DESIGN WORLD SEPTEMBER 2018

www.designworldonline.com

September 2018

inside: Motion Control: Motors boost efficiency and

torque

p. 58

Linear Motion: Linear actuators based on

shape-memory alloys

p. 66

Internet of Things: Intelligent machines

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p. 74

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Mission Possible: Sending bearings into space page 82

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Telling the stories of women engineers My alma mater, Georgia Tech, is known as an engineering school.

When I was in college a couple of decades ago, we didn’t have many nonengineering degrees even offered. If you decided you didn’t want to go the engineering route, you could go into business or architecture, but there wasn’t a whole lot more. As a result, the “ratio” — famously quoted by male undergrads at Tech to complain about the lack of suitable potential dates — was about three to one.

Today, those numbers aren’t much different. According to the Society of Women Engineers (SWE), in the United States, women have increased their numbers in many professions previously dominated by men, including law, business, medicine, and other STEM — but the number of women in engineering in the U.S. has not increased since the early 2000s.

Most studies show that, depending on the exact field, females make up somewhere between 12% and 14% of the domestic engineering workforce. So, we certainly have a long way to go in encouraging young women to pursue engineering careers.

What’s more, while women have always made important contributions to the engineering field, they have not often been acknowledged. The editorial staff at Design World is undertaking a new project, where we will recognize women in different points in their engineering careers, across our industry.

We’ll be unveiling a special Women in Engineering issue in November, and it will celebrate some of the most inspiring women in the design engineering space. Our editorial team will highlight female engineers who are positively influencing design technology or engineering practices. And I’m proud to say that fully 50% of the gross proceeds from this issue will be donated to charity or scholarship relating to STEM/STEAM work. The women we profile will together choose the donation recipient.

So let me throw it open to you: Do you work with any brilliant, creative and driven female engineers, the type of coworkers whose accomplishments could serve as an inspiration to young women? If so, please drop me an email at the address below with their story, so we can follow up with them in advance of the issue. DW

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Teschler on Topic Are non-STEM courses the secret

to good engineering?

Most engineers who have cable are probably familiar with the original Mythbusters show which ran for 14 seasons on the Discovery Channel. It made celebrities out of the cohosts, Jamie Hyneman and Adan Savage, who used elements of the scientific method to test the validity of rumors, myths, movie scenes, and urban legends.

Hyneman and Savage may have been, for a time, the most well-known techies in America. They drew crowds when they made public appearances, and they were known as big promoters of STEM (science, technology, engineering, and math) education.

The irony, though, is that neither Hyneman nor Savage has a STEM background. Hyneman has a bachelor’s degree in Russian linguistics (though he also received an honorary engineering Ph.D. from Villanova). Savage doesn’t mention any university degree in his past, though he, too, has an honorary Ph.D. However, the Mythbusters duo have a solid background in the arts. Savage has been a graphic designer, carpenter, and model maker. Hyneman has been an animatronics technician and runs a company that specializes in creating special theatrical effects.

You’d have to say that their arts background and lack of STEM

credentials didn’t seem to prevent either of these two from doing some pretty interesting and wellthought-out engineering work.

And that conclusion would fit with a recent study coming out of the National Academy of Sciences. The Academy says employers, even the high-tech kind, put critical thinking, communication, and teamwork on a par with technical skills. And those soft skills are more likely to come from an educational process that integrates STEMM (the extra M stands for medical) work with humanities, arts, crafts, and design (HACD) practices.

It turns out there is a lot of evidence that adding HACD topics can improve performance in STEMM. Robert Root-Bernstein, a MacArthur Fellow at the Mich. State University Physiology Dept., reports that individuals who practice the arts are more likely to file patents than those who are less artistically inclined.

Similarly, he’s also found that STEMM workers who pursue wood and metalworking, painting, and music composition are more likely to file patents and start companies than those who don’t.

Root-Bernstein says STEMM practitioners often link HACD with STEMM practices via mental tools for thinking that include observing, imaging, abstracting, pattern recognition, pattern forming,

dimensional thinking, analogizing, empathizing, modeling, playing, and transforming between various ways of thinking. For example, drawing develops observational and visual thinking skills that facilitate STEMM learning. Musical teaching improves visual and aural observational skills among STEMM students. And having to come up with a scientific game or model develops transformational and synthetic thinking skills more fully than does just playing one.

Some colleges are already trying to integrate HACD ideas into STEMM classes.

The NAS report cites a class at the Olin College of Engineering in materials science that incorporated elements of history. In fact, it was co-taught by engineering and history faculty. Students in the course were more motivated and engaged than those in ordinary mat sci classes. Additionally, students claimed they used critical thinking skills in their work more frequently than those in the ordinary course.

The NAS report says courses like Olin’s history/mat sci effort help teach complementary principles and ideas in a way that helps prepare students for real-world problems that span disciplinary boundaries.

But I think the report writers may have missed the most important reason for mixing in arts and humanities classes with the standard STEMM fare: The combination just makes potentially dry STEMM training a heck of a lot more fun and easier to tolerate. DW

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

6

September 2018 www.designworldonline.com

Lee Teschler Column 9-18_V3_LT.LL.indd 6

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Technology Forward

Is the IoT still hype or a good solution?

When the Internet of Things arrived on the scene a few years ago, it seemed like déjà vu for me, especially in applications of discrete manufacturing. Back in the late 1980s and early 1990s, connecting discrete manufacturing machinery and systems to various versions of Ethernet was all the rage. Back then, the goal was to gather tons of data from Ethernet and send them to executive suites for “dashboard” applications on computers that gave executives a look at every click, every switch, every On/Off point generated by all the equipment on the manufacturing floor.

It wasn’t long before executives were saying it was too much data, and manufacturing moved to “management by exception.” All that data proved equipment was running well, and the only time anyone needed to get involved was when a switch didn’t flip, or a click didn’t happen. These developments led to preventive maintenance services and more efficient planning of equipment operation to take advantage of time periods when the cost of energy was low.

So how is the Internet of Things different from the activities of those days? Some users installing IoT systems report some savings and productivity improvements. But were these savings because they hadn’t taken advantage of the developments back in the ‘90s and only now have done so? In several cases, that was the scenario — making the IoT approach a bit less impressive.

The Internet of Things arose out of a speech given by former GE CEO Jeff Immelt. Under Immelt, GE made a large commitment to bring Internet connectivity to all departments and branches and reap the benefits of data collection. In a recent conversation with Rich Carpenter of GE Automation & Controls, Carpenter brought up some things GE has learned over the last several years.

Most IoT systems are heavy users of the Cloud. But, as Carpenter notes, the cloud does not solve all problems. Huge amounts of unanalyzed data are stored on the cloud, usually at a high cost. To Carpenter, and a number of other users of the cloud, cloud-only solutions no longer make sense. Carpenter believes the next iteration of the IoT will involve edge devices and the cloud. Edge devices will bring analytics closer to the production situation, reducing the amount of cloud storage needed.

Increasingly, customers will see a field agent, a gateway, or a platform for

running analytics near equipment.

However, IoT is still at the stage of collecting lots of data then discovering what data is necessary for analysis.

The low-hanging fruit of the IoT is to use the data in preventive maintenance, something that discrete manufacturing has been doing for a couple of decades now.

One notable development is that increasingly, machine maintenance is being pushed back to the OEM by the customer. Depending on the industry, IoT equipment can be useful to handle this situation.

Carpenter sees changes coming to software analytics. Customers are interested in software platforms they can customize. Analysis programs will get to the point where they behave like PC software, upgrading on their own as analysis programs determine. According to Carpenter, that’s the end goal.

Still, the IoT industry seems very much to be a solution looking for a problem. But who knows? With strong software analytics, maybe IoT will solve more manufacturing efficiency problems. DW

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

8

September 2018 www.designworldonline.com

Tech Forward 9-18_Vs2.LL.indd 8

DESIGN WORLD

8/30/18 8:37 AM

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Green Engineering Paul J. Heney

• VP, Editorial Director

Car heating technology for EVs Zemission has developed a zero-emission catalytic burner for heating in electric and hybrid vehicles. The device promotes the uptake of plug-in electric vehicles (EVs) by increasing their driving range.

With EVs and plug-in hybrid EVs (PHEVs), the waste heat from internal combustion engines normally used to warm passengers is either not available or insufficient. This is creating a growing need for auxiliary cabin heaters. In cold climates with a -7° C, studies show that the battery of EVs suffer a decrease in range of up to 60%.

Some 3 million hybrid vehicles will be built by the year 2020, and an estimated 9 to 10 million by 2025. Rising sales of EVs and PHEVs are therefore creating a need for either fuel-operated or electric-powered auxiliary heaters. However, currently available fuel-operated heaters produce levels of emissions that do not comply with current regulations. And electric heaters drain the main battery of power, depleting vehicle range.

The EU-funded Horizon 2020 z-BURN project addressed this challenge by helping

commercialize a novel burner developed by the Swedish company Zemission, which uses catalytic combustion to give clean, flameless combustion.

“We have developed and tested a patented device that is simple, silent, can be fuelled with any liquid biofuel and boasts superior efficiency with zero emissions,” said CEO and project coordinator Anders Vestin.

Catalytic combustion involves the oxidation of hydrocarbon fuel, which takes place in the presence of heat and a catalyst. There is no flame involved, and no nitrogen oxides are formed due to the relatively low temperature.

Advantages include long life, robustness, and compact size. The burner can be used in autonomous heaters to avoid increased emissions and the rapid battery depletion experienced with off-the-shelf auxiliary heaters.

“For passenger vehicles, z-BURN offers a world-beating solution that minimises the impact of cold climates on passenger comfort and vehicle performance,” Vestin said. “For commercial vehicles z-BURN provides a solution with multiple

applications like cabin heating, battery heating, and the heating of exhaust after treatment systems.”

End customers include hybrid vehicle owners around the globe; the burner will make a significant impact on driving range, as well as allowing the battery pack to be reduced in size.

“The project’s key result is a better understanding of the total market and the needs of our main customers and contact with new potential customers, it was also extremely valuable in updating our business plan. For example, we found there is also great need for this technology in heavy goods vehicles,” said Vestin. z-BURN provides a better understanding of the market and the requirements of customers like the procurement and technical development departments of large automobile manufacturers, such as the Volkswagen group.

“We achieved a deeper appreciation of the main challenges currently facing the industry, including which type of vehicles will be early adaptors of the technology, and where there is the greatest willingness to invest in solutions.

The next stage is to industrialize the heater and build the supply chain,” Vestin said. DW

| istockphoto.com

promises zero emissions

Zemission | zemission.se

DESIGN WORLD

Green Engineering 9-18 Vs1.indd 11

www.designworldonline.com

September 2018

11

8/30/18 8:46 AM

Contents 9 • 2018

•

vol 13 no 9

•

designworldonline.com

Medical www.designworldonline.com

58 58 _MOTION CONTROL

82 _MECHANICAL

Motors boost efficiency + torque

Mission possible: Sending bearings into space

Seven innovations that advance medical device design Medical Tips cover 9-18_FINAL.indd 103

• 3D printing or injection molding?

Which is better for medical devices?

With a few tweaks in design, transverse flux motors with internal permanent

A new satellite rests silently on a launch

magnets lead to improved efficiency

pad before blasting off on a rocket

and higher torque output.

traveling thousands of miles an hour.

Aboard the satellite are precision ball

bearings that must perform their duties

flawlessly for years to come.

66 _LINEAR MOTION Linear actuators based on shape-memory alloys

Now, one new actuator uses bundles of

SMA wire made of specialty nickel-

titanium alloy for reliable linear motion.

and laser sensors all provide position

74 _INTERNET OF THINGS

sensing — but depending on the

Intelligent machines meet their makers

application, some shine and

reflect better.

Intelligent equipment developed by today’s OEM machine builders helps

their end user customers be more

efficient than ever. Using IoT technologies,

these smart machines report back to

their OEM makers with performance and

diagnostic data to improve support.

12

ON THE COVER Small precision bearings make a big impact for satallite applications.

97 _ELECTRONICS How to calibrate scope probes and make good measurements

It’s a good idea to tweak probe parameters so what you see on the scope reflects reality.

September 2018 www.designworldonline.com

CONTENTS 9-18_Vs2.LL.indd 12

• ResMed uprising: Disrupting connected health

Wide and narrow views of position sensors

Limit switches, photoelectric switches

• Seven innovations that advance medical device design

88 _SENSORS

8/27/18 9:15 AM

103-120

A Supplement to Design World - September 2018

| photo courtesy of The Timken Company

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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2018 Regional

2018 National

Fostering B2B editorial excellence

Fostering B2B editorial excellence

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9.18

• contents departments 04 Insights 06 Teschler on Topic

Highest Torque in the Smallest Space

08 Technology Forward

... or the largest.

1 1 Green Engineering

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16 Design For Industry 30 Design Notes

AS9100C:2009/Certified

40 Internet of Things 48 CAE Solutions

121 Product World 136 Ad Index

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CONTENTS 9-18_second page_Vs1.indd 14

September 2018

DESIGN WORLD

8/30/18 9:19 AM

DESIGN WORLD

Follow the whole team on twitter @DesignWorld

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 Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon

DIGITAL MEDIA/WEB/ DEVELOPMENT

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

Videographer Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh

Customer Service Representative Julie Ritchie jritchie@wtwhmedia.com

Videographer Derek Little dlittle@wtwhmedia.com @wtwh_derek Videographer Graham Smith gsmith@wtwhmedia.com DIGITAL MARKETING

CREATIVE SERVICES

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

Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

Customer Service Representative Tracy Powers tpowers@wtwhmedia.com

VIDEO SERVICES

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

Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer

Customer Service Manager Stephanie Hulett shulett@wtwhmedia.com

Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com

Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

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

PRODUCTION SERVICES

Webinar Manager Lisa Rosen lrosen@wtwhmedia.com

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

FINANCE

Controller Brian Korsberg bkorsberg@wtwhmedia.com Accounts Receivable Specialist Jamila Milton jmilton@wtwhmedia.com

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

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

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Medical Design & OUTSOURCING

DESIGN WORLD

Staff page 9-18_Vs1a.indd 15

September 2018

15

8/30/18 9:15 AM

Design for Industry Aerospace

Rugged PC includes removable storage

T

The Department of Defense has a requirement that computer data can be quickly and securely erased if needed. The A172 low-power, rugged compact PC (RCP) comes with a removable storage module that meets the DoD 5220.22-M requirement. Â The 1 TB, secure SSD offers MLC and SLC NAND Flash as well as a sustainable read/write speed of up to 400 MB/sec.

The RPC is a compact 10.24 in. x 7.09 in. x 1.8 in. (260 mm x 180 mm x 46 mm), featuring an Intel Core i7 or Xeon processor and multiple standard modules. Easily customizable I/O, CPU, storage and operating system options enable the unit to be cost-effectively engineered for specific application requirements.

In addition, the RCP offers design flexibility with DVI and RS-170A RGBHV video output options, optional WiFi and frame grabber video inputs as well as TPM (trusted platform management) and a 50 ms holdup option for increased system reliability.

Available with three Intel processor options and two standard I/O versions, the modular A172 can be configured to handle several data processing environments, especially in high impact, space-constrained applications that need high throughput

September 2018 www.designworldonline.com 16

DFI 9-18 Vs4.LL.indd 16

DESIGN WORLD

9/5/18 12:28 PM

and secure storage. These typically include manned and unmanned robotic ground and underwater vehicles (UGV/ UUV) as well as manned and unmanned fixed- and rotarywing airborne (UAV) platforms. The RCP can also be used in complete mission computers for these types of unmanned vehicles.

Designed using a standard Type 6 COM Express module, the flexible A172 can be customized with specific processor types for less complex system integration. Equally as important, this facilitates cost-effective technology insertion upgrades as needed.

The rugged unit offers two standard I/O variants, with user-specific configurations available. Options include up to four independent Gigabit Ethernet interfaces, four USB 2.0 interfaces and eight serial ports with multiple RS232, RS422 or RS485 configurations as well as two CANbus and eight singleended, buffered LVTTL discrete digital I/O ports. Two single link DVI outputs and an audio line with stereo in/out round out the available I/O. An optional frame grabber provides up to eight channels of composite PAL/NTSC inputs, capturing all channels simultaneously, for image capture and stabilization with or without graphics overlays. This aids in ISR red/blue force tracking and threat assessment.

The unit includes two standard mini PCIe slots and two mSATA sites to further increase system functionality and optional internal SSDs provide data capture and sensor logging.

Operating systems include 64-bit Windows (7 and 10), Linux, VxWorks, custom or no OS preinstalled as ordering options. Cadmium-free units can also be chosen.

The IP65 environmental sealing and natural convection cooling contribute to the A172’s ability to withstand harsh, rugged environments.

With an integrated power input line filter and supporting a wide input voltage range from 10 Vdc to 32 Vdc, the A172 increases system power flexibility. The input is also MIL-STD-704 and MIL-STD-1275 compliant for power and electrical integrity across the entire voltage range. Operating temperature is -40°C to +65°C (-40°F to +149°F). DW

Aitech Defense Systems Inc. rugged.com/a172-rugged-compact-pc

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Design for Industry Aerospace

Better transmission of

machine vision images

A

Adoption of the CoaXPress (CXP) machine vision standard has opened up applications beyond the factory floor and into a variety of market segments ranging from agriculture to medical science. One segment receptive to CXP is defense and aerospace. Next generation drones and other unmanned systems can acquire 4K UHD images by deploying CXP to meet the military’s demand for sharper quality and higher frame rates. Older airborne systems are replacing analog technology producing only 11 MB/s with CXP digital cameras and frame grabbers that upgrade bandwidth up to 6 GB/s. Existing coaxial cables in helicopters, fixed-wing aircraft, ships, land vehicles and observation towers are re-purposed, eliminating the cost of new Ethernet or fiber cabling. Camera connectors, installation and maintenance procedures remain unchanged.

Aerospace and defense vision systems were once equipped with film-based cameras. However, lengthy time delays between snapping a photo and delivering it to commanders limited film’s usefulness as a reconnaissance tool. Analog cameras overcame this constraint yet shielding was needed to protect them from electromagnetic sources. In addition, analog data still needed to be converted into digital format

so it could be applied in a visualization program.

A CXP digital camera and frame grabber system provides the needed real-time access to highresolution imagery while making it easy to overlay sensor data into a single view for observation. A CXP system only requires a single coaxial cable for all functions so it can be reliably integrated into 360° rotating stations with slip rings to allow continuous panning for gun turrets or rotating cameras.

Along with resolution and speed, factors such as distance, latency, power, connectivity and reliability are considered critical by the military in locating targets, providing reconnaissance, searchand-rescue, and protecting forces. CoaXPress excels in each of these factors and combines the best attributes of all current vision interfaces into one simple solution. For example, CoaXPress can handle full HD video at 60 fps, while Camera Link cannot. Also, CoaXPress allows video, camera control for triggering, and up to 13W of power to be transferred without latency on off-the-shelf coaxial cables up to 100 meters in length or approximately three times that of USB3 or GigE Vision.

The latest version of CXP, CoaXPress 2.0, will increase the maximum connection bit rate to 12.5 Gbps. Currently, the maximum data rate over a single connection is 6.25 Gbps (CXP-6). The next revision of the standard will specify two additional data rates, CXP-10 (at 10 Gbps) and CXP-12 (at 12.5 Gbps). With four cables and CXP-12 connections, the maximum data transfer rate will be 50 Gbps, or 5 GByte/s. DW

BitFlow | www.bitflow.com

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September 2018 www.designworldonline.com

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Cham pions M12 Power S & T Code

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Binder 9-18 (pack expo show info).indd 19

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8/31/18 9:32 AM

Design for Industry Packaging/food and beverage

IS

Wireless sensor networks

O

0 90

1

ISO 13485

handle the special needs of food and beverage Bill Steinike • Vice President of Business Development for Laird Connectivity Steve Getraer • President of ComplianceMate

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Monitoring and maintaining temperature is critical to safety in the food service industry. According to the U.S. Centers for Disease Control (CDC), every year foodborne illness affects millions of people: 48 million people get sick, 128,000 people are hospitalized, and 3,000 people die.

According to the U.S. Food and Drug Administration (USDA), temperatures between 40°F and 140°F enable bacteria to grow rapidly. Within that range, pathogens like salmonella and E. coli can potentially double in number in as little as 20 minutes. Thus, food should be cooked to at least 140°F to kill any existing pathogens and be stored at temperatures under 40°F to slow the growth of any dangerous bacteria.

Automated temperature sensors alert if temps are too low/high. But equipment that might use such sensors can face particularly difficult environments, such as in restaurants. One reason is the communication protocols used in most wireless temperature sensors struggle to transmit through a kitchen environment filled with heavily insulated coolers and freezers, stainless steel hardware, steel-and-concrete super structures,

Eagle Stainless

Tube & Fabrication, Inc. Franklin, Massachusetts

Phone (800) 528-8650

www.eagletube.com 20

September 2018

DFI 9-18 Vs3.LL.indd 20

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IS

an environment similar to the one faced by many industrial automation applications.

Signals might struggle to cover the required distances, for example when food is stored away from the kitchen or serving areas.

The LoRa wireless communication protocol is one solution to this challenge. ComplianceMate, which offers a monitoring system for food safety compliance, has designed and deployed digital temperature sensors for use inside of coolers, walkins, freezers, hot food holding stations, and other food service equipment.

Traditionally, wireless temperature sensors have used a variety of technologies, including Bluetooth to communicate temperature readings. While such communication technologies have their benefits, ComplianceMate wanted to develop automated sensors that would perform better even in kitchens with the most difficult wireless signal environments, without adding cost. They wanted new sensors that would work everywhere.

Pursuit of that goal led ComplianceMate to Laird, a global leader in state-of-the-art wireless communication and smart system solutions. Laird evaluated a variety of communication technologies and realized that LoRa would best meet ComplianceMate’s goals.

LoRa, which is also referred to as a LPWAN/Low-Power Wide Area Network, is an ultra-low power wireless technology that provides secure, bi-directional data transfer and communications for sensor networks. It can communicate over distances of up to 10 miles – extendable to hundreds of square miles with additional gateways.

Using sensors designed and manufactured by Laird with its Sentrius IoT platform, ComplianceMate technicians were able to install wireless sensor networks that can readily penetrate the stainless steel, heavy insulation, and concrete construction of a commercial kitchen while providing enhanced security and functionality compared to traditional sensors. The sensors also use LoRa to achieve battery efficiency, able to last for years without a battery change. DW

DFI 9-18 Vs3.LL.indd 21

ISO 13485

perfection in stainless Eagle has the skills and the technology required to produce all of your custom exotic metal parts.

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ComplianceMate | www.compliancemate.com www.designworldonline.com 

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Laser machining

Laird | www.lairdtech.com

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Design for Industry Food and Beverage

3 Tips for choosing sealing systems in food and beverage applications

S

Selecting food and beverage sealing solutions is more complex due to a variety of factors. The

complexity can be simplified, and decision-making made more straightforward with a step-by-step approach to the sealing solution for a product design that will keep food and beverages safe.

The approach consists of: 1. Identify applicable regulations, 2. Consider material compatibility for

required product performance, 3. Focus on hygienic design.

Freudenberg clamp

seals guarantee secure and hygienic tube connections in machines that are operated continuously.

22

1 Fulfilling regulations First, identify the regulations a product must meet by asking these questions: Where will the product be made? Where will it be sold? The answers are important because regional standards and regulations that apply to the industry vary from the U.S., to Europe and in the rest of the world – especially in China.

In the United States, the U.S. Food and Drug Administration (FDA) maintains a list of authorized materials suitable for use.

A primary standard is FDA-21CFR177.2600, which establishes standards for rubber articles intended for repeated use. The

September 2018 www.designworldonline.com

DFI 9-18 Vs3.LL.indd 22

European Regulation (EC) 1935/2004 sets guidelines for materials that contact food and beverages in the EU. In China, the framework for materials used in the industry is provided by GB 9685-2016.

Further, there is NSF 51 from NSF International, which independently certifies compliance to the FDA standard. NSF 51 is one of the most DESIGN WORLD

8/30/18 9:49 AM

important Food & Beverage certifications in the industry.

2 Material compatibility Determine the right material to use. Ask: What must the product do? Where, and under what conditions must it do it?

Decisions about material for safe sealing in food and beverage equipment also must include answers to questions regarding temperature variations (both within the equipment and in the environment where it will operate), ingredient combinations, bottling requirements and, as noted in step one, prevailing regional regulations.

Materials certified to meet a wide selection of global regulation offer important advantages. In addition to eliminating the need for discrete sealing materials in various regions, materials that simultaneously meet global certifications have been developed – and tested – to the highest levels of performance.

Freudenberg-NOK Sealing Technologies, for example, has a variety of globally certified sealing materials, including its 70FKM727 low-temperature Fluorocarbon (FKM) material, its Fluoroprene XP family of highly fluorinated premium materials and its 70 EPDM 291 material. These materials all meet U.S. and EU food industry requirements and resolve a variety of industry challenges.

Resistance to flavor absorption and transfer is a critical material characteristic.

For example: a variety of drinks may run on the same line, requiring frequent cleaning of the equipment. Materials that effectively resist flavor absorption are essential. Cola must not taste like orange soda.

Predicting how the material will perform is also critical. Mapping material properties during CSR (compressionstress-relaxation) testing offers the best analysis of performance over time.

However, most sealing material suppliers do not have the needed analysis or equipment capabilities to carry this mapping out.

growth of harmful bacteria.

CIP (Clean-in-Place) and SIP (Sterilizationin-Place) cleaning conditions and sterilization procedures using steam or other cleaning solutions, including peracetic acid, cannot have a negative effect on the performance of the seals.

Consider the nightly cleaning of a fast food restaurant beverage machine. What happens if the cleaning solution is left in the filling line or dispenser longer than recommended; perhaps overnight? The right material should not be negatively impacted.

Today’s global industry means engineering for multiple markets and multiple regulatory compliance to ensure that sealing solutions keep food and beverages safe and pleasing to the consumer. Compliance with diverse regulations, and meeting consumer tastes can be challenging, so engineering sealing solutions must be considered early and with a straightforward approach to minimize complexities and deliver a final product that performs as required in any environment. DW

Freudenberg-NOK Sealing Technologies www.fst.com/en

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3 Hygienic design The third step emphasizes the importance of making certain that the sealing solution has a hygienic design. It must be easy to flush and clean – with no free spaces that can trap food or provide a place for the

DESIGN WORLD

DFI 9-18 Vs4.LL.indd 23

For motion control innovation, Solution City never sleeps.

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9/5/18 12:29 PM

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

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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8/30/18 9:50 AM

Power Review

Altra Industrial Motion Vol. 7 | No. 3 | 2018

The Power Brands in Power Transmission

Featured in this Edition...

The latest product solution from Ameridrives and Bibby Turboflex

Altra Provides Advanced Power Transmission Solutions for Outdoor Power Equipment Applications Bauer Stainless Drives Take Over at Fish Processing Plant Huco Piston Air Motors Out Perform Vane Air Motors Boston Gear Rapid Response Delivery

Tri-Bushing™ Design

NEW Warner Linear B-Track K4x Rugged Duty Actuator NEW Compact Hydraulic Brake Packages for Single-Source Convenience

Find Altra Industrial Motion on:

Altra Industrial Motion Ameridrives Bauer Gear Motor Bibby Turboflex Boston Gear Delroyd Worm Gear Formsprag Clutch

Altra Industrial_#1_9-18.indd 25

The Power Of Experience

Guardian Couplings Huco Industrial Clutch Inertia Dynamics Kilian Lamiflex Couplings

Marland Clutch Matrix Nuttall Gear Stieber Stromag Svendborg Brakes

TB Wood’s Twiflex Warner Electric Warner Linear Wichita Clutch

For more information contact us at: info@altramotion.com or visit www.altramotion.com

Scan to download the interactive version of the Power Review

8/31/18 3:19 PM

Ameridrives and Bibby Turboflex Introduce the New Tri-Bushing™ Design Ameridrives and Bibby Turboflex have developed the Tri-Bushing™, a unique flex element/blade triangular bushing design. The revolutionary cost-saving design improves axial capability on high performance flexible disc couplings used in turbomachinery applications.

Altra’s exclusive, patent-pending, Tri-Bushing™ design features two straight profiles that significantly reduce and redistribute the stresses that occur around the disc pack bushings.

Utilizing this new bushing design can increase a couplings axial capability by more than 33%. Given this significant increase in axial growth capability, in many applications, coupling designers no longer need to upsize their coupling to accommodate this growth. In addition to the cost-saving benefit, lateral vibration problems may be avoided with a smaller coupling.

FEA stress comparison of a typical round bushing and a Tri-Bushing™ Traditional round bushing

Tri-Bushing

For more information, visit www.Altramotion.com/Tri-Bushing

Blade failures where the disc material bent around the traditional round bushings.

Boston & Bauer Washdown Gear Drives & Gear Motors for the Food & Beverage Industry As the leading innovators in gearing and gear motor technology, Boston Gear and Bauer Gear Motor present a full line of Stainless Steel and Aseptic products that provide sanitary protection and optimal performance in the toughest caustic environments.

Distinct Advantages of the Boston Gear and Bauer Gear Motor offering: 1. Wide Breadth of Products • Worm / Helical-Worm / Helical-Bevel or Helical / Parallel Shaft • Gear Drives (Speed Reducers) / Gear Motors / Shaft Accessories • Reductions of 3:1 thru 10,000:1 • Output Torque from 100 lbf-in thru 7,500 lbf-in 2. Critical Product Features for Washdown Suitability and Sustainability • NSF International Certified (Worm Gear Drives) • UL/ULc Certified (Gear Motors) • IP67 / IP69K Compliance • The Original Domed CrownTM Technology • 316SS Cast Housings

3. Performance Competitive Advantages • Proven: Longer Product Life • Proven: Higher Motor Efficiency • Proven: Higher Gearing Operating Efficiency • Proven: Lower Gearing Operating Temperature • Proven: Reduced Installation Time & Maintenance Cost

Scan to watch Boston & Bauer Washdown video

For more information download P-8026-BBG from www.AltraLiterature.com

Altra Certified Rebuild Services – Marland, Formsprag, & Ameridrives Marland: Your old, worn Marland clutches can be refurbished for substantially less than the cost of a new replacement clutch. Our economical rebuild service applies to all Marland Clutch BCMA, CECON and CEBMAG models. The local Marland Rebuild Service team will perform the following to restore your clutch to likenew condition: Inspect and replace seals, energizing springs, alloy steel rollers, aluminum cages, bearings and fasteners as required, inspect and precision grind the outer race and cam if required, assemble and test to meet Marland original design and performance specifications, paint and prepare for shipment. For more details on our cost saving certified Marland Rebuild Program, call 1-888-216-3515.

Formsprag: Send Formsprag your old clutches to make them like new again. The difference is not just cosmetic. Consider these advantages: Price – A guaranteed savings of at least 30% or more versus new product, Speed – Clutches are received, inspected and rebuilt in the shortest possible time frame, Warranty – 1 year on labor and materials, same as new clutches, and Emergency Breakdown Program – All products that are air freighted into the Warren plant are processed immediately and, in most cases, are able to be rebuilt within a 24-hour period. For more information download Application Guide P-1465-FC from www.AltraLiterature.com. n Altra Industrial Motio

I N T R O D U C I N G

Ameridrives Rebuild Service

Ameridrives remanufactured couplings look like new, perform like new and are warrantied like new For more information call (814) 480-5095 or visit www.Ameridrives.com.

The Ameridrives Rebuild Service Team will conduct a comprehensive inspection of your coupling and perform the following to restore your coupling to its original specifications with a new coupling warranty: • All potential wear components – metallic and gear flex elements, shims, and fasteners are refurbished or replaced to new performance standards.

• Magnetic Particle Inspection (MPI) on all torque transmitting

your old, worn couplings for Ameridrives Rebuild Service can refurbish replacement coupling. The economical ® substantially less than the cost of a new , Ameridrives couplings including Ameridisc rebuild service applies to all ® high speed couplings used primarily Ameriflex® and Amerigear high performance, applications in the power generation, on turbomachinery, compressor and pump brands are accepted on a case-byoil & gas and marine industries. Other coupling case basis.

Ameridrives has the team, facilities, As a leading global coupling manufacturer, experience to rebuild and replace and nearly 100 years of inspection and repair are completed to meet the exacting all coupling components as required. Repairs standards of the original coupling.

components.

• Removal and repair of surface defects on a lathe and glass bead blasting as appropriate while maintaining original coupling integrity.

• Precision dimensional and Total Indicator Run-out (TIR) measurement • Rebalancing to original API 671 certification if applicable. This recertification requires the return of the entire coupling structure.

Ameridrives: Ameridrives Rebuild Service can refurbish your old, worn couplings for substantially less than the cost of a new replacement coupling. The economical rebuild service applies to all Ameridrives couplings including Ameridisc®, Ameriflex® and Amerigear® high performance, high speed couplings used primarily on turbomachinery, compressor and pump applications in the power generation, oil & gas and marine industries. Other coupling brands are accepted on a case-by-case basis. For details on the rebuild program, call 1-814-480-5095, download P-7948-AC from www.AltraLiterature.com or visit www.Ameridrives.com.

in the shortest possible time frame.

Couplings are received, inspected and rebuilt down schedule.

We will work to accommodate your shut call (814) 480-5095 or visit For details on our cost-saving program www.Ameridrives.com. www.ameridrives.com 1802 Pittsburgh Avenue Erie, PA 16502 - USA 814-480-5000 Fax: 814-453-5891

P-7948-AC

10/15

Printed in USA

Altra Industrial_#2_9-18.indd 26

8/31/18 3:20 PM

Sure-Flex Plus® Maintenance Savings Calculator Customers often debate the cost savings they will receive when deciding to use a lower standard product or one that is made for high performance. Now, there is a program to allow users to quantify just how significant the savings can be when replacing a copy-cat coupling sleeve with the high performance Sure-Flex Plus EPDM or Neoprene sleeve. The new Sure-Flex Plus Maintenance Savings Calculator does that for you. This program saves money over the long term and satisfies applicable distributors’ cost savings program requirements.

Available both on our website, or installed as a smartphone app on your Android or Apple device. Simply input your current maintenance interval, cost of downtime, sleeve replacement cost, etc. and the program will show you just how much you could be saving by using genuine TB Wood’s Sure-Flex Plus sleeves.

Sure-Flex Plus Maintenance Savings Calculator App • Save hundreds – or thousands – on maintenance • Sure-Flex Plus sleeve life is over 3x that of imitators • Maintenance intervals can be extended by 3x or more using Sure-Flex Plus • More durable: Minimize downtime from competitors’ premature sleeve failure For more information, download P-8367-TBW from www.AltraLiterature.com

Scan to download the Sure-Flex Plus® Maintenance Savings Calculator

www.SureFlexPlus.com

Twiflex USA Brake Calipers Twiflex offers the largest range of industrial disc brake calipers in the world. Spring applied units may be retracted pneumatically, hydraulically or electrically (depending on caliper design) while most direct acting brakes have some form of positive retraction device.

Pneumatically Applied Brakes are best suited for light to medium stopping duties and for tensioning applications where a high degree of control is required.

Hydraulically Applied Brakes address higher torque requirements, while spring applied calipers are essential where braking must be maintained in the event of supply system failure Mechanically Applied Units are suitable for light tensioning duties or where no external power is available; they may also be specified when designers wish to use their own means of actuation.

For more information download P-1648-TF from www.AltraLiterature.com

Call Twiflex Toll-Free: 844.723.3483

EM 210/ERS 68 Brake for Bucket Conveyors A conveyor OEM was looking for a reliable braking solution for a bucket conveyor unit being built for a West Coast dry food manufacturer.

Working closely with the OEM, Warner Electric engineers defined the correct amount of torque needed for the application. They determined that an EM210/ERS 68 spring-set/electrically-released brake could be located between the 5 HP 215TC frame motor and reducer that would exceed the load-holding requirement.

• NEMA C-Faced compatible mounting • Max. holding torque: • 100 lb.ft. (135.5 Nm) • Max. speed rating of 2000 rpm • • Compact packaged design • Completely assembled

and preburnished High torque, lead-free and asbestos-free friction material Easy to install

Matrix Servo Motor Brakes (SMB) Servo-driven solutions can achieve faster speeds with more precise accuracy while providing greater flexibility and quicker changeover in various industrial applications including: automation & robotics, machine tools, packaging & material handling, medical, assembly & semi-conductors and military.

Matrix currently supplies many key servo motor OEMs and has proven to be one of the leaders in this industry.

Matrix now offers its range of standard sizes reducing engineering review time and insuring quick order processing to meet customers’ needs.

For more information, download P-8475-MX from www.AltraLiterature.com

For more information, download P-8160-WE from www.AltraLiterature.com

Altra Industrial_#3_9-18.indd 27

8/31/18 3:20 PM

A New Prescription for Coupling Stress Relief Ameridrives and Bibby Turboflex have developed the Tri-Bushing™, a unique triangular bushing design Ameridrives and Bibby Turboflex introduce a revolutionary costsaving design that improves axial capability on high performance flexible disc couplings used in turbomachinery applications.

Altra’s exclusive, patent-pending, Tri-Bushing design features two straight profiles that significantly reduce and redistribute the stresses that occur around the disc pack bushings.

Utilizing this new bushing design can increase a couplings axial capability by more than 33%. Given this significant increase in axial growth capability, in many applications, coupling designers no longer need to upsize their coupling to accommodate this growth. In addition to the cost-saving benefit, lateral vibration problems may be avoided with a smaller coupling.

FEA stress comparison of a typical round bushing and a Tri-Bushing™

Tri-Bushing™ Design Traditional round bushing

Tri-Bushing

For more information, visit www.Altramotion.com/Tri-Bushing Altra Industrial_#4_9-18.indd 28

Scan to visit the Tri-Bushing website

8/31/18 3:22 PM

M a c h i n e To o l

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

Control Techniques www.ControlTechniques.US

DESIGN WORLD

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September 2018

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8/30/18 9:54 AM

Design Notes

The concaves and grain bin where Thomson Electrak HD actuators are used.

Smart linear actuators

help with harvest

Edited by Mike Santora • Associate Editor

When Tribine Harvester, a new entrant into the grain harvester market, was in the design phase for its products, control was an early issue.

“A couple of challenges that we faced during the design were the control of the concaves around the rotor and the opening and closing of the grain bin extension,” said Russell Secrest, Control Systems Engineer at Tribine Harvester. “The needs for the grain bin extensions became broad because we have two large doors that we had to open and close. We also have another element in the middle which is the auger that brings the grain up into the bin.”

Creating a versatile harvester that can handle different jobs was also a challenge. “The concaves need to be in a certain location, and that location varies from crop to crop,” added Bryan Clearhout, Senior Mechanical Engineer at Tribine Harvester. “You need to be

30

able to control it and know where they are, depending on your crop conditions.” said.

The Tribine Harvester team tested several different applications before their final selection. Initially, they tried using a hydraulic actuation system but quickly ruled it out because of the complexity required for accurate and reliable position feedback. Traditional electromechanical actuators also were scratched as they needed additional wiring of external devices.

The Tribine Harvester team recognized that improving productivity would require precise control over threshing and grain bin operations; therefore, they decided to focus on using electric actuators for the concaves around the rotor and the grain bin extension.

September 2018 www.designworldonline.com

Design Notes 9-18_Vs4.LL.indd 30

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9/6/18 10:48 AM

WE POWER

YOUR

POWER

- ENERGY PETROLEUM - ENERGY DISTRIBUTION - ENERGY STORAGE - ENERGY HARVESTING - WINDMILL - TRANSMISSION PARTS - OIL RIGS - WATER - POWER PLANTS - NUCLEAR POWER PLANTS - ENERGY SAFETY

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

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Design Notes Having consulted with experts at Thomson Industries, Tribine Harvester decided that the Electrak HD actuator would be suitable for their design needs and used three actuators to position the concaves and five more for the bin extension.

The Electrak HD is a smart linear actuator that offers cleaner installation and easy setup and maintenance, dynamic braking, which improves position accuracy by preventing coasting, communication across a CAN bus network, providing full control and diagnostics, and others.

These actuators require only two wires for CAN bus communication and two wires for power. This configuration differs from a traditional H-bridge in that there is no need for a separate relay or a controller that is switching power to drive the motor in either direction.

“Another feature the HD presents is that I can

right angle servo gearheads



Did you mean: DieQua Corporation?

Russell Secrest, Control Systems Engineer for Tribine Harvester.

monitor exactly how much current it’s using and determine a fault state,” said Secrest.

“Just by reading a simple CAN message, I know if one of them has failed, which I can use to prevent damage to the system and be able to report that back to the operator.

Whereas with the traditional H-bridge, that’s much more difficult to achieve.” DW Tribine Harvester is already shipping vehicles with this design.

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

Thomson Industries thomsonlinear.com

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Design Notes

One of the main challenges in tape manufacturing is round-theclock regulation of web tension. | credit: @frog - stock.adobe.com

Automatic tension control

helps aluminum tape producer Edited by Mike Santora • Associate Editor

To improve its existing tension control system, a Southeast Asian aluminum tape manufacturer wanted to shift from a manual procedure to a more automatic tension control system. The original system was a Warner Electric MTB 10-0-2 modular electromagnetic disc brake equipped with two twin magnets, so the first step was to contact the manufacturer to see what options were available.

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One of the main challenges in tape manufacturing is round-the-clock regulation of web tension according to tape width and roll diameter. By applying an automated solution that continuously adapts to changing conditions, this aluminum tape manufacturer was able to upgrade its tension control system, increasing productivity and product quality.

Unwinding operations are indispensable in tape manufacturing. However, these can be extremely sensitive processes that can affect the quality of the final product. For example, too much tension applied to the tape can damage the web structure, causing it to snap or stretch. More precisely, as the roll diameter decreases roll speed will increase to maintain a constant line speed, but brake force must adjust, so that tension on the web remains consistent.

Therefore, tension control is an essential quality assurance tool.

Warner Electric, which is part of Altra Industrial Motion Corporation, is known for developing and supplying electromagnetic clutch and brake solutions. With the original manual system, the tension in the tape making machine used to be adjusted by an operator through a manual control that would adjust the brake system.

September 2018 www.designworldonline.com

Design Notes 9-18_Vs4.LL.indd 34

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POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

The solution combined the pre-installed Warner Electric brake with a new sensor communicating with a control.

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By working closely with the aluminum tape manufacturer, Warner Electric found that quality consistency issues arose when the tape making-machine was operating at lower tensions and with thinner webs. In fact, besides variations in roll diameters, tape width also determined the tension applied.

Therefore, improving the tension control system required the ability to manage the wide performance range of the tape-making machine and provide a solution that would adapt to the changing conditions. In this case, the tape webs manufactured on one single machine ranged from approximately 2.5 to 7.5 centimeters, with a 10:1 range of tension.

Building strong customer relationships, with daily interaction between the teams, was crucial and allowed Warner Electric to discuss this issue and provide a suitable solution promptly, minimizing any machine downtime.

The ultimate solution combined the pre-installed Warner Electric brake with a new sensor communicating with a control.

The Warner Electric UT30 analog ultrasonic sensor now sends a signal to the control, reporting in real-time the diameter of the roll while it unwinds. The control (TCS 200-1) receives the signal and adjusts the brake tension automatically, without the need for any external input.

By shifting from a manual tension control system to an automated solution, it was possible to free up the machine operator, who could then focus on other tasks. The new automation ultimately improved both productivity and throughput of the entire system. Also, the automated system solved the quality consistency issues that had been experienced in the past.

Additionally, an examination of the new application’s performance revealed that it was not always necessary to use two brake magnets to adjust the tension: one single magnet was sufficient for thinner webs. Therefore, it was possible to further optimize the system by introducing a switch that could disable or activate one brake magnet, based on the presence of thin or heavier webs. In this way, the energy and resource consumption for the machine were lowered. DW

Altra Industrial Motion | altramotion.com

DESIGN WORLD

Design Notes 9-18_Vs4.LL.indd 37

September 2018

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8/30/18 10:56 AM

Design Notes

Understanding the physics behind

constant force springs Edited by Mike Santora • Associate Editor

Constant force springs are manufactured by wrapping a flat piece of steel around a drum, or by coiling a steel ribbon around itself with a virtually constant radius.

As you walk into your office building on the way to work each day, or into your local bank, or any commercial facility, you probably pull open a heavy glass door. As you pass across the threshold, the door closes behind you. You don’t give it a second thought. However, that heavy glass door was probably closed by a constant force spring.

Constant force springs are used in a range of everyday applications. From door closers to cord and hose retractors, to exercise equipment, toys, electric motors, and more, constant force springs are at work applying force with amazingly high frequency and consistency. Let’s take a closer look at the basic physics behind constant force springs.

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In the 17th century, British physicist Robert Hooke outlined a formula for force and elasticity that is now known as Hooke’s Law. Hooke’s Law states that the force (F) needed to extend or compress a spring by some distance (X) changes in a scaled linear relationship to that distance. The formula is F=kX, where k is a constant that represents the stiffness of the spring.

Hooke’s law is nominal regarding real spring performance. In the equation, X, the distance the spring moves, is meant to be a relatively small number. Ultimately, any elastic body that is stretched or compressed beyond the stress limits of its material composition shows signs of deformity.

Force properties that rely on a state of consistent shape and tension will, therefore, change in a deformed state.

September 2018 www.designworldonline.com

Design Notes 9-18_Vs4.LL.indd 38

Ideally, constant force springs would apply consistent force over a given range of motion, repeatedly without change.

In reality, constant force springs, like all elastic bodies, are limited by the stress limits of their materials. They deform if pushed beyond the limits of material stress or begin to weaken as their material fatigues over time. So, Hooke’s Law does apply to constant force springs.

However, it is the way constant force springs are made, and their particular physical properties, that lead to the terminology “constant force.” By taking a closer look at the physical properties of constant force springs, we can better understand how the name constant force is derived.

Commonly made of steel, constant force springs are manufactured by wrapping a flat piece of steel around a

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drum, or by coiling a steel ribbon around itself (with a virtually constant radius). The spring is mounted in its application, and one end of the spring is attached to a load. The spring exhibits torque forces when movement of the load causes the spring to wind against its resting state. The spring wants to return to its resting state, so it exerts force against the load.

In application, constant force springs rest in a pre-tensioned state. The act of coiling a ribbon of steel around itself, or wrapping it around a drum, puts the structure in a state of tension. If one were to measure the force of the spring in this state of tension, it would not be zero. In other words, constant force springs have a measurable force in the resting position. When the load moves against the spring, the spring moves a relatively short distance in a circular direction (most commonly in the direction of the initial wind, resulting in a small decrease in diameter).

If we compare the springs force value in the loaded state versus its force value in the resting state, we find the difference in force to be relatively small. In more general terms, outside of the realm of physics, the slight difference in force between the spring’s resting state and loaded state is considered insignificant. The spring’s force is, therefore, termed to be “constant.”

In reality, constant force springs apply near constant force.

Constant force springs reach maximum rated load when the deflection distance reaches 11/4 times the spring’s diameter. The width and thickness of the spring material and the diameter of the spring’s outer coil generally determine load rating. In most cases, constant force springs are designed to provide force by turning in the same direction as their initial wind. Unless specifically designed to do so, reverse winding a constant force spring frequently causes deformation.

Constant force springs can operate effectively for long periods of time. Most can function from thousands to millions of cycles before material fatigue reduces their effectiveness. Constant force springs are ideal for applications such as commercial door closers where tens of thousands of people may pass through a building’s doorway each year.

There are numerous, essential engineering parameters to consider when designing or specifying a constant force spring. Materials, fatigue life, tensile load, torque and friction, speed and acceleration, mounting, safety considerations, and application environment are all critical factors.

The knowledgeable engineering staffs at leading spring manufacturers, such as Newcomb Spring Corp, can help refine constant force and other spring designs to deliver optimum performance in any application. DW

4/9/18 2:55 PM

9/5/18 12:32 PM

Internet of Things

Expect more cyber attacks on manufacturing because of IIoT devices and Industry 4.0 initiatives

V

Vectra, a leader in AI-powered cyberattack detection and

threat hunting, claims that the manufacturing industry exhibits higher-than-normal rates of cyberattack-related reconnaissance and lateral movement activity. This is due to the rapid convergence of enterprise information technology and operational technology networks in manufacturing organizations.

As part of key findings in its 2018 Spotlight Report on Manufacturing, Vectra revealed that attackers who evade perimeter security can easily spy, spread and steal, unhindered by insufficient internal access controls.

The manufacturing industry has had a lower profile as cyberattacks against the retail, financial services, and healthcare industries have made headlines. However, intellectual property theft and business disruption are primary reasons why manufacturers have become prime targets for cybercriminals.

“Recent reports about nation-state cyberattacks against U.S. utility control systems show that cybercriminals are intent on surreptitiously taking inventory of critical industrial assets and intellectual property to disrupt manufacturing business operations,” said Vikrant Gandhi, industry director at the analyst firm Frost and Sullivan.

Other key findings from the report include: A much higher volume of malicious internal behaviors, which is a strong indicator that attackers are already inside the network.

An unusually high volume of reconnaissance behaviors, which is a strong indicator that attackers are mapping out manufacturing networks in search of critical assets.

An abnormally high level of lateral movement, which is a strong indicator that the attack is proliferating inside the network.

“The increase in industrial IoT devices exponentially increases the attack surface for manufacturers,” said Jürg Affolter, CIO at Brugg Cables. “Implementing continuous monitoring of the internal network for attacker behaviors as well as additional access controls are important since an agent-based solution isn’t possible for industrial IoT devices.”

“The interconnectedness of Industry 4.0-driven operations, such as those that involve industrial control systems, along with

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Internet of Things_9-18_Vs2.LL.indd 40

the escalating deployment of Industrial Internet-ofThings (IIoT) devices, has created a massive, attack surface for cybercriminals to exploit,” said Chris Morales, head of security analytics at Vectra.

The 2018 Spotlight Report is based on observations and data from the 2018 Black Hat Conference Edition of the Attacker Behavior Industry Report, which reveals attacker behaviors and trends in networks from more than 250 opt-in enterprise organizations in manufacturing and eight other industries.

From January through June 2018, the Cognito threatdetection and hunting platform from Vectra monitored network traffic and collected metadata from more than 4 million devices and workloads from customer cloud, data center and enterprise environments. The analysis of this metadata provides a better understanding about attacker behaviors and trends as well as business risks, enabling Vectra customers to avoid catastrophic data breaches.

The Cognito platform enables enterprises to automatically detect and hunt for cyberattacks in real time. Cognito uses AI to perform non-stop, automated threat hunting with always-learning behavioral models to quickly and efficiently find hidden and unknown attackers before they do damage. Cognito provides full visibility into cyberattacker behaviors from cloud and data center workloads to user and IoT devices, leaving attackers with nowhere to hide.

Cognito Detect and its AI counterpart, Cognito Recall, are the cornerstones of the Cognito platform.

Cognito Detect automates the real-time detection of hidden attackers while giving Cognito Recall a logical starting point to perform AI-assisted threat hunting and conduct conclusive incident investigations. DW

Vectra | vectra.ai

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The groundbreaking i500 is size-optimized and allows for zeroclearance mounting, saving valuable cabinet space. And thanks to the innovative interface options, it’s easy to commission in minimal time. The best thing of all is that the modular structure adapts to different production configurations in no time at all.

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Internet of Things

Stepper drives support an extended range of Ethernet and fieldbus network protocols

S

Series of stepper drives support a range of industrial Ethernet and fieldbus network protocols including EtherCAT, EtherNet/IP, CANopen, Modbus, Ethernet and RS-485, as well as a proprietary Serial Command Language (SCL) for efficient network communications over Ethernet (UDP or TCP) and RS-485.

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The drives accept high-level commands through a network connection, allowing designers the flexibility to control step motors using the network protocol of their choice. These stepper drives simplify the programming by consolidating motion control functions into the application software of the primary logic or machine controller, rather than in individual axes.

These dc-powered microstepping drives also run stored programs created with the Q Programming language. Q Programming provides a range of motion profiles, multitasking, math functions, conditional processing, data register manipulation and more in a simple, text-based programming language. Operators can configure drives and create Q programs using STF Configurator software.

September 2018 www.designworldonline.com

Internet of Things_9-18_Vs2.LL.indd 42

DESIGN WORLD

8/30/18 11:53 AM

Designed to work with a range of 2-phase step motors, the drives offer advanced current control with an antiresonance algorithm that electronically dampens motor and system resonances to improve motor smoothness and maximize torque over a wide speed range. Torque ripple smoothing decreases motor noise and vibrations.

Your Partner in Packaging Solutions Are downtime and inventory costs interfering with your productivity? PHD’s packaging solutions can help.

The STF Stepper Drives come in three power ratings: STF03: 12 to 48 Vdc input, up to 3.0 A/ phase (peak-of-sine) current output.

Lowest power of the series suits smaller motors starting at NEMA 8 frame size.

STF06: 12 to 48 Vdc input, up to a 6.0A/ phase (peak-of-sine) current output.

Mid-range power within the series.

STF10: 24 to 70 Vdc input power, up to a 10.0 A/phase (peak-of-sine) current output. Highest power for largest step motors including high torque NEMA 34 frame size.

All STF Stepper Drives have two communication ports (dual-port) for daisy-chain connections of multiple drives to the central processor, HMI or PLC. DW

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Internet of Things_9-18_Vs2.LL.indd 43

September 2018

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8/30/18 11:53 AM

Internet of Things

Collecting, analyzing, storing, and transmitting data in mobile applications

T

TDC-E gateway system: Multi-sensor networking with mobile communication Collecting, analyzing, storing, and transmitting data in mobile and stationary applications

The TDC-E Telematic Data Collector offers extended functions for capturing, processing, and transmitting process and sensor data. As a high-performance communication platform with an open end-to-end IoT architecture, the TDC-E offers many analog and digital connectivity options for connecting autonomous sensors and sensor systems.

The mobile communication options have been extended with WLAN and WPAN – thereby creating the conditions for additional functions such as the indoor localization of mobile machines, for example.

The data collected, analyzed, and individually visualized by the TDC-E means that the operational status of the networked sensors, as well as the processes in which they are used, are transparent. SICK also offers customer-specific cloud solutions for further processing at a higher level. These solutions support the TDC-E with the MQTT, OPC UA, and JSON protocols via suitable interfaces such as GSM 3G+, WLAN, and Ethernet.

As a physical device, the TDC-E acts as the connection point between controllers, sensors, and intelligent devices and the cloud. The gateway system with SSI, RS-232, RS-485, RS-422, an analog output, digital I/Os, CAN bus, Ethernet, WLAN, and WPAN offers common interfaces used in industry for connecting sensors and sensor systems. Once real-time performance data, such as levels, drive temperatures, protective field infringements, reading rates, uptimes, or collisions, has been collected, this information is summarized and analyzed in the TDC-E to minimize the data volume that is forwarded to external applications or to the cloud. The advantages are optimized response times and reduced network transmission costs.

On the basis of pre-processed data, the TDC-E can carry out analyses which cause an alarm to be emitted via the switching outputs or an alarm message to be sent via SMS, if preset sensor values are exceeded or if faults occur, for example. The collected and processed data can also be used beyond machine and system operation on higher IT levels or in the cloud for intelligent services and applications. These Smart Services ensure that the operational status of the sensors in the field, as well as the entire process, are as transparent as possible. The TDC-E generates active and predictive information for prompt process optimization and system maintenance at a precise time.

44

The TDC-E accesses process and sensor data, which creates transparency and therefore enables significant increases in productivity thanks to processes being optimized. With its open interfaces, direct sensor connection, browser-based configuration with the SICK Engineering Tool SOPAS – without additional software and without license costs – as well as on-site or webbased data visualization, the TDC-E is also a crosssystem data hub which is independent of manufacturers.

It ensures that machines, plants, and processes are fit for Industry 4.0 and therefore for the future.

The gateway system with mobile connection from SICK, and the new TDC-E in particular, are used as reliable, adaptable security and management tools for the sensor-supported management and monitoring of production lines, mobile machines, plants split over several different locations, wind farms, and similar facilities. Typical applications include tank and operational monitoring on ships and trucks, status logging and localization of swap bodies, remote control of systems containing large tanks and storage silos, remote system monitoring of natural gas transfer stations, operational monitoring as well as indoor and outdoor localization of vehicles, industrial trucks, and mobile machines. Further applications include recording events in crane systems, at level crossings, or in underground stations, as well as generally monitoring field instrumentation installed in a plant, including its integration into concepts for the purposes of preventative maintenance. DW

SICK | www.sick.com

September 2018 www.designworldonline.com

Internet of Things_9-18_Vs2.LL.indd 44

WHAT DO YOU THINK?

Connect and discuss this and

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DESIGN WORLD

8/30/18 11:55 AM

Industrial compact Gigabit media converter with fixed fiber

T

The IMC-C1000-XX series is a compact IP30 rated gigabit Ethernet-to-fiber media converter featuring a 10/100/1000Tx Ethernet port and a fixed fiber interface supporting ST or SC connectors depending on the model.

There are models that support Multi-Mode and Single-Mode to support applications with a variety of fiber distances. It suits industrial applications that require distance extension and high bandwidth capabilities. This small form factor saves space in outdoor applications such as factory automation, security, ITS transportation, power/utility, water wastewater treatment plants, and any other extreme ambient weather environments.

The IMC-C1000-XX series has a built-in “Link Fault Pass Through” (LFP) and “Far End Fault” (FEF) function with 1248 Vdc redundant power inputs with reverse polarity and overload current protection. This product series supports DIN-Rail as well as wall mountable orientations and provides operating temperature range models in STD: -10°C to 70°C and EOT: -40°C to 80°C. DW

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September 2018

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Secure Your

Connection

Internet of Things

Specification integrates “CSP+ for Machine” into OPC UA technology

The premier supplier of power system components worldwide, Interpower® presents an innovation of safety and security with the new Interpower Connector Locks.

A

As described by the OPCF, OPC UA (Unified Architecture) is a platformindependent, service-oriented architecture that integrates the functions of the individual OPC Classic specifications into one extensible framework. It delivers the necessary infrastructure for interoperability and for moving data and information from the embedded world to the cloud. It also addresses cyber security with technology that has been assessed by the German Federal Office for Information Security (BSI). Hence OPC UA is a key component in the drive towards Industry 4.0.

The companion specification will increase process and system transparency for end users, enabling more efficient operations, better product quality and higher productivity.

CLPA’s activity with the OPCF aims to expand its existing CSP+ (Control & Communication System Profile) technology from just describing individual devices and to apply it to complete machines and production lines. This is the key concept behind CSP+ for Machine.

CSP+ has been providing drag and drop network configuration using CSP+ files from CLPA partner vendors, by allowing the creation of device libraries. However, the new CSP+ for Machine extension of CSP+ provides easy network configuration and maintenance by offering profiles that describe whole machines instead of just devices on a CC-Link IE network.

Via XML, CSP+ for Machine provides information concerning machine specifications, application software, data to be acquired and how, as well as relationship between machine data and information. As a result, end users will have easy access to meaningful data from each machine such as production volume, operating performance, energy consumption, etc., this will ensure the highest levels of connectivity and interoperability and allow information to be easily shared throughout an enterprise and beyond. DW

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September 2018

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SmartProducts 9-18.indd 47

8/30/18 10:22 AM

CAE Solutions Status report on the PLM market

C

CIMdata, Inc., a global PLM strategic management consulting and research firm, recently completed an analysis of the PLM market and released a report, the “CIMdata PLM Market and Solution Provider Analysis Report. The report provides detailed information and indepth analysis on the worldwide PLM market during 2017.

It contains analyses of major trends and issues; revenues of leading PLM solution providers; and revenue analyses for geographical regions, industry sectors, and historical and projected data on market growth.

The PLM market grew to $43.7 billion overall in 2017, 7.6% growth over 2016, greater than our forecast. SI/Reseller/ VAR and EDA were unexpected stars and Simulation & Analysis were strong. Looking toward 2022, CIMdata forecasts the PLM market to grow at a compound annual growth rate (CAGR) of 6.9% to $61.0 billion.”

Companies make PLM investments in many different areas and with many types of solutions including mechanical CAD, simulation and analysis, visualization and collaboration, building design, and others. This diversity is reflected in the different solution providers to the PLM market and in the fact that no single type of provider dominates the industry. During 2017, a

number of providers generated substantial revenues that represent PLM-related investments.

Sixteen providers generated PLM revenues in excess of $500 million from both the tools and the cPDm segments. Three solution providers, Dassault Systèmes, PTC, and Siemens PLM Software, are major providers of both tools (such as MCAD) and cPDm technology while others, such as Autodesk and Cadence, are primarily tool providers that focus on specific segments within the overall market.

The CIMdata PLM Market Analysis Report Series is packaged as five modules:

1 The CIMdata 2018 Executive PLM Market Report provides an overview of CIMdata’s complete global analysis. It includes key charts on PLM market investment statistics through 2017, forecasts of investments for 2018 through 2022, and a summary of PLM solution providers’ performance in 2017.

2 The CIMdata 2018 PLM Industry Review and Trends Report is mainly qualitative in nature, and focuses on key issues facing the global PLM ecosystem of solution providers and end user organizations. It highlights

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Companies who derived the most revenues from the PLM market. This graph illustrates the breadth of companies that participate in the overall PLM market, even though they may not all compete directly with each other.

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changes that occurred in 2017, what effects those changes may have in the short and medium term, and what is on the horizon in the years to come.

3 The CIMdata 2018 PLM Market and Solution Provider Analysis Report details measures of and forecasts for the overall PLM market and its key segments, including Tools, cPDm, and Digital Manufacturing. The Tools section has additional details on sub-segments, including MCAD, NC, S&A, EDA, and AEC. It also includes CIMdata’s estimates of PLM solution provider revenues in these segments and sub-segments for 2018 through 2022.

5 The CIMdata 2018 PLM Market Industry Analysis Report provides an industry segmentation view of the 2017 market results. CIMdata’s 2017 estimates and market forecasts for PLM and cPDm are provided for eight different industry sectors: aerospace and defense; automotive and other transportation; electronics/telecommunications; fabrication and assembly; process-packaged goods; process-petrochemical; utilities; and construction, infrastructure and shipbuilding.

4 The CIMdata 2018 PLM Market Geographic Analysis Report provides an additional view of the 2017 market results, by major geography. CIMdata’s 2017 estimates and market forecasts for PLM and the major PLM market segments are provided for the Americas, EMEA, and AsiaPacific. In addition, the report includes estimates and forecasts for the cPDm segment within specific European and Asia-Pacific countries and regions.

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The CIMdata PLM Market Analysis Report Series is available as a five-module set or each module can be purchased separately.

DW

www.designworldonline.com

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CAE Solutions Increase machining efficiency with CAM software

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The hyperMILL 2018.2 is the latest version of the manufacturer’s comprehensive CAM software. hyperMILL 2018.2 offers a range of new features for 3D Shape Z-level Finishing and 3D Optimized Roughing, greater CAD functionality and more.

For reduced programming times and improved milling, 3D Z-level Shape Finishing, available in hyperCAD-S, has two new features. Automatic face extension can be used during CAM programming to automatically extend the selected milling surfaces, eliminating manual CAD work for cleaner corner cuts. Also, 3D Z-level Shape Finishing supports conical barrel cutters in addition to general and tangential cutters.

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CAE Solutions

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During 3D Optimized Roughing, multiple allowances are recognized and accounted for when using free tool geometries, resulting in easier programming and flexibility for defining special tools. hyperMILL 2018.2 can define different allowances and adapt the machining process accordingly.

High-feed cutters have a special cutting geometry that is easy to define using tool management, and hyperMILL 2018.2 uses the free geometries of the cutting tool edge for calculation, simulation and collision checking. hyperMILL 2018.2 functionality also includes enhancements to its hyperCAD-S module, including the ability to measure and record the distances between two shapes such as face models, solids, meshes or stock.

In addition, for easy changes to milling boundaries and turning contours, hyperMILL 2018.2 offers a ‘V sketch’ command that assigns geometric constraints to 2D contours. When individual contours are changed, the sketch is automatically updated using their dependencies.

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CAE Solutions

Utilities for Autodesk software

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KML file into Civil 3D to create a baseline for the design.

IMAGINiT Utilities for Autodesk Vault Client IMAGINiT Utilities for Vault Client help CAD managers and non-CAD users better manage data workflows. New tools for 2019 are: Create Local Folders allows users to generate folders in their Windows working folder hierarchy to match the Vault folders.

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IMAGINiT Utilities Availability IMAGINiT Utilities for Revit, IMAGINiT Utilities for AutoCAD Civil 3D and IMAGINiT Utilities for Vault Client are available to customers maintaining their annual Autodesk subscription through IMAGINiT. These free software utilities can be accessed via IMAGINiT’s ProductivityNOW Portal. Those who are not already IMAGINiT customers may purchase these utilities directly from the IMAGINiT eStore. DW

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M o t i o n

C o n t r o l

motors boost

efficiency + torque

With a few tweaks in design, transverse flux motors with internal permanent magnets lead to improved efficiency and higher torque output.

O

Donald Labriola II, P.E. | QuickSilver Controls, Inc.

One of the persistent challenges that any motor design faces is improving efficiency. While many methods have been devised to solve this challenge, one of the latest solutions is the transverse flux motor.

Transverse flux motors provide excellent torque and efficiency in direct drive applications covering a wide range of speeds. They take advantage of all three spatial dimensions in their flux paths, folding the magnetic paths around the copper to minimize the non-torque producing sections of the stator windings – thus reducing losses and improving efficiency.

This structure also generates stators which may be easily produced with multiple stator poles per winding; the increase in pole count further increases the available continuous torque from the motor allowing for their

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These X34 series hybrid servomotors from QuickSilver Controls use advanced techniques, such as a high torque constant with low winding resistance and field-weakening techniques, to boost efficiency up to 80% over a 4:1 speed range.

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M o t i o n

C o n t r o l

use in direct-drive applications. Also, the use of internal permanent magnets – those having iron between the magnet and the rotor/stator gap – allows the use of field weakening to dynamically adjust the effective magnetic strength of the gap field to optimize the efficiency over a wide range of speeds.

The internal (or buried) magnet structure helps protect the brittle magnets while also allowing for many poles to be produced in the rotor with one to a few magnets.

Here, we’ll start with the results comparing these motors to axial motors and then proceed to the details of how this is accomplished. The efficiency was measured from the dc input power into the controller to motor shaft output. System efficiency was above 65% from approximately 140 rpm, and near to 80% from 500 through approximately 2,000 rpm. Thermal measurements indicate that the motor and controller/driver were

Transverse flux motors provide improved torque and efficiency in direct drive applications covering a wide range of speeds.

roughly splitting the losses, and thus each was operating at an estimated 90% efficiency.

High pole count and low winding losses The transverse design accommodates high rotor and stator pole counts in a given diameter, while simultaneously reducing the copper losses in the motor. The combination results in a high continuous torque capability with much lower waste power as compared to a conventional axial motor.

Quantitatively, this effect is called the Motor Quality, and allows a direct comparison of motor configurations without being influenced by the motor winding targeted voltage range.

The Motor Quality factor is defined as: Kq = Torque x Power

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M o t i o n

C o n t r o l

The transverse design accommodates high rotor and stator pole counts in a given diameter, while simultaneously reducing the copper losses in the motor.

THE COUPLING. SIMPLY UNBEATABLE 2-25,000 NM.

To compare the copper losses between two motors operating at the same output torque, we use the equation: Power = Torque x Kq2 It should be intuitive that torque increases with current (if below the magnetic circuit saturation point), and resistive losses go up as the current squared. What is interesting is that the waste power also goes down by the square of Kq. It’s common when comparing similarly sized transverse flux motors to axial flux motors to see the transverse flux motor having a Kq that is 4 to 5 times higher than the axial flux motor. This comes both from the higher available pole count and from the reduced copper losses obtained by better use of the copper. This results in typically 16 to 25 times less resistive power losses for low speed operation.

The table below shows the results of comparing three-inch tall NEMA 34 frame motors, comparing an axial magnetization versus a transverse flux motor (normalized for 2 vs. 3 phase): WWW.RW-AMERICA.COM

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M o t i o n Motor

Kt (V/radian/sec) Rm (ohms)

Kq

Transverse (A34HC-1)

0.214

0.06

0.874

Axial (3431P)

0.12

0.355

0.201

The transverse flux motor tested has a back EMF 1.8 times larger than the axial motor, with the winding resistance that is almost six times lower. The Kq figure is calculated using the equation: Kq = Kt/R (Kt in Nm/A = Kv in V/Rad/sec) The ratios of the quality factor of the two motors is 4.3. Squaring this gives the ratio of resistive heating as 18.6.

Torque

Axial Heating (W) Transverse Heating (W)

1 Nm

24.5 W

1.3 W

2 Nm

98 W

5.6 W

3 Nm

220 W

12 W

4 Nm

390 W

21 W

577 W (motor only)

31 W (measured: motor+driver)

4.85 Nm

For motors whose motions include low speed operations at high torque, this is a substantial difference in heating. The effect on battery life in a remote vehicle, such as a warehouse robot, is also quite significant.

This efficiency advantage is not just when stationary, but also over a wide range of speeds. In this case, the continuous rated torque of the axial flux motor was 2.7 Nm, and peak was 4.85 Nm. For the transverse flux motor the continuous (up to 800 rpm) was 4.85 Nm, dropping to approximately 2.7 Nm (continuous rating of the axial) near the peak speed of the axial motor (both motors running from 48 Vdc).

Internal permanent magnet and wide efficiency curves Internal permanent magnets (IPM) — also known as indirect permanent magnets or buried permanent magnets — are useful in a number of ways. First, the brittle high-energy magnets are physically protected

inside the steel magnetic structure of the rotor. Combined with the transverse design, many magnetic rotor poles can be constructed with a few magnets, even a single magnet. Adding magnetic material between the magnet and the gap allows for field weakening of the motor. A sensible question would be: Why would it ever be desirable to lower the magnetic field strength?

The back-EMF (and torque constant) of the motor vary with the number of turns per pole, the number of poles, and the strength of the magnets. Having a higher torque constant greatly benefits the low-tomid speed continuous torque as well as efficiency of the motor. This same high torque constant also results in a high back-EMF as the speed increases, which can limit the motor speed. Field weakening allows the torque constant to be adjusted down as a function of speed to keep the motor back-EMF in the sweet spot – just below the power supply voltage – over a wide speed range, producing almost constant efficiency over that wide speed range.

Field weakening is much easier to implement with internal permanent magnet motors than with face-mounted magnets typical of axial permanent magnet motors. That said, IPM technology has started to appear in a relatively small percentage of axial permanent magnet motors for the above reasons (other than the high pole count advantages).

Flux weakening is implemented by controlling the phase and magnitude of the current to allow a portion (Iq) to produce torque, while the balance (Ii) is used to oppose the magnetic field from the permanent magnet, and thus weaken the field from the internal permanent magnet that is present in the rotor-stator gap.

Studies have shown the field weakening strategy to be most effective for high saliency motor designs – those which combine significant reluctance torque with the magnet torque generation. The “hybrid” in hybrid servo refers to this combined torque generation methodology, which is available with these IPM motors. DW QuickSilver Controls, Inc. | www.QuickSilverControls.com

This graph shows efficiency vs. speed for a transverse internal permanent magnet motor (blue curve) compared to a permanent magnet servo motor.

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The graph shows a plot of efficiency vs. speed for a transverse internal permanent magnet motor and drive combination at different operating voltages with efficiency reaching 80%.

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L i n e a r

M o t i o n

Linear actuators

based on shape-memory alloys

Now, one new actuator uses bundles of SMA wire made of specialty nickel-titanium alloy for reliable linear motion.

Dean Pick, P.Eng. | President | Kinitics Automation

•

Lisa Eitel | Motion Editor

Shape-memory alloys (SMAs) are those materials that respond to temperature changes by changing form factor. Originally funded by the U.S. Navy, SMA technologies were first commercialized by Raychem Corp. (now of TE Connectivity) during the 1950s. But the unpredictable nature of early material versions proved a challenge. So over the decades, manufacturers investigated ways (with mixed success) to boost the durability, consistency, and applicability of SMA-based designs.

Now one new SMA-based linear-motion offering uses advanced SMA material for repeatable and predictable motion. The manufacturer bundles wires made of SMA and anchors them to an actuator housing. Current through the (electrically resistive) SMA generates this heat; when warmed past a transition temperature, the wires’ atoms realign to another crystalline structure. This results in wire contraction when heated and re-extension when cooled — which in turn makes for linear motion output.

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L i n e a r

In fact, this reversible behavior makes SMAwire-based actuators suitable for an array of motion applications — including those on high-cycling machine axes. The rod is the sole moving part, so the actuator exhibits zero backlash or mechanical slop — regardless of how many times it’s cycled. Research and testing have yielded quantitative industrystandard information about the linear actuators to allow application to real-world motion designs.

Here’s how an SMA linear actuator works over a linear-stroke cycle: During an initial stroke phase, the bundled-wire SMA linear actuator uses electric power to move a piston towards a fixed end. The amount of power applied dictates piston speed.

Next, during an optional hold phase, the piston can hold position for a set amount of time.

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Then during the return phase, the bundled-wire SMA linear actuator uses heat transfer and force biasing to return the piston to the home position. The rate of cooling and amount of biasing force dictate piston speed.

By adding feedback sensors and a controller to the design, design engineers can even get bundled-wire SMA linear actuators to output complex motion profiles … and fine positioning and force control. For the latter, a specialized drive-controller regulates current input to control output precise linear motion.

Though beyond the scope of this article, variations on the bundled-wire SMA arrangement for piston-pump operation can deliver fine pressure control, discharge temperature control, and volumetric displacement control.

www.designworldonline.com

M o t i o n

Kinitics Automation Bundled Wire is a proprietary technology of assembling and connecting shape memory alloy (SMA) wires in a dense array.

Bundled Wire technology gives Kinitics Automation SMA linear actuators a high strength-to-size ratio. Plus it retains high wire surface area to allow for forward-stroke times in just 200 msec (or less) and full cycles in less than 5 seconds.

When connected to a piston pump as shown here, the technology can be applied to fluid-power applications.

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L i n e a r

M o t i o n

Your worldwide source for high performance Tapes, Films, Fabrics, and Silicone Force and stroke ratings can be used to select the appropriate Kinitics Automation actuator model, and design engineers can configure the actuators to work with myriad power sources to tailor the response time to the application (and for compatibility with existing infrastructure).

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How SMA linear actuators compare to traditional designs Bundled-wire SMA linear actuators are unique to the linear-motion industry: They don’t use motors or magnetic fields to generate force. Instead, the technology uses shape-memory alloy to generate motion.

They’re often less costly than comparably sized electric motors. In addition, SMA linear actuators avoid some of the electricalnoise issues of electromagnetic arrangements

and the acoustic noise of mechanical devices such as gearboxes. In fact, bundledwire SMA linear actuators work without power-transmission components such as gearboxes and ballscrews to translate rotary to linear motion.

Because they’re a new technology, SMA linear actuators defy the traditional classifications of traditional motion designs.

The best way to summarize the bundledwire SMA linear actuator is to describe

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www.cshyde.com sales@cshyde.com 800-461-4161 Lake Villa, IL 60046 Linear Motion (Kinitics) 9-18_Vs3 edited.LE.indd 68

Kinitics Automation actuators use a nickel-titanium shape memory alloy (the NiTi in Kinitics) in a bundled-wire arrangement. The actuators satisfy certain applications better than other linear-motion technologies. On the right, notice how much simpler Kinitics Automation actuator setups are than comparable hydraulic systems.

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L i n e a r

M o t i o n

For design engineers developing machine axes requiring positioning or force control, the Kinitics Automation linear actuator is one new option. When paired with a Kinitics controller (such as the KCA020) an analog controller input signal can modulate the actuator gain.

Alternatively, the Kinitics controller can also accept a pulse-width-modulation (PWM) signal to dynamically drive the actuator. Combining a Kinitics actuator and controller with a feedback sensor and plant controller yields a closedloop motion system. Programmers can leverage the actuator’s linear responsiveness when developing their control strategy. Usually it’s possible to use a PI function block — and eliminate the need to develop complex high-order programs.

Kinitics Automation’s bundledwire SMA technology

T

The direct-drive concept of Kinitics Automation’s bundled-

wire SMA technology arose from an automotive application within sister company Biperformance Development Corp. (ShiftFX). In short, ShiftFX wanted to build an optimized clutch control for motorcycles capable of acting as a master cylinder — essentially a piston pump.

“Conventional technologies — in particular, ballscrew-driven

actuators — didn’t have enough power density to do the job within the space allotted in the motorcycle footprint,” said Kinitics Automation’s president Dean Pick. “So we stumbled across the shape-memory-alloy technology and began five years of R&D work on adaptations. At that time, nobody had successfully applied it to a linear-motion application.”

In fact, Pick rides motorcycles and served as the test guinea pig

for many of Kinitics Automation’s early uses of the shape-memoryalloy products. Once perfected, the team at Kinitics realized the technology might be useful for other linear applications in other industries. So now, it’s established an entire family of SMA linear actuators and piston pumps.

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Dean Pick in the lab: For quality control and MTBF testing, Kinitics Automation runs a laboratory that includes several wire dynamometers that have logged more than 2 million cycles on single pieces of SMA wire.

September 2018

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it as a high-force short-stroke option — scalable to about 2,000 N or roughly 500 lb of force. Strokes are to 10 mm or about 0.375 in. Suitable applications are those that need short strokes with exceptionally precise positioning. At MD&M West 2018 in Anaheim, Calif., one demonstration showed a small bundled-wire SMA linear actuator accurately lifting and lowering 160 lb worth of metal weight-training plates with accuracy — to position the weight into within 5 mm.

Such linear motion isn’t possible with most other technology.

When used for positioning, Kinitics bundled-wire SMA linear actuators output repeatable accuracy and precision to within 5 µm (0.0002 in.). Shown here are the performance characteristics of a KLA05 SMA linear actuator running off 120-Vac input to move 725 N (163 lbf ) over three positions. By limiting the KCA020 controller gain (as between step one and two shown here) it’s also possible to control the rate of acceleration.

1 Solenoids deliver excellent on-off “bang-bang” strokes — as in poppet valves for fluid-process applications, for example.

These valves need a lot of force to act on the spring maintaining pressure during the static state. In contrast, shape-memory

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

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

motion? plastics!

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M o t i o n

alloy linear actuation can serve to make such installations function as proportional valves … because unlike solenoids, controls can drive the actuator to any position to control flow.

ISO 9001:2015/AS9100D CERTIFIED

2 Bundled-wire SMA linear actuators can also work as positioners (to compete against piezo technologies) in some cases. Stroke lengths go beyond those of piezos, so design engineers who need more than 0.1 mm — say, to as much as 10 mm — may consider bundled-wire SMA actuation as an option.

Applications here include fine positioning of machining tables, mirror instruments, and other applications that otherwise need the accuracy and precision of piezo actuators but with longer range.

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3 Where stroke lengths are short, SMA actuators even compete against traditional linear-motion actuator setups that pair a rotary electric motor with a rotary-to-linear mechanical device. Elimination of the lost motion, backlash, and wear surfaces of couplings, gearboxes, and other mechanical components makes for higher precision as well as longer life. Potential applications here include those in consumer robotics and electronics, HVAC installations, and medical devices. DW

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| PC11-47USA |

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The compact and cost-effective CP6706 Panel PC for all-in-one HMI and control.

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Intelligent

machines

meet their

makers

Intelligent equipment developed by today’s OEM machine builders helps their end user customers be more efficient than ever. Using IoT technologies, these smart machines report back to their OEM makers with performance and diagnostic data to improve support.

Benson Hougland | Opto 22

Manufacturing companies consider many criteria when shopping for production machinery. The equipment needs to perform correctly, reach proper throughput, be easy to operate and function reliably. To achieve these goals, today’s OEM machine builders are employing advanced automation techniques and adding Internet of Things (IoT) technologies. In fact, because powerful control and visualization devices are now available, end users expect this type of advanced functionality and interfaces in all the equipment they purchase.

As it turns out, many existing industrial automation technologies can enable much deeper interactions between machine builders and their customers, fulfilling the promise of the IoT. Traditionally, OEMs might hear back from their customers only for replacement part orders, or perhaps a service call for repair or preventive

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I n t e r n e t

maintenance. Today’s more sophisticated OEMs, on the other hand, can apply automation techniques so the machine can securely report back to the builder through the internet with extensive performance and diagnostic information. Enhanced machines of this type are often referred to as “smart” or “intelligent.”

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With feedback from intelligent machines, equipment builders can more quickly and effectively support their customers. Furthermore, OEMs can use the information to pinpoint problem areas or identify operating trends. The data exchange thus benefits both OEMs and their end-user customers. www.designworldonline.com

o f

T h i n g s

Smart-enabled machines deployed at customer sites can not only produce parts and assemblies, but also provide a wealth of operational and performance data. | Courtesy of Opto 22

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Today’s OEM machine builders are looking to “close the loop” by gathering information from machines they have deployed in the field at customer sites.

But although a wealth of information is available, transporting it can be challenging. End user networks may be configured and secured in a way that restricts communications outside the plant walls. Fortunately, several standard technologies can overcome these difficulties, and do so with appropriate security.

Machine Tool Components

Let’s look at common challenges and solutions, starting with the types of machine data valuable to OEMs and end users alike.

Spring Plungers

Valuable data OEM machinery provides immediate and tangible value when it runs well, produces efficiently, and rarely requires any attention. Many end users would not look far beyond these basics. Yet OEMs and their end user customers alike can find more value by delving into the extensive data many machines can provide, and analyzing these data to create actionable information.

Here are several categories of data that can inform machine builders:

speed and production throughput • Equipment and cycle counts • Runtimes • Uptime/downtime usage • Energy • Alarms • Events • Operator actions and responses

Clamps

And here are some of the ways OEMs can use these data:

overall equipment effectiveness (OEE) • Evaluate machine uptime • Improve problems before they occur • Predict operators respond more quickly to problems • Help fixes to existing machines • Develop • Engineer improvements to new machines

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www.fixtureworks.com Fraser, Michigan 888.794.6887 Internet of Things feature 9-18_Vs3.LL.indd 76 FXW-210 3x10.875.indd 2

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Viewing operational data sourced from equipment installed at customers’ sites allows machine builders to respond more quickly to issues, and to predict problems before they occur.

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Your Global Automation Partner

WARNING

Outbound connections initiated by intelligent OEM machines overcome the complexity of network address translation and firewalls, allowing machines to report critical performance data to the builder.

Fundamental metrics such as equipment operating speeds, production throughput, runtimes, and cycle counts are basic information required by most end users.

Similarly, tracking uptime versus downtime can provide insight into how well the machine is running.

Knowing what constitutes “good” or “bad” values could be tough for end users to discern, even if they have several machines to compare. On the other hand, these data can take on new meaning for OEMs when it can be viewed in the context of many machines across a broader sample of deployments.

As experts in the design of their machines and their capabilities, OEMs are best positioned to critically review performance data. Through analysis, normal operating ranges can be determined, so it becomes far clearer when a machine is or is not operating at peak performance.

With the right source data, it is possible to develop OEE measurements for comparing machines. OEE calculations quantify the availability of the machine, including when it is expected to run, the speed at which it operates, and the amount of quality output it produces.

Identifying the sources of downtime is always of interest to improve uptime.

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Not suitable for repairing crummy sensors

Downtime can be due to stoppages downstream, shortages upstream or on-machine problems. When OEMs can quantify the root causes of downtime, they can address any problems on the machine, or point end users to other in-plant problems.

Energy usage is typically considered from a cost-to-run perspective, but it can also be used to pinpoint failing bearings or other drive equipment problems. Similarly, high alarm counts indicate trouble areas for investigation. OEMs can use this type of data to predict problems before a complete breakdown occurs.

Any number of other machine-specific events can be monitored and acted upon in the same way. In fact, it is often instructive to monitor operator actions and how operators respond (or don’t) to problems.

This provides OEMs with some insight into how the equipment is being used and often reveals areas for improvement.

Implemented properly, an entire OEM machine can become an IoT edge device of sorts. Short-term goals for obtaining and using data are simply to keep the end user’s machines running well. But the long game is for OEMs to keep learning from their machines. This can enable them to develop fixes for existing machines where necessary,

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September 2018

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T h i n g s

Your Global Automation Partner

An edge programmable industrial controller, such as this groov EPIC from Opto 22, can be used by machine builders to collect, process, store and share operating data—as well as directly controlling equipment.

and can also provide an experience base for building improvements into future machines.

But getting the data from OEM machines at customer sites can pose challenges.

Data connection challenges It is already quite common for most manufacturing sites to maintain a highspeed internet connection and multiple Ethernet networks. Likewise, most modern IoT devices and intelligent machines either use networking elements or offer a network connection. For OEMs to access machine data and support their customers, intelligent equipment must take advantage of these on-site networks and the internet. However, making this connection can be challenging.

The most common issue is that most sites protect themselves behind a firewall, as they should for security reasons, which prevents devices outside the firewall from initiating communications. While this is the established method for preventing digital intrusion, it can also prevent outside OEMs from connecting to their machines.

Compounding this issue, many customers prefer to keep their machinery isolated on a manufacturing network, separate from the business network, to ensure a higher level of security.

Another complication is when manufacturing facilities operate many identical machines, each of which is supplied from OEMs with a typical IP address. A

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WARNING

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

common approach is to install these identically addressed machines behind network address translation (NAT) devices. Making use of NAT is an ideal solution for internal purposes, but this interposing layer further complicates the ability for an OEM to connect to their smart machines.

As long as customers are willing to connect intelligent equipment to an internetcapable network, there are ways to enable communications through firewalls and NAT devices. Dedicated virtual private networks (VPNs) are a primary way, but they require involving a site’s information technology (IT) personnel. Unfortunately, IT personnel typically have little familiarity with operations equipment, and configuring the desired communication paths can be tricky to set up, and cumbersome to maintain and troubleshoot.

A different method is therefore required for OEMs to easily and reliably make the connection with their customers’ machines.

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A better way to communicate Over the years, industrial automation products and technologies have improved in performance, ease of use and capabilities. One important development is communication methods. While there are many missionspecific fieldbus protocols, we will take a closer look at how Ethernet connectivity and protocols have evolved to achieve remote connectivity.

Adoption of an open-source communication protocol called message queuing telemetry

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September 2018

Custom Connectivity Whether it’s a harness with custom wiring topology or a custom cable color for a standard connector, Turck’s expertise creates your best solution.

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QUALITY & PRECISION MATTER

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transport (MQTT) has been a key development. A related specification called Sparkplug defines an industrial-friendly data-messaging format. Combined, these technologies enable what is called publishsubscribe communications.

Instead of an outside entity (the OEM, for instance) attempting to poll customer machines for data following a requestresponse model, MQTT and Sparkplug enable a machine to establish an outbound publish-subscribe connection. Because it is outbound, this connection immediately overcomes the firewall and NAT challenges described earlier. The OEM machine develops the communication link to an outside “broker” with no IT involvement necessary.

MQTT is very lightweight and able to withstand slow network connections or interruptions. It also does not place heavy burdens on networks, ensuring there are no negative impacts on a customer’s site or operations. The data from any number of machines or user sites worldwide can be published to a centralized cloud location where the OEM can subscribe to access it as needed.

Because these communications are outbound only, customers can leave all sitesecurity systems in place. These internet communications can also take advantage of industry-standard Transport Layer Security (TLS) provisions, such as banking-grade authentication and data encryption. MQTT itself offers an additional layer of credential checking to ensure proper clients are connecting with the broker. Thus, there are many protections to safeguard sensitive data.

OEM machine builders can take advantage of commercial off-the-shelf (COTS) products that combine all these abilities and more. For instance, Opto 22’s groov EPIC (edge programmable industrial controller) includes the necessary data collection, storage, processing, and sharing features. It also contains a full-fledged controller and human machine interface (HMI). OEMs can economically layer the groov EPIC on top of existing automation to gain the new capabilities, or they can adopt it as an all-in-one solution.

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Your Global Automation Partner

T h i n g s

There are many reasons for enabling smart machines to connect to their OEM makers. Not only can OEMs benefit from these communications, they can also better serve their end user customers who operate the equipment daily. Common technical and security challenges can readily be overcome using a new generation of COTS devices, open-source protocols and IoT technologies.

DW

Opto 22 | www.opto22.com

WARNING Not suitable for repairing flimsy controls (or your reputation).

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M e c h a n i c a l

Mission Possible: Sending bearings into space

“Satellite applications account for a relatively small

portion of our overall business, but they sometimes drive the extreme end of what’s possible with our technology,”

Edited by Mike Santora

says John Lowry, chief engineer—aerospace for The Timken Company. “Space forces us to think in different ways about materials, thermal variation, lubrication and other factors than we do in a typical industrial application.”

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| Courtesy of Timken

A new satellite rests silently on a launch pad before blasting off on a rocket traveling thousands of miles an hour. After cutting through the atmosphere, it endures near cryogenic temperatures in the vacuum of space. Aboard the satellite is precision ball bearings that must perform their duties flawlessly for years to come, some 1,200 miles from Earth and any hope of repair.

These specialized bearings—which can be as small as the tip of a pencil—can operate in this extreme environment for ten years, twenty years or more as the mission demands. This long-term reliability requires manufacturing methods and testing techniques that are themselves unique and, at times, well beyond what goes into producing standard bearings.

DESIGN WORLD

9/6/18 11:46 AM | Courtesy of Timken

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M e c h a n i c a l

A satellite may use several micro-precision ball bearings to operate mission-critical equipment—three of these bearings can fit on a single dime.

Strong materials Material selection is a critical consideration in the design of any bearing. In ball bearings, the interaction of the balls, races, retainer, and lubricant with each other and the environment, contribute to the limit of overall performance.

Every component and raw material purchased by the aerospace bearing maker is controlled by stringent manufacturer,

customer, and industry specifications. All materials are certified and checked against specifications before being released to production. Bearing materials are inspected for properties such as hardness, grain size, chemical analysis, and carbide and inclusion ratings. Bearing rings and rolling elements are also checked in-process at multiple stages for hardness, dimensional stability and, if applicable, corrosion resistance.

In many applications, the bearing material is further subjected to advanced heat-treating processes using vacuum furnaces and other specialized equipment.

Vacuum hardening allows the material to meet the strictest military and commercial requirements for product uniformity.

Keeping bearings lubricated In most industrial machines, bearings

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are packed with grease or lubricated with generous amounts of oil. In certain space applications, however, there may be only a small amount of lubricant impregnated into a porous container that creates a continuous monomolecular film of oil on the bearing surfaces. Other times, bearing components are dipped in oil and spun “dry” in a centrifuge, so that only the minimum amount of lubricant remains on the part. In either case, the goal is to minimize viscous drag due to excess lubricant.

Bearing lubricants also must be designed to eliminate the risk of chemical outgassing in aerospace applications, where the slightest contamination can have severe consequences for the highly sensitive instrumentation used on satellites and spacecraft. These special lubricants are an alternative to conventional oil or grease. Engineers select these lubricants primarily when operating environmental conditions are beyond the allowable limits of traditional oil and grease—such as where extreme temperatures are encountered or in a vacuum environment.

On the rover Curiosity, which landed in Gale Crater in August 2012, a quarter-

inch miniature precision radial ball bearing from Timken supports the shaft for the rover’s turbomolecular pump. As Curiosity searches for early signs of microbial life, it collects rock and soil samples in a carousel.

The bearing—operating at 100,000 rpm— then rotates the pump to create a vacuum condition inside the carousel so the sample can be analyzed.

Because it is immensely challenging to operate bearings in a vacuum in lowlubrication conditions at very high speeds, a special lubricant solution was selected for this Mars-bound bearing that’s a mixture of grease and oil. As the grease starts to wear out, the oil is released from the retainer and re-lubricates the bearing.

It’s further evidence of the vast amount of engineering and tribological expertise that space exploration demands, and why something as seemingly ordinary as a ball bearing is essential to reaching the places we still hope to go.

Increased Reliability for Industrial Applications

Advanced machining and inspection for mission success Precise grinding and finishing of the rolling element contact surfaces are another way

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September 2018

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M e c h a n i c a l

When the nearest service technician is 35 million miles away, bearings must function flawlessly.

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that aerospace bearings take manufacturing to the extreme. At times, the ground surface must be finished to a precision level measured in fractions of a micro-inch. In other words, less than one-millionth of one inch (or in metric terms, one 39,370th of one millimeter).

At the Timken aerospace facility in Keene, NH, machining specialists modify ground surfaces to a consistency that allows aerospace bearings to achieve perfect rolling motion. It is this superior rotational accuracy and consistency that precision applications like a satellite or space telescope demand.

Finished parts are assembled in a clean room to ensure they are thoroughly free of particulates and surface contaminants. Any contaminant can prove catastrophic in space; in some cases, even a single speck of dust, skin cell or flake of dander. Inside the clean room, clothing requirements are such that not one cotton fiber is shed. Also, the bearing contact surfaces must remain spotless and conducive to wetting to create a continuous oil film, as chemical contamination of any kind can threaten to end a mission unexpectedly. It is also common for manufacturers to perform particle counts on bearing assemblies to validate the cleaning process.

Control moment gyroscopes are the devices within a satellite that help keep it in place—known as geostationary orbit—or help reposition and accurately point the satellite so it can gather information for predicting weather, tracking climate trends, sending GPS directions, and even providing TV and radio services.

Many satellites also include rotating optical imaging equipment, or scanning devices, that rely on precision bearings to rotate and position them. Because even an eyelash can cause problems for precision bearings, manufacturers adhere to intensive protocols to keep environments ultra-clean.

Currently, active Timken-equipped satellites include the JPSS1 NOAA-20 Weather Satellite, which produces daily maps of temperature, water vapor, and other factors to assist with everything from identifying weather patterns to planning commercial aviation routes. Another is the Suomi NPP NASA Weather Satellite, which collects data on long-term climate trends.

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Because even an eyelash can cause problems for precision bearings, manufacturers take extraordinary steps to keep environments ultra-clean.

“These satellites typically use miniature precision bearings due to the requirements for extreme accuracy when being positioned and when taking images of specific parts of Earth,” says Lowry. “Think about when you try to point your camera at something far away, and as you zoom in you can’t hold your hand steady enough to get a good shot. It’s even harder from the distance of outer space. The vibration transmitted through the satellite must be exceptionally low, and that requires unbelievably round, smooth and centered components. It’s very challenging.”

No space for mistakes There’s no opportunity for rework, repair or relubrication in spaceflight applications, and that’s why most aerospace bearings are designed to three times mission life expectancy. Once they’re in space, bearings aren’t accessible in any way. If a bearing in a critical position were to fail and the satellite or imaging equipment could not be pointed in the right direction, it could result in total mission failure.

A planetary rover, meanwhile, may use bearings to operate gearboxes on wheel

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transmissions, solar array panel drives and rock abrasion tool drives in addition to the actuators that deploy, rotate and maneuver the camera mast.

“Just one poorly functioning bearing in space could be the difference between a successful mission and a failed one,” Lowry says. “That’s why such rigorous testing and requirements go into making these precision assemblies.” DW Timken | Timken.com

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S e n s o r s

Limit switches, photoelectric switches and laser sensors all provide position sensing — but depending on the application, some shine and reflect better.

Wide and narrow views of position sensors

Andrew Waugh | Product Manager for Sensor and Safety Products | AutomationDirect.com

When the word “sensor” is used in industrial automation, it usually refers to presence sensing devices such as limit switch, photo eye (photoelectric) and laser sensors.

There are many options and technologies to consider when specifying the use of these presence sensors in automated machines.

A quick discussion of the technology used in each of these devices can help in their selection.

There is much overlap in functionality of these sensors, and there are also some selection considerations, as each device has its own advantages and disadvantages.

What is a position sensor?

Three common position sensors are mechanical limit switches, photoelectric sensors and laser sensors.

Mechanical limit switches are used in industrial automation systems to detect presence or position. Physical contact with the switches’ actuator, usually adjustable, activates these electromechanically operated devices.

Photoelectric sensors, also called photo eyes, detect object presence or distance using light. Operation combines a light source and an emitter, and a receiver that detects changes in light intensity reflected by the target object, Figure 1.

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Both short-range CMOS and this long-range, time-of-flight Wenglor photoelectric laser sensor are often used in material handling applications.

There are many options and technologies to consider when specifying the use of these presence sensors in automated machines.

Laser sensors operate like photoelectric sensors but with a much more focused light source to detect presence or measure distance, depending on the configuration.

Laser photoelectric sensors detect presence.

Laser distance sensors measure distance, as the name implies.

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The tried and true limit switch Limit switch actuators are available in many forms including an adjustable arm or a plunger, each mechanically linked to an electrical switch block inside the housing.

Rotating the arm or depressing the plunger provides a mechanical action to operate the www.designworldonline.com  

switch’s electrical contacts. These contacts are available normally open or normally closed in a variety of numbers of poles and throws.

Purely mechanical in operation, most limit switches use linkages and movement of the sensed object to operate the switch contacts.

Heavy-duty contacts are common in limit September 2018

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S e n s o r s

switches, enabling switching of higher currents than other presence and position sensing devices.

Screw terminals inside the switch housing provide convenient electrical connections. A common configuration of the housing includes threaded openings for conduit or cord grip installation. A removable cover provides environmental protection for the switch and its electrical connections.

Diffuse, retro-reflective and through-beam photoelectric sensors The typical light source used in the emitter, or sender, of a photoelectric sensor is visible red or infrared. The light is collected by a receiver where the intensity is measured. These emitter and receiver elements can be installed in the same housing or in different housings.

Diffuse and retro-reflective configurations are available when an emitter and receiver are integrated together. Diffuse sensing bounces emitted light directly off an object and back to the receiver in the same housing.

A retro-reflective, also called reflective, configuration uses a single housing as well, but bounces emitted light off a fixed reflector, not an object. The reflector must be attached to a fixed surface and can be polarized to improve sensing by eliminating unwanted reflections.

A through-beam photoelectric sensor uses a configuration where the emitter and receiver are in different housings. Through-beam photo eyes provide the longest operating distances since the emitter shines light directly to the receiver.

Laser sensor operating principles Laser distance sensors are available in diffuse, background suppression and retroreflective types. These sensors provide accurate distance measurements using CMOS (complementary metal-oxidesemiconductor) or transit time technologies, Figure 2.

Laser light is focused, keeping it in a narrow beam over long distances. The light color is also held to a narrow spectrum. This wellcontrolled light source can be triangulated or pulsed, with each emission or pulse measured to enable distance readings.

Table 1: Selection considerations for presence or position sensing Specification

Limit switch Contact with part needed

Photoelectric sensor

Speed of operation

Slow, 2 Hz, and also has limits on actuation speed.

Fast enough for most applications between 25-2,000 Hz.

Faster than photoelectric sensors with speeds up to 50,000 Hz.

Repeatability

Depends on the model but certain units are the most repeatable options available.

Can be very repeatable but depends on the fluctuation in reflectivity.

Can be very repeatable but depends on the fluctuation in reflectivity.

Environmental issues

Can operate in rugged environments without influence on operation because it touches the part or object.

Although the product and housing are rugged … dusty, wet and harsh environments can affect reflecting light.

Protected against most areas but must be aware of the Laser Class to avoid eye contact. Harsh environments can affect reflecting light.

Installation

No set-up but needs to mount close, in order to touch object.

Easily mounts with brackets but often needs “teaching” to set switching thresholds.

Easily mounts with brackets but often needs “teaching” to set switching thresholds.

Construction

Either rugged plastic or heavy-duty metal.

Usually basic plastic, sometimes a metal housing.

Usually basic plastic, sometimes a metal housing.

Sensing distance

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Close to far

September 2018

Laser sensor Close to extremely far (100 m)

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S e n s o r s

Short-range, high-precision laser sensors often use CMOS technology.

Optical triangulation is the principle of operation. Diffuse triangulation transmits laser light through a lens, and then bounces it off a target and back to a separate receiving lens that focuses the light onto a CMOS linear imager.

Distance to the target changes the angle of where the focused point of reflected light is received on the linear imager.

Long-range, precision laser distance sensors use time-of-flight technology and are often called rangefinder laser sensors. A laser diode in the transmitter generates a very precise, short pulse of visible red or infrared light. Accurate and high-speed electronics measure the light transmit time from transmission to reflection off the target object and back to the sensitive, laser energy detector — the receiver diode. Using the light transit time and the constant for the speed of light, the object’s distance from the sensor can be calculated.

These photoelectric sensors detect object presence or distance in a wide range of industrial applications, and typically contain all required optics and electronics in a single unit.

Selection considerations With any presence or position sensing application, it’s important to understand the devices specifications. These specifications along with specific application requirements drives the selection considerations, Table 1.

Limit switches must touch an object to detect it, which limits sensing distance to the travel distance of the switches’ rotary lever arm or plunger type actuator. However, this short sensing range provides reliable detection of an object regardless of its color, shape or size. Care must be taken to ensure the object touching and activating the actuator roller or plunger does not damage it.

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A common application for a limit switch is detecting the closed position of a conveyor lift gate.

Both photoelectric and laser sensors have a sensing range from close to far.

Adjustable light intensity and sensing thresholds help tune this range. This wide and adjustable detection makes the photo eye a popular choice for presence detection, and it has an excellent sensing range-to-size ratio. As the sensing distance increases or a more accurate or a smaller spot size is needed, laser becomes a popular choice.

Mechanical limit switches have moving parts that can wear out, so the speed of actuation must also be limited, making it unsuitable for high-speed applications. The electronics in both photoelectric and laser sensors enable fast switching operation.

With operation speeds — from 25 Hz on the low end to thousands of times per second on the high end — high-speed applications are possible, and the number of actuations is not a concern.

When looking at presence sensors’ repeatability, or repeat accuracy, it is

important to understand when it’s needed, because many sensors do not excel in this area. For applications where a high degree of repeatability is needed, precision touch limit switches are available with an accuracy of 5 microns or less.

Photoelectric sensors can be very repeatable, but it depends on the type and how it is installed. Its repeatability also varies due to fluctuation in reflectivity. Laser sensors are typically more repeatable than photoelectric sensors. Those designed for measurement have a measurement accuracy around 10 microns or less, depending on the range, but repeatability can be affected by fluctuations in reflectivity.

Environment, installation and construction Because a limit switch touches a product, flag, carrier, trollie or traveler on a machine or automated process to operate, it works well in rugged environments. However,

guards are often needed to protect the switch from accidental operator actuation, and the switch should be mounted to keep water or debris from accumulating around the actuator arm, seals and bearings.

Although a photo eye’s housing is rugged, a dusty, wet or harsh environment can affect

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S e n s o r s

operation by dispersing the light reaching the target and its reflection. Many laser sensors are protected against harsh environments. Dirt and debris may be a problem, but the light intensity can often be increased to burn through these airborne interferences. However, it is important to understand the Laser Class to avoid eye contact.

When it comes to installation, limit switches must be mounted to touch the object when actuated, and the actuation must operate the switch properly, perpendicular to the arm for example, and possibly through use of cam action or a ramp.

Photo eyes easily mount using offthe-shelf brackets, but many times need “teaching” to set switching thresholds.

Lasers sensors often mount like photo eyes, but if measurement accuracy is required, both the sensor’s and the object’s mounting point must be rigid and stiff, so

vibration or other movement does not cause measurement errors.

Construction of presences sensors are similar among all devices, but there are differences such as rectangular or tubular housings, and materials such as plastic or metal. While mechanical limit switches are the most rugged, photo eyes and laser sensors are also built to survive harsh industrial environments.

Applications touch, light and laser There is much overlap in the application of limit switches, photoelectric sensors and laser sensors, so carefully check the device’s specifications; how it will fit into an application; and how it will be used. Limit switches are just one of the many solutions to use in automated applications, but they are a simple and rugged choice for presence sensing, providing reliable detection of many components or parts, Figure 3.

Photo eyes are probably the best general-

purpose position sensor. They have a longer sensing range than other presence sensing options such as inductive, magnetic, capacitive and ultrasonic.

As they are available in a wide range of configurations and housing sizes, they fit well in many applications.

Lasers are best for precise measurement of distance in applications where the part or component can’t withstand contact with a mechanical switch. Close, far, dusty or clean — they work well in most environments. They also work well for small part detection, much better than the other two technologies. DW AutomationDirect www.AutomationDirect.com

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E l e c t r o n i c s

How to

calibrate scope probes

and make good measurements

It’s a good idea

That high-frequency single-ended probe and the differential

to tweak probe

probe you just bought make you feel pretty good about your

parameters so

measurements and rising-edge times when you use the two probes side-

measurements. However, you notice differences in vertical voltage

what you see

by-side. So you wonder whether your measurements really reflect what

on the scope

alone. Let’s walk through the causes of these differences and the steps

your device-under-test (DUT) signals look like. Don’t worry, you’re not

reflects reality.

Boon Campbell • Keysight Technologies, Inc.

needed to correct them.

The signal path from the DUT to the oscilloscope creates distortions in the signal and cause amplitude and timing differences. When you probe your DUT, capacitance and inductance in the probe may distort the signal.

Incorrect skew and amplitude on signals cause significant measurement errors. Skew is defined as the difference in bit timing relative to the same point on two waveforms. Along with these pesky timing differences, the amplitude differences cause DUT eye patterns to look more closed than they are. This makes it seem like there is a lot of jitter or noise in the DUT, but the noise is coming from the signal path.

Not seeing a true representation of the DUT signals on the oscilloscope makes it difficult, if not impossible, to debug or complete design work.

Leland Teschler | Executive Editor

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An example of how a signal representation changes as it passes

• • •

Connect the probe tip to the calibrator HI output. from the tip of a probe Connect the probe ground lead to the to an oscilloscope calibrator LO output. and through to DSP Original Signal at Signal at the Signal display For certain models, connect the probe Signal probe tip is oscilloscope with DSP correction. output to the 50 Ω feedthrough changed correction termination (11048C). Connect the output of the 11048C to the DMM. Passive probe compensation For all other models, connect the If you use the passive probe for critical You can adjust a passive probe’s variable probe output to a PV fixture 50-Ω measurements, it is good practice to capacitance so the compensation matches trace input. The trace is terminated check the attenuation ratio and resistance the oscilloscope input. Most oscilloscopes with a 1 MΩ± 0.1% precision resistor. periodically. have a square wave output for calibration or Connect the output of the 50-Ω trace reference. Probe this connection and check to the DMM. Use these process steps to test your that the waveform is square. Adjust the probe’s Verify that the measured value is probes attenuation ratio: variable capacitance as needed to eliminate any Set the digital multimeter (DMM) to dc between the limits listed in your undershoot, overshoot, or rounding. voltage measurement mode. Configure probe’s data sheet or manual. For The oscilloscope may have a feature that the input resistance to > 10 GΩ. Shorten most passive probe manufacturers, will adjust the probe compensation, or you can the tip and perform the “Null” function. the attenuation ratio is specified change it manually. at ±2%.

Set the calibrator to 10 V.

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6

Most oscilloscopes have a square wave output for calibration or reference. Probe this connection and check that the waveform is square. Adjust the probe’s variable capacitance as needed to get rid of any undershoot or overshoot or rounding.

Use these process steps to test the probe input resistance:

• •

Turn on the DMM. Short the DMM probes and run the “Null” function.

Connect the DMM probes to the probe tip and the ground at the tip of the probe.

Connect the probe’s output to one of the oscilloscope’s input channels. Set the oscilloscope’s input impedance value per your probe’s data sheet or manual.

Set up the DMM to measure resistance. Calculate the error percentage using the equation

•

•

Error % =

Certain oscilloscopes recognize active probes and give a message on the screen if the probe is not calibrated to your oscilloscope. Active probes are becoming more widely used because passive probes are limited in frequency to around 500 MHz and further limited due to the high harmonic content of square waves.

As oscilloscope performance rises to multi-gigahertz levels, the use of the dc correction method becomes insufficient to characterize and correct for the high frequency response. AC correction adjusts a probe’s ac response qualities in line with an ideal probe’s flat frequency response. Probe manufacturers measure and store specific

probe and probe head S-parameters within the probe EPROMs. This data creates a correction filter for the probe that represents the probe and oscilloscope system response. This form of correction leads to significantly better accuracy over a nominal dc correction.

Also, note that probe correction methods work for the standard configuration of the probe and probe tip accessories, as offered by the manufacturer. But using custom or altered probe tips drastically change a probe’s behavior. This makes it difficult, if not impossible, to correct the probe’s flatness.

Measured Value — Target Value x 100 Target Value

Active probe calibration is sometimes forgotten, but it is important to ensure the most accurate measurement possible.

Both single-ended and differential probes come with a calibration certificate. These certificates give you confidence the probes meet their stated specifications.

However, the probe and oscilloscope are a measurement system, which means each probe’s output characteristics and each oscilloscope’s input characteristics will vary. The coupling in the signal path creates three variabilities: 1. Coupling from the DUT to the probe, 2. Coupling from the probe output to the oscilloscope input, and 3. Coupling from the oscilloscope input through its DSP circuitry. You can take some of this variability out of the system by calibrating the probe to improve amplitude and skew.

This equipment or something similar is necessary for checking the attenuation ratio and resistance of a passive probe.

ed

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E l e c t r o n i c s

All in all, the probing system that links the DUT, probe, and oscilloscope can cause errors in measurements of signals that are on the DUT. Always calibrate the probe with the oscilloscope you are using for the best fidelity in measured signals. DW

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generator before probing, using a deskew fixture (yellow trace). The signal is also sent through a differential probe and shown on channel two of the oscilloscope (green trace). The generator output on channel one is 1.04 Vp-p and the probed signal on channel two is 965 mV. In addition, the skew from channel one to channel two is massive (around 3 msec), which means the rise times do not line up at all. After calibration, note the calibration results, bottom figure. The screen shot is after amplitude and skew calibration. The amplitude has improved to 972 mVp-p and the skew has been corrected with both rise times lining up.

References https://www.keysight.com/upload/cmc_upload/All/ How-to-do-Probe-Compensation.mp4

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Medical

A Supplement to Design World - September 2018

Seven innovations that advance medical device design Medical Tips cover 9-18_FINAL.indd 103

| Image courtesy of Spectrum Plastics Group

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M e d i c a l

T i p s

3D printing or injection molding?

Which is better for medical devices?

3D printing and injection molding have their own benefits and limitations when it comes to making medical device parts, according to experts from PTI Engineered Plastics, Carbon and Protolabs.

Danielle Kirsh • Assistant Editor

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Medical device parts makers are increasingly turning to 3D printing, but additive manufacturing has yet to reach the tipping point where it could supplant injection molding in medtech parts manufacturing, according to a panel of experts at the AD&M Cleveland show.

Whether a manufacturer uses 3D printing or injection molding depends completely on what a customer’s needs are, the experts from PTI Engineered Plastics, Carbon and Protolabs explained during the March 8 panel.

In fact, the two processes may be more of a dynamic duo.

3D-printed Tyrannosaurus rex models, made with Carbon’s proprietary CLIP technology. | Image courtesy of Carbon

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M e d i c a l

T i p s

Medical device parts makers are increasingly turning to 3D printing, but additive manufacturing has yet to reach the tipping point where it could supplant injection molding in medtech parts manufacturing, according to a panel of experts at the AD&M Cleveland show.

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One of the advantages of 3D printing is that a manufacturer can get their hands on a product quicker than they would be able to with injection molding, while having the ability to completely customize the product. In contrast, injection molding allows parts to be produced in mass volumes.

“3D printing allows you to get parts in your hands very quickly without an investment in your tooling and it allows you to also [make] some parts that may not be necessarily designed for injection molding, but allows you to do geometries that are unique,” said John Budreau, director of new business at PTI.

“I think it’s great when it’s not a part that’s actually injection moldable,” Budreau said of 3D printing, adding that it can be costly to buy a mold up front for a unique and complex part design.

Budreau and his fellow panelists, Thomas Davis of Protolabs and Carbon’s Scott Kraemer, listed three limitations they said are holding 3D printing back:

1 Machine throughput One of the shortcomings associated with 3D printing is machine throughput, according to Davis, an applications engineer at Protolabs.

“It’s traditionally a layering process.

The layering process has mechanical properties that fall short, from the isotropic standpoint. and the ‘Z’ when compared to the ‘X’ and ‘Y,’” Davis said.

2 Tolerancing Another limit of 3D printing is tolerancing.

Although Carbon, with its Continuous Liquid Interface Production (CLIP) process, created software that can fine-tune parts as opposed to welding or having to manually adjust things in order to make a specific part, tolerancing is still one of the biggest problems manufacturers can face.

“We’re pretty close to what injectionmolded parts can do, but [tolerancy] is still the biggest hiccup or disruption in our technology,” expained Kraemer, a production development engineer at the 3D printing firm.

September 2018 www.designworldonline.com

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3 Limited materials options New and emerging materials could also change the game for 3D printing — but not yet.

That won’t happen until OEMs open up to 3D-printing-friendly materials other than polycarbonate or ABS that perform similarly to those medtech mainstays.

“Efficiency is going to increase and once we can start using 3D printing more for production, I think that the materials will follow. There will be more material choices and colors and it won’t be considered as niche and expensive,” Davis noted.

For now, there are a limited number of materials for a set number of unique 3D printing applications.

“With injection molding, we’ll probably run 1,500 different engineered materials this year of everything you can imagine, whether it’s glass fillers or other content in the materials, to achieve certain properties,” Budreau added. “Once the 3D printing world can do that with their properties, that’s when you can use the process for parts that are not injectionmoldable.”

“It just depends on where [customer] product development needs are and where they’re at in the project. 3D printing really does serve a purpose for a lot of our production manufacturing processes,” he said.

So when does 3D printing make sense over injection molding?

Depending on what the customer needs, injection molding might be a better fit than 3D printing, which is better suited to the product development process.

“Basically 3D printing is just another tool in the toolbox for the engineers to get their goals accomplished. It just depends on what the goal is,” Davis said, adding that the geometry and importance of a part come into play in making the choice.

“If it’s really complex, if it’s a highvalue-proposition part that’s low

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volume — [those facto types of parts] great fits for 3D printing. If it’s not, higher quantities would be better for injection molding,” he said.

Part size also plays a role, Kraemer said.

“You can only make X amount of parts. So, if you look at the size of a matchbox car and under, we can compete against injection molding in price range,” he said. “When you start getting parts that are 6-by-6, somewhere around that range, that’s where it starts to lean little bit more towards injection molding” in terms of pricing.

It’s also important to recognize that each tool has its limitations.

Injection-molded parts can’t always be 3D printed, and 3D-printed parts can’t always be injection molded, so

it’s important to have engineers who can recognize the difference.

“Certainly 3D printing will take some of the injection molding market away, but I think the market will continue to grow,” Budreau said.

“Honestly, it’s not necessarily a tipping point. It’s where you’re at in your project development process. What is the value of having an injectionmolded part versus a 3D-printed part?

Now certainly if the design is not injection-moldable, that’s when you 3D print it.” DW

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M e d i c a l

T i p s

Seven innovations that advance medical device design

The finished medical devices often get the publicity.

But in many cases, innovations out of contract manufacturers are helping to enable advances in the medtech space. Here are some examples.

Nancy Crotti • Senior Editor

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Charles Darwin wrote, “In the long history of humankind (and animal kind, too) those who learned to collaborate and improvise most effectively have prevailed.”

Medical device manufacturers get the credit for many innovations, but many need the ingenuity and commitment of contract manufacturers who design and produce the components that make those big splashes possible. The end result of such collaborations may improve or even save lives.

September 2018 www.designworldonline.com

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Spectrum Plastics Group has refined a rapid prototyping technology for finished catheters. | Image courtesy

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Plastics Group

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T i p s

Maxon Motor’s ENX Easy is a steam-sterilizable encoder for surgical robots and handheld surgical power tools. | Image courtesy of Maxon Motor

Here are some examples of recent advances out of contract manufacturers that are enabling medical device innovation.

“In the long history of humankind (and animal kind, too) those who learned to collaborate and improvise most effectively have prevailed.”

Maxon Motor’s steam-sterilizable encoder Maxon Motor introduced a steamsterilizable encoder for surgical robots and handheld surgical power tools. The ENX Easy encoder’s ability to withstand sterilization enables medtech manufacturers to assemble motors that can be completely autoclaved, according to Carsten Horn, business development engineer for Sachseln, Switzerland–based Maxon.

ENX Easy is available in an incremental (1,024 counts) and absolute versions (4,096 steps), both designed for 1,000 autoclave

Charles Darwin

cycles. The ENX Easy can be combined with matching BLDC motors and planetary gearheads. The encoder can be integrated into the brushless drives ECX 13 and ECX 16 Speed (up to 120,000 rpm and 104 W) without any increase in length. When the gearheads GPX 13 and GPX 16 SPEED (0.2 Nm max. continuous torque) are added to the combination, customers receive a fully sterilizable positioning system.

“That’s the missing part to really generate a drive system for a closedloop drive,” Horn told Medical Design & Outsourcing. “It gives the engineers many more options. They now have the option to do positioning requirements in an autoclavable system, which hasn’t been so easy for a while.”

Autoclave cycles are hard on materials, so the company had to take measures to protect the motor’s chip and printed circuit board (PCB).

“You need to take care so no water or steam can come in between the pins and the PCB because that will immediately destroy the PCB,” Horn said.

Heraeus’ coil technology with dualdirectional torque response Heraeus Medical Components developed a coil technology that the company said could disrupt the catheter-based treatment of complex coronary and peripheral artery diseases.

Heraeus’ three-layer TriFlex coil technology platform with dualdirectional torque response was designed for numerous therapies. It resists compression, providing better pushability for improved access to hard-to-reach places, can cross Heraeus’ TriFlex is a three-layer coil with dual-directional torque response designed for use in microcatheters and other medtech applications. | Image courtesy of Heraeus

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complex lesions and delivers the flexibility needed to go through complex, tortuous anatomy. The company says the unique coil configuration can enable design teams to develop delivery systems with improved device deployment accuracy, and ultimately an improved experience for both the physician and the patient.

Heraeus (Saint Paul, Minn.) uses TriFlex in its own latest microcatheter to address critical clinical issues such as improved torque transmission for optimal vessel selection. The technology is used to treat cardiovascular disease, and chronic total occlusions (CTO) in coronary and peripheral vasculature such as critical limb ischemia (CLI), which frequently results in the amputation of lower limbs.

The coil’s precise torque response makes it a suitable component for inclusion in devices designed for other conditions that require precise therapy delivery to hard-to-reach parts of the body such as transcatheter aortic valve replacement (TAVR), mitral valve replacement (MVR) and repair, atrial septal defect (ASD) occlusion and left atrial appendage (LAA) occlusion.

The innovations could result in faster procedures, a reduction in failure rates, and a reduction in overall treatment costs, the company added.

Guill Tool & Engineering’s one-bolt extrusion crosshead Guill Tool & Engineering completely re-engineered a crosshead that the company believes could streamline the extrusion process for thin-walled jacketing and precision ID/OD tubing.

Standard crosshead designs with four adjustment bolts located 90° apart require operators to loosen one bolt and tighten the opposing bolt in order to yield a tube with a uniform wall thickness. Adjusting out any unacceptable eccentricity requires obtaining a measurement of the product’s current concentricity, which is either done as an inline process or after the extrudate has been fully cooled and cut for sampling.

“The whole time you’re making these adjustments, you’re wasting time and plastic,” product development engineer Denis Finn Jr. told us.

The new Micro Medical crosshead has just one bolt that controls 360° of concentricity adjustment.

Having just one bolt that can orbit freely around the outside of the die should reduce the time it takes to get the line running and producing quality product versus standard concentricity adjustment, Finn said.

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Guill’s Micro Medical is a single-bolt crosshead that controls 360° of concentricity adjustment and can help keep extrusion work flowing. | Image courtesy of Guill Tool & Engineering

If point A is your design concept and point B your finished product, then you can consider this the straightest line for pumps and compressors.

NittoKohki.com

The advantages are pointed: • Exceptional reliability y • Low noise & vibration n • Long service life • DC-motor driven

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Concentricity adjustment precision with the Micro Medical reaches 0.008 in. or finer per revolution, according to Guill (West Warwick, R.I.). The single-point crosshead includes a patented camlock deflector for quick changeovers.

The deflector has a residence time of 1 min. at 0.5 lb/hr material flow. It has optimized usage with extruders measuring 0.5 in. and 0.75 in., and a max die ID of 0.25 in.

“In essence, it’s a total overhaul of an offering that’s existed for awhile,” he added. “Every single facet of it has been carefully revised to keep operators’ efficiency as high as possible. We’re maximizing the efficiency of the die assembly.”

The Micro Medical crosshead also accepts both vacuum and micro-air accessories and works well in pressure and sleeving applications, according to the company. Fluoropolymer designs are available upon request.

“Medical device manufacturers need the ingenuity and commitment of contract manufacturers who design and produce the components that make big innovative ‘splashes’ possible.”

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3M 4077 tape is a singlecoated, water-resistant, non-woven elastic blend with omnidirectional stretchability and improved air penetration. | Image courtesy of 3M

3M medical tape that sticks for up to two weeks The latest addition to 3M’s line of medical-grade tape can remain in place on the skin for up to two weeks, according to the company.

That’s good news for users of infusion pumps, cardiac monitors, glucose monitors, health monitors and other devices worn on the skin, who have long complained that existing adhesives are not good enough. Long-term adhesives have had issues with lift (in which part of the adhesive loses stick), pain at removal, and skin conditions under the adhesive.

3M 4077 is a single-coated, water-resistant, non-woven elastic blend with omnidirectional stretchability and improved air penetration. It combines adhesive with a white meltblown elastic nonwoven backing on a silicone release liner. It is compatible with ethylene oxide sterilization, electron beams and gamma sterilization, compliant with ISO:10993 sections 5 and 10, and is approved for use on intact skin.

Medical device manufacturers and engineers need long-term wear adhesive solutions that increase patient comfort and provide strong and reliable bonds in challenging applications when adhering to skin, according to Marcello Napol, global business director in 3M’s critical and chronic care solutions division.

“As soon as we launched the 4076 about a year ago, we knew we were going to have to produce 4077 to add to our family of go-to products, giving design engineers even more skin-friendly options,” Napol told MDO. “Our newest product, 4077, is water-resistant, breathable and offers improved conformability with omni-directional stretch. Design engineers have a variety of factors to consider when selecting adhesives for skin, so we’re constantly iterating in response to market needs. We anticipate leveraging this technology to expand our long wear platform with additional products in the future.”

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TE Connectivity has a simpler ultrasonic air bubble detector TE Connectivity has fine-tuned its AD-101 ultrasonic air bubble detector by making its electronics less complex.

Using analytics to model the behavior of the device’s ultrasonic waves, the company’s engineers altered its sensors so they could drastically simplify its printed circuit board, explained Susan Zaks, product manager for TE Connectivity (Schaffhausen, Switzerland). The ultrasonic waves detect air bubbles in infusion lines, which deliver fluids to the body. If allowed to enter the bloodstream, these bubbles could cause a heart attack or a stroke.

“We modeled it using finite element analysis so we could predict the behavior of the ultrasonic waves so we could reduce the electronic complexity,” Zaks said.

“It’s all in the modeling.”

The refined bubble detector may be used as part of any manufacturer’s infusion pump or dialysis machine.

Upon detecting a bubble, it produces a flashing red LED signal. The sensor output can also be used to generate a sound alarm for a nurses’ station.

Although the PCB was designed specifically for air bubble detectors, the company has used the same analytical methodology to design other sensors for improved performance and to hasten the development cycle. For example, TE Connectivity is using the same modeling process to design new ultrasoniclevel sensors to detect the liquid level in a container.

Simplifying the circuit board has also reduced prices significantly, Zaks added. She declined to reveal prices, saying they depend upon order volume.

“To offer competitive performance at this big of a cost advantage is a big deal,” Zaks said. “And it opens up some huge markets that we weren’t looking at before.”

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TE Connectivity used analytics to model the behavior of ultrasonic waves to make its AD-101 ultrasonic air bubble detector less complex | I mage courtesy of

TE Connectivity

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Integer’s improved feedthrough for implantable devices Integer (NYSE: ITGR) has found a way to enable manufacturers of neuromodulation and other implantable devices to significantly shrink their products. The company has designed a feedthrough that is much smaller than the traditional feedthrough and is hermetically sealed to protect the electronics and the patient, according to Keith Seitz, senior director of research and development for Frisco, Texas–based Integer.

The traditional feedthrough is formed of aluminum oxide with gold-brazed platinum wires. The new technology injects platinum into a green aluminum oxide ceramic body and is then co-fired at high temperatures to form a biocompatible hermetic feedthrough.

The proprietary forming method for the co-fired platinum/aluminum oxide technology enables the creation of smaller openings and less

Integer’s new feedthrough is much smaller than the traditional feedthrough and is hermetically sealed to protect the electronics and the patient. | Image courtesy of Integer

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less aluminum oxide ceramic between vias when compared to traditional feedthrough insulators that require core rods to be extracted from the green body during pressing of aluminum oxide-pressed ceramics.

Heraeus introduced a similarconcept feedthrough late last year, the CerMet. Integer says its technology is different in a couple of ways. For example, Integer claims its platinum conductor is of the same purity or higher when compared with the standard platinum in use for pin feedthroughs by other manufacturers.

This is meant to ensure the same or better electrical performance and attachment by soldering, welding or wire bonding as the present feedthrough technology. Integer’s technology also demonstrates perfect alignment layer-to-layer, yielding very consistent conductor diameter control, the company added.

“We’ve gone from tens of channels to hundreds if not thousands of channels with this technology,” Seitz said.

The technology has potential uses in cochlear and retinal implants and for deep brain and spinal cord peripheral nerve stimulators, as well as for implantable cardiac defibrillators and pacemakers, Seitz said. It’s been under development for six years and is the subject of several patents.

“Now we’re moving forward with specific customer shape and product development,” he said. “This new feedthrough technology is extremely exciting and is being deployed in a wide variety of med device applications.”

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| Image courtesy of Spectrum Plastics Group

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Spectrum Plastics Group and rapid prototyping for finished catheters A Spectrum Plastics Group company has refined a rapid-prototyping technology so it may be used for finished catheters.

Vector+ allows customers to design a catheter component in any shape, and the company can produce it with the same speed and design of prototyping, according to Mike Schultz, vice president of operations for Spectrum’s Apollo Medical Extrusion, Sandy, Utah.

“Currently, catheter components are either injection molded or 3D printed. This is a huge roadblock in designing catheters,” Schultz said. “With only a limited number of materials that can be 3D printed and product design being limited by what shapes can be injection molded, a lot of product design is constrained by what’s achievable.”

Vector+ is fabricated from medical grade, USP Class VI and /or ISO 10993 certified materials and additives. It is thermally welded to the catheter, creating a seamless dimension that allows for a smooth, low profile, but high-strength transition, according to the company. Traditionally, such a process is limited to early prototyping through 3D printing. Vector+ makes it possible for the full-scale production of the component and catheter, leading to lower tooling costs and a fast track to manufacturing.

By using the same materials for the catheter shaft and for the Vector+, customers reduce the numbers of materials in their device and thus reduce waste and material testing costs associated with catheter design and development. DW

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ResMed uprising: Disrupting connected health Here’s how a respiratory firm took control of the medtech digital revolution.

When you think powerful digital connected devices, the first thing to pop into your head probably isn’t a CPAP. Continuous positive airway pressure products have been shown in numerous studies to be effective in improving sleep apnea and preventing a host of co-morbidities such as obesity, congestive heart failure and chronic obstructive pulmonary disease. But the buy-in from patients is notoriously lacking.

The AirView patient screen shows data capture for patient’s use, but only alerts a caregiver with “by exception” events.

Heather Thompson • Senior Editor

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Respiratory companies have been struggling with this challenge for many years. Designers and developers have made both iterative and innovative improvements, without demonstrably moving the needle on patient behavior change. For the most part, compliance for the machinery hovers around 50%.

One company, ResMed (San Diego), has taken on the challenge of helping users become more compliant, the ecosystem more costeffective, and customers more loyal through a model of connected health.

ResMed’s quest to improve patient compliance began over a decade ago, explained CEO Mick Farrell. “We started our first digital health experiments with UC San Diego in 2002 and learned a lot over a decade.”

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That work lead to a reinvention of the company in 2014, with 100% cloud-connected medical devices across all of its sleep apnea therapy platforms.

“We’re first in the industry to put a cellular communication chip inside every sleep apnea device,” Farrell told Medical Design & Outsourcing.

Since then, the company has made impressive strides. Berg Insight, an independent research organization, estimates that 7 million patients worldwide use remote monitoring products. Of those, more than 5 million are cloud-connected to ResMed’s remote monitoring platform. In 2016, Berg noted in its “mHealth and Home Monitoring”

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report that sleep therapy remote monitoring grew by 70%, surpassing cardiac rhythm management. The report noted that the growth was “driven by the vendor ResMed that has made connected healthcare a cornerstone of its strategy.”

That success changed the thinking around connected medical devices, blazing the trail for other medical device makers to follow.

Actionable insights Farrell called out two key acquisitions that helped ResMed make the transition: Umbian, a digital health provider for sleep apnea management, in 2012, which has helped innovate its world-leading remote monitoring platform, AirView; and Brightree, a provider of software-

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Woman-sleeping, airsense-sleeping.

The AirMini, the smallest PAP available, was released by ResMed in 2017. AirSense 10 was introduced in 2014. All of ResMed’s home sleep devices come cloud connected right out of the box.

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The AirView platform captures 1.5 billion nights of medical sleep and respiratory care data, enabling analysis of large patient populations to glean insights that influence standards of care and patient outcomes.

as-a-service for out-of-hospital care management, in 2016. In addition, ResMed acquired another SaaS provider focused on serving home health and hospice agencies, HEALTHCAREfirst, in July 2018.

Their combined technology led to ResMed’s release of the “world’s largest remote patient monitoring network, AirView,” said Farrell.

AirView captures nightly sleep data from more than 8 million sleep apnea and COPD patients via the cloud.

Umbian’s U-Sleep features have helped improve the AirView offering by introducing “AirView Action Groups,” in which patients are automatically grouped by therapy issue via smart algorithms, enabling clinicians to efficiently manage patients “by exception.”

Brightree helps customers improve both the clinical and business performances of sleep disorder devices.

Another part of Air Solutions is ResMed’s patient engagement app, myAir, which scores sleep apnea patients on a scale of 100 based on how well they slept using CPAP therapy, plus personalized coaching to improve results. Worldwide, 1,500 new patients sign up for myAir every day, Farrell told us.

As of August 2018, more than 1 million patients use myAir. Each signup represents a paver on the road to Farrell’s holy grail when it comes to data: actionable insights.

“Leveraging deep neural networks and sophisticated virtuous feedback loops of learning to discern actionable insights is the key to success,” he explained. The AirView platform captures 2.5 billion nights of medical sleep and respiratory care data, enabling analysis of large patient populations to glean insights that influence standards of care and patient outcomes.

Automatic user adoption Although data collection alone would make ResMed a stand-out organization, there are tricky issues at play when it comes to gaining access to said data. That’s where userfocused design comes into play.

According to designers specializing in patient behavior, the key to user adoption of connected devices is really not to give them an option. Bill Evans — founder and former innovation SVP at Bridge Design, a Ximedica

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company — noted that every moment a device maker puts a barrier in front of a patient presents a risk that the patient will abandon the device.

“We tell our customers, ‘Don’t make it hard to get in the cloud, meet your users where they are, not where you want them to be,’” Evans told us.

ResMed took this lesson to heart “You lose health adopters every time you ask a patient or provider to perform a set-up step, select a network or flip a switch,” Farrell agreed. “You’re asking them to do something before they see the value. We flip that around and only ask them to do something after we’ve generated the value for them. We took all the work out of it.”

Every Air Solutions device is cloudconnected out of the box. Data from the cloud can be seen the next morning by the patient or (with the patient’s permission) a doctor, enabling the monitoring and support of patients without an office visit.

“All the patient has to do is go to sleep,” Farrell said.

“[ResMed] has thrown every best design practice in the book” at helping patients get connected with their medtech devices, Evans said.

And it appears to work. A November 2017 study of 128,000 patients published in the journal CHEST showed that sleep apnea therapy users whose nightly use was remotely and selfmonitored via ResMed’s AirView and myAir platforms, respectively, were more than 87% adherent on therapy.

A three-legged stool Evans and other device developers often talk about three-legged stools when discussing what makes a product successful: Cost, outcomes and loyalty.

The decisions ResMed made on how to best collect, store and share data with patients and caregivers led to better outcomes. And patients get immediate feedback from their device, including prompts to order new supplies or replace parts and assessments of sleep

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improvement. All that helps build loyalty.

The third leg is cost, and that’s where ResMed solves one of the stickiest issues in the medtech space: Reimbursement.

Although every payer is different, all want proof of compliance. For example, Medicare requires that a patient use a PAP for more than four hours per night on 70% of nights during a 30-day consecutive period during the first three months of use. Farrell said myAir and AirView improved that number to 87%.

A connected future ResMed has plans to expand its connected health solutions worldwide, leveraging data for actionable insights and, according to Farrell, “exploring ways where all this smart data can take us next” —

particularly when it comes to using artificial intelligence models through machine learning and predictive models.

And the CEO has his eye on therapeutic areas beyond sleep apnea and COPD; he’s asked his team to consider possible applications in cardiovascular disease, Type II diabetes and other severe chronic diseases.

Nick Vassilakis, founder & CEO of remote patient monitoring company Astute, noted that integration of sensors and data into a unified platform, “to get a more holistic view of a patient’s overall wellness,” is a significant challenge.

Farrell understands that realizing his vision will require an entire ecosystem, with the pharma, medtech and software industries combining to “bend the rising healthcare cost curve together.”

“Everyone wants healthcare data streamlined and in one spot,” he said, and he sees ResMed playing a role by giving patients a single app for sleep, exercise and nutrition.

“We see big tech companies like Apple creating consumer facing health applications and Google/Verily looking to create an ecosystem. Most recently we have seen Amazon talking about getting into the delivery space,” he explained.

ResMed’s Air10 sleep apnea devices and Astral and Stellar in-home ventilators can already connect to the devices’ built-in cloud connection, he added, noting that the company plans next to connect its portable oxygen concentrators to the cloud.

And although Farrell wasn’t willing to discuss his plans beyond that, it’s clear that ResMed plans to continue to lead the connected space. DW

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As a result, our portfolio includes: • Gas Springs (Standard, Locking, Traction, Stainless Steel, and Customized Gas Springs) • easyE® (Electric Linear Actuators) • Easymotion (Linear Hydraulic Actuation Systems) • Rotary Dampers and Shock Absorbers • Micro-Hydraulics We pride ourselves on having the highest quality motion control products in the industry. Our products fulfill even the highest requirements of many industries including Medical, Aerospace, Furniture, Industrial, Marine and Military. Bansbach® products are manufactured from the highest quality materials. Consistent quality is guaranteed because of diligent monitoring of raw materials, an aggressive testing program and a redundant quality control program throughout production using our technologically advanced manufacturing processes.

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BAYCABLE is vertically integrated and can offer a wide range of manufacturing capabilities including custom cable constructions, full turnkey cable assembly and molding services, component customization, specialized testing, and in house mold tool manufacturing.

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DC Motor-Driven Pumps Nitto Kohki’s DC motor-driven air compressors and vacuum pumps are ideal for applications requiring exceptionally reliable air flow, pressure or vacuum performance.

Featuring oil-free operation, a single moving part, low noise, and low vibration, this line of linear air compressors comes in 12V and 24V models. Other benefits include: • • • •

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Product World Advanced stepper drives Applied Motion Products applied-motion.com This series of stepper drives supports a range of industrial Ethernet and Fieldbus network protocols including EtherCAT, EtherNet/IP, CANopen, Modbus, Ethernet, and RS-485, as well as a proprietary Serial Command Language (SCL) for efficient network communications over Ethernet (UDP or TCP) and RS-485.

By accepting high-level commands via a network connection, STF stepper drives

give system designers and machine builders the flexibility to control step motors using the network protocol of their choice. These stepper drives simplify the programming by consolidating motion control functions into the application software of the primary logic or machine controller, rather than in individual axes.

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Integrated stepper motors and drives AutomationDirect automationdirect.com Ballscrews & Rollerscrews

SureStep integrated drive/motor units provide accurate micro-stepping position and speed control for smooth motion and step response and require only 2 components, power supply and integrated stepper motor/drive. Standard motor/drives and Advanced motor/drives are available.

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Product World Vision sensors for reliable color inspections Banner Engineering bannerengineering.com iVu Color vision sensors can be used to monitor objects for color or color variations, determine the presence and color of one or more features, and verify that an object matches a reference color or colors. iVu Color vision sensors can also inspect objects based on type, size, orientation, or position. The tools that enable all these inspections can be used alone or in combination to solve more complex applications.

iVu Color vision sensors have a graphical user interface and menu-driven tools to simplify

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iVu Color vision sensors are all-in-one solutions that combine camera, controller, lens,

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Magnetic incremental encoder ASM asmsensors.com The posirot PMIS4/PMIR7, is a non-contact, wear-free magnetic incremental encoder solution designed for harsh WE Series Linear Guideway Wide Series Ball Type.

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Product World Flex element/blade triangular bushing design Altra Industrial Motion AltraMotion.com/Tri-Bushing The Tri-Bushing is a flex element/blade triangular bushing design that increases the axial capability of flexible disc couplings used in turbomachinery applications. Flexible couplings for critical equipment must accommodate angular and axial movement due to thermal growth. In steam and gas turbine applications, machinery shafts, casings and piping expand as their temperature increases.

When axial deflection is significant, spacers are purposely made short to stretch the coupling statically. As the machines grow

toward each other, the coupling is designed to grow into its neutral, relaxed position. In many cases, however, couplings must operate in a compressed mode to handle this movement. Extensive FEA testing has shown that when approaching the axial limit of a disc coupling, while accommodating for angular mis-alignment, the disc packs become highly stressed in the area around the traditional round bushings.

The patent-pending Tri-Bushing design has two straight profiles that reduce and redistribute the stresses that occur around the disc

pack bushings. Using this new bushing design can increase a coupling’s axial capability by more than 33%.

Stop corrosion in its tracks.

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

Sensorless speed and torque control Maxon maxonmotorusa.com LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

This is a sensorless speed and torque control solution called “HPSC.” This technology allows FOC (field-oriented control) for brushless motors without sensors from full stop to full speed under load. This HPSC uses a signal injection algorithm which determines the rotor position for a smooth startup each and every time.

• Low noise, no vibrations

• Maximum power efficiency

• Robust and reliable

KA Type Linear Actuator / SAR Ballscrew or belt driven, exible design.

This system contains an HPSC module 24/5 — dimension and power range can be adapted if required. The firmware of the module may be customized for every drive system. HPSC is a custom-made solution suitable for surgical systems, fluid delivery systems, rehabilitation, and prosthetics.

KK Type Linear Actuator / SAR Ballscrew driven, high accuracy and reliability.

Cartridge Check Valves

KS Type Linear Actuator / SAR Ballscrew driven for clean room applications.

Designed for Installation into Plastics • 100% Performance Tested • Simple Press-In Installation • Wide Range of Cracking Pressures • 2.5, 5.5, and 8 mm Sizes • All Stainless Steel

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AC Servo Motors.

For more information, contact The Lee Company

Innovation in Miniature

The Lee Company 2 Pettipaug Road Westbrook, CT 06498 USA Tel: 860-399-6281 shanleyg@theleeco.com www.leeimh.com

Hiwin D1 and D2 Servo Drives for Servo Motors, Torque Motors and Linear Stages.

See Us at MD&M Minneapolis, Booth #1728 LEE_CartCheck_DW_4-16.indd DESIGN WORLD

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Product World Plastic bearings Kashima Bearings Kashimabearings.com Anticorrosive, chemical resistant, nonmagnetic, and lubrication-free, these plastic bearings are designed to meet the varying and long-term demands of a range of applications.

The unique properties of these plastic bearings make them particularly suitable

for the wet environment of the food-processing industry. As 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 of the bearings also makes them suitable for use in medical equipment or control units where the development of any static and noise should be prevented.

Two-part epoxy withstands repeated thermal cycling Master Bond masterbond.com This solvent free, two component, toughened epoxy system is called Supreme 62-1. It is serviceable from -60° to +450°F (-51° to +232°C).

Most noteworthy, Supreme 62-1 provides chemical resistance to a range of acids, bases, fuels and solvents even at elevated temperatures. It can be used as an adhesive/sealant for aerospace, electronic, optical and specialty OEM applications.

Supreme 62-1 is easy to use and has a working life of more than 12 hours after mixing

a 100 gram batch. Typical cure schedule options range from 4-6 hours at 140-158°F (6070°C) to 20-40 minutes at 176°-212 °F (80-100°C) to 10-20 minutes at 257°F(125°C).

This compound has an elongation of 5-10% and a Shore D hardness of 75-85. Volume resistivity of the cured epoxy exceeds 1014 ohm-cm. Supreme 62-1 is available for purchase in ½ pint, pint, quart, gallon and 5-gallon kits.

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Brushless DC motor design Dunkermotoren Dunkermotoren.com

DEVELOP TOMORROW’S

BG 65/BG 66 dMove servomotors are successors to the BG 65(S) servomotor, a popular servomotors with completely

PRODUCTS IN-HOUSE

integrated motor electronics.

The BG 65/ BG 66 series has the

same outward appearance as the BG 65 series with simple electronic controls.

Take control of your process, by cutting prototypes with affordable CNC.

Those motors formerly designated “SI” motors are now called “dMove” and are mechanically interchangeable with previous versions. Inside, the motors have completely new control electronics.

Instead of farming out your parts out to a job shop and playing the waiting game, get in on the accessible and easy-to-learn modular machines of Tormach.

Already in I/O version, the electronic

controls allow the assignment of functions to the digital inputs from simple speed control via analog inputs to fixed speeds via digital inputs or combinations of current and speed control. Digital outputs also can be assigned to functions.

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Product World Chlorine dioxide sensor Endress + Hauser us.endress.com The Memosens CCS50D chlorine dioxide sensor supports safe and effective disinfection for clean drinking water, pathogen-free cooling water, and high-quality process water.

The chlorine dioxide sensor features a convex membrane made of

Memosens CCS50D is able to deliver reliable

dense, dirt-repellent material which prevents soiling and makes it resistant

disinfection measurements at low flow rates. In combination

to biofouling. Ultrasonic welding of the membrane to the sensor cap

with the Flowfit CCA151 assembly, the required flow rate

ensures its integrity, preventing dilution of the electrolyte. This guarantees

is as low as 1.3 gal/h (5 l/h), which means only a minimum

long-term stable measurements and gives a plant manager the security

amount of water is consumed in the bypass and the

that the disinfection process is running smoothly.

required disposal capacities are reduced.

rotary flange servo gearheads

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Did you mean: DieQua Corporation?

The search is over!

The Sesame® rotary flange servo gearheads provide unmatched performance, durability, and design flexibility.

Look no further than DieQua. • Multiple frame sizes: 42-255mm • ISO-9409-1 standard robot flange • Torque capacity from 11Nm - 2000Nm • 3 backlash levels • Ratios from 3:1 - 100:1 • Square servo and step motor input To find what you’re looking for, check us out on the web, or give us a call.

diequa.com/dw 800-310-9569

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DESIGN WORLD

8/30/18 3:23 PM

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

Sensor fusion inclinometer Joral Joralllc.com This G-force compensated inclinometer provides feedback for pitch, yaw, and roll. The new technology uses sensor fusion, which is the combining of more than one complementary sensing method. The SGAM and DGAM incline sensors take input by a gyroscope, accelerometer, and magnetometer to provide a 3-axis output for X, Y, and Z as well as new feedback for pitch, yaw, and roll.

The GAM Series sensor provides steady feedback during motion, allowing users to

eliminate complex sensor networks with a single G-force compensated inclinometer. Rather than depending on encoders, string pots, laser gates, and proximity sensors to monitor the position of a ladder, fork or platform, users can place one of these sensors on the application to get real-time feedback for absolute control.

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

Your Partner moving forward!

Registered and Certified to ISO_9001 and AS9100.

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

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POWER TRANSMISSION-PART CONVEYING

PYRATHANE® BELTS With Lifetime Warranty Against Manufacturing Defects

LINE SHAFT CONVEYOR BELTS - Original Equipment & Connectable CUSTOM MADE IN INCH, METRIC & O-RING SIZES Round, Flat and Connectable Polyurethane Belts • Very Clean Operation • Eliminates Tensioning Devices • Exceptional Abrasion Resistance

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Product World USB digital accelerometer PCB mts.com This USB digital accelerometer is designed for use in predictive maintenance and condition monitoring applications. The Model 633A01 is

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the standard of the industry!

a high-resolution, broad-frequency piezoelectric accelerometer with integrated internal digital data processing for USB plug-and-play

AN ISO 9001 CERTIFIED COMPANY

capability as well as easy data collection and sharing

pyramidbelts.com • 641.792.2405 • sales@pyramidbelts.com

The product has a wide frequency

range (1.5-11,000 Hz with a ±10% tolerance) packaged in a stainless steel, hermetically-sealed housing with

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Key Bellevilles, Inc.

integral cable.

LARGEST MANUFACTURER OF DISC SPRINGS IN THE WORLD Live Load with Belleville Disc Springs LARGEST STOCK OF STAINLESS STEEL AND INCONEL SPRINGS IN THE WORLD HIGH TEMPERATURE FLANGE BOLT

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

MANUFACTURED TO DIN AND NACE SPECS Metric and English sizes available

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

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

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

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

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Case hardened tapped or threaded shafts NB nbcorporation.com These shafts are never annealed, so outer

PEM® VariMount® Bonding Fasteners

diameters are precise – tolerances are always reliable. Tapped shaft can be ordered with one or

Ideal for fastening or bonding to assorted panel types

both ends tapped in either case-hardened carbon steel or stainless steel. Threaded shaft can be ordered with one or both ends threaded in casehardened carbon steel. Diameters range from ¼ to 1-1/2-in. Travel lengths sections available from 6 to 36-in.

Guaranteed diameter tolerance of ISO g6

and straightness tolerances of 0.001 to 0.002in. per foot. The case-hardened steel, precision ground shafts have a 10-16rms micron finish. Case

VariMount® assembly is comprised of standard PEM nuts, studs and standoffs mounted permanently into a base plate--available with either steel or stainless steel base plates depending on the fastener selected. Key feature is the base plate’s radial holes which provide various mounting options.

hardness is Rockwell C60-C64.

Radial holes allow: • Better attachment with adhesives • Encapsulating into plastic • Attachment with standard sized rivets • Attachment with standard sized clinch fasteners No head or shoulder protrusion

PEM® self-clinching flush-head stud permanently installed into baseplate Ribs on fastener provides torque resistance

30 mm baseplate provides generous footprint

Host metal of base plate flows into undercut of fastener “clinching” it permanently in place

Flush mounted

Mounts On Or In:

• Composites • Plastics • Metal • Wall Board • Any Rigid Material or Panel

Free PEMSpec™ app now available

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Optical encoders

YOUR SOURCE FOR SEMICONDUCTORS, RELAYS, SWITCHES, CAPACITORS, RESISTORS, AND MORE

Grayhill grayhill.com The Series 62AG, 62NG and 62SG Optical Encoders have optical switching technology for high operational life and tactile feedback to the user. The Series 62AG, 62NG

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Cross references for over 525,000 industry part numbers

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Expanded range of high quality product offerings

systems, navigation devices, precision test

Convenient global distributor network

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assembly and patented Light Pipe design,

Volume discounts available

are quality components for a range of

Active/passive/ electro-mechanical/ interconnect and optoelectronics

advantages over other switch technologies in healthcare electronics, communication and measuring equipment, sound editing

Cost engineered with a single PCB

the Series 62AG, 62NG and 62SG encoders applications.

Output options include absolute or

quadrature 2-bit binary code. Custom shaft and threaded bushing sizes are available, as well as other customized features like detents and tactile feel, termination and cabling, and mounts.

www.nteinc.com 800-631-1250

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Hybrid stepper motor/lead screw actuator Thomson thomsonlinear.com Thomson Industries has expanded its line of stepper motor linear actuators with models featuring built-in anti-rotational guidance. The new motorized lead screw actuator (MLA) product saves designers of high-precision, shorter-stroke applications the cost, time and maintenance worries related to designing and building externally guided systems themselves.

The load of a typical stepper motor linear actuator attaches to a nut that rides back and

forth as the screw turns. Translating the rotational motion of the motorized lead screw into the axial motion needed to move the load back and forth requires restraining the nut. Traditionally, application designers accomplish this with external guidance assemblies, but these can take up valuable space and add cost and complexity.

The MLA is best suited for space-constrained, force-sensitive applications requiring shorter strokes that must be repeated with

high precision. Examples include adjusting a microscope slide stage, tilting a computer monitor or vertically positioning a pipette onto a test tube array. Ideally, applications will have stroke lengths shorter than 2.5-in and require speeds below 20 in/s.

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binder USA Now Offers M12 A-, D-, X-Code Industrial Ethernet Connectors and Cordsets binder USA offers Industrial Ethernet – M12 Automation Technology with A-,D-, and X-Code industrial Ethernet connectors and cordsets. The binder connectors and cordsets deliver high-speed transmission up to 10 Gbps with superior overmold tools, cable flex rating, jacket material, color and inside/outside usage with cordset lengths up to 90 m. binder M12-A locking connectors are used for industrial networks needing power or signal using CAN, CANopen, PROFIBUS PA and DeviceNet devices. The Series 713 offers many different cable connectors, panel-mounted receptacles, and accessories. Connectors have industry-standard A-coding and have “Hexagon” locking sleeves for hand-tightening or torqueing of connections.

• Some with UL approvals • Plastic, metal or stainless-steel shells • 8 contacts binder industry-standard D-coded connectors used for EtherNet/IP, EtherCAT, and PROFINET devices. The IP67 field-attachable connectors offer cage clamp or screw termination, both aimed at providing quick and easy installations. Some connectors feature an Iris Spring for quick and reliable termination between the plug and the cable shield.

• 250 V / 4A • IP67 rated • 5-8 mm Cable Outlet • 4 contacts binder industrial Ethernet X-coded connectors are ideal for industrial network applications in harsh environments. It is possible to transmit up to 10 Gbps and the X-coding design conforms to IEC 61076-2-109. Overmolded male M12 double-ended cordsets and male M12 to male RJ45 Cat6A cordsets are currently available. All cordsets are available in standard 2, 5 and 10 meter lengths.

• 50 V / 0.5 A • IP67 rated • 5.5-9 mm Cable Outlet • 8 contacts binder USA also manufactures custom cordsets: M8, M12, and 7/8” cable assemblies to meet many custom requirements in the US.

www.designworldonline.com

Media Contacts: Agency: Julie Eleftheriou | Longren & Parks julie@longrenparks.com Mobile: 952.913.3065 Company: Greg Harter | binder USA, LP greg.harter@binder-usa.com Office: 805.437.9925 Ext. 1004

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Ad Index

Medical Tips Supplement Bansbach Easylift ................................ 114 Bay Associates Wire Technologies Corp. ........................ 107 Nitto Kohki USA, Inc. ..............................111

icotek Corp ................................................45 igus ............................................................... 71 Interpower ................................................ 46 ITT Enidine ................................................54 J.W. Winco, Inc. ...................................... 125 Keller America ......................................... 83 Key Bellevilles Inc. ................................ 132 Keystone Electronics Corp. ..............7,91 Lenze Americas .......................................41 Mach III Clutch Inc. .................................87 Master Bond .......................................... 123 Memory Protection Devices ................31 Micromo .................................................... 98 Miki Pulley US ..........................................24 NB Corporation .......................................33 Neugart ..................................................... 101 Novotechnik ...........................................100 NTE Electronics, Inc. ............................ 134 OKW USA .................................................. 131 PAVE Technology .................................. 49 PBC Linear ......................................... 92,93 Penn Engineering ................................ 133 PHD Inc. .....................................................43 Prince Manufacturing Co. .................. 121 Pyramid Incorporated ......................... 132 R+W America ............................................62 ROLEC ........................................................29 Rotor Clip .................................................. 90 Rutronik .................................................... 86 RYCO Hydraulics .....................................70 SEW Eurodrive ....................................... BC SIKO Products ........................................100 Smalley Steel Ring ..................................10 Smart Products USA .............................47 Southco .....................................................35 Tensility International Corporation ........................................ 95 The Lee Company ............................... 127 THK America, Inc ................................... IFC Tompkins Industries, Inc. .....................78 Tormach ................................................... 129 Trim Lok .......................................................51 Turck ................................................ 77,79,81 Whittet-Higgins .......................................37 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

www.designworldonline.com

Medical Tips cover 9-18_FINAL.indd 103

tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom

Jim Powers

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

Courtney Seel

cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

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

David Geltman

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

FOLLOW US ON

A Supplement to Design World - September 2018

Seven innovations that advance medical device design

Tom Lazar

Mike Francesconi

Medical

| Image courtesy of Spectrum Plastics Group

Accumold ................................................ 102 Aerotech ................................................... 96 Aggressive Hydraulics ........................ 80 Aignep USA ..............................................45 Allied Electronics & Automation ............................Cov,3,122 Allied Moulded Products .....................57 AllMotion ...................................................... 4 Altech Corporation ............................ 15,17 Altra Industrial Motion Corp. ..................... 25,26,27,28 AMETEK DFS ............................................23 Anchor Fluid Power ............................. 126 Applied Motion Products, Inc. ...........52 Aurora Bearing Company .................. 131 Automation24, Inc. ................................ 36 AutomationDirect ..........................1,Insert Beckhoff Automation ...........................73 Beta Layout ............................................. 60 Bimba ............................ Inside gate cover Binder USA ................................................19 Bishop-Wisecarver ..................................61 Bison Gear and Engineering ............ IBC BRECOflex ................................................ 56 Brother Gearmotors ............................. 63 Caplugs ..................................................... 39 Carlo Gavazzi ......................................... 124 Carlyle Johnson .......................................14 Century Spring ........................................55 CGI Motion ............................................... 50 CIT Relay & Switch ............................... 128 CS Hyde Company ................................ 68 Del-tron ......................................................72 DieQua ............................................... 32,130 Digi-Key ......................................................13 DMIC ........................................................... 94 Eagle Stainless Tube .......................20,21 ebm-papst .................................................. 9 Elesa USA Corporation ........................53 Encoder Products Company ............. 84 EXAIR Corporation ................................... 5 Fixtureworks .............................................76 Graybar ..................................................... 64 Harwin ....................................................... 85 HIWIN ........................................... .123,125,127

SALES

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9/6/18 2:01 PM

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The key to productivity...

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