DESIGN WORLD OCTOBER 2018

www.designworldonline.com

October 2018

inside: Motion Control: How to kill your favorite

variable frequency drive

p. 84

Linear Motion: Linear motors make

inroads into test equipment

p. 90

3D CAD: How driverless cars will

change design

p. 106

Robots

handle functional testing on nanosatellites page 62

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Monika certainly stood out in the room, often as the only woman amongst hundreds of (mostly graying) men. But what first caught my attention was her utter passion for fluid power. She was constantly asking questions after the technical presentations, probing into the hows and whys of a design and going deeper than anyone else in the room. Her comprehension of the fluid mechanics and physics issues at hand eclipsed most of the rest of us in the conference halls.

Her R&D lab was the subject of some friendly jealousy across Europe, as she successfully attracted major players — and major dollars — to Hamburg. Now, if I was envious of anything, it was that European universities in general were so far ahead of U.S. ones in the field of fluid power… their work with industry and research and development programs were on a different level. I wrote about it numerous times, pleading for change. So, when news broke in 2004 that Monika was leaving Europe — and coming to Purdue University as MAHA Professor of Fluid Power Systems — I knew that this was huge.

Upon starting here at Design World in 2010, one of the first things I did was to call Monika and ask if I could come visit her lab at Purdue and shoot some video. Not missing a beat, she told me to come as soon as I wanted, and we set a date. She was, of course, brilliant on camera, and spoke at length about her students, the projects they were working on together, and her excitement about the future of fluid power. In person, she was as intense as when she was grilling conference presenters, but always incredibly friendly and gracious.

I was so saddened to hear that Monika passed away on August 11 after a four-month battle with cancer. I last saw her in Germany in March. I’d seated myself strategically, to speak with an important speaker at the end of his talk before he snuck out of the room. But the one person who beat me to him was Monika. She winked at me as she flew past, intercepting him and firing off several questions before he could answer the first one.

I’ll miss seeing her at industry events, but I’m grateful for her friendship and her many contributions to the fluid power industry. Today, the United States has a far more advanced role on the world stage of fluid power R&D than it did two decades ago — and I’m sure that a portion of that is due to Monika’s passion, drive, magnetism and leadership. DW Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com On Twitter @ DW—Editor

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Teschler on Topic Living with Dilbert-style

management

Engineers tend to have a dim view of managers, often with good reason.

The comical scenarios depicted in Dilbert cartoons are popular precisely because they hit so close to home for the techies who make up much of the cartoon’s readership.

But despite the impression you might get from the lampooning in Dilbert, sometimes management can have a positive impact. For an example, consider an incident related by Leif Babin, a former U.S. Navy SEAL officer.

For a while, Babin was also one of the instructors who helped put SEAL candidates through the infamous hell week training characterized by little sleep and near constant harassment.

Babin relates a story about a particular class in which one of the student groups, called boat crews, excelled at nearly every task. Another boat crew habitually came in last. This dubious distinction got the last-place finishers extra work and needling from the instructors. It also led to a lot of bickering, blaming, and sharp exchanges among the members of that team.

Then one of the SEAL instructors got the idea of swapping leaders between the two boat crews. Surprise! The

perpetually losing crew began coming in first or second in competitions.

Meanwhile, the other team, perhaps because of good habits previously learned, still put in strong showings.

Babin says the whole exercise was a learning experience for everyone involved.

Readers who feel their superiors aren’t first-rate might be wondering how to go about swapping their own management for the SEAL trainee who ran that boat crew. Unfortunately, bad management is common – so much so that companies try to invent processes that will work even when individual managers aren’t super competent.

Procedures collectively called “structured management practices” are one such attempt. They seem to be beneficial, at least in manufacturing companies. That’s one conclusion from a paper written by a group of economists at the Center for Economic Studies. Analyzing U.S. Census Bureau data from 32,000 manufacturing firms, the researchers – who hailed from Stanford, M.I.T. University College London, and the Census Bureau -found companies that used structured management practices grew faster, were more profitable, had a more productive workforce, and were more

innovative than those that didn’t.

The structured management practices revolve around quantitative metrics, keeping people informed, and paying for performance. For example, researchers asked manufacturers in the study about the number of key performance indicators that were monitored, how frequently managers reviewed them, who at the firm was aware of production targets, and how non-managers were typically promoted.

Higher scoring companies tended to perform better than firms whose management practices were more lackadaisical.

The problem is, of course, the quantification you find in structured management works well when the plant output is something you can count, as is the case with manufactured parts.

But it may not be a net positive where the finished product is more nebulous.

When people use creative initiative to get things done, there’s often nothing concrete to look at. Trying to put numbers on knowledge work can lead to its own Dilbertisms. Real managers know when to quantify and when not to.

With that truism in mind, it would have been interesting to ask the SEAL boat crew leader how many key performance indicators he was monitoring. DW

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

6

October 2018 www.designworldonline.com

Lee Teschler Column 10-18_V2_LT.indd 6

DESIGN WORLD

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Technology Forward The digital transformation—making

design and manufacturing seamless More companies are combining the Internet of Things, Artificial Intelligence, Generative Design and 3D printing into platforms that bring design and manufacturing closer together and transform these functions into a digital process. A number of companies are moving in this direction, including Siemens, PTC, Dassault Systemes, and Autodesk.

The recent Accelerate Conference from Autodesk focused on this trend of connecting design and manufacturing into a single, seamless process, emphasizing the goal of enabling anyone to make anything.

As guest presenter William Bridgman, Chairman, Warren Services, said, “We must stop treating design and manufacturing as separate things.

Digitization is not a choice for manufacturers. It’s a must.”

The usually stated goals of cutting costs are actually a small part of the digital transformation. The real goal is to drive innovation, to enable companies to create unique products that will deliver competitive advantage.

Generative design (GD) is a major engine in driving such innovation.

(Generative design, as viewed here, is the process that delivers hundreds

“The electric light did not come from the continuous improvement of candles.” of possible solutions based on design parameters. It differs from topology optimization, which delivers one solution based on defined constraints.)

A common result of using GD is the exclamation, “I never would have thought of that.”

Thanks to 3D printing/additive manufacturing, these innovative designs can be made. Designer-engineers are not limited to just machining, casting, or injection molding.

The Autodesk strategy is to build a platform, which it has been doing with the purchase of many CAD-based tools like NetFabb and combining them with Fusion 360 and others, and then connect all the components. Then, build a pipeline than automates as many tasks as possible. The next step is to build a community around all of these elements; hence, the Accelerate Conferences. Ultimately, the goal is to move from a task-focused approach to one that shifts resources to those with the best value.

AI, the cloud, GD, and other tools will automate design for automated

manufacturing processes. These tools help the individual designerengineer to expand the problem space rapidly and explore a solution they may never have envisioned.

The cloud will play a key role in this transformation too. Despite concerns expressed by presenters, the next trend will be to share your data among customers and competitors. It will help everyone push ahead faster. Plus, the cloud, as of now, is being viewed as a secure, hack-free zone for data.

In one example, Vincent Wegener, co-founder of RAMLAB, discussed his goal of developing warehouses in the cloud instead of at sea ports. RAMLAB uses robotic-based additive wire welding to make largescale metal parts on demand. He’s addressing spare part storage at places like the port of Rotterdam, which is filled with containers filled with parts. According to Wegener, 60% of the contents of these containers will never be used within a 3-year period. Thus, manufacturers are making parts that essentially will be thrown away as waste. Wegener hopes to eliminate some of that waste.

The tools of the IoT, AI, Generative Design and 3D printing open the doors to potentially truly innovative developments. DW

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

8

October 2018 www.designworldonline.com

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Green Engineering Paul J. Heney

• VP, Editorial Director

Energy Observer Project features zero-emissions vessel

The world’s first oceangoing vessel powered by hydrogen and renewable energy, the Energy Observer, is on a sixyear trip to 50 countries around the world to prove a potential energy system of the future. It has already covered more than 9,600 nautical miles. The vessel is also serving as a media platform, intending to provide positive and inspiring content, demonstrating innovative green solutions.

DESIGN WORLD

Green Engineering 10-18 Vs2.LL.indd 11

Rockwell Automation has become an official supplier and service provider for this project, providing automation systems that help power the vessel, which operates with zero greenhouse gasses or fine-particle emissions.

To help ensure 24-hour energy autonomy throughout its global expedition, the Energy Observer uses a combination of intermittent renewable energy: solar panels, wind turbines, lithium-ion batteries and a hydrogen production system.

The Energy Observer team turned to Rockwell Automation for advanced automation technology to help control the vessel’s energy management system.

The solution consists of an Allen-Bradley ControlLogix programmable automation controller, Allen-Bradley PowerFlex drives, Allen-Bradley POINT I/O, FactoryTalk View Site Edition (SE) supervision software and FactoryTalk Historian data-capture software, all of which integrate seamlessly to monitor and control the system. A central human machine interface (HMI) completes the solution, delivering realtime information to the crew.

www.designworldonline.com

The energy management solution helps the Energy Observer team monitor, control and optimize the distribution of energy sources and make smart decisions about when and how to switch from one energy source to another. It also records the vessel’s operational data throughout its journey and communicates it back to the rest of the team on shore.

One example of this is the lithiumion battery power being used to drive on-board systems such as propulsion and desalination. Solar panels and wind turbines charge the batteries using PowerFlex drives. Should unfavorable environmental conditions cause the battery level to reach 30% or lower, the vessel’s hydrogen power source — fed from hydrogen created during the ocean water desalination process — activates to supply additional charging capabilities.

You can follow the vessel’s journey with the real-time tracking map at: energyobserver.geovoile.com or follow the hashtag #energyobserver on Twitter. DW Rockwell Automation www.rockwellautomation.com

October 2018

11

9/28/18 2:26 PM

Contents 10 • 2018

•

vol 13 no 10

•

designworldonline.com

October 2018

106

Design equipment faster, smarter, and under budget with TiPS from leading suppliers. | istockphoto.com

AEROSPACE COVER_FINAL__10-18.indd 52

9/28/18 2:38 PM

52-82 • The first cable on the moon

84 _MOTION CONTROL

100 _FLUID POWER

How to kill your favorite variable frequency drive

Hydraulic seals keep tunnel boring machinery moving

• How do you size a reservoir for aircraft hydraulic systems?

Though not a complete list, following are

The complex design of tunnel boring

some tried-and-true methods some

machinery requires hundreds of hydraulic

have unintentionally used to destroy

seals to maintain clean, efficient operation.

variable frequency drives (VFDs). Avoid

the following situations to help your VFD

live a long and fruitful life.

90 _LINEAR MOTION Linear motors make inroads into test equipment

New test equipment designs are adopting

linear motors, especially those requiring

low-force applications, where it ‘s

possible to reach higher frequencies and

better performance than with traditional

servo-hydraulics.

• System simulates testing of nanosatellites • Electron Beam Additive Manufacturing process used for fuel tanks

106 _3D CAD

• Space exploration provided explosion in materials development

How driverless cars will change design

Automated vehicles (AVs) will disrupt

the way mechanical engineers work

with their peers and how they share

design information. Here’s what you

can expect.

112 _MECHANICAL

ON THE COVER

New products show us what they’re made of

A Comau robot helps recreate the movement of a satellite in orbit, helping engineers test nanosatellite opertion.

New material advances are allowing

| photo courtesy of Comau

bearing companies to create components with increased wear resistance, higher temperature ratings, and overall increased performance.

12

October 2018 www.designworldonline.com

CONTENTS 10-18_Vs3.LL.indd 12

A | S | B | P| E

A | S | B | P| E

A | S | B | P| E

American Society of Business Publication Editors

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October 2018

DESIGN WORLD

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DESIGN WORLD

Follow the whole team on twitter @DesignWorld

DIGITAL MEDIA/WEB/ DEVELOPMENT

EDITORIAL

VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion

Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave Senior Digital Media Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick

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Customer Service Representative Julie Ritchie jritchie@wtwhmedia.com

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Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

Customer Service Representative Tracy Powers tpowers@wtwhmedia.com

VIDEO SERVICES

Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

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October 2018

15

9/28/18 2:33 PM

Design for Industry Aerospace

True flexibility in

aerospace applications Flexible shafts transmit rotary motion much like a solid shaft, but can be routed over, under and around obstacles where a solid shaft cannot be used. Flexible shafts are used in a variety of applications, including many capacities in aerospace — such as in thrust reverser actuation systems, flap and slat systems, variable bleed valves, jet afterburner nozzle control systems, cargo door actuation systems, valve override and many more.

While used in many systems on various aircraft, one significant aerospace application is to manually actuate valves if the automatic system in place were to fail. Any number of valves may be manually actuated using a flexible shaft assembly, including Air Turbine Starter and anti-ice valves, as well as those applications mentioned in the paragraph above.

The ability to control the valves manually in the event of the automated system’s failure means the aircraft can still be safely “dispatched” on time, avoiding the time and costs associated with having to find a substitute aircraft.

In addition to the ability of flexible shafts to enable manual overrides of aircraft systems that are usually automated, they are also the preferred rotary motion technology in aerospace applications for a number of other reasons.

Benefits of flexible shafts include: • eliminate alignment problems • dampen vibration • absorb shock • accommodate relative movements • possess a 3:1 weight advantage over other design solutions while transmitting greater power loads • lower overall cost due to fewer parts needed and faster installation time • provide greater design freedom than other shaft technologies S.S. White manufactures custom flexible shaft solutions designed for specific applications.

The company produced its first flexible shaft in 1874 for a high-speed dental engine used for drilling teeth. Today, its flexible shafts for aerospace applications are used in thrust reverser, flap, slat actuation systems and manual overdrive systems of air and space craft, in the ammunition magazine drive of the AC-130, in many Airbus & Boeing thrust reverser systems, in the Hubble Space Telescope, on the international space station and as part of the V-22 Osprey’s rescue hoist system. DW

S.S. White | www.sswhite.net

October 2018 www.designworldonline.com 16

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DESIGN WORLD

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

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demonstrated its effectiveness in situations where extreme hot or cold temperatures affect operation. This technology is currently used the Patriot missile system, Growler aircraft, and other applications.

Useful in hazardous applications, it operates without the need for external power, and changing pressure does not affect its function. Specific uses include freeze protection, scald protection, electronics cooling, mixing and diverting fluids, thermal based permissives and others.

The valves incorporate phase change technology to manage temperature’s effect on flow. The key is a refined paraffin wax that changes from a solid to a liquid, or vice versa, at specific temperatures. The temperature at which this wax changes phases is so repeatable and reliable that the ASTM uses it to calibrate temperature instrumentation.

This paraffin wax is incorporated into the Thermoloid material, and allows the valves to open and close.

When the Thermoloid material is heated above its melting point it begins to expand and push on the diaphragm, which in turn pushes on a piston. This piston acts as a valve stem, opening or closing a valve. Then, as the Thermoloid material cools below its melting point it compresses and a spring returns the piston and diaphragm to its cold position. Because of the gradual transition from solid to liquid of this material, these valves act more like modulating valves rather than quick opening/closing valves.

The developers direct acting valves are designed to be open when the actuator is in the cold position while reverse acting valves are open in the hot position. DW

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Design for Industry Medical

Tubing from durable elastomers withstands stresses of pump action

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The Medalist compounds exhibit a low level of extractables, are compatible with a range of chemicals, and can be sterilized by e-beam, gamma, and ethylene oxide. Specialty grades are available for biopharmaceutical applications with extreme low-temperature requirements.

The materials are made with FDA listed ingredients, are certified to ISO 10993-5 standards for biocompatibility, and are REACH SVHC compliant. They are free of DEHP and other phthalates, BPA, and latex.

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Design for Industry Medical

3D printing helps developers

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reinvent orthotics

The North American foot orthotic insoles market is expected to grow to more than 1.7 billion U.S. dollars by 2022, according to a Statista report.

Despite advances in technology and innovative manufacturing methods, custom orthotic manufacturing has not changed much since the 1950’s. The preferred method still in use today by the majority of North American Podiatrists, Pedorthists and Chiropodists is vacuum-forming plastic over a positive of the foot.

This decades old subjective manufacturing method, still taught in colleges, takes no dynamic measurements into the design of the device and the materials used through subtractive manufacturing limit the functional capabilities.

HP Inc. saw an opportunity to use 3D printing to modernize this process. HP formed an alliance with Go 4-D, a 3D printed medical orthotics industry visionary, to create custom orthotics.

As part of the alliance, Go 4-D will distribute FitStation powered

by HP throughout the North American medical market. HP’s FitStation platform combines 3D foot scanning with dynamic gait analysis to enable orthotic recommendations and 3D printed custom orthotics, prescribed from each person’s unique biomechanics. This will enable Go 4-D to manufacture comfortable, precise, and cost-effective custom orthotics using HP Jet Fusion 3D printing systems.

The FitStation platform uses specialized hardware and software components to capture an individual’s unique 3D foot scan, dynamic gait and pressure data. This data is automatically analyzed to provide manufacturing instructions for 3D printed custom foot orthotics. DW

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Design for Industry medical

Distributed antenna system reduces

cabling and connectors

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When the National Highway Traffic Safety Administration (NHTSA)

contracted Diversified Technical Systems (DTS) in 2017 to integrate THOR-50M with SLICE6 in-dummy Distributed Antenna Systems (DAS), it was SLICE6’s military experience that caught the attention of the automotive industry. Developed by DTS for the U.S. Army, WIAMan, the first vertical load ATD, SLICE6 is quickly making its mark in automotive testing for two key reasons. First, its proven track record in extensive laboratory drop tests and live-fire testing. Second, SLICE6’s ultra-compact design and integration solution significantly reduces in-dummy cabling and connectors.

With today’s higher channel count tests, ATD manufacturers are also embracing embedded solutions. The new EuroNCAP “iTHOR” model 477, scheduled to be available in the fall, is manufactured to universally accept several in-dummy DAS solutions, including SLICE NANO and SLICE6 from the California-based DTS. In addition, SLICE6 works with both the NHTSA and EuroNCAP lumbar adjustment design.

A range of SLICE6 Integration Kits are available to support 118, 135, 139, 151 and 156-channels, as well as the 96-ch EuroNCAP and the 100-ch NHTSA configurations. Integration can be done by the ATD manufacturer, in-house at DTS or by the customer. DW

Based on its proven performance in the U.S. Army WIAManvertical load dummy, SLICE6 is quickly becoming the next-gen in-dummy DAS for automotive crash safety.

Diversified Technical Systems | www.dtsweb.com

Direct-mount SLICE6 landing pads on the THOR T12 and femur load cells eliminate all sensor wiring. SLICE6 reduces in-dummy cabling and connectors by up to 75%.

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DESIGN WORLD

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M a c h i n e To o l

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Sealed electronic actuator simplifies upgrade from

mechanical actuation

Electronic actuators in a sealed version simplify the upgrade from mechanical to electronic actuation. Capable of accommodating high mechanical loads, the AC-EM 10 Electronic Actuator facilitates the electronic actuation of Southco’s R4-10 Rotary Latch series and other latching mechanisms.

The AC-EM 10 actuator is efficient, accommodating heavier loads with minimal current draw. When connected to an electronic access control device, it can be used to remotely actuate a mechanical latch to open or unlock a door or panel.

With its small profile design and efficient gear motor operation, the actuator is suitable for concealed applications with physical space constraints. For remotely actuating rotary locks and latches, the AC-EM 10 is tested to IP55 for water and dust protection and can be easily retrofitted using a standard cable connection for manual override. DW

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Design for Industry M a c h i n e To o l

Your Global Automation Partner

Gesture touch operation comes to machine controls The TNC 640 is a mill-turn control with a workshop-oriented operational design. Now it includes touch technology that supplements its cycles and functions. It allows the user to operate the control screen with gestures, similar to smartphones or tablets.

With the TNC 640 touch screen, an operator navigates quickly and intuitively through long lists, programs, tables and other content by what is known as kinetic scrolling. The kinetic scroll converts the impulse of hand contact into a particular scrolling speed. A short, slow swipe scrolls the screen over a few lines, while a long, fast swipe scrolls it over many lines.

The user can stop dynamic scrolling at any time with a short tap. That makes it possible to easily find an NC block, for example, or a tool in long NC programs or tool tables. The user moves the programming and 3-D test graphics directly on the screen—dynamically, smoothly and without jerks. The desired graphic view can be adjusted conveniently by touch. The user can also use touch gestures to zoom in for details and out again, as well as move or rotate graphics.

The minimum requirement for NC Software version is 340 59x-07 SP2. The hardware enabling touch control are the MC8532 main computer and the BF 860 color flat-panel.

These units come without hardware keys as they have been designed for touch operation. The MC 8532 features a 19 in. touchscreen, an Intel Core i7-7-3 processor with 1.7 GHz on SSDR and 4GB RAM memory. The BF 860 offers 4 USB ports. The TE 745 (FS) remains unchanged and does not to be upgraded with the hardware. In that way, the operation of the TNC 640 remains familiar to existing TNC 640 users. DW

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Design for Industry M a c h i n e To o l

Your Global Automation Partner

Servo drive for high axis systems

For high axis count automation systems, Unidrive M750 provides all of the benefits of a modular system with a common dc bus, with standalone drive flexibility. This Digitax HD servo series (0.7 Nm – 51 Nm with 153 Nm peak / 1.5 A – 16 A with 48 A peak) delivers motor control and flexibility from a compact package.

Focused on high overload, pulse duty applications the series also provides continuous servo control, induction motor control, and is initially available with two function levels.

Digitax M753 is an optimized amplifier for high performance centralized control with EtherCAT integrated on-board and simple rotary switches for fast network address assignment.

The flexible Digitax M751 Base option allows design engineers to add up to two option modules from the existing Unidrive M range such as PROFINET, Ethernet/IP or an IEC61131 high performance motion controller for decentralized machine control.

For single and multi-axis configurations, the Digitax HD series offers compactness – the M753 EtherCAT variant is 40 mm wide – that is 5 axes across the width of this A4 piece of paper with 10 mm spare, or 7 axes if you turn it to landscape. The drive is also designed to fit within shallow 200 mm cabinets.

Its Ultraflow system allows machine builders to reduce cabinet size by up to 50% through expelling heat from the drive directly outside the cabinet. This approach also allows the drives to be stacked without the need for a large air channel between them.

The Digitax HD’s has 300% peak performance pulse-duty overload capabilities, along with its 62 µs current loop and 16 kHz switching frequency.

Its flexible speed and position feedback interface supports a range of feedback technologies, from resolvers to single cable digital encoder technologies.

With a wide torque range, from 0.72 Nm up to 85 Nm with 255 Nm peak, rated speeds from 1,000 to 6,000 rpm, several inertia levels and a broad selection of feedback options, Unimotor hd offers the perfect fit for high dynamic applications. DW

Reduce PLC Costs with Multi-protocol On-Machine I/O Expand your communication capabilities and reduce costs with innovative multi-protocol on-machine I/O. Whether you are using one communication protocol or several, Turck ensures you get flexible, futureproof fieldbus solutions. Our vast range of rugged onmachine I/O streamlines your processes and is ideal for out of the cabinet applications.

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1-800-544-7769 www.turck.us

9/28/18 3:48 PM

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

Wheel loader solutions uplift machine and operator performance

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Wheel loader OEMs are looking for ways to optimize profitability and increase market share through

differentiation in today’s competitive market. They aim to shorten time to market and optimize engineering efforts while meeting rigorous safety standards.

Wheel loader OEMs are faced with considerable options and strategies to enhance their machines. The Danfoss team helps OEMs develop wheel loader systems that address their unique challenges. These systems can include steering systems, telematics, working systems, transmissions and thermal management.

For example, optimized joystick steering solutions have shown reduction in operator muscle activity by 65% combined with an increase in machine productivity by 6% compared to conventional steering. Refined driving modes can reduce fuel consumption by up to 15% for hydrostatic transmissions, while maintaining productivity levels and improving operator comfort.

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October 2018 www.designworldonline.com

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Options include electric or hybrid power solutions, which can enable better power distribution management to the transmission and thermal management, while also saving fuel and reducing emissions.

DW

Danfoss | danfoss.com

DESIGN WORLD

10/3/18 1:00 PM

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Design Notes

CT scan helps get new

electric motorcycle on the road Edited by Mike Santora • Associate Editor The design team at Tooling & Equipment International (TEI) had just three weeks to cast, clean, heat treat, machine and inspect a motorcycle swing arm with aggressively intricate architecture. Created by 3D software design company, Autodesk, the swingarm was developed for the Lightning LS-218, an all-electric motorcycle produced by Lightning Motorcycle. TEI, a prototype/ low volume foundry and machine shop, was commissioned

by Autodesk to create the prototype.

“As a prototype casting supplier, we understand time to market is critical for our customers. There have been some job requests we were given three days to complete, and in some cases, only twenty-four hours, but the geometry of this particular design created a significant challenge to complete in the time frame given,” Said Oliver Johnson of TEI. Designed to reduce the mass of the swing arm by 10% while increasing torsional and bending stiffness, the new part will replace

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Designed to reduce the mass of the swing arm by 10% while increasing torsional and bending stiffness, the new part will replace a three-part billet machined into a box section. The organic shape shows what is possible in metal casting and the opportunities that additive manufacturing techniques can bring to metal casters.

DESIGN WORLD

9/28/18 3:55 PM

a three-part billet machined into a box section. The organic shape is an excellent indicator of what is possible in metal casting and the tremendous opportunities that additive manufacturing techniques can bring to metal casters. To ensure the part meets mechanical torsion and bending needs, casting engineers use Computed Tomography (CT) to understand how to improve production quality Medical professionals have been using CT technology since the 1970s.

Now, CT scanning is finding applications as an observational tool in the industrial realm. A CT scan is a three-dimensional density map of any object that can be penetrated by the scan beam. The CT scan is generated from 2D projection images of the part onto a digital detector array (DDA), or from single rows of CT slices from a linear diode array (LDA). Once these images have been reconstructed, CT analysis software

cycloidal reduction gears

allows users to virtually slice the object in any direction allowing them to measure internal structure and flaws. Adoption of this technology enables users to visualize internal structures in ways that previously could only be done by destructive methods.

CT scanning has become an essential tool for many industrial and safety-critical applications where the manufacturer needs to “see” inside an object or measure hidden or hard to reach features without destroying the object in the process.

“With designs as intricate as this one, we couldn’t detect and measure the quality of internal structures correctly with x-ray alone,” said Johnson. “That’s why we relied on the accuracy of YXLON CT to ensure that the integrity of the design was not compromised during the prototyping process.”

CT scanning is an option for applications that require visualizing an

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October 2018

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Design Notes object’s internal features or inspecting it for defects or inclusions with high resolution.

It is gaining in popularity for metrology applications, such as CAD comparison, nondestructive internal measurements (such as wall thickness measurement and geometric dimensioning), and reverse engineering.

Due to the intricacy of the motorcycle swing arm, TEI needed to ensure structural integrity was in place after prototype production. Engineers used white light scanning to do the casting of dimensional measurements and touch probes for inspection of the machined areas. And, as safety is critical when you’re making a part for a motorcycle that can reach up to 218 mph, perfect casting without defects is an absolute must. So TEI turned to CT for internal inspection.

“Our digital x-ray is ok to check some parts, but for premium engineered aluminum castings with complex geometry like the swing arm, CT is superior,” said Johnson. “The crystal-clear images that CT provides allow us to evaluate the quality of the casting integrity without destroying the part. We can measure things, overlay machine parts from the data we export from the CT scanner, and see exactly what we are going to get.”

After TEI’s CT dimensional checks with white light scanning were conducted before and after heat treating, engineers were able to confirm that the two molds both produced good parts and machining operations were completed. The swing arm was ready for the customer within the three-week deadline.

CT scanning can help build confidence in testing results to solve challenging NDT problems facing Additive Manufacturers.

For example, some of the typical flaws that come from the powder bed fusion process are porosity, lack of fusion, balling, which comes from surface tension of the liquid metal, surface roughness, and micro-structural issues. CT scan data makes it fast and easy to identify these issues sooner, reducing time and increasing productivity.

For industrial CT scanning, the ability to see inside an object is beneficial because engineers can view internal structures in their functioning position.

Parts can be analyzed without disassembly. Some software programs

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DESIGN WORLD

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POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

for industrial CT inspection allow for measurements to be taken from the CT dataset. These measurements are useful for determining the clearances between assembled parts or a dimension of an individual feature. CT can also be used to verify geometric dimensions and tolerances (GD&T) in accordance to ISO 1101 and Y14.5 or a comparison against nominal CAD models.

Density variation, embedded features, organic part design, and dissimilar metals or materials are all easily detected by CT better than other NDT techniques. With CT you can scan it and resolve all these issues quickly.

TEI relies heavily on the technology of CT imaging in their prototyping and machining process. Engineers tested their CT inspection system before purchasing and benchmarked it with a complex cylinder head with intricate passageways. The CT scan performed by the YXLON CT Compact detected a collapsed gas bubble that showed up as a small “eyelash� inside the part.

The compact system is equipped with a high-power X-ray tube and a line detector array developed by YXLON. CT Compact generates high energy to effectively penetrate iron components up to 65 mm (ca.2.6-in.) thick and aluminum parts up to 250 mm (ca.9.9-in.). In 30 seconds, you can start analyzing the first CT slices. The mechanical capacity and performance are complemented by a variety of processenhancing software tools integrated into every CT Compact set-up. Automated center determination and beam hardening corrections eliminate the need for time-consuming manual interaction.

Designs like the swing arm are great showpieces, but Johnson believes the impact can go far past prototyping for manufacturers like his company. “You might not see parts like the swing arm on a high- or even medium-volume massproduced vehicle, but you could apply the same approach of advanced CT and non-destructive testing applied to routine manufacturing quality and inspection,� he said. DW

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Design Notes

Transport of the Delta topsides to Hartlepool.

PPU helps pilot barge on

100+ mile journey SafePilot from Trelleborg’s marine systems operation successfully helped pilot Allseas’ 200 meter-long barge, Iron Lady, from the Tees Bay to Able UK’s Seaton Port in Hartlepool, which then transported Shell’s 24,200 ton Brent Delta topside to Able’s facility on 2 May, 2017.

36

Edited by Mike Santora • Associate Editor

The Shell-operated Brent field, is located 115 miles east of the Shetland Islands, in 140 meters water depth, and has been in production since 1976. As part of Shell’s complex Brent Decommissioning Project, the Brent Delta topside, was lifted from the concrete legs of the Gravity Base Structure using single lift technology. This was made possible by Allseas’ 382 meter-long Pioneering Spirit vessel, marking the world’s heaviest offshore single lift. Pioneering Spirit then transported the Brent Delta topside to Tees Bay where it was transferred to the Iron Lady, before embarking on its journey along the Seaton channel to Able UK’s decommissioning port, where around 98% of the platform topside will be recycled.

To ensure the safe and efficient piloting of the Iron Lady to Able UK’s Seaton Port, Tees Bay Pilots, the official maritime pilot group for the ports of Tees and Hartlepool, required holistic oversight of the 1,000 meter-long Seaton Channel.

October 2018 www.designworldonline.com

Design Notes 10-18_Vs3.LL.indd 36

Trelleborg supplied Tees Bay pilots with a Safepilot Portable Pilot Unit (PPU), an “all in one” unit with built in roll and pitch sensors, and SafePilot CAT II, a precise, reliable tool for navigation and berthing, providing all required navigational data.

Mark Green, Senior Tees Bay Pilot, commented: “The pilotage of the Iron Lady and platform topside from Tees Bay to its final resting place at Able Seaton Port, provided the opportunity to use an advanced high accuracy piloting and navigational tool to effect a safe and efficient operation.”

SafePilot PPU software provides a touch screen interface, which facilitates quick interaction to make piloting smoother. The instant zoom function and new intelligent chart structure improves response and decision-making times, giving pilots greater control and more accurate piloting and navigational maneuvers. DW

Trelleborg | trelleborg.com DESIGN WORLD

9/28/18 4:03 PM

kelleramerica.com

rfid pressure transmitters

Keller’s I 2C pressure transmitters are purpose-built for integration into low-power system designs dependent on reliable pressure measurements. These fully compensated digital instruments are available in pressure ranges up to 15,000 PSI with various pressure and electrical connections, and are available in vented, sealed, and absolute -reference versions for maximum versatility. For more information, contact Keller America toll-free 877-253-5537 or email sales@kelleramerica.com.

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Design Notes

Laser bevel cutting system helps

build folding bike Edited by Mike Santora • Associate Editor When Helix Bikes set out to create the most compact, lightest and safest folding bike available, they knew they wanted to automate its manufacturing facilities. A key part of the process was using a LASERDYNE 430 BeamDirector fiber laser machining system to precisely bevel cut the titanium tubing used throughout the bicycle.

Working closely with Prima Power Laserdyne applications engineers, Helix has created a robust bevel cutting capability based on the 430BDY system. For Helix, the steeply beveled edges of the

The steeply beveled edges of the titanium tubing required precise and clean cuts to accomplish perfect fit-up of the tubing for accurate robotic welding.

Additionally, the 430BD fiber cutting system produces holes and slots in the tubular parts.

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Titanium is the ideal material for the Helix Bike design because of its strength, light weight, corrosion resistance and durability. titanium tubing required precise and clean cuts to accomplish perfect fit-up of the tubing for accurate robotic welding. Additionally, the 430BD fiber cutting system produces holes and slots in the tubular parts.

The key is the steep angle bevel cutting of the titanium tubes. The 430BDY capability allowed Helix engineers the flexibility to design the bike assembly for maximum rigidity and strength with the least weight where other tube cutting systems had limited or no titanium angle cutting capabilities.

“A key system feature uses a horizontally mounted rotary table with a through-bore chuck to locate and hold the titanium tubes for cutting to shape. Titanium is the ideal material for the Helix Bike design because of its strength, light weight, corrosion resistance and durability,” said Corey Hansen, regional sales manager for Prima Power Laserdyne.

Titanium can be challenging to process though. The 430BD produces the beveled cuts up to 45° from the surface without dross or spatter residue so tubes mated perfectly ready for the automated welding operations.

No secondary deburring or tube cleanup was needed prior to welding.

Another helpful 430BDY feature is the system’s integrated control of 6-axis laser motion allowing LASERDYNE application engineers to develop the process for anglecutting the titanium tubular components. The 430 BeamDirector system allows bevel cutting as well as drilling cylindrical and shaped holes and welding a range of materials in addition to titanium, all with the same system.

Helix CEO Peter Boutakis stated, “The 6-axis LASERDYNE 430 BeamDirector is fast, flexible and provides the processing that we needed to produce a bicycle for our customers. The addition of the 430BD was a critical aspect of our manufacturing.” DW

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Internet of Things

Secure transfer of process data to mobile devices

T

The TwinCAT IoT Communicator makes it easy for PLCs to communicate with mobile devices by connecting the PC-based TwinCAT controller directly and securely to a messaging service through TLS encryption. For smartphone and tablet users, the associated IoT Communicator App ensures that process data can be represented on all mobile devices in a clear overview. Alarms are sent to the device as push messages.

The TwinCAT 3 IoT Communicator exchanges data using a publish/subscribe mechanism. Since no special firewall settings are needed, integration into an existing IT network is easy. Information is exchanged via a message broker that uses the standardized MQTT protocol and acts as a central messaging service in a cloud or local network. A high level of communication security is guaranteed by proven TLS encryption (up to version 1.2).

Transmitted process data can be displayed on mobile devices using the IoT Communicator App, which is available for both Android and iOS operating systems. The IoT Communicator App also incorporates an integrated QR code scanner to facilitate entry of access data for communication between the broker and individual users.

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The TwinCAT IoT Communicator simplifies the transmission of push messages in industrial applications. It offers a number of advantages over conventional email and SMS messages by visualizing live data, variables and status values.

This makes the IoT Communicator an ideal addition to the related TwinCAT IoT and TwinCAT Analytics software products. DW

Beckhoff Automation | www.beckhoff.com

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Industrial IP67 waterproof PoE+ Ethernet switch

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The LNP-0800G-M12-67-24 Layer 2 unmanaged series switch is dependable and easy to use in harsh industrial environments. The IP67-rated switch was designed for industrial applications that are subject to high vibration and shock.

The switch offers 24 to 55 Vdc redundant power inputs through 4-pin M12 T-coded male connector. A total power of 180 W is available for supplying up to eight IEEE 802.3af (PoE) & 802.3at (PoE+) devices. Built-in fault tolerance ensures against PoE system or PD overloads thanks to the PSE management system. In the cases of complete power failure, the LNP-0800G-M12-67-24 uses bypass technology to keep data communication flowing even if the switch is offline.

Easy to manage, the 8-port 10/100/1000 Mbps LAN M12 ports offer 148,800 pps for fast packet switching with store and forward technology. The 8-pin M12 CAT6A sockets with X-coding female connectors feature auto negotiation speeds, full/half duplex mode, and auto MDI/MDI-X connections. DW

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Internet of Things

The Industrial Internet vocabulary Technical Report V2.1

For motion control innovation, Solution City never sleeps.

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The Industrial Internet Consortium (IIC), an organization facilitating

the adoption of the Industrial Internet of Things (IIoT), announced V2.1 of the Industrial Internet Vocabulary Technical Report. Designed to reduce confusion in the marketplace, the document provides a common set of definitions for IIoT terms used in all IIC documents. It is also intended as a reference for anyone working in

IIoT, including those in IT, OT and vertical industries.

ability of a system or app to communicate The new version of the report serves with other systems or apps via networks. a need in the industry by defining new “Interoperability” means the ability of two or IIoT vocabulary terms that are widely more systems or apps to exchange and use used across many vertical industries. that information.

The report adds definitions for terms “Edge and edge computing are hotly used in data management, edge and debated topics in IIoT this year,” said edge computing, IT/OT convergence, Marcellus Buchheit, one of the primary connectivity, interoperability, brownfield authors of the IIC IIoT Vocabulary Technical and greenfield.

Report, and President & CEO, WIBU-SYSTEMS “People from different backgrounds USA Inc. and Co-Founder, WIBU-SYSTEMS and different vertical industries will AG. “IIoT stakeholders in every industry have often use different terms to mean the been asking ‘where is the edge,’ or ‘what same thing. Additionally, the industrial is edge computing.’ The report defines the internet has core concepts that mean ‘edge’ as the boundary between pertinent different things to different people,” digital and physical entities, delineated said Anish Karmarkar, Co-Chair of

by IoT devices, and ‘edge computing’ as the Vocabulary Task Group, and distributed computing that is performed Senior Director, Standards Strategy & near the edge, where the nearness is Architecture at Oracle. “Without an determined by the system requirements. At agreed upon vocabulary, there’s room the moment, the IIC is the only consortia for misunderstandings. For example, to provide definitions for ‘edge’ and ‘edge we’ve defined IT/OT convergence as a computing.’” process of interweaving IT and OT in The IIC will continue to revise the IIC IIoT order to create IIoT systems. While IT/ Vocabulary Technical Report with definitions OT convergence is a hot topic today, not for new IIoT terms. DW everyone is on the same page as to what it exactly means.”

The report provides definitions for Industrial Internet Consortium data management, including data, data www.iiconsortium.org/pdf/IIC_ at rest, data in motion, data in use, Vocab_Technical_Report_2.1.pdf data integrity and many others to make communication on this subject easier for IIoT stakeholders. The report also clears up confusion on “connectivity” and “interoperability,” which IIoT stakeholders often mix up. “Connectivity” means the

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October 2018

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10/4/18 10:39 AM

Internet of Things

Positioning controllers for industrial Ethernet connectivity

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The devices from the EPOS4 Compact series can now also

be incorporated into EtherCAT networks.

The EPOS4 positioning controllers comply with the CoE standard (CAN application layer over EtherCAT) and can be easily integrated into existing EtherCAT networks.

These units offer real-time communication in a simple, plug-and-play format for controlling brushed dc and brushless

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EC motors (BLDC) with peak currents of up to 30 A. The modular design suits applications with single or multi-axis systems in small devices and machines, as well as robotics.

A range of accessories make the connection and integration process easy. Besides the intuitive “EPOS Studio” software, Windows DLL and Linux Shared Objects Libraries are also available for incorporating the controllers into a variety of master systems. A detailed set of product documents rounds out the offer.

The EtherCAT controllers are available immediately in two power versions: 50V/8A and 50V/15A. Other variants in the Compact series (EPOS4 Compact 24/1.5 EtherCAT & EPOS4 Compact 50/5 EtherCAT) will follow by the end of 2018.

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CAE Solutions Making design upgrades fast and easy

This new version of SOLIDWORLS 2019 includes view manipulation on the scene. Large Assembly Mode, for example, will disable model edges, shadows, real view and more.

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The Canada-France-Hawaii Telescope (CFHT) Corporation operates a world-class, 3.6-m optical/infrared telescope from an observatory atop the summit of Maunakea, a 4,200-meter dormant volcano located on the big island of Hawaii.

When the CFHT Observatory was built in the 1970s, design work was done through drawings. Stacks of vellum were stored at the observatory’s headquarters in Waimea, located in the saddle between Maunakea and the Kohala Mountains.

According to Instrument Designer/Machinist Greg Green, new instrument development, observatory maintenance, and facility upgrades require frequent access to that legacy data.

Green, who has used several CAD packages in the past found he needed a 3D solution for the latest upgrade. “With the myriad of projects and constant upgrades that we face, the more efficiently we can access and adapt existing designs to support new requirements, the better,” Green explains.

Green persuaded management to use SOLIDWORKS Research Edition 3D design software to boost design productivity, improve design visualization, and support greater portability.

Since moving to SOLIDWORKS software, CFHT has cut its design cycles for instrument and facility upgrades in half. One recent example is a dome-venting project that required the installation of large, garage-type doors.

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“Whether I’m opening an existing 3D model or drawing and extruding a sketch, SOLIDWORKS allows me to work faster and smarter,” Green adds. “With fully dimensioned, intelligent SOLIDWORKS models, I can open a design for something that already exists, make some changes—such as taking existing structural steel beams out and putting new beams in—and complete the project quickly and easily.”

The transition to SOLIDWORKS software has improved CFHT’s ability to complete design work on site as well as support compatibility with vendors. “Our manufacturing partners use SOLIDWORKS more than other CAD packages, which simplifies collaboration,” Green explains. “However, what I really like about SOLIDWORKS is that it runs on my laptop, which allows me to do design work when I’m physically at the observatory. I regularly need to be on-site to measure things and model new designs, and can’t pack up a workstation every time I go up to the summit.

Portability is the key, and with SOLIDWORKS, I can take my laptop up to the observatory and model a structural steel beam, for example, while I’m sitting on a ladder right next to it.”

The Maunakea Spectroscopic Explorer (MSE) is a 10-meter-class telescope that is fully devoted to

October 2018 www.designworldonline.com

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CAE Solutions SOLIDWORKS 2019 includes Assembly Performance, which offers a large design review and edit mode, toolbox rotation lock, silhouette defeature, and exploded views overhaul tools. spectroscopic exploration of the universe. The only facility of its kind, MSE will replace the current 3.6-m telescope with a large, wide-field telescope operating a dedicated suite of spectroscopes. By breaking light down into its component colors, or spectra, MSE will give scientists valuable information not available with images alone.

“On the MSE project, we’ve incorporated the design into a model of the surrounding landscape,” Green says.

“Our consultants use the model to support wind flow and structural analysis, and I used PhotoView 360 to render a compelling image of the new facility— including a sunset and section view of the dome. SOLIDWORKS provides the design visualization tools that we need to conduct design reviews while also promoting the project to the public.” DW

Dassault Systèmes | www.3ds.com

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Visualization and rendering features deliver faster views. The AI (Artificial Intelligence) Denoiser uses AI to decipher and eliminate noise from renders, while the integrated Physics Engine & Vehicle Driving Simulator deliver faster scene setup and real-time design review.

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CAE Solutions Altair democratizes simulation access for new-tech and emerging-markets entrepreneurs through Global Startup Program Bruce Jenkins • Ora Research

A

Altair on the last day of July announced immediate availability of its “simulation-

driven innovation” software to qualified startup companies through its newly formed Altair Startup Program. “Tailored specifically to the unique needs of the startup community,” the company says, “the global program offers preferential pricing for its simulation-driven design, computer-aided engineering, cloud computing and Internet of Things software solutions.

The program also provides no-cost expert consulting to quickly ramp up startup organizations with the industry’s leading multiphysics optimization platform, Altair HyperWorks, used by thousands of manufacturers worldwide.”

“The startup community has always been at the forefront of innovation in new and high-growth markets of shared interest,” said Altair Corporate

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Marketing SVP Michael J. Kidder. “This program provides a powerful vehicle for Altair to connect more directly with hardware startups to help mitigate product performance and financial risks early, realize a successful exit, and costeffectively scale for growth with Altair’s open-architecture simulation solutions.”

The program includes full-featured access to all Altair software titles, more DESIGN WORLD

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than 150 Altair Partner Alliance software applications, instructor-led/online/selfpaced training courses, expert consulting support and numerous co-marketing opportunities to build startup brand awareness.

“My business could not exist were it not for Altair, and our working relationship has been absolutely fantastic,” says Adam Wais, owner and startup cosfounder of Rolo Bikes. “We chose HyperWorks because it offers us the most powerful tools for our optimization and development tasks all within one suite. I’m not sure we’d have been able to take what we had to market without Altair.”

The Altair Startup Program is also available to, and can be customized for, business incubators and accelerators who are interested in expanding the resources

available to support startup portfolios.

Altair notes that SMB companies falling outside the Altair Startup Program qualification criteria may still apply for incentivized offers to get started with Altair solutions. DW

Altair | www.altair.com

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The first cable

on the Moon

We all know about “The First Man� on the Moon.

However, when Neil Armstrong took his historic step on the surface of the Moon, he was wearing a bio-belt that was fitted with a Cicoil engineered Biomedical Harness.

Without this important piece of the Space puzzle, who can say that the Moon landing would have taken place on July 29, 1969.

Once NASA was established in 1958, the Race for Space between the USA and Soviet Union began. If the United States was to send a man into orbit, walk in Space or to land on the Moon, then vital signs of the astronauts, such as heart rate, blood pressure, respiration, body temperature, and pulse rate would need to be recorded and evaluated.

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Quick facts of Cicoil’s and NASA’s partnership Cicoil has been a partner to NASA since its inception in 1958.

Cicoil is the only company in history to develop and manufacture a Biomedical Harness that was used successfully on another planetary body — the Moon.

Cicoil was the first company to develop a dedicated zero gravity, low Earth Orbit Biomedical Harness.

Cicoil’s Biomedical Harness was the only tested harness design which met IVA (Intravehicular Activity) and EVA (Extravehicular Activity) needs during all phases of the Apollo Space Missions.

Cicoil has proven internal systems and manufacturing processes that meet all Spaceflight requirements.

When Neil Armstrong stepped onto the surface of the Moon, he wore the world’s first wireless biotelemetry system, which was helped made possible by Cicoil’s innovative biomedical harness design concept.

Through the use of Cicoil’s bioharnesses on the Apollo Space Missions, the first Intensive Care, Emergency Room and Critical Care Unit monitoring systems are introduced.

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| courtesy of Smithsonian National Air and Space Museum

The actual Bio-Harness used by Neil Armstrong during the Walk on the Moon.

“We all know about “The First Man” on the Moon.

However, when Neil Armstrong took his historic step on the surface of the Moon, he was wearing a bio-belt that was fitted with a Cicoil engineered Biomedical Harness.”

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Unlike the Mercury and Gemini missions that focused on historical data, the Apollo missions to the Moon would require continuous monitoring of the astronauts during all intravehicular (IVA) and extravehicular (EVA) activities. Due to the uncertainties associated with the effects of Space flight and normal bodily functions, biotelemetry technology would enable flight surgeons at the Ground Command Center in Houston to identify problems in real time and provide quick solutions.

NASA would need a lightweight, bioinstrumentation harness that could reliably function when continuously exposed to human movement, vibration, zero gravity, and mechanical stress. The cable would need to be flexible, be routed in multiple directions and function well in tight space, especially once placed within the IVA and EVA bio-belts for the Apollo Program flights.

Unfortunately, this task was considered almost impossible due to

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the difficulties of working with stiff and bulky round cable, or even loose wires that would not be able to survive constant physical abuse. However, NASA was fortunate to have a cable supplier of specialty molded flat cables who could hopefully provide a flexible solution to an inflexible problem.

Just as they did while developing the Ultra-Flex IDC Flat Ribbon Cable for IBM and the mainframe computer industry, Cicoil’s engineers were tasked by NASA to solve this problem. Fortunately, they figured out a way to not just encase twisted pairs of multiple AWG sizes within the same thin flat cable, but to precisely control the spacing between each. By creating this durable cable package, electronic interference and crosstalk would be prevented, and the fully terminated harness would provide uninterrupted signal integrity during the harsh rigors of Space flight.

Unlike, the standard straight ribbon cable design, Cicoil also developed a concept of forming the DESIGN WORLD

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Every U.S. astronaut in the history of NASA has worn a Cicoil Biomedical Harness.

cable into various shapes that would save additional space, protect the inner wires during bodily movements and not give up any signal degradation during the entire Space mission. Cicoil was also able to replace stranded wire with extra fine wire into their designs, which would allow the cables to perform exceptionally well in tough environments, but could be formed in 90° angles and even folded over.

Up until this time, the concept was not considered a possibility. However, Cicoil’s out-of-the-box thinking engineers were once again able to provide yet another innovative solution.

In addition to offering an almost impossible space savings design, Cicoil’s biomedical harness was also chosen due to exceptional performance when exposed to temperature extremes (–65° to 260°C); resistance to UV light, radiation, flames, and vibration; high efficiency in dissipating heat between inner cable components; highly flexible and lightweight materials; and high reliability in mission critical applications.

To help prepare for the Apollo 11 Mission to the Moon, the 26-in. long electrical biomedical harness was worn by the astronauts during the Apollo 9 Flight (Commander Jim McDivitt) on March 3, 1969 and the Apollo 10 “Dress Rehearsal” Flight on May 18, 1969. The “Bio-Harness” was worn underneath the Intra-Vehicular Constant Wear Garment when in the Spacecraft, and under the extra-vehicular (EV) pressure suit during Spacewalk activities.

On July 20, 1969, the Cicoil Bio

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Medical harnesses made history by being an integral part of the Historic Apollo 11 First Moon Landing. The Intravehicular Harnesses were worn

by Apollo 11 Astronauts on board the Columbia Command Module during the Lunar orbit and the “Eagle” Lunar Module that landed on the Moon’s Surface.

The Cicoil Extravehicular BioMedical Harness was worn by Apollo 11 Commander Neil Armstrong as he took his historic “First Small Step for Man, and One Giant Leap for Mankind,” and was also worn by Eagle Lunar Module Pilot Buzz Aldrin as he took the famous “2nd Walk.”

The Cicoil assembly successfully enabled continuous monitoring of all vital signs for each Apollo 11 astronaut during flight, orbit, Moon walk operations and reentry back to Earth. The flawless operational performance of Cicoil’s Bio-medical Instrumentation and Telemetry Harness designs were, in NASA’s words, “Vital to the successful achievement” of these history-making flights.

In addition to helping NASA put a man on the moon, Cicoil’s Biomedical Harnesses were also “there” for the First American to Travel in Space in 1961 (Alan Shepherd), the First American Orbit of the Earth in 1962 (John Glenn), the First Space Walk in 1965 (Edward White) and all Space Shuttle Missions.

Today, Cicoil’s Space Flight Approved cable assemblies are utilized on The Mars Rover, Space Transport Rockets, satellites, probes and the www.designworldonline.com

International Space Station.

The mission critical success of biotelemetry in Space was just not beneficial to the Apollo Program, it was also beneficial to all of mankind as well. Today, biomedicine is now found in almost all intensive care units, emergency rooms and critical care units throughout the world, and Cicoil is proud to have played an instrumental part in helping to make this “Giant Leap” in medical technology a reality. AD Cicoil | cicoil.com

| courtesy of Smithsonian National Air and Space Museum

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How do you size a reservoir for aircraft hydraulic systems?

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Reservoirs in a hydraulic system primarily serve as storage tanks to contain sufficient volume of hydraulic fluid and subsequently cater to the fluid demand by the pump during system operation. Additionally, the reservoirs account for the thermal expansion/contraction of the hydraulic dynamic seals.

On a broad scale, the reservoirs are classified into two categories — namely, vented to atmosphere type and not vented to atmosphere type.

The reservoirs that are vented to atmosphere cannot provide a positive suction pressure at the pump inlet. This will lead to cavitation problems in the pump. However, in not vented reservoirs, a positive suction pressure at the pump inlet is always maintained. This is accomplished by pressurizing the fluid in the reservoir either through spring loading, compressed air or use of high-pressure fluid from the system itself.

The chamber that contains the pressurized fluid is called the bootstrap chamber and thus this reservoir is commonly referred to as a bootstrap

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| istockphoto.com

fluid and also provide for acceptable levels of external leakage at the

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Pressure Relief Valve Piston

Pressurized Fluid Chamber

Return Flow Drain

To Pump Inlet

reservoir. Bootstrap reservoirs are commonly used in most civilian aircraft hydraulic systems. While Airbus A320 family and Boeing B737 use bleed air (from engine) pressurized reservoirs, Airbus A350 and Boeing B787 use hydraulic type reservoirs.

Reservoir capacity is one of the foremost things to be defined by the designer. As a rule of thumb, the reservoir capacity should be three times the output rating of a fixed displacement pump operating in the system. That is, if pump rating is 6 lpm, then the reservoir capacity is 18 L. However, in case of mobile hydraulics and in particular aircraft hydraulic systems, this rule of thumb doesn’t hold. Aircraft hydraulic systems operate variable delivery pumps, so the pump output is continuously regulated depending on the requirement. This avoids unnecessary pumping of the fluid.

Because demand is reduced, a designer can opt for a smaller sized reservoir that will eventually result in optimization of critical parameters

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High Pressure Line High Pressure Hydraulic Fluid

like weight and space. In practice, aircraft hydraulic system reservoirs are sized for only 10% capacity of the pump output rating. In addition, few actuators and accumulators may have large volume capacity. Thus one must consider their respective differential volume.

Further, a well-designed reservoir accommodates thermal expansion/ contraction of the fluid due to rise/ fall in fluid operating temperature. For a known value of thermal expansion co-efficient of the fluid (Lt/Lt/Deg.C) and known value of net increase in operating temperature (from thermal analysis), the thermal expansion space can be exactly quantified. As a rule of thumb, about 10% of the reservoir capacity is reserved for thermal expansion. It must be noted here that the presence of an external heat exchanger can greatly reduce the size of reservoir. If an external heat exchanger is not in place, reservoir surface with protruded fins is recommended.

Finally, care should be taken to ensure that the fluid entering the

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To Ground Service Panel

reservoir will not immediately re-enter into the pump inlet port. Sufficient time has to be allotted for the re-entry of such solid contaminants that would settle down and for the fluid to be deaerated. Allowing the aerated fluid into the pump inlet may again result in pump cavitation, defeating the whole purpose of opting for a bootstrap reservoir. To avoid this scenario, baffles are placed within the reservoir to slow down the fluid. All these considerations along with features like on-ground maintenance ports, drain ports, pressure relief valves etc., should suffice the preliminary sizing of a reservoir. AD Contributed by Harshavardhan Joshi Aircraft Hydraulic Systems Engineer CSIR

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System simulates testing of nanosatellites Paul J. Heney • VP, Editorial Director

Comau has partnered with Argotec, an Italian aerospace engineering company, to develop ATENA (Advanced Testing Emulator for Nanosatellite Arm), an innovative system aimed at testing and validating the functionality of nanosatellites. ATENA simplifies simulations of satellite performance, generally carried out through complex numerical analysis and tests of hardware, software, navigation and control algorithms — which generally return results that are difficult to interpret.

The system consists of a satellite or part of it, an electronic control unit and a Comau robot. The nanosatellite (or part) is fastened to the wrist of the robot which, thanks to a closed loop configuration, recreates the movement of the satellite in orbit, during the different phases of a mission.

This solution allows to test all the communication protocols of the system, also verifying the interaction between the various components. The robot chosen is the Racer7 1.4, the fastest in its class, which ensures reliability and precision in a compact mechanism. This new approach is so realistic and versatile that it can be used from the early design stages of a satellite.

ATENA represents a real breakthrough in the aerospace sector. Using the robot, it is possible to monitor the satellite’s functionality and observe its behavior directly.

This provides a more immediate and simple visualization of the test results, as well as the possibility to carry out flight

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demos. Moreover, two or more robots can faithfully reproduce in-orbit satellite docking.

“Argotec is constantly looking for reliable technological solutions which can improve the quality of space systems and also allow possible Earthrelated effects,” said David Avino, Managing Director. “In fact, according to our company vision, everything that is designed for space activities can have an immediate return on Earth, resulting in benefits in our daily life and meeting needs which haven’t been met yet. The ATENA project … represents our dynamic vision,

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our desire to innovate and, above all, the ability to collaborate with a multinational company like Comau, pursuing a common goal: obtaining outstanding results of international relevance by exporting the excellence of Made-in-Italy technology in the world.”

“We are proud to have contributed to the implementation of the innovative project developed by Argotec, in an extremely technological sector such as aerospace, where precision and reliability are essential components,” said Massimo Calvetto, Sales Manager GI Italy of Comau.

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“Our robots have proved to be the right choice to guarantee the achievement of excellent results. Comau is renewed as a leader in the automotive sector, but the company has always been ready to open up and extend its areas of application to all the other sectors as well: our advanced skills, the levels of technological excellence we have achieved and our flexible, modular and high-performance solutions are now also available to the SMEs operating in the General Industry.” AD Argotec | www.argotec.it Comau | www.comau.com

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Electron Beam

Additive Manufacturing

process used for fuel tanks Paul J. Heney • VP, Editorial Director

Sciaky Inc. has achieved qualification for its Electron Beam Additive Manufacturing (EBAM) process, stemming from the completion of qualification testing performed by Lockheed Martin Space on a multiyear development program to create giant, high-pressure tanks, which carry fuel for satellites. The 46-inch titanium fuel tank domes will become the largest additively manufactured parts in space.

Lockheed Martin, which 3D-printed both halves of the 46-inch titanium fuel tank domes on an American-made Sciaky EBAM 110 machine, announced that the tanks met or exceeded the performance and reliability required by NASA, allowing it to become a standard product option on LM 2100 satellites.

Satellite fuel tanks must be both strong and lightweight to withstand the rigors of launch and decade-long missions in the vacuum of space. Even the smallest leak or flaw could be catastrophic for a satellite’s operations, so Lockheed Martin engineers went to great lengths to ensure the tanks would meet NASA’s stringent requirements. In the end, the testing was an overwhelming success.

To top it off, Lockheed Martin reduced production time of the fuel tank domes by 87% while reducing delivery time from two years to three months. Furthermore, with traditional manufacturing techniques, 80% of the expensive titanium material was wasted.

However, with the EBAM 3D printing process, material waste is a nonfactor and the titanium used for printing is readily available, with no wait time.

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“Sciaky’s EBAM technology is now the world’s only large-scale metal 3D printing process that has qualified applications for land, sea, air, and space,” said Scott Phillips, President and CEO of Sciaky. “We are delighted to work with the innovators at Lockheed Martin Space and will continue to push the boundaries of additive manufacturing.”

As the most widely scalable metal additive manufacturing solution in the industry (in terms of work envelope), these EBAM systems can produce parts ranging from 8-in. (203 mm) to 19 feet (5.79 meters) in length. EBAM is also the fastest deposition process in the metal

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additive manufacturing market, with gross deposition rates ranging from 7 to 25 lb of metal per hour. EBAM brings quality and control together with IRISS — the Interlayer Real-time Imaging and Sensing System, which is the only real-time adaptive control system in the metal 3D printing market that can sense and digitally self-adjust metal deposition with precision and repeatability.

This innovative closed-loop control is the primary reason that Sciaky’s EBAM 3D printing process delivers consistent part geometry, mechanical properties, microstructure, and metal chemistry. AD Sciaky | www.sciaky.com

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Space

exploration

provided explosion in

materials development Edited by: Paul J. Heney • VP, Editorial Director

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t The space race led to the creation of many outstanding inventions, which have not only benefited the aerospace industry, but also computer technology, industrial productivity, transportation and consumer technologies. According to Melissa Albeck, CEO of online materials database Matmatch, it was NASA’s determination to solve out-of-this-world problems that led to the creation of many things we take for granted.

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Across NASA’s 60-year history, one in every 1,000 patents granted in the U.S. is believed to have been filed by someone working on one for the organization’s projects. With so many prolific problem solvers, it was inevitable that some of these inventions would make their way into the mainstream and be used in everyday applications.

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The space race resulted in many inventions that have benefited the aerospace industry, computer technology, industrial productivity, transportation and consumer technologies.

NASA spinoff technologies are commercial products and services that have been developed with support from NASA, through research and development contracts, licensing patents, use of NASA facilities or even data from research. The NASA Technology Transfer Program has connected the space agency’s resources to private industry for more than 50 years, leading to the creation of a number of every-day materials.

Some examples follow.

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Memory foam — In 1966, scientist Charles Yost and Chiharu Kubokawa invented ‘temper foam,’ a temperature-sensitive memory foam that aimed to improve the safety of aircraft cushions. Created by feeding gas into a polymer matrix, the foam has an open-cell solid structure that slowly returns to its original shape once pressure has been released.

In 1967, Yost in collaboration with NASA, established Dynamic Systems Inc to commercialize the foam. Since

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then, memory foam has been used for a multitude of applications; from shoe insoles and mattress pads to helmet lining and prosthetic limbs.

Anti-corrosion coating — One of the most destructive forces in engineering is the corrosive effect of saltwater.

This natural process converts a refined metal to a chemically-stable form, such as oxide, hydroxide or sulphide and is particularly prevalent in marine and coastal built environment applications.

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In the 1970’s, NASA researchers discovered that by coating equipment with a protective layer containing zinc dust and potassium silicate they could prevent the corrosion process.

Inorganic Coatings Inc. took this concept one step further in the 1970s, when it produced IC 531 zinc silicate, a non-toxic, water-based coating that bonds with steel to create a ceramic-like finish that prevents corrosion.

Scratch-resistant lenses — There was a time when eyeglasses were made of glass, but in 1972 the U.S. Food and Drug Administration declared that all lenses should be shatter-resistant, which in turn led to the introduction of plastic lenses.

While plastic is more durable than glass, it is much easier to scratch. However, a discovery by NASA scientist Ted Wydeven, would change this.

While developing a water purification system for a spacecraft, he coated a filter with a thin, plastic film.

The surprisingly tough film formed the basis for an abrasion-resistant coating for space helmet visors. The concept was commercialized in 1983 by Foster-Grant to make scratch-resistant sunglasses.

From healthcare and the environment, to education and technology, there are materials and innovation challenges that can draw inspiration from grand engineering, such as the space race. To tackle these issues, cross-sector collaboration, particularly between the public sector and private sector organizations such NASA, will be imperative.

While businesses may be reluctant to share their findings about material applications, resources such as Matmatch’s online materials database can easily supply all the information an engineer might need, from tensile strength to heat dissipation. As we enter the fourth industrial revolution, manufacturing can learn from the attitudes of NASA scientists and their willingness to share knowledge. AD Matmatch | matmatch.com

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Returning to Mars in 2020 — with 3D vision Edited by Paul J. Heney • VP, Editorial Director

In 2020, mankind is heading back to Mars, with the ExoMars Rover, developed by the European Space Agency. The vehicle will be equipped with nine scientific instruments, including one that will be mounted on a two-meter mast on the neighboring planet. Developed by the British Mullard Space Science Laboratory (MSSL), the Panoramic Camera will take stereo images of the planet.

Called Pancam for short, the camera features a rotating filter system in front of its lenses that enables it to take three-dimensional images of panoramic landscapes, close-up structures, and detailed soil samples at various wavelengths. Stepper motors from Faulhaber drive the rotation shaft for the filter change system. Needless to say, requirements for equipment planned for use on Mars are so stringent that nothing quite compares to them.

If the mission for 2020 goes according to plan, the rover will start searching the surface of Mars for past or present biological activity as soon as it lands. This will require not only obtaining soil samples with a core drill, but also performing analyses with an extensive science package.

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The ExoMars Rover is supposed to search for biological activities on Mars after landing. The camera system is mounted on a 2 m high mast. | Source: ESA/ATG medialab

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The panoramic camera consists of two wide-angle cameras, in front of which a rotating wheel with different filters is mounted. This allows three-dimensional, 300-degree-wide panoramic shots. Another high-resolution camera provides additional detail shots.

Meanwhile, the ExoMars Trace Gas Orbiter will stay in orbit, in order to help the rover phone home and ensure that the data and measurement results it collects can make it back home.

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Improved images and protection from dust The ambient conditions on Mars require for every single piece of equipment to deliver unrivalled performance. For starters, the rover will be working under an atmospheric pressure of 0.00636 bar, which is equivalent to the pressure found at an altitude of 35 km on Earth. And to push the envelope even further, the planet is characterized by temperature fluctuations that go from just under 20° to -120° C.

Additionally, the dust kicked up by the rover is expected to have a negative effect on the operational reliability of its high-

precision measuring and analysis instrumentation, which is one of the reasons why the Panoramic Camera will be suspended two meters above the ground on its mast.

“This will, of course, protect the lenses, but there’s another important advantage in that kind of elevated position … that’s the fact that we’ll be able to get significantly better panoramic images,” said Jonathan Jones, a mechanical and thermal engineer at the Mullard Space Science Laboratory, south of London.

While its dimensions of 7 x 5 x 6 cm mean that the Pancam is just as small as an action camera, it also features two lenses that provide it with stereoscopic photography capabilities.

In addition, with the filters in front of these lenses, MSSL has managed to create a system that will be able to

The filter wheel rotates in front of the two wide angle cameras. For sharp images, the lens filters must be positioned exactly.

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Stepper motors adapted to the harshness of the Martian surface drive the rotation axes of the filter wheels and the focusing system of the high-resolution camera.

take pictures at various wavelengths during the mission scheduled for 2020 and use them to generate images with varying content.

“The plan is to send ten images to Earth every day,” said Jones.

While that may not sound impressive, a closer look reveals that this is actually quite an ambitious target. For starters, the camera would generate three pictures for a single image, and these pictures would then need to be superimposed on top of each other and sent to Earth. And then there are the limitations imposed by the low data bandwidth available with radio communications between the two planets, which simply makes it impossible to send more than ten images per day.

Stepper motors position lens filters With its 11 filters, it is possible for the Pancam to take a wide variety of pictures under various light conditions. These filters rotate in front of the two lenses — and must be brought exactly into position in order to obtain sharp images. For driving the rotating filter system, MSSL makes use of two stepper motors from the Faulhaber PRECIstep port.

These two units have been passing the endurance tests currently being conducted on them with flying colors.

During the development process for the camera, British aerospace experts looked for motors that

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would not only be able to deliver reliable and precise positioning performance, but that would also be extremely compact. Stepper motors were the natural choice given these requirements. They are able to precisely position objects with a resolution of 1280 steps per revolution without the need for a separate feedback system — and are also much sturdier and easier to use that conventional servomotors.

Moreover, the stepper motors in the Faulhaber PRECIstep series are able to exactly follow an externally applied field without requiring timeconsuming and complex adjustments.

“While newer technologies are allowing businesses to augment human performance in previously difficult environments, the true benefits lie in an effectively designed and specified device.”

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Laser machining

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Aerospace/Defense

“It is the perfect solution for optical applications, as it can hold the lens position even without current thanks to its residual torque.

Moreover, the control in open loop allows to get rid of jittering effects and therefore obtain very sharp and clear images,” said Sébastien Vaneberg, who works as a Sales Manager at Faulhaber Precistep SA. This Swiss company, which is part of the Faulhaber Group, specializes in miniature stepper motors. “In short, it features a simple electronic system with outstanding availability.”

Miniature motors approved for use on Mars In the camera of the Mars Rover, each drive has a diameter of just 10 mm. The stepper motor counts 20 steps per revolution and is combined with a precision gearhead of the same diameter with a gear ratio of 64:1. On top of this, the company worked closely together with MSSL in order to further customize the engineering behind its two drives so that they would meet the required specification posed by its use on Mars’

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surface. The resulting changes include, for instance, a dry lubricated and custom sintered bearings.

In order to ensure that nothing will be left to chance after the landing, the Mullard Space Science Laboratory is currently testing the components in the Panoramic Camera in a testing environment. The test conditions are even harsher than those on Mars. The positioning drives must complete 5,000 positioning cycles — with temperatures oscillating between -130° and 50° C.

“The test is still ongoing, but the motors are really showing what they’re made of,” said Jones.

During the development of the drives, there was nothing else on the market that could come even close to the Faulhaber units. Not to mention the fact that the company was already a go-to partner for the European Space Agency (ESA), which, together with the Russian Roscosmos space agency, is responsible for getting the ExoMars project to its launch pad by 2020.

A heavy-duty design, wide speed range, and high-power density with a powerful torque are just some of the characteristics that made PRECIstep AM1020 drives the right choice to lift off to Mars. Not to mention, of course, the fact that the simple position control made possible by stepper motors will enable the Pancam rotating filter system to reliably carry out its positioning tasks regardless of how tough operating conditions get. AD Written by Thorsten Sienk

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Aurora Bearing Company 3 Piece Metric Rod Ends.... ideal for high loads or high vibration levels Metric rod end bearings built to DIN ISO 12240-1 ( formerly DIN 648 ) schedule K typically are made with inner races or inner rings made of brass, bronze or copper. For many low demand applications, these bearings have proven to give satisfactory service. However, in applications with high loads and/or high vibration levels, they can quickly develop excess clearance do to the deformation of the softer race material. They are typically manufactured with low carbon steel bodies, with limited high strength options. For applications with high loads or high frequency reversing loads, parts in this type of configuration can give less than desired performance.

Aurora Bearing Company offers 3 different series of parts to address these shortcomings.

The Aurora MM-M and MW-M series parts are made with a low carbon steel raceway. This construction offers ball/race durability greater than brass race parts, with a load capacity comparable to the more common configurations.

For applications with vibratory loads, where the body strength or load capacity is not an issue, but severe demands are placed on the bearing itself, the Aurora KM-M and KW-M series offer a heat treated alloy steel raceway around the alloy steel ball in a low carbon steel body.

Concerning the most demanding applications , those that see high loads and vibratory conditions, the AM-M and AW-M series feature the heat treated raceway bearing construction combined with a heat treated alloy steel body. Combining the standard feature of a one piece steel raceway, the MM/MW-M and AM/AW-M series are also offered with Aurora's exclusive AT series PTFE liner for the optimum in self lubricating/ long life service.

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Eagle Stainless Tube & Fabrication Inc. 10 Discovery Way Franklin, MA 02038 E-mail: info@eagletube.com www.eagletube.com Tel: 1-800-528-8650 Fax: 508-520-1954

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Cost and comfort: a delicate balancing act Consider the assembly before compromising either For commercial airline design engineers and commodity purchasers, the desire to make flying as enjoyable as possible often conflicts with the need for cost savings, potentially leading to compromises that can negatively affect comfort and cost.

If engineers compartmentalize component selection rather than approaching an assembly from a systems perspective, they may choose bearings that cost less on their own but result in a far more expensive overall assembly—and decrease passenger comfort, which is already the worst-ranked* aspect of air travel.

For example: A 3-cent savings per bearing could drive up the assembly cost by 20-30 cents. In a project that uses 80,000 bearings, this would cost the manufacturer $24,000 more than needed.** Plus, if the final design is uncomfortable, such interior components will be a hard sale to make.

By partnering with tribology experts at GGB, engineers and purchasers can take a systems approach to the assembly, revealing unseen costs in the design, incorporating new technologies and improving passenger satisfaction. GGB’s application experts consider the entire tribological system from early in design all the way through manufacturing to ensure reliability, performance and cost-effectiveness. *As reported by 2017 ACSI Travel Report **Based on GGB in-house projections

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J.W. Winco, Inc. Stainless Steel Multiple-Joint Hinges from JW Winco Concealed and highly flexible – these requirements apply to JW Winco’s new GN 7237 stainless steel multiple-joint hinges. They are installed on the inside of flaps, hatches, hoods, trunks, and doors to save space and ensure protection against vandalism. The hinges have a maximum opening angle of 180° that provides optimal accessibility to cargo hatches or maintenance doors on buses, for example. They are generally used in pairs, meaning that one type L (left-hand) and one type R (right-hand) are typically used together per opening. Spacer plates and mounting plates are available as additional mounting accessories.

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LAPP USA Power, Signal and Data in a Single Connector LAPP’s EPIC MH series is a robust, easy-to-install modular connector system capable of transmitting power, signal and data—making it a flexible solution for demanding industrial applications. Capable of 138 million housing variations, it supports power up to 200 A, voltages up to 1,000 V and 10-Gbit/s data rates.

Modules easily snap into a fixed frame, which makes assembling your connector quick and reliable.

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maxon precision motors Drives for Unmanned aerial and ground vehicles Unmanned vehicles, both airborne and terrestrial, need to have reliable components. The devices often face harsh conditions and have to withstand shocks and vibrations without any problems. The drives also need to be energy-efficient for long periods of operation. Maxon DC motors meet all these requirements. Automated production lines help maintain the high quality standards these applications require.

Maxon’s robost brushless series combined with our gearheads are ideal for such applications featuring: • Maximum robustness due to welded connections • High energy efficiency ensures long battery life • High power packed into a small volume • Precise speed or position control • Very high output torque and linear force

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New England Wire Technologies Advancing innovation for over 100 years Why accept a standard product for your custom application?

NEWT is committed to being the premier manufacturer of choice for customers requiring specialty wire, cable and extruded tubing to meet existing and emerging worldwide markets. Our custom products and solutions are not only engineered to the exacting specifications of our customers, but designed to perform under the harsh conditions of today’s advanced manufacturing processes. Cables we specialize in are LITZ, multi-conductor cables, hybrid configurations, coaxial, twin axial, miniature and micro-miniature coaxial cables, ultra flexible, high flex life, low/high temperature cables, braids, and a variety of proprietary cable designs. Contact us today and let us help you dream beyond today’s technology and achieve the impossible.

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Stock Drive Products/Sterling Instrument Comprehensive Mechanical Solutions for Critical Motion Control Applications Aerospace and defense components require high accuracy and tight tolerance machining. Established in 1950, SDP/SI’s combination of design, manufacturing and assembly capabilities allow us to meet the critical tolerances and functionality needs that the defense and aerospace markets demand. Our expertise includes custom design and assembly of gearboxes, planetary gearheads, differentials, and more. Custom material and plating options are available.

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The Lee Company Miniature Latching Solenoid Valve for Power Sensitive Applications The Lee Company’s new Latching Solenoid Valve is the ideal solution for power sensitive applications. By incorporating permanent magnets into the coil design, this miniature solenoid valve offers a dramatic reduction in overall power consumption, particularly when operating with extended “ON” periods. Unlike traditional designs that require continuous voltage to energize the valve from its natural state, this latching solenoid requires only a momentary pulse of less than a Joule to switch to and remain in state.

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Automation & Control Freak?

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How to

l l i k your favorite variable y c n e u q e r f drive ery Paul Avraining

T Product r at e in Eng e a a Americ Yaskaw n io t nd Mo Drives a Division 84

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Though not a complete list, following are some tried-and-true methods some have unintentionally used to destroy variable

Y

frequency drives (VFDs). Avoid the following situations to help your VFD live a long and fruitful life.

e

You once loved your VFD. Shiny and new, it earned rebates

from the local power-supply company so happy to see your facility becoming more efficient (by consuming less power during lightly-loaded conditions). The VFD also earned accolades for driving its connected motor in a way that was electrically and mechanically gentler than alternatives. Plus with its Ethernet option board, it tied into your facility’s ever-expanding network of devices.

But now, the VFD’s reliability has worked against you, and your coworkers think

that it will never break down — and that they don’t need you anymore. So now you must kill that once-loved VFD before there are more of them. Just trip on a fault would be insufficient because you need it to die. But how?

Bad power input into the VFD

A VFD will accept any power sent its way. Enough voltage of short duration (in the form of a voltage spike) exceeding the rating of the bus capacitors will: • Stress the VFD’s capacitors to beyond their breaking point and • Destroy the VFD’s metal-oxide varistors (MOVs) and diode bridges.

Sometimes even lesser amounts of voltage — those that are below the peak value the capacitors can withstand, but present over longer periods of time — can kill a drive.

That’s especially true if there’s no way for the VFD to disconnect itself from the high incoming line. So in the case of spikes, avoid the use of line reactors or instantaneous overload devices if you truly want to end the VFD’s tyranny.

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Under-sizing or overloading the VFD for the application

Wherever a VFD is undersized for the load that it will regularly experience, that drive (with its overload-protection function) will most likely trigger frequent trips. So great — how do we kill the VFD if it’s protecting itself?

Well, overload protection is there to protect the drive components from enduring too much current for too long a time. Key parameters here are current and time because in certain combinations, they may not trip instantaneous overload devices such as fuses. Even so, current over time can contribute to thermal issues that drastically shorten a VFD’s life. Excessive heating-tocooling cycles occur as the drive trips, is reset, and then trips again. This thermal cycling induces the premature demise of critical VFD devices such as IGBTs. Poor cooling of the VFD This VFD was subject to fire. Avoid such situations to make your VFD last longer.

Speaking of cooling, nothing kills drives like too much heat. Some drives will shut down if any of the cooling fans fail. What’s more, nearly every major VFD product has some kind of heatsink temperature monitoring. If the drive gets too hot because the heatsink is caked in oil and dirt, the drive will shut down before the devices attached to the heatsink reach thermal breakdown. So to ensure a premature demise for a VFD, simply run the drive until it overheats and

trips, and then let it cool down … and then repeat this process over and over again without fixing the underlying problem.

Wrong VFD enclosure type

Industrial devices operate in various environments. Each setting presents unique dangers to electrical devices such as VFDs. Specifications for enclosure types from the National Electrical Manufacturers Association (NEMA) outline which can withstand each environment type. For instance, basic NEMA Type 1 enclosures are suitable for indoor settings that aren’t overly dusty. Such NEMA 1 enclosures have solid tops to protect the VFD from falling debris but have vented sides to allow cooling air to flow through to the drive. So if an environment calls for protection from liquids (whether it’s directed from a hose or falling from above) then using a NEMA Type 1 enclosure will surely lead to a very early dirt nap for the VFD. For hose-down applications, a NEMA Type 4 enclosure is more appropriate … and for outdoor rain protection, it’s better to use a NEMA Type3R-enclosed VFD. Unqualified personnel working on VFD

It’s not just a program to protect electricians’ jobs: Having unqualified or unknowledgeable personnel doing VFD wiring or preventative maintenance can

This VFD died after conductive washers dropped into the top of the drive and short circuited the dc bus.

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A VFD will accept any power sent its way. Enough voltage of short duration exceeding the rating of bus capacitors will stress the VFD’s capacitors and destroy the VFD’s metal-oxide varistors (MOVs) and diode bridges ... spell doom for wonderful drive. Let’s just consider things that can go very wrong during initial wiring and operation of the drive.

it’s because some motors are dual voltage, or maybe it’s because some people are unaware, but VFDs are not dual voltage. It’s either 240 or 480 Vac here in (most of) North America.

If you’re lucky and try to apply 240 V to a 480-V drive and discover the error before attempting to drive a motor, you may only suffer slight embarrassment. However, if you apply 480 V to a VFD manufactured to only handle 240 V plus 10% (~264 V) then you’ll quickly discover which device in the VFD is the weakest link.

Switch the VFD input and output power leads — Even though nearly every

major VFD manufacturer defaults to input power terminals on the left and output power terminals on the right, it’s still a regular occurrence that said manufacturers’ repair departments receive damaged drives where the connections are reversed. Some of October 2018

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today’s VFDs can withstand being powered up with the power leads reversed, but the failure rate increases if the RUN button is pressed.

Unintentional single phasing – Most but not all of today’s VFDs can operate with single-phase input … especially in sizes below 100 hp. But to source three-phase power out to the motor while only getting single-phase input power, the internal components of the VFD must be overrated for the application — or else the load must be decreased. Either way, the VFD in singlephase applications must be oversized to endure the increased bus voltage ripple and increased input currents. If your true intent is to ensure the VFD “buys the farm” way before its time, then don’t oversize the drive for the motor in single-phase applications … and wait for the continuous faults and eventual drive failure.

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Miscellaneous VFD abuse and a final serious note

Other things that will also prompt a VFD to cross the river Styx include bashing it with a hammer, running into it with a forklift, lighting it on fire, or purposely short circuiting the dc bus by dropping quarters into the top of the drive.

Of course, this article presents VFD pitfalls in a tongue-in-cheek way. Few engineers would wish ill on their VFDs. These drives improve and simplify a vast array of automated processes. So as a public service, we offer the preceding methods of killing VFD as list of what not to do. With a little care and some reasonable forethought, your favorite VFD will still be there when you finally “leave the building” — and by that we mean retire. DW

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Linear motors

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Alexandre Barthlen European Control Systems Manager

Marcel Harter Student at ESTA Belfort

Joseph A. Profeta III, Ph.D. Director, Control Systems Group

Aerotech, Inc.

Ironless linear motors from Aerotech feature a noncontacting forcer coil and U-channel or flat rare-earth magnet track. The design eliminates backlash and wear and maintenance issues associated with ball screw, belt, and rack-and-pinion-based positioning systems.

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New test equipment designs are adopting linear motors, especially those requiring low-force applications, where it ‘s possible to reach higher frequencies and better performance than with traditional servo-hydraulics.

Motion technologies are central to many test instruments, especially those doing mechanical testing of specimens. Case in point; Dynamic Mechanical Analysis (DMA), where the apparatus produces motion and exerts forces on a test specimen.

Such tests are undertaken in order to better understand the material and can include the dynamic modulus (elasticity, tensile strength, etc.) that describes the relationship between stress and strain in the material. The machines that test specimens typically apply a force and then measure displacement, or cause a displacement and then measure force, or measure velocity and acceleration.

Traditionally these applications use servo-hydraulic actuators and controls.

However, lately there is interest in using electric actuators and servo controllers to provide characterizations not possible with servo-hydraulic solutions, in addition to the “green” factor that electric solutions provide.

Design factors to consider To properly determine material or part characteristics it’s important to create motion or apply forces in a perfect sinusoidal pattern. The quality of the sinusoidal movement/force depends on the actuators, measurement devices, machine frame mechanical structure, and the controller used.

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Aerotech’s ball screw-driven linear stages use precision-ground ball screws pre-loaded to eliminate backlash.

High force applications require servohydraulic solutions, while high frequency, small displacement applications require piezo actuators.

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Depending on the specific application, electric, servo-hydraulic, or piezo actuation may be best. There are a number of factors to consider when designing a system including the magnitude of applied force, the amount of displacement required, the frequency of movement, resolution of displacement measurement required and the control architecture.

The current trend in many manufacturing and test facilities is to be “greener.” This leads to end-users seeking alternatives to traditional servo-hydraulic solutions. Where higher performance is called for, more complicated motion profiles are required, and lower force resolution and better force control are needed.

Two motion types are normally used with samples or the UUT (unit under test): sinusoidal motion or a replica of the motion the UUT will experience in operation.

Sinusoidal motion Sinusoidal motion is required to understand the frequency response of the UUT. Higher performance systems demand higher frequency testing and better sinusoids to stimulate the UUT. Typically phase is not important but amplitude and sine-wave fidelity are critical. In this case, Total Harmonic Distortion (THD) can be used to measure sine-wave fidelity. Achieving this motion is not the usual control problem of minimizing following error but rather ensuring that a perfect sine wave is applied to the UUT over the frequency range of interest. The algorithms used and tuning techniques will differ. When tuning for low servo error higher bandwidth is usually better; however, to achieve low THD, www.designworldonline.com

loop shaping can be more effective. The controller used is as important as the actuation technology. For instance, if the actuator is perfect (no cogging distortion, no friction, and no force limitations) but the motion commanded is imperfect, the results will be equally imperfect and the measurements will be unreliable.

Replicating operation When replicating the motion the UUT will experience in actual operation, it’s necessary to collect data during UUT operation and then replay that on the machine. Here, trajectory generation and controller sample time is critical to represent the motion properly. In playback testing the phase is more important than in sine-wave testing and often machine setup optimizes the traditional servo tracking error. In playback mode it’s usually important to replicate the motion experienced by the UUT in operation (sometimes in multiple directions, i.e. multiple axes of motion) to fully characterize the durability and operation of the UUT. In sine-wave testing usually the material properties are being measured and the fidelity of the sine wave (but not the phase) is important for this calculation.

The accurate and coincident measurement of the displacement and forces applied are important for the accurate measure of modulus, as well as to understand how the UUT responds in actual use. So it’s necessary not only to have the correct actuator but also the appropriate instrumentation (feedback devices for displacement and force) that can be sampled simultaneously, continuously, and with sufficient resolution. To accommodate both types of testing the controller should be flexible October 2018

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enough to switch machine setups quickly to test a variety of samples for a variety of characteristics.

When comparing different motion technologies, the easiest parameter to compare is displacement. Displacement of more than 600 microns eliminates piezo actuators and more than 10 cm rules-out voice coils. Ballscrew-driven actuators are limited to about 30 cm. Linear motors and servo-hydraulics are both capable of 5.0 meter displacements, which is enough for 99% of DMA applications.

Applications requiring forces higher than 50 kN require servo-hydraulic solutions. Iron-coretype motors are applicable below 50 kN and ironless motors are applicable below 10 kN. The highest frequencies (1,300 Hz) can be obtained with piezo actuators followed by ironless motors and voice coils at 1,000 Hz. Servo-hydraulic systems are usually limited to 100 Hz. The smallest displacement resolution, 0.3 nm, is achievable with piezo actuators, followed by 1 nm achieved by servomotors.

Broadly speaking, high force applications require servo-hydraulic solutions, while high frequency, small displacement applications require piezo actuators. Below 10 kN electric motor technology is optimal. Which electric motor technology is selected (ironless, iron core, or voice coil) depends on the displacement and quality of motion required.

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Electromechanical solutions A rotary electric motor is used for system input. And using mechanical conversion, rotary motion is converted to linear motion in electromechanical actuation. The most common technologies used to convert rotation into linear motion include crankshaft and rod, lead screw or ball-screw systems, belt and pulley, and rack and pinion or gears.

The main advantage of these systems is their price. None of the rotary motors used for these applications would be as expensive as a comparable direct-drive linear motor. These electromechanical actuators are suitable for lower performance, less versatile analyzers.

Limitations of electromechanical actuators include: • Less flexibility for variable testing • Mechanical errors such as backlash

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This graph shows the oscillation in the position error (bottom blue trace) without the use of harmonic cancellation.

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Here, the oscillation amplitude in the position error signal is significantly reduced by using an harmonic cancellation filter.

• Limited lifetime due to wear • Disturbances in applied linear motion • Poor accuracy • Complex feedback systems with dual encoders • Larger structures to isolate induced vibration • Displacement limited to 30 cm

drive linear actuation available: cylindrical moving magnet, flat iron-core and ironless, and U-channel ironless linear motors.

Cylindrical moving magnet linear motors Cylindrical moving magnet linear motors were the first electromagnetic linear motors to find significant commercial application because they’re the same shape as hydraulic cylinders Direct-drive linear actuation Direct-drive systems don’t require mechanical making them easy replacements. They work the same way as magnetic actuators (voice coils) but conversion of rotary to linear motion and so with a replicated number of coils to extend the don’t suffer from issues inherent in electrostroke. mechanical solutions. There’s no need to Common limitations of cylindrical moving convert rotary to linear motion and no need magnet linear motors are cogging torque and for rack and pinions or gears or belts and flux leakage. Cogging torque, also known as pulleys. Linear motion is generated by the interaction of magnetic fields and permanent “no current” torque, comes from the magnetic flux and the iron core of the forcer. It causes magnets. There are several types of direct-

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Linear Motor

This plot compares displacement vs. frequency for a servohydraulic system and a linear motor. In the middle range of frequencies (40 to 90 Hz) and displacement (0.8 to 3 mm), both produce about the same motion. However, at higher frequencies the linear motor is superior in the frequencies that can be reached (below 1 mm displacement).

disturbances in motion and in certain cases creates large friction preventing small moves. Cogging torque can even be observed when moving the motor manually, as might occur while attempting to prevent small forces from being applied to soft test materials. Cogging torque may preclude this motor’s use depending on the frequency range and displacement requirements of the mechanical analyzer.

Flux leakage refers to the lack of containment of the magnetic field.

This should be considered with care, especially if other components or the sample under test are sensitive to magnetic fields.

The main advantage of cylindrical moving-magnet linear motors is that they’re compact. The bearing is usually integral with the motor and it can also achieve higher forces than an ironless linear motor.

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U-channel ironless linear motors Two parallel magnet tracks with an ironless forcer running between them form a U-channel linear motor. The device design must have a bearing system to handle the loads required and to maintain the forcer between the magnet tracks. Magnet tracks can be added together for longer travels. Displacement is limited by cable management, the encoder length, the ability to machine long, flat, stiff structures, as well as the machine size and bearing length.

In contrast to cylindrical moving-magnet linear motors, U-channel linear motors are designed to reduce magnetic flux leakage. The forcer is made of coils and epoxy for a reduced mass allowing high acceleration, which is useful for fatigue testing. The key advantage here is that due to the ironless design, there are no cogging forces. As a result, there are a number of advantages: • The forcer can be moved manually when not powered • No motion disturbances are experienced at any velocities • No minimum force limits – very small forces can be applied • No minimum displacement • Freedom to design the bearing system for specified use • Higher accuracy and repeatability • No attractive force – requires lower cost bearings than iron core motors • Less wear of the bearings due to no attractive force equals lower cost of ownership

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The disadvantages include higher cost to force ratio and that it may require a mechanical brake for vertical operation.

Iron-core linear motors These motors have a track with a single row of magnets with coils mounted on an iron-laminated plate to focus the flux towards the magnets. The presence of iron in the motor amplifies the force generation but also causes attraction force between the forcer and the magnet track. This introduces cogging forces that cause errors in the motion. Another variant is the slotted design where the coil windings are inserted into a steel structure to create the coil assembly. This also significantly increases the force output as well as the cogging effect.

Iron-core linear motors do have a few disadvantages including cogging torque and flux leakage. This should be considered with care, especially if other components or the sample under test are sensitive to magnetic fields.

Depending on the final application, these motors could be used when high force is needed. Nevertheless, cogging will cause issues with the motion imparted to

••••••••••••••••••••••••••••••••••• ••••••••••••••••••••••••••••••••••• ••••••••••••••••••••••••••••••••••• ••••••••••••••••••••••••••••••••••• ••••••••••••••••••••••••••••••••••• ••••••••••••••••••••••••••••••••••• the UUT as it will add to or subtract from the force applied resulting in incorrect motion. However, if the displacement is small relative to the pole pitch of the motor, the cogging will not have a significant effect on the motion over the distance traveled – essentially the cogging force will be a constant value. But in this case the controller must be able to eliminate a constant force disturbance. Moreover, if a different size UUT is put in the machine for testing, the amount of constant cogging force applied will be different since the dynamic test will occur in a different location relative to the electrical cycle. To help reduce this phenomenon, magnets could be skewed, but this will not prevent cogging completely.

Voice coils A voice coil works on the same principle as a linear motor but is composed of only one coil and two magnets. Voice coils are easy to control but offer limited stroke and suffer from a decrease in power as the displacement

increases. Voice coils are suitable for applications that don’t require large amplitude but a high frequency, especially for DMA. Electrodynamic shakers often are voice-coilbased systems.

Piezoelectric actuators Piezoelectric actuators use the physical behavior of piezo crystals. In this case, an applied voltage to the crystal causes it to expand, creating linear motion. These actuators are highly reliable and suitable for sub-micron precision applications at extremely high frequencies. However, piezos are expensive compared with other motor technologies.

Servo-hydraulic systems This technology has been the workhorse of the industry for many years. Servo hydraulics are required for high force testing such as hard materials or large industrial parts (e.g., complete aircraft landing gear) for frequencies less than 100 Hz.

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•••••••••••••••••••••••••••• •••••••••••••••••••••••••••• •••••••••••••••••••••••••••• •••••••••••••••••••••••••••• •••••••••••••••••••••••••••• •••••••••••••••••••••••••••• The drawbacks are: • Force disturbances at low force level measurements especially noticeable during reversal of motion • Low accuracy and repeatability due to backlash, hysteresis, and oil sensitivity to aging • Extreme space budget both inside (hoses, distributors, accumulators, etc.) and around the device (e.g., fluid barrels in stock, hydraulic power unit, etc.)

• High cost of ownership (e.g., oil replacement and infrastructure required) • Dirtiness – every hydraulic system leaks

Ironless linear motors These motors are among the newest technology used in DMA. One advantage is that they can be grouped together to create more force. For instance, grouping four motors in one machine yields a continuous force of 6,400 N and a peak force of 25,600 N.

Servo controller capabilities Linear motors require a servo controller. The quality and performance of the DMA machine is equally affected by the controller and amplifier selection. When selecting a controller some consideration should be given to the control law—does the structure minimize tracking errors by including feedforward control and disturbance rejection? The sample time must be sufficiently fast not just for the servo loop computations but also for the amplifier switching frequency and the commutation of the linear motor. To generate a high fidelity 300 Hz oscillation, the trajectory must have sufficient points and the actuating command must be calculated fast enough.

Beyond the basics, what algorithms does the controller have for optimizing the output sinusoid? For instance, advanced time-varying filters can be used to eliminate unwanted harmonics in the motion. Use of a harmonic cancellation filter can provide a drastic improvement in sine-wave fidelity.

When considering the frequency range of interest, the tuning capability of the controller is also important. For instance, measuring the frequency response (bode plot) of the machine and being able to loop-shape the bode plot to meet specific gain and phase criterion in a frequency range can reduce the Total Harmonic Distortion (THD) resulting in higher fidelity sine waves in the frequency of interest.

Another controller consideration is the resolution of the feedback device that can be used. Two common encoders are TTL and Amplified Sine (AS) encoders. TTL have less resolution than AS encoders after multiplication. Controllers that have the ability to multiply the AS signal to fine resolutions (such as 2 nm) will improve the control of the system and allow higher frequencies to be reached.

One final consideration for the controller is its ability to collect data from multiple sensors in real-time. Precise measurements captured at the same sample time of both force and displacement (and sometimes velocity, acceleration, and temperature) are critical inputs to these calculations to characterize the UUT. Other factors to consider are resolution of the measurement, sample period, and how many samples can be collected. DW Aerotech | www.aerotech.com

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Hydraulic seals

keep tunnel boring machinery moving

Daniele Agnesi | Engineering Manager | Hallite Italy

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The complex design of tunnel boring machinery requires hundreds of hydraulic seals to maintain clean, efficient operation.

A global trend in increased spending on road, railway and infrastructure projects is driving demand for the tunnel boring machinery (TBM) needed to do the work.

In countries like China, Japan, Italy, South Korea, Norway, and Germany — where some of the world’s longest and most extensive tunnel networks connect major cities and oftentimes neighboring countries — TBMs are used by public utilities and transport companies to improve mobility of people and goods, minimizing commute time and stimulating commerce.

TBMs are massive, ranging from 1 to 20 m (3 to 66 ft) in diameter, weighing thousands of tons, and more than 100 m (328 ft) long.

Composed of a complex assembly of several systems with circular cross-sections including a rotating cutter head, TBMs are used to excavate soil and rock for development and expansion of railways and utilities like water, sewage, hydropower and pipelines. To contain the pressurized fluids in a TBM’s hydraulic cylinder system and keep it in motion for efficient operation through a specific terrain and rock type, an equally complex configuration of hundreds of high-performance, fit-for-purpose hydraulic seals is required.

Tunnel boring machines help construct the long, complex tunnels that connect cities and | shutterstock.com countries.

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Contamination can cause significant damage to the rod, cylinder wall, seals ... and is one of the primary causes of premature seal and component failure in a fluid power system.

We will examine some specific types of hydraulic fluid power seals commonly used in a TBM along with their material composition. We will conclude by reviewing an innovative sealing application on a TBM used in Italy that demonstrates how OEMs can achieve optimum reliability and productivity when they choose sealing products supported by a manufacturer with deep engineering design and field experience.

Hallite’s P16 singleacting piston seal

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Seals and materials Piston seals, rod seals, rotating/swivel seals and wipers/scrapers are some of the most commonly used seals in a TBM cylinder system. Each seal performs a unique function while working together with many others. Working together, they offer the TBM hydraulic cylinder system the highest level of protection from excavated material.

Piston seals prevent pressurized fluid from leaking across the piston as system pressure pushes the piston and rod assembly down the cylinder bore. Both single- and double-acting piston seals are manufactured in materials such as high-performance polyurethane, rubber/fabric composite, PTFE or polyester elastomer. A piston seal is selected based on the amount of time and work to be done by the cylinder and in what direction and at what pressure. Since a TBM tunnels hard rock over long distances, it requires piston seals designed to operate in heavy duty, high-pressure, high-temperature environments.

Piston seals are used with integrated or separate back-up rings and guide rings.

Guide rings are manufactured of resinbonded fabric and engineered plastics that steer the piston in the cylinder bore and rod in the cylinder head of a hydraulic cylinder, preventing damage from side loading as they hinder metallic contact between axial and rotational components.

Rod seals hold pressure in the cylinder by preventing fluid leaks.

Leakage through the rod seal can reduce equipment performance and in extreme cases cause environmental issues. Rod seals manufactured in high-quality PTFE products combined with an elastomer energizer provide maximum performance.

Wipers composed of high-performance PTFE materials — like Armorlene HLX, a special bronze-filled PTFE based sealing material — offer robust wear and scraping

capability and a large temperature and media compatibility range.

Rotating/swivel seals are designed for slow rotary applications, such as hydraulic swivels, which allow the transmission of pressurized services between the chassis and body of mobile hydraulic equipment.

Seals manufactured of high-performance PTFE provide low-friction qualities that eliminate potential sticking on start-up.

Wipers/scrapers prevent contaminants such as dirt, dust and moisture from entering the cylinder as they retract back into the system. Contamination can cause significant damage to the rod, cylinder wall, seals and other components, and is one of the primary causes of premature seal and component failure in a fluid power system. A wide range of hydraulic wipers are manufactured in high-performance polyurethane, such as Hythane TPEs, nitrile and other polyester based materials. Pressfit metal caged ranges are also available.

The case for Italy Italy is predominantly mountainous and hilly (approximately 77%) making it a major focus for tunnels and host to some of the

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Hallite’s modified R16 single-acting rod seal

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To contain the pressurized fluids in a TBM’s hydraulic cylinder system and keep it in motion for efficient operation through a specific terrain and rock type, an equally complex configuration of hundreds of high-performance, fit-for-purpose hydraulic seals is required. world’s largest road and rail TBM projects.

Consider for example the 15.87-m diameter (52.06 ft) Santa Lucia road tunnel for the A1 motorway near Firenze south of Bologna.

This project involved one of the largest TBMs ever used on a project in Europe.

Others include the 15.55-m (51.01 ft) A1 Sparvo highway tunnel and Sicily’s 15.08m (49.47 ft) Caltanissetta highway tunnel.

Railway work is also a significant focus1.

The Lyon-Turin railway project, one of the largest rail projects in Europe, includes a 57.5-km (35.7 mile) base tunnel that will link the international stations of Saint-Jeande-Maurienne and Suse, reducing travel time between Lyon and Turin from almost four hours to less than two2.

These kinds of projects define the Italian market where demand for reliable, high-quality hydraulic sealing solutions designed to keep pace with the country’s strong TBM market resulted in development of a durable, high-performance sealing application for a local OEM. Hallite developed a sealing system to address a challenge the OEM faced in the heavyduty, high-pressure, and high-frequency — influenced by a short stroke — operation of two crawler tensioning cylinders.

The bore dimension of the first cylinder was 450 mm (17.72 in.) with pressure around 450 bar, and the bore dimension of the second cylinder was 320 mm (12.59 in.) with standard 400 bar pressure and potential peaks of 600 bar. This was impacted by a high gap on the piston and the rod.

To resolve the issue, a sealing package was designed for both cylinders that

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included rod and piston seals manufactured in a range of profiles and PTFE materials, and based on a robust buffer and rod seal designed for high pressure. Included were special modified R16 single-acting rod seals featuring an anti-extrusion ring and supported by the SRB — a unique high-pressure buffer seal design from the Armorlene range. The piston seal assembly included double-acting GP2 seals supported by special P16 single-acting piston seals on each side. The P16 seals feature the same anti-extrusion ring as the R16 for effective, low-friction sealing. Tests performed in the customer’s facility validated the effectiveness of the solution.

As TBM projects increase in Italy and worldwide, Hallite will continue to partner with equipment manufacturers to develop new fluid power sealing materials and technologies to meet their unique requirements. DW Hallite | hallite.com

References: 1: Tracking the world’s Mega TBMs – TunnelTalk, Discussion Forum 2: S2IP consortium wins Lyon-Turin rail tunnel contract - Railway Technology

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How

driverless cars will change design

Jean Thilmany | Senior Editor | Courtesy of Volkswagen

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Automated vehicles (AVs) will disrupt the way mechanical engineers work with their peers and how they share design information. Here’s what you can expect.

Tomorrow’s vehicles will be electrified, connected, and will include many automated functions, including the capability to navigate roads on their own—without a driver’s intervention.

In other words, they’ll be incredibly complex systems comprised of mechatronics, sensors, radar, automated functions, and many other features. And, like other incredibly complex systems introduced within recent years, they’ll disrupt the way mechanical engineers work with their peers and share design information.

The age of the automated vehicle (AV), also known as the driverless car, is upon us, says Scott Shogan, connected and automated vehicles market leader at WSP, an engineering firm.

Government officials and industry leaders expect AVs will begin to make their way to U.S. streets within the next decade, says Shogan, who follows AV trends on the local, national, and international levels.

AVs probably won’t be the personal, driverless cars you may be imagining—instead, they’re likely to take the form of

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ACM uses Prescan, part

of the SimCenter suite of Siemens simulation and test solutions. Designers use the program to physically and virtually test and validate AVs and connected vehicles.

The program produces physics-based simulation of raw sensor data of the potential driving scenarios and traffic situations in which AVs could drive themselves. These simulations help developers better understand how to position Lidar and radar on their vehicles, as well as improve upon many other aspects of design.

AVs probably won’t be the personal, driverless cars you may be imagining— instead, they’re likely to take the form of shared-ride cars or small buses that pick you up at your home.

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shared-ride cars or small buses that pick you up at your home. The driverless vehicle will shuttle you from your door to the nearest automatedbus stop or train station to continue you on your driverless commute, says Shogan.

While AVs may not yet be on the scene, connected vehicles—AVs cousins—are increasingly common today. They include features like advanced driver’s assistance systems with lane centering, adaptive cruise control, and swerve detection, notably seen on Tesla vehicles.

None of these features let the car drive itself, but they do help a driver avoid crashes, Shogan says.

The move toward electric is already underway. GM has announced it will launch AV taxies next year at three sites, Shogan says.

“What they’ll look like we don’t know. But it shows how quickly things are moving.”

Volvo announced it will stop making internalcombustion-engine vehicles in the next few years, Shogan says.

Already there are around 350 types of electrical vehicles on the market, O’Brien says. “There has been a huge increase in the complexity of these electrical systems,” he adds.

Future electric vehicles will use sensors to gather instant information about what’s going on in the world around the vehicle to help automated systems make split-second decisions.

They’ll also include 40 percent more hardware than today’s vehicles and have safety, security, and power demands not seen in present-day automotive needs.

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Systems of design As you might expect, automated vehicle design is a different ballgame as compared to the way non-automated and nonconnected vehicles are designed today.

Whether connected or automated, these vehicles will likely be built on an electric platform, Shogan says.

Engineering AVs and other new, complex machines like collaborative robots require close collaboration among engineers who must take a “systems engineering” approach to design, validation, testing and prototyping, says Martin O’Brien vicepresident of the integrated electrical systems division at Mentor, which makes software for electronic design.

Like cobots, AVs will consist of electrical, mechanical, and software systems as well as sensors that provide feedback about the world around the vehicle, he says.

While CAD has a place in automated vehicle (AV) design, CAD models are part of all the models that make up the larger design system, O’Brien says. The CAD models become part of a model-based system engineering process, which is a method of systems engineering based on creating and exchanging models rather that documents.

All the systems within complex machines like AVs need to be designed to work together, O’Brien says. So software and DESIGN WORLD

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mechatronic models are shared for a systemsengineering approach to design.

A systems-modeling approach allows engineers to bring together all the knowledge from the multiple domains into one location, he says.

“Systems that used to be tested independently of one another are now so tightly integrated that we have to engage all the systems and test them simultaneously,” he says.

“The electrical system has to be designed in the context of the software system and the entire 3-D system.”

Recognizing this, the makers of engineering software are increasingly creating software that can help carry out the design of AVs across the lines of engineering—electrical, mechanical, and software.

The software depicts how all these functions will work together in a real-life operating machine. When the digital systems are all running at the same time and in intended manner, developers often refer to the product mock-up as a digital twin.

SimCenter 3D, from Siemens PLM Software, for example, allows engineers to create models to connect their designs and to carry out 1D simulation, test, and data management functions on those designs, says Dave Taylor, Siemens vice president of global marketing.

While the solution is tied to Siemens NX CAD software on the mechanical-creation side, it can import geometry from any CAD source and prepare analysis models for a range of multiphysics simulations including finite element, boundary element, computational fluid dynamics, and multi-body dynamics, Taylor adds.

Usually a company will use its product lifecycle management system to coordinate efforts across various applications, he adds.

To take the Siemens example, Teamcenter PLM, from Siemens, can be used to coordinate mechanical designs created with Siemens’ NX software, and electrical designs created with Capital electrical design software from Mentor, a Siemens company, O’Brien says.

Once it meets everyone’s specifications, the model of the entire system—the entire AV in this case—becomes the digital twin, used to virtually test the AV. Because the digital twin simulates exactly how a machine will function,

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Future automated vehicles will consist of complex systems that are comprised of mechatronics, sensors, radar, automated functions, and many other features.

Safe validation must include a structured combination of three methods: testing the digital twin, testing the vehicle on a controlled track, and testing it on the actual road. engineers are able to find and fix design problems before the expensive products are produced.

This is where the digital twin comes in.

The digital twin links those models to focus on one aspect of a product or the entire product.

While the CAD model is a part of a digital twin, so are the models that make up the electrical and software systems. Sensor information is incorporated into the digital twin as well, O’Brien says.

“Developing a functioning twin is a systems integration task,” he adds. “Modelbased engineering is central to successful outcomes to integrate functions, devices and signals into the platform.”

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Simcenter allows engineers to share their model across domains to create a systemwide simulation of a product to be used for a digital twin, Taylor says.

A digital twin is increasingly used for testing today because building a prototype to test all the functions of sophisticated machines like an AV or a collaborative robot is often just not possible, O’Brien says.

“Multi-physics simulation is critical for autonomous vehicles, where the digital twin can drive billions of virtual miles and our solutions can predict exactly what’s going to happen in the real world,” Hemmelgarn adds.

Some parts of the AV won’t require a systems-engineering approach.

The way CAD works in the automotive industry today will still be part of the design process when other aspects like electric and software don’t come into play, for example, for the features found inside the AV. Of course, the interior of the vehicle will look quite different than it does today, as there won’t be a need for the steering wheel, or really, the driver’s seat. To save space within

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the vehicle’s compartment, riders might sit facing each other, or they may not sit at all, Shogan says.

But a seat is still a seat. And mechanical engineers will be called upon to use their CAD systems for seat design.

Perhaps the interiors of some AVs will look like the trains in airports that ferry passengers between terminals: they’ll include a few seats around the perimeter, though most of the AV’s occupants will remain standing for their short ride.

On the right track But testing and validating AV design goes beyond the digital twin, of course. Testing the AV needs to happen with a real-life vehicle.

Safe validation must include a structured combination of three methods: testing the digital twin, testing the vehicle on a controlled track, and testing it on the actual road, says Mark

In July, Volkswagen confirmed plans to produce its upcoming all-electric microbus and its crossover vehicle in the United States.

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Chaput, vice president of construction and infrastructure development at the American Center for Mobility (ACM) in Ypsilanti Township, Mich.

The Michigan center is an AV proving ground where the technology can be tested safely. The U.S. DOT designated 10 of these sites in 2017. After a testing period, officials from those sites will their share best practices to safely test and operate AVs. That information will enable participants and the public to learn about AVs and will accelerate the pace of safe deployment, Chaput says.

ACM is an open track that companies come to independently to test their AVs. AVs can operate at the proving grounds much as they would on the street, so engineers can get sensor feedback and, of course, perfect their vehicles.

The proving grounds are necessary because these prototypes need to be tested within a closed environment.

“You won’t be able to develop this

technology in a traditional way,” Chapaut says. “Vehicle makers need to test perceptions of the world around the AVs and traditional automotive proving grounds aren’t equipped for that.”

The test vehicles will need to be tested across millions of miles to verify all its technological functions, he adds.

“AV makers, for example, wonder how to integrate Lidar and radar and the many sensors needed to automatically see the road into their AVs,” he says.

Lidar allows AVs to calculate the distance to an object. It measures the distance by illuminating a target with pulsed laser light and measuring the reflected pulses with a sensor.

In May, ACM brought in Prescan, part of the SimCenter suite of Siemens simulation and test solutions. The program is used to physically and virtually test and validate AVs and connected vehicles.

It produces physics-based simulation

ALL the power.

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of raw sensor data of the potential driving scenarios and traffic situations in which AVs could drive themselves. By running these kinds of tests and simulations, developers can better understand how to position Lidar and radar on their vehicles, as well as improve upon many other aspects of design.

When the AV prototype is finally ready, it can be tested in real life, on the ACM roads, which include stoplights, curbs—essentially everything found while driving on a road, including bikes and pedestrians, Chaput says.

When driveless vehicles finally do become a common part of the landscape, you’ll know the time, commitment, collaborations, and the many tests and validation scenarios that went into their safe creation. DW Siemens PLM Software www.plm.automation.siemens.com

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M e c h a n i c a l

Bearing Materials: New products show what they’re made of

New material advances are allowing bearing companies to create components with increased wear resistance, higher temperature ratings, and overall increased performance.

Advances in the mechanics of basic bearing design are a rarity. They have been for years. The engineers for most companies have already solved their bearings’ fundamental structural challenges.

Consequently, the majority of design changes involve slight, application-specific, modifications to an existing product. But this is not the case for the materials used for bearing components.

Edited by Mike Santora

The demands of ever more extreme environments are keeping bearing engineers busy. Better, smarter, and tougher materials are one way they are handling new challenges. Here are some of the best new examples.

Tribo-Plastic igus has developed a tribo-plastic material for clip and flanged bearings that is highly elastic, chemical resistant and withstands moisture.

The wear-resistant material, iglidur K230, will be used in clip and flanged bearings, which are commonly used in the sheet metal industry. The bearings are

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used because of their ease of installation and design, especially in sheet metal feedthroughs.

Generally, those feedthroughs do not allow a plain bearing to be pressed into a mounting hole or housing. Instead, a bearing must align with the punch hole, which is usually quite rough, and thus guide the shaft safely.

This clip bearing is guided through the hole using the smaller of the two flanges and then clipped into place. The lubrication-free

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The wear-resistant material, iglidur K230, will be used in clip and flanged bearings, which are commonly used in the sheet metal industry.

K230 material is highly elastic and flexible, making it a suitable choice for flange and clip bearings.

In addition to the standard range of clip bearings, there are also customized solutions available for the K230 material.

Its properties are also suitable for bearings in which a second flange is formed after inserting the bearing into the hole. Those bearings are frequently used in reducing friction and noise in car seats, and in other applications that require high flexibility and durability.

Igus reports that its in-house laboratory confirmed that the K230 material resists wear, absorbs moisture only in minimal quantities and offers good universal media resistance. It can also be used in humid environments and in applications in which temperatures reach up to 266° F.

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Hand-machined plastic bearings Anticorrosive, chemical resistant, nonmagnetic and lubrication-free, Kashima plastic bearings are designed for the longterm demands of a range of applications.

Kashima Bearings Inc., a manufacturer of plastic components in Japan, is known for hand-machined plastic bearings.

The dimensional tolerance, linear thermal expansion and water absorption characteristics of the company’s plastics are evaluated with each design.

The company states that it selects the materials for bearings based on users’ requirements, including superengineering plastic. Examples include, PTFE or UHMWPE selected for chemical environments due to their corrosion resistance and non-absorbency. PEEK and PPS are also used for various applications for

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their high chemical and heat resistance and dimensional stability.

These bearings are suitable for applications including the wet environment of the food-processing industry. These plastic bearings do not require grease or oil, they meet the clean-room demands of the semiconductor industry, and they do not rust when exposed to chemical cleaners or rinsing water in semiconductor applications. The non-magnetic design also makes them suitable for use in medical equipment or control units where the development of any static and noise should be prevented.

Specialty lubricants for sintered metal bearings For many bearing applications, the lubricant is as critical to performance as any of the mechanical components themselves. For example, in electric motors or fans, sintered metal plain bearings are often specified over rolling bearings or plastic plain bearings.

In an application like this, it is critical to ensure that the bearing lubricant fulfills the operational requirements of the component in each case.

In addition to specific bearing design requirements, it is essential that sintered metal bearings are impregnated with a highquality lubricant.

Klüber Lubrication has several lubricants specially designed to help sintered metal bearings meet all operational requirements. In this range are universal lubricants for many applications as well as niche products for extreme requirements.

Klüber Lubrication states that it subjects these products to comprehensive testing under conditions typical of sintered bearing applications.

Each lubricant option provides particular benefits for individual application conditions, such as high-speed suitability with lowest self-generated temperature increase, combined with lowest start-up wear characteristics and high thermal stability, thus improving the lubricant’s aging resistance and prolonging bearing service life. Good low-temperature stability preventing squeaking noise, thus ensuring lowest drive power in micro motors.

Oil or fluid?

Klüber has developed both oils and fluids for the impregnation of sintered metal bearings.

Impregnating oils are often recommended for applications at constant rotational speeds. Impregnating fluids are generally the lubricant of choice when more problematic friction conditions are present such as mixed friction, as may occur in applications with

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very high or very low peripheral speeds or frequent changes in the direction of rotation. Fluids often lead to a longer service life of the sintered bearing, and they also enable smoother running. Experience has also shown that the noise behavior of fluids is better than that of oils.

The dimensional tolerance, linear thermal expansion, and water absorption characteristics of these bearing plastics are evaluated with each design.

Light-weight engineered plastic GGB’s EP30, is a recent addition to the company’s lightweight engineered plastics product range. EP30 tribolological material is made-to-order in a variety of standard and custom shapes and provides good dry and lubricated performance in applications as diverse as office and sports equipment, automobiles, domestic appliances, and chemical-processing equipment.

More specifically, EP30 extends the current engineered plastics product range regarding improved temperature resistance and damping effect to reduce noise. It provides the combination of performance and price for certain applications, such as water pumps both in automotive and industrial applications, pulley dampers, automotive interiors, seat sliders, and hydrodynamic applications.

EP30 also provides Good bushing performance in dry working conditions, lubricated or marginally lubricated

™ QUANTiC digital incremental encoder Easy installation

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GGB’s EP30, is a recent addition to the company’s light-

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Igus | www.igus.com Kashima Bearings | www.kashimabearings.com Klüber Lubrication | www.klueber.com GGB | www.ggbearings.com

NEW Network-Capable Absolute Encoder from EPC For EtherCAT communication in a precision absolute encoder, we’ve got your solution.

EPC’s Model A58 features networking capability and is EtherCAT ready. With its minimal setup, you can install these encoders quickly and easily. The Model A58 offers: • 58 mm packages • Shaft or Hollow Bore construction • Variety of mounting options • Flexible, low-cost, and network-compatible industrial Ethernet solution • Maintains position information even in power-off scenarios • Up to 16 bits single turn resolution • Up to 43 bits multi-turn resolution

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Product World Edge programmable industrial controller Opto 22 opto22.com Current IIoT solutions require moving parts, stitched-together software technologies, bolted-on communications protocols, legacy controllers and I/O, and gateways. These solutions are expensive, difficult to troubleshoot, and are unsustainable over the long term. The new groov EPIC system helps solve these problems by combining I/O, control, data processing, and visualization into one secure, maintainable, edge-of-network industrial system. groov EPIC lets engineers and developers focus on delivering value, not on triaging loosely connected components.

Combining intelligent I/O with an embedded Linux real-time controller, gateway functions, and an integrated display,

groov EPIC offers industrial hardware design with a modern software ensemble, to produce results. Connecting legacy systems, controlling processes and automating machines, subscribing to web services and creating mashups, acquiring and publishing data, visualizing that data wherever it is needed, and mobilizing operators—all of these are now within reach. In addition, groov EPIC simplifies commissioning and wiring and helps engineers develop rapidly and deploy quickly.

Non-contact safety sensor Altech Corp. altechcorp.com The SMART non-contact safety sensor SRF protects machine operators from injury by monitoring moveable separating protective devices (such as doors, gates, panels, and hoods) and shutting down or preventing startup of a machine when a device is not properly closed. Additionally, the SRF sensor is the only safety sensor currently integrating an intelligent diagnostic system, which collects data for early detection of machine faults and allows for timely maintenance fixes. Sensors are available with diagnostics function that can be monitored with I/O Link supporting Industry 4.0 implementation and Smart Factory operations.

SRF (Safety RFID) sensors are compact (36.5 x 26.2 x 15 mm)

and will suit any application where safety switches (Type 2) or sensors (Type 4) would be used, including machines for packaging, turning and milling, food processing, woodworking, and injection molding, among many others.

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Product World Right angle gear drives Zero-Max zero-max.com Motion system designers looking for a smooth operating, quiet right angle gear drive will find Crown Gear Drives s suitable choice.

Lubricated for life with Beacon 325 premium grade grease, these Crown drives

have heat treated AGMA Class 10 spiral bevel gears. This combination of bearing design and lubrication formulation ensures long-term, maintenance free operation for high performance, industrial applications. The drives have precision hardened and ground ball bearings handling speeds up to 2000 rpm in most operating environments. The internal gears are permanently mounted to the shafts with the use of a press-fit and locking pins. This provides a very resilient and durable connection for use in heavy load applications while requiring no maintenance.

Lubrication with Beacon 325 grease ensures optimum performance in temperature ranges from -50° to

120° C without evaporation. This is especially important in sealed for life systems using motors, generators and similar equipment in industrial applications.

DESIGN WORLD

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Sensor for hygieniccritical applications Hoffmann-Krippner www.hoffmann-krippner.com The P53 sensor is fully encapsulated in edgeless stainlesssteel housing (rated up to IP68/IP69K, so it’s easy to clean even with harsh chemicals.) It’s robust against dust, moisture, steam, and high temperatures.

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

Very few sensor manufacturers offer sensors or

accessories in hygienic EHEDG-compliant designs, due to the high costs of certified hygienic development.

For this reason, many hygienic-critical applications rely on conventional sensors that require special cleaning considerations.

Thanks to a high degree of protection (meeting lP68

and IP69K ratings), a fully encapsulated gap- free design

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

made of V4A steel, and an allowable temperature range from -15°C to 80°C (5°F to 176°F), the P53 sensors can be easily cleaned with high-pressure or steam jet cleaners as production facilities wash their machines normally.

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

Distributed servo system Beckhoff Beckhoff.com The AMP8000 distributed servo drive system from Beckhoff promotes advanced motion control architectures that are cost-effective, efficient and easily adjustable. By combining a servo drive and servomotor into one device, the AMP8000 system reduces overall packaging machine footprint and space requirements inside control cabinets and enclosures. A single coupling module can operate up to five drives using the EtherCAT P One Cable Automation solution that supplies industrial-grade power and EtherCAT industrial

ratings from 4.10 to 9.7 Nm with an F5 flange. The servo

Ethernet communication.

drive system also represents the Beckhoff commitment

to promoting safety technology in all areas via integrated

Requiring no alterations to the existing machines, the AMP8000 has power

ratings from 0.61 to 1.23 kW and standstill torque ratings from 2.00 to 4.8 Nm

STO and SS1 safety functions.

at an F4 flange size or power ratings from 1.02 to 1.78 kW and standstill torque

Custom Features: • Integrated linear position sensors

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

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

• Internal Cushioning options for deceleration of motion

• Multi-stage telescopic

Visit us at: www.PrinceHYD.com

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Product World Ground fault sensor with large sensing window NK nktechnologies.com The AGT-FD Series ground fault sensors detect faults to earth from 0 to 100 mA and produce an output signal of 0–10 VDC in proportion to the amount of current passing to ground. The output is equal to the RMS value of the earth leakage. The AGT’s sensing window is large enough to monitor 100-amp circuits. It can also be used to measure and monitor any low-value AC circuit current by passing just one of the conductors through the sensing window.

The AGT-FD Series is suitable for monitoring earth leakage current for applications including: electric heating processes, AC motor

loads, semiconductor wafer fabrication, plastic molding processes, heat trace cable systems, and snow melt protection.

Features: • Analog output signal, 0–5 or 0–10 VDC proportional to 0–100 mA • Externally powered, 24VAC or DC(20-30V) • Factory calibrated, warranted to stay accurate for minimum of 5 years • Panel mount or simple snap onto DIN rail

SJ-Series of Preform Jumpers:

A Reliable, Affordable Solution for SMT Design Requirements The reliable SJ-Series from Components Corporation is the first true surface mount jumper developed specifically for SMT applications, offering strength and stability when mounted.

Stainless steel fork sensors Balluff balluff.com These stainless steel fork sensors resist aggressive cleaning agents, chemicals, coolants or other media and provides a solution for demanding

• Ultra-low profile with sufficient clearance for circuit paths.

environments in a variety of applications including hygienic.

The sensors are suitable for the packaging, food and beverage industries.

• No insulation required.

• Available in 1206 and 0805 package sizes.

light sources — red light for easy setup or infrared light source for highly contaminated or environments with water or mist in the air — provides application versatility. The pigtail with M12

• RoHS/Reach/Conflict Materials compliant.

connector and integral LED’s for output function and power on indication aids in fast and easy troubleshooting.

• No alignment required, self-contained through beam sensor

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The new sensors have normally open and normally closed

outputs for easy integration into control systems. Multiple

• PMMA optic lenses and stainless-steel housing for food and beverage applications.

• IP67/IP69K housing for washdown

DESIGN WORLD

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

Epoxy with low coefficient of thermal expansion

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Master Bond masterbond.com EP30LTE-2 has been developed for joining dissimilar substrates exposed to thermally or mechanically induced stresses. It can be used for sealing, coating and encapsulating, especially for small to medium

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sized castings where a very low coefficient of thermal expansion (CTE) is required.

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system with low linear and volumetric shrinkage upon curing. The compressive strength of the cured material is 24,000-26,000 psi and its CTE is 10-13 x 10-6/in/in/°C. It is a reliable electrical insulator featuring volume resistivity of more than 1015 ohm-cm. EP30LTE-2 meets NASA

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Product World Custom linear axes Vention vention.io This platform allows for the design, order and commissioning of automated equipment in just days.

Custom linear axes can be designed and customized in the MachineBuilder, Vention’s free cloud-based CAD. Combined with Thomson Linear’s shafts and linear bearings, this collaboration enable a new range of high-duty cycle applications such as 7th axes, palletizers, cartesian robots, and more.

Benefits: • Accelerated design and delivery of linear axes • Real-time pricing of full solution while designing in the MachineBuilder • Available for timing belt- and ball screw-driven applications • 4 lengths available for next-day delivery (585, 855, 1530, and 2295mm)

Customizations & Accessories for your NEMA 4X / IP66 Nonmetallic Enclosures

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Modifications

• Modifications include: – Custom holes & cutouts – Color matching – Silk screening – EMI/RFI shielding – And many more!

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

500-ft-lb flexible coupling

Precision rotary indexer line expansion

Twin Spring Coupling twinspringcoupling.com

Nexen nexengroup.com

The TSC500 (500-ft-lb) flexible coupling is made

The Motor Ready Sealed (MRS) precision rotary indexer maintains the benefits of its

from two counter-wound torsion springs and

existing roller pinion drive design while delivering significant new benefits. A high

no internal components. This design creates a

roller pinion-to-gear ratio lets users direct drive the system with the addition of a

maintenance free flexible coupling that can work

servo motor – eliminating the cost of a reducer. This also reduces engineering and

at larger angles than traditional universal, CV,

installation time.

Cardan, beam, bellows and other flexible coupling

units, at both low and high speed.

reducer/motor combination. Additionally, the gear-to-pinion reaction loads

are fully supported so the servo motor shaft is not subjected to radial loading,

The flexibility of the springs means it can

For high load applications, the customer can drive the system with a

operate over a wider range of angles and can

which eliminates the need for costly high output capacity reducers in high load

take punishment that would destroy most other

applications. All of these features reduce engineering and installation time.

couplings. The two springs means the unit is also

multi directional offering the same amount of

Features:

thrust in either direction. Minimal backlash and

torsional stiffness creates the ability to swap

one-way repeatability up to ± 5.2 ArcSec

out existing coupling technology and makes the

• Zero Backlash

TSC300 or 500 a suitable choice for engineers

• Acceleration- up to twice as fast as other technologies

looking for an improved customer experience.

• High Speed- up to 304 RPM

• Motor/gearbox ready for faster installation

• Sizes: 150, 250, 350 mm output bolt circle diameter, with large open center

• Fully sealed, IP65 rated

• Low maintenance and Long Life

DESIGN WORLD

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• High Indexing Precision- one-way positional accuracy up to ± 31 ArcSec and

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Ad Index ABB Motors and Mechanical ........... 9 Accumold ............................................ 104 ACE Controls .........................................14 Aignep USA ...........................................41 Allied Electronics & Automation ........ ...................................................Cover,3,83 Allied Moulded Products ............... 126 AllMotion .................................................. 4 Altech Corp ...............................................1 AMETEK DFS ........................................43 Anchor Fluid Power ...........................44 Automation24, Inc. ..............................19 AutomationDirect .................. Gatefold AZCO Corp. ...........................................97 Bal Seal Engineering ........................34 Beta Layout ........................................... 51 Binder USA ...........................................26 Bodine Electric Company ................39 Canfield Industries ............................122 Carlo Gavazzi ..................................... 102 Carlyle Johnson ..................................95 Century Spring ....................................49 CGI Motion ............................................47 Clippard ................................................. BC Components Corporation ..............124 CS Hyde Company .............................114 Del-tron ..................................................87 DeviceTalks .......................................... 119 DieQua ............................................ 33,88 Digi-Key .................................................. 13 Dorner .....................................................94 Encoder Products Company ......... 118 Fischer Connectors ...........................28 Graybar ................................................... 31 Harwin .................................................. 103

SALES

HP 3D Printing ................................... IBC icotek Corp .............................................41 IDEC Corporation ................................115 IKO International Inc. ........................ 89 ITT Enidine ............................................121 Keller America ...................................... 37 Keystone Electronics Corp. ......23,117 Madison Co. ......................................... 98 Memory Protection Devices ............ 17 Nason ......................................................111 NBK America LLC .............................. 109 NTE Electronics, Inc. ........................ 125 OKW USA ............................................. 105 Opto 22 ..................................................42 Oriental Motor ....................................48 PBC Linear .......................................20,21 PCB Cart ................................................38 PHD Inc. .................................................45 Prince Manufacturing Co. ..............123 Renishaw ............................................. 116 ROLEC ..................................................... 15 Rotor Clip .............................................. 99 Rutronik ..................................................18 Smalley Steel Ring ..............................10 Smart Products USA ............................7 Sorbothane .........................................122 Southco ................................................... 5 The Lee Company .............................97 Tompkins Industries, Inc. .................92 Traco Power ........................................ 96 Trim Lok .................................................. 22 Turck ........................................... 25,27,29 Whittet-Higgins ...................................35 Zero-Max, Inc. ........................................ 2

Jami Brownlee

jbrownlee@wtwhmedia.com 224-760-1055

Mike Caruso

mcaruso@wtwhmedia.com 469.855.7344

Garrett Cona

gcona@wtwhmedia.com 213.219.5663 @wtwh_gcona

Bill Crowley

bcrowley@wtwhmedia.com 610-420-2433

Michael Ference

mference@wtwhmedia.com 408.769.1188 @mrference

Michelle Flando

mflando@wtwhmedia.com 440.670.4772 @mflando

Tom Lazar

tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom

Jim Powers

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

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LEADERSHIP TEAM

Publisher Mike Emich

memich@wtwhmedia.com 508.446.1823 @wtwh_memich

Managing Director Scott McCafferty

smccafferty@wtwhmedia.com 310.279.3844 mfrancesconi@wtwhmedia.com @SMMcCafferty 630.488.9029

Mike Francesconi

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dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david

EVP Marshall Matheson

mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

Neel Gleason

ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

Aerospace & Defense Tips Supplement Aurora Bearing Company ..................70 Eagle Stainless Tube ...................... 74,75 GGB Bearing Technology ................... 68 J.W. Winco, Inc. .......................................70 Lapp USA, Inc. .........................................53 maxon precision motors .......................61 New England Wire Technologies & New England Tubing Technologies....... ...................................................................... 69 RelChip ........................................................ 71 SDP/SI-Stock Drive Product ................76 The Lee Company ................................ 77

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