep Cage Technology, guarantees zero slippage. By placing studs in the center roller and machining a correspondingly dimpled path in the rail, NB has produced a retainer that never slips. (Patent Pending) Also, load capacities are increased 1.4 to 2.3 times over the standard SV type. Roller-to-rail contact area is extended 42-58%, while the number of rollers is increased 20-55%. STUDROLLER, lowers component costs and allows more compact designs.

Industrial power supplies Pepperl+Fuchs pepperl-fuchs.com The high-efficiency PS1000 industrial power supplies combine optimal performance and high efficiency with durability and reliability and more than 95% efficiency. The PS1000 offers N+N and N+1, two reliable redundancy methods that guarantee system functionality will continue even during a power supply failure, resulting in a very low MTTR (Mean Time to Repair).

The PS1000 line of power supplies from are DIN-Rail mount, providing an interruption-free power supply ranging from 5 to 40 Amps, with options for 12VDC, 24VDC, or 48VDC output. The PS1000 offers a small footprint and has the most compact design available in the marketplace. Rated up to 70° C and certified for installation in Ex-rated hazardous locations, the PS1000 power supplies can be used in the most extreme applications. The PS1000 comes with ATEX, IECEx, and either CSA or UL approvals.

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Product World Magnetic ring encoder for machine tools Heidenhain heidenhain.us/about-us This ECM 2400 encoder supplements an existing portfolio of absolute angle encoders and is designed for machine tool applications that require a sturdy encoder with medium accuracy. The ECM 2400 is suitable for applications with high rotational speeds, angular accelerations, and limited space due to the low overall height of the complete system.

The ECM 2400 works particularly well on B-axis lathes with motorized milling spindles or on the A and C axes of milling machines where a large hollow shaft encoder is necessary. In general, it is suitable on all rotary axes that require the following attributes: 1. Safety-oriented application (mechanical fault exclusion) 2. Sturdy angle encoder 3. Large inside diameter 4. Lower position accuracy than an optical measurement system 5. Dynamic positioning accuracy (simultaneous multi-axis machining)

3D safety systems for harsh environment Leuze leuze.com The LBK safety radar system implements an operating principle new to safety technology. As a result, it can also provide a solution for applications that previously could not be solved reliably using optical sensors. Even

than sound waves. Unlike light, the radar waves can

in harsh environments where sparks, dirt, and dust occur. The

penetrate non-metallic objects. The compact sensors

manufacturer of the new 3D safety system is the Italy-based

with their integrated antennas emit electromagnetic

company Inxpect S.p.A. The LBK safeguards danger zones close

waves. These waves are reflected off objects. The sensors

to machinery and systems. To do this, it uses a radar technology

receive these reflections and then evaluate them. The

that is also used for locating aircraft or ships.

electromagnetic waves of the LBK radar system are

The LBK system operates in a frequency range of 24 GHz.

completely harmless to personnel.

This means that the electromagnetic waves are much shorter

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Multi-purpose, energy-efficient suction cup Piab piab.com The MX suction cup can work across various applications such as bin picking, order fulfillment, box depalletizing, and parcel sorting. This multi-purpose, energy-efficient suction cup has extreme gripping capabilities on many surfaces and materials.

The MX suction cup can create a hard seal when using a low-vacuum flow, contributing to a more sustainable energy output. The MX suction cups are available in five sizes: 35, 42, 50, 57, and 65 mm in diameter and are compatible with our extensive piGRIP fitting program. For extra safety and robustness, opt for the aluminum clamp fittings.

Piab’s MX suction cup is optimal for handling pouches, cardboard boxes, recycled objects, and difficult to grasp bags such a thin bags, plus much more. When you need to address a broad pick spectrum of various objects, the MX suction cup is the obvious choice for all your picking needs.

Stainless steel shaft collars for food processing applications Stafford Manufacturing staffordmfg.com A broad line of over 1,000 stainless steel shaft collars, couplings, and mounting components for applications requiring frequent wash-down has been introduced by Stafford Manufacturing Corp.

These Shaft Collars, Couplings & Mounting Components are machined from FDA- and USDAapproved 303 and 316 stainless steel and are fully corrosion-resistant. Suitable for building food processing equipment, conveyors, and packaging systems requiring frequent wash-down, they are offered in 1-pc, 2-pc, hinged, set-screw, and flanged styles with various bore configurations and special features, including keyways and special mounting modifications.

Suitable for use as stops, spacers, and mounting devices, Stafford Shaft Collars & Mounting Components come in 0.25 to 10-in. standard I.D. sizes, and the couplings come in 0.25 to 3-in. I.D. sizes with standard metric sizes also offered in both. Specials can include threads, keyways, and other bore modifications and external flats, tapped holes, and knurls.

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Ad Index

SALES

Accumold .......................................99

John Evans’ Sons, Inc. .............. 81

Actuonix Motion Devices ........96

Keystone Electronics Corp ........5

AllMotion ...........................................4

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Altech Corporation .....2,3,17,19,21

Master Bond ................................96

Aurora Bearing Company .......36

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Mitsubishi Electric

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binder USA ................................... 97

OKW Enclosures, Inc. ................. 41

Bodine Electric Company ........45

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Boker’s Inc .....................................88

OTTO Engineering ...................... 31

Bunting Magnetics ....................36

PBC Linear .................................... 33

Canfield Connector ....................88

PI (Physik Instrumente) LP ...... 32

Carlyle Johnson .......................... 43

Pyramid Inc. ..................................89

Computer Aided

ROLEC Enclosures Inc. .............. 15

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Smart Products USA .................. 91

Eagle Stainless Tube ................ 35

The Lee Company ......................39

ebm-papst, Inc .............................. 11

THK America, Inc ........................IFC

Fabco-Air, Inc. ..............................101

Trim-Lok ......................................... 23

FAULHABER MICROMO .......... IBC

Verder Inc. .....................................94

igus ..................................................50

Wago ...............................................49

Interpower ...................................... 14

Whittet-Higgins ........................... 25

Ryan Ashdown

rashdown@wtwhmedia.com 216.316.6691

Jami Brownlee

jbrownlee@wtwhmedia.com 224.760.1055

Mike Caruso

mcaruso@wtwhmedia.com 469.855.7344

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FOLLOW US ON A Supplement to Design

World - May 2021 www.therobotreport. com

The Robot Report DreamVu ........................................61

Evolution of Boston Dynamics’ box-moving

Festo ..............................................58 FUTEK Advanced Sensor Technology, Inc. ..................... 71 Honeywell Intelligrated ...........67 MOTUS LABS ..............................59 SICK, Inc. .......................................52

robots

INSIDE:

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• WTWH Media acquires Mobile Robot Guide ...................... .................................53 • Designing an omnidirectio manipulator with 7 DoF nal mobile ...................................62 • 5 critical sensor integration challenges for AMRs ...................... ......................................68

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