Applications Casebook 2023

NOVEMBER 2023

DESIGNWORLDONLINE.COM MOTIONCONTROLTIPS.COM

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igus linear motion slides and actuators offer an economical solution for creating a motion system with up to 3 axes of motion. Components are available with belt driven or lead screw driven slides. They are easy to assemble, stackable, and can be configured as a single axis, double axis, dual drive axis, or as a complete 3-axis XYZ system.

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igus actuators feature: • Maintenance and lubrication free operation • 14 belt driven actuators from 200mm travel length to 1000mm travel length • 13 lead screw driven actuators from 100mm travel length to 750mm travel length • Rails made from durable 6061-T6 aluminum with hard anodized finish • Motor mounts for SureServo and SureStep motors • T-slots in rails allow switches and sensors to be easily installed

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editorial

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UP WITH DEMOCRATIZATION IN ENGINEERING Recently our office received an article by electrical engineer Bernard Ang of Keysight Technologies (previously Hewlett-Packard and Agilent Technologies) about new ways software tools are helping to advance engineering education for design engineers. If you want to get specifics on Keysight’s tools, visit 3dcadworld.com and search Bernard Ang.

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It’s one of several stories we’ve recently received on the topic of democratization in automation and manufacturing education.

Of course, software and the internet are core to making engineering knowledge accessible to everyone. Consider the efforts of Kazakhstani computer programmer and creator of the website Sci-Hub.se Alexandra Elbakyan covered in an April 2023 RadioLab podcast. Her crusade to liberate scientific research papers and other technical literature from paywalled internet zones seems to have been at the vanguard of a larger trend. Now over the last few years, numerous academic journals have suddenly come to support open access of their libraries (finding other ways to monetize their editing and publishing work) and in the U.S. by 2026, all federally funded research will be made immediately available to anyone for free.

Democratization in engineering and automation also takes the form of diverse training, degree, and even job types — a topic we cover in the 2023 Design World Diversity issue.

Besides jobs needing bachelor’s degrees, the National Science Foundation also defines those requiring no such degree, including: • Middle-skill occupations requiring STEM certification and on-the-job training — common in installation, maintenance, and production.

• Skilled technical workforce occupations requiring some other specific industry knowledge … positions in which 57% of male STEM workers are employed.

Wherever engineering functions can be properly and safely executed by middle-skill staff, our industry should allow it — especially as software tools become safer and easier than

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ever to use. The problem is that (at least in the United States) training programs for such roles are often lacking.

As a solution, some suppliers have adapted overseas approaches to U.S. training programs and networks. Case in point: Automation company Festo offers job-specific fluid-power, electronic, PLC, digitalization, and leanproduction training programs for maintenance technicians, operators, and production planners as well as shop-floor workers and managers.

Likewise, the German-American Chambers of Commerce continues to support a workforcedevelopment apprenticeship program to give high-school graduates as well as working employees dual-vocational training modeled after German approaches to merge local community classroom time with hands-on work experiences. I had a positive Praktikum experience during a college engineering internship in Germany via a Berufsakademie years ago and would love to see new generations of young folks benefit from the same.

Most inspiring is hearing about programs in my own community. Here in Northeast Ohio, Lorain County Community College director of advancement Michael Morgenstern champions several such LCCC programs through which students can earn associate of applied science degrees; take courses on smart automation and smart manufacturing; as well as access an automation lab, Fab Lab, SMART Microsystems Center, and Digital Manufacturing lab for handson learning. Just one county over, Cuyahoga Community College offers (among other tracks) smart manufacturing and mechatronics tracks.

Drop me a line if your own community college or company has a program that constitutes an effort towards democratization in engineering ... and if you’re a young person who’s completed a program you felt was particularly well designed, reach out.

Lisa Eitel | linkedin.com/in/elisabetheitel

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Precise. Powerful. Modular.

Servo motors and gear units from SEW-EURODRIVE Servo motors and gear units from SEWEURODRIVE offer a high degree of dynamics and performance with a compact design, making them excellent for confined spaces. Multiple frame sizes and torque ratings makes them the perfect fit in material handling, hoist and gantry applications, and a wide variety of

machine automation applications. Their modular design allows for direct gear unit mounting without adapters or couplings. Pair that with the option of single-cable technology and you’ve got a flexible, precise servo drive solution.

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applications casebook

CONTENTS v o l u m e

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04 EDITORIAL 08 STAFF & AD INDEX 11 CONTROLS 16 DIGITAL TRANSFORMATION 24 GEARING 30 AUTOMATION IN AGRICULTURE 34 VIBRATION MITIGATION 36 PACKAGING 40 WINDUP

37

17 On the Cover: Multiple conveyor technologies automate a cartoning application.

Image: Dreamstime

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What does it take to keep your industry alive?

Connections by LAPP. They are the lifelines that transport energy and distribute power where it‘s needed. These connections also create the central systems that synchronize the seamless interaction of machines, devices, and plants.

LAPP‘s powerful solutions offer the most in-depth expertise and most reliable connections on the market. For every project, for every undertaking, for every industry. lapp.com/us/alive-by-lapp

AD INDEX v o l u m e

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n u m b e r

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Ace Controls......................................................................33 AllMotion.............................................................................4 Automation Direct...............................................................1 Beckhoff Automation........................................................18 CGI Inc...............................................................................22 Chieftek Precision.............................................................31 CMT ..................................................................................38 Del-tron.............................................................................32 Diequa...............................................................................24 Digi-Key Electronics............................................................3 Dura-Belt...........................................................................39 Encoder Products Company.............................................17 Faulhaber..........................................................................12

EDITORIAL VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com Executive Editor Lisa Eitel leitel@wtwhmedia.com Managing Editor Mike Santora msantora@wtwhmedia.com Senior Editor Miles Budimir mbudimir@wtwhmedia.com

ONLINE DEVELOPMENT & PRODUCTION

KHK USA Inc......................................................................30 LAPP Group USA.................................................................7 Maxon...............................................................................10 Mitsubishi Electric Automation.........................................20 mk North America, Inc......................................................21 NB Corp............................................................................28 PBC Linear........................................................................BC POSITAL FRABA................................................................13 Pyramid, Inc.......................................................................37 Quantum Devices..............................................................25 Renishaw...........................................................................19

VP, Creative Director Matthew Claney mclaney@wtwhmedia.com

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

PRODUCTION SERVICES Customer Service Manager Stephanie Hulett shulett@wtwhmedia.com Customer Service Representative Tracy Powers tpowers@wtwhmedia.com

Senior Digital Media Manager Patrick Curran pcurran@wtwhmedia.com

Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com

Digital Production Manager Reggie Hall rhall@wtwhmedia.com

Customer Service Representative Renee Massey-Linston renee@wtwhmedia.com

SALES

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

2011- 2020

Digital Marketing Manager Taylor Meade tmeade@wtwhmedia.com

Graphic Designer Shannon Pipik spipik@wtwhmedia.com

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

Harmonic Drive.................................................................26 iNTECH Power-Core...........................................................6

CREATIVE SERVICES & PRINT PRODUCTION

Customer Service Representative Trinidy Longgood tlonggood@wtwhmedia.com

Digital Design Manager Samantha King sking@wtwhmedia.com Webinar Manager Matt Boblett mboblett@wtwhmedia.com

2014- 2016

FINANCE Controller Brian Korsberg bkorsberg@wtwhmedia.com

2014 Winner

Accounts Receivable Specialist Jamila Milton jmilton@wtwhmedia.com

LEADERSHIP TEAM

2013 - 2017, 2021

VP of Sales | Co-Founder Mike Emich memich@wtwhmedia.com 508.446.1823 CEO Scott McCafferty smccafferty@wtwhmedia.com 310.279.3844

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EVP Marshall Matheson mmatheson@wtwhmedia.com 805.895.3609

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CFO Ken Gradman kgradman@wtwhmedia.com 773.680.5955

Jim Dempsey jdempsey@wtwhmedia.com 216.387.1916 Mike Francesconi mfrancesconi@wtwhmedia.com 630.488.9029 Jim Powers jpowers@wtwhmedia.com 312.925.7793 Publisher Courtney Nagle cseel@wtwhmedia.com 440.523.1685

Rotor Clip................................................................ Snipe, 9 Ruland Manufacturing.....................................................IBC SEW-Eurodrive....................................................................5 Sorbothane........................................................................35 Stock Drive Products/Sterling Instrument.........................14 THK America, Inc............................................................. IFC Zero-Max, Inc......................................................................2

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controls The Orthrus Matrix Seam Sealer from Pyramid Engineering is a 7 axis, vision, pick & place, tack and weld matrix system that allows minimal handling of product and maximizes throughput.

CONTROLLERS ENSURE QUALITY WELDS

By Cliff Jolliffe Physik Instrumente (PI)

Martin Slater Pyramid Engineering

High-precision laser welding has carved a niche into many industries where processing precise and complex features is a routine and sometimes high throughput requirement. Control is key for quality, and the choice of systems, as well as hardware components for system builds, can have a significant effect on overall manufacturing and running costs. New developments continue to bring cheaper – but still high quality – options into this competitive marketplace, giving users more flexibility and carving out even more potential applications for laser welding.

Welding background Welding is a widely used fabrication process integral to many sectors that serves as a great example of where advances in technology can be effectively applied to leading industries.

Techniques vary from more traditional resistance welding to newer methods using lasers. YAG lasers have been successfully used for many years, but the recent introduction of new fiber lasers has significantly improved performance and cost. The choice

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of technology depends on the specific application, but fiber lasers are creating new opportunities where accuracy, control and price can work in harmony.

High-precision welding is important in many industries — especially sectors like semiconductors, electronics and telecommunications — that rely on the ability to process precise features and paths on delicate devices. Techniques satisfying this challenge are more traditional resistance welding and increasingly common laser welding. The latter has gained ground in recent years because of its ability to accurately deliver heat to a small area, without damaging the material around it and avoiding tool wear and tear. On the other hand, resistance welding is still widely used because it’s perceived as better suited for the fabrication of larger volumes.

Control for uniformity One thing that’s crucial to both welding techniques is control. A uniform weld relies on the same energy being consistently applied to the whole path and, if this fails, it can create heat-affected zones that break easily, or gaps in the weld. This means that laser power, firing time, and position all need to be carefully controlled and monitored.

Creating a uniform weld when the path is straight is relatively simple, but when it is curved or has corners, it can be tricky. When moving in a straight line with the same speed, the two velocity components x and y remain constant, but they will change when making a turn, even if the total velocity is still constant.

This effect needs to be considered by the laser, adjusting either the frequency or the power to deliver the same effect to the whole path. This puts a lot of demand either on the welding instrument itself, or on the positioning tool, since both need to work together to achieve high quality results. For example, YAG lasers can be held at a fixed spot, with the motion stages responsible for moving the product along the desired path. There is also an option to use a continuous wave (CW) laser with a galvanometer head that works in unison with the motion stages to correctly position the product.

Purpose-designed control systems, such as those developed by ACS (a PI

11 • 2023

motion control company), can give users far more flexibility in how they build and then repurpose set-ups. Even tiny changes to a fixed configuration can be complex and time consuming if each of the different parts needs to be programmed separately and, until recently, it has been common for companies to have one set-up made for each specific task. However, newer controllers that connect the motion stages and the laser pulsing hardware through EtherCAT make it far more straightforward to change an existing build. This flexibility also reduces the complexity of drives that are needed, and so cuts costs.

Reducing costs for welding Anything that can reduce costs in this way is welcome in the extremely competitive laser welding market. Making a high throughput process automatic can also help; Industry 4.0 is all about using machine-to-machine communication – either directly or wirelessly – to automate the manufacturing procedure, and several companies have already started to adopt this approach for quality control purposes.

For the same reason, less expensive components are now available and can make a significant difference to overall costs. Not every application needs every component to be at the highest possible specification; for example, for some tasks, lower specification stages – such as the new L-812 range from Physik Instrumente (PI) – are significantly cheaper than high end stages but still provide accurate motion control. Similarly, finding a supplier that has the expertise to build a system around an application can be a cost-effective approach. For example, the UK company Pyramid Engineering specialises in the final sealing of electronics packages and offers its client expertise in combining the best of hardware components with control and automation to sharpen up processes and deal with high throughputs, when accuracy and time mean money.

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dx applications

SOFTWARE SUPPORTS DIGITAL TRANSFORMATIONS IN MANUFACTURING

In the manufacturing industry, deploying new technology involves significant investment. Every choice must be carefully considered to ensure it satisfies organization needs and can securely deploy with minimal disruption. Key is software — the selection of which involves choosing the right solutions to align with organization goals, processes, and technology infrastructure to deliver tangible benefits in three key areas: Digital transformation efforts, boosting safety, and mitigating risk.

Software selection and digital-transformation efforts Digital transformation (DX) is foundational to modern manufacturing and software selection plays an essential role in driving and enhancing this transformation. Historically, inadequate interoperability across incompatible technologies, including enterprise resource planning (ERP), supply chain management (SCM) manufacturing execution systems (MES), allied to disparate data types, has left data unleveraged.

Interoperability: Digital transformation involves disintegrating these incumbent silos and improving collaboration across departments. Dynamic manufacturing requires data flows

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applications casebook

Software makes it possible to optimize and interconnect manufacturing processes. The best software also helps manufacturers boost plant safety … and in fact, some software can help manage technical, schedule, and commercial risks.

from different components, systems, or technologies to work seamlessly together, usually from different vendors and on different standards. Here, software is key to enabling the interoperability and connectivity essential to complete and smooth integration between different systems and holistic views of the production process.

Software selection must therefore prioritize tools that facilitate communication, data sharing, and crossfunctional collaboration among various devices, systems, and processes within a manufacturing environment. Open application programming interfaces (APIs) and standardized interfaces make it easier for different software applications to connect and interact. This allows manufacturers to mix and match software solutions from different vendors while ensuring they work together seamlessly.

With that in place, production teams can establish and implement standardized agnostic communication protocols and data formats. These protocols ensure that information can be exchanged accurately and consistently between different components of the manufacturing process. This is important, as digital

transformation relies heavily on data-driven decision making.

Insights and adaptability: Within digital transformation, software integrates physical machinery with digital systems for cyber-physical systems that can communicate and adapt in realtime.

This integration allows for advanced automation, monitoring, and control of manufacturing processes. Software enables data from these various sources to be integrated, with advanced analytics and data visualization capabilities applied to help manufacturers gain insights, identify trends, and make informed decisions to optimize production and drive innovation.

Digital transformation also requires the ability to quickly adapt to changing market conditions and customer preferences.

Therefore, software selection should focus on solutions that let manufacturers nimbly scale, modify processes, and introduce new products.

Software that allows for the creation of digital twins lets manufacturers create virtual representations of physical assets, processes, and systems for optimization. Such digital twins even let

manufacturers virtually analyze workflow automation to find ways to streamline operations and boost efficiency.

Quality control: This and management are key to manufacturers, so selecting the right software can help ensure consistent product quality by implementing robust quality control processes. Through software selection, manufacturers can comply with industry standards, track defects, and manage corrective and preventive actions.

Software selection and industrial safety The second area where software selection in manufacturing plays a crucial role is in ensuring industrial safety, providing tools and systems that help manage and mitigate potential risks and hazards.

Manufacturing software should include modules or features for conducting risk assessments and managing risks associated with various processes and provide realtime monitoring of equipment, processes, and environmental conditions.

Hazard monitoring: Software that powers potential hazards identification, likelihood and severity level and triggers alerts in case of deviations from expected norms or unsafe conditions is vital to preventing potential safety breaches and product loss.

Software can drive manufacturing improvements by unifying manufacturing ecosystems and facilitating collaboration.

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dx applications

Software enables digital transformations by serving as the foundation for process optimization and automation.

Having these measures in place enables manufacturers to proactively address safety concerns and implement measures to control or eliminate issues before they escalate to become significant.

Building on this, software can support continuous improvement initiatives by providing tools for root

cause analysis, corrective actions, and performance tracking. By analyzing historical data and trends, manufacturers can identify patterns of safety incidents or near-misses, allowing them to take proactive corrective actions to prevent similar occurrences in the future.

Furthermore, some software solutions include emergency response planning features, which allow manufacturers to develop and implement comprehensive plans for responding to safety incidents.

These plans can include evacuation procedures, communication protocols and coordination with emergency services.

Safety training: Health and safety training and simulations are additional areas where software can be deployed to

help manage employee training programs, providing a pathway for personnel to uplevel their skills and grow within an organization. This is a rapidly evolving area that can incorporate onsite and virtual training, track progress and record achievements. This ensures workers are adequately trained to operate machinery safely and follow proper safety protocols that are compliant with safety regulations and standards, reducing the risk of legal and regulatory issues.

Accounting for safety lifecycles: Software supports the implementation of industrial safety standards and technologies, which can help improve risk management and reduce injuries. Software can also be used to incorporate the safety lifecycle into manufacturing operations to increase the effectiveness of machines while mitigating risks and decreasing operational and engineering costs.

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dx applications

The term safety lifecycle refers to a formalized engineering process that helps create a safety system that works effectively throughout its lifespan and is described by Intl. standards set by the Intl. Electrotechnical Commission (IEC). By standardizing the safety lifecycle, the IEC provides a benchmark for industries and companies that want to meet an acceptable occupational safety level.

The safety lifecycle can be thought of as a series of phases.

Each phase is designed to maximize productivity while also improving safety for employees by identifying the necessary steps for assessing and mitigating risks. Software is essential at every phase to ensure process consistency and automation, comprehensive data gathering and quality, and standardized reporting.

Performing a risk assessment to identify hazards and estimate the risk associated with them is the first step. This assessment determines the needed performance level for safety functions.

Based on that, manufacturers can then determine the functional safety system’s requirements to mitigate any identified risks. Once a system is determined, the architecture can then be selected, and the safety circuit design documented. The design is verified to meet all requirements, including software and programming, and then installed and validated to verify operation within defined parameters and compliance with standards. A safety

system must be monitored and evaluated frequently. Regular verification ensures that the system requirements operate within specified parameters for production, and system upgrades and improvements can be made, as necessary.

Predictive maintenance: Software systems for maintenance planning and asset management assist in scheduling regular equipment inspections, maintenance, and repairs. Predictive maintenance helps ensure that equipment is well-maintained, using condition-monitoring tools and techniques and asset information to track equipment performance and next, to anticipate failure before it happens. This improves safety, reducing the likelihood of malfunctions or breakdowns that could lead to accidents.

Critical to success is knowing what products are run and when, the cost of all activities, and when maintenance was last performed, among other factors. There are several technologies that can help manage a predictive maintenance program, from ERPs to MES and computerized maintenance management system (CMMS) software. Software especially provides the means to drive predictive maintenance, leveraging data across Internet of Things (IoT) devices, the cloud, mobile applications, AI, and machine learning (ML) to analyze and predict insights and share entire operational data in one place.

Monitoring machine sensors, predictive maintenance software can detect changes in the way assets are operating, and the

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dx applications software schedules maintenance and then notifies technicians of the newly scheduled task on their device of choice. The net benefit of predictive maintenance is that it keeps maintenance frequency low while reducing time spent on unplanned maintenance that can cause production delays.

Lockout and tagout procedures: So-called lockout/tagout procedures are used to ensure equipment is fully shut down, inoperable and isolated from all energy sources. It ensures employees stay safe from unexpected and potentially dangerous start-ups when equipment must be serviced or maintained.

Keeping a manufacturing facility’s lockout/ tagout procedures updated and accurate can be challenging, especially as facilities change equipment and staffing.

Software simplifies critical lockout/tagout management and compliance by digitizing these procedures to make them easier to access and manage. Digital lockout/tagout software tools provide authorized users with access to historical data, employee audits, procedural updates, and other features.

Though some level of tagging like QR codes or RFID, employees can scan the equipment using a smartphone, tablet, or mobile device for instant access to audit procedures and related documentation. This confirms nothing ever gets lost, and employees always have the most up-to-date lockout/tagout procedures when needed. What’s more, digital lockout/ tagout procedures give safety managers and other authorized users access to a dashboard containing data for equipment and employees.

Having these software-driven processes protect employees from harm.

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

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gear components

Gearmotor-animated elements abound in the Sphere Las Vegas entertainment venue. These include animated sculptures in the atrium; humanoid welcome robots; and (in the main theater) 4D effects along with haptic seats that move to match events depicted onscreen. Images: Sphere Entertainment

GEAR ASSEMBLIES COMPLETE ENTERTAINMENT AND HOSPITALITY DESIGNS motioncontroltips.com | designworldonline.com

Gears function in an array of applications and are the natural complement to electric motors in industrial as well as consumer designs.

Consider some examples: Amusement rides to consumer-grade home printers make use of spur gears. These roll through meshing for up to 98% or higher efficiency per reduction. The only caveat is that they exhibit tooth sliding and noise due to initial tooth-totooth contact and audible shock loads.

Helical gear reducers are costlier than spur sets but work in designs needing high horsepower and efficiency. Textile machinery, conveyor drives, rolling mills, and elevators all use helical gearing to engage gradually over tooth faces for smooth operation and high load capacity. The only caveat is that the machine setup must include

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framing or supports to resolve thrust loads originating from the gears.

Non-parallel and right-angle gears go into motion applications for material handling, aerospace and defense, packaging equipment and food-processing machinery. Input and output shafts protrude in different directions; gear teeth are worm, hypoid, bevel (straight, spiral or zerol) as well as skew or crossed-axis helical.

Common bevel gearsets often go into material-handling and packaging equipment. Hypoid gears (useful for high-toque applications) are like spiral-bevel gearsets, but output and input shaft axes don’t intersect … and that simplifies integration of supports.

Common in aerospace, zerol gearsets have curved teeth that align with the shaft to minimize thrust.

Consider one recent rightangle gear application: IP65-rated crown gear drives now complete an automated glass-wall enclosure built by retractable-roof maker OpenAire.

The manufacturer uses Zero-Max DESIGN WORLD — MOTION

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gear components right-angle gear drives for dependable and economical transfer of speed and power as well as quiet and smooth operation — key objectives due to its operation near vacationing guests.

Spiral bevel gears with curved teeth maintain tooth contact for minimized vibration and noise during operation. Other features include a nickel-plated aluminum housing, stainless-steel shafts, and purposebuilt shaft seals. Plus the IP65-rated crown gear drives are a lubed-for-life design offering maintenance-free operation … and an independent laboratory certified their IP65 rating for protection against dirt and water ingress.

One OpenAire patio system uses the IP65 crown gear drives to quickly move 12 x 15-ft wide wall panels and retractable roof panels open or close during cooler or rainy days. For each movable window, two gear drives are inside a header beam.

A gear drive on each side of the window (with gear drive pairs interconnected by an intermediate shaft) lets one motor drive the system. Vertical leadscrews flanking the window system connect to the crown gears’ output shafts to run the windows up and down. An intermediate shaft connecting the crown gear-drive pair synchronizes the assembly so that each window lifts evenly.

The framework conceals all mechanical and electrical components.

of motors) alter output torque — usually as an increase proportional to rpm reduction. Common in material-handling setups, shaft-mounted gear reducers come in designs that use special couplings to address reactionary torque. Other shaft-

mounted reducers actually mount to the machine housing (especially in machine setups with surrounding enclosures) so the input shaft doesn’t support the reducer.

Consider worm-gear reducers.

These typically go into low to moderate-

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Andantex rack and pinions are available in straight or circumferential pitch versions to deliver both power and precision. With their modular design, rack segment lengths from 0.5 to 2 m can join end-to-end to deliver great travel lengths. Shown here is one application in an animated hotel sculpture.

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OpenAire uses a Zero-Max right-angle gear drive for dependable and economical transfer of speed and power.

horsepower motion applications because they have high ratios and output torque but are cost effective and compact. Most worm gears are cylindrical with teeth of consistent size; some worm-based reducers have double-enveloping tooth geometry (in which pitch diameter is deep and short and then deep again) to boost tooth engagement. Metal cutting and forming machinery, construction equipment, and packaging machinery all benefit from the low backlash of this gearing type.

To illustrate, printing-press rolls hold tight print registration at high speeds thanks to the ability of double-enveloping worm gearing to withstand shock and extreme acceleration. The gearing’s low inertia also lets presses start and stop more quickly than those with multi-stage gearing.

Gearheads like gear reducers are useful where applications call for high torque at low speed. They reduce a load’s reflected mass inertia, so ease the acceleration of big loads ... which in some cases, even lets machines run off smaller motors. Gearheads range from basic spur gearheads to complex planetary gearheads and strain-wave gearheads, all exceling in select applications. For example, strain-wave gearing excels in robot-arm articulation, medical equipment, and offshore drilling ... and helps designs with zero backlash and high torque density.

Much machinery integrates servogears motioncontroltips.com | designworldonline.com

into application-specific electromechanical arrangements, and several of these arrangements are common enough to have their own labels. Gearmotors (most useful in machines that move heavy loads) include a gear reducer integrated with an ac or dc electric motor. Gearboxes are contained gear trains; planetary gears are a common form. Planetary gears often go in servo systems. Usually, the planet gears mount on a movable arm that rotates relative to a sun gear. In most applications, an outer annulus meshes with planet gears.

Planetary gearsets offer applications advantages over other gearsets, including multiple kinematic combinations, power density, big reductions from compact setups, and pure torsional reactions.

Planetary gearboxes also boost overall design efficiency. Losses never exceed 3% per stage, so the sets transmit most energy for productive motion output. In applications driven by servo systems, gearboxes also reduce settling time … which is otherwise a problem when load inertia is high compared to motor inertia.

Consider another recent application example: Kinetic-stage fabricator Show Canada Industries often uses Andantex gearing products in its stages — especially racks and pinions inside elevators and lifts. Three such projects run in 11 • 2023

an atrium at the Wynn Palace near Macau, China.

The atrium’s Iris Ceiling is a 65-ft diameter sculpted-dome ceiling divided into 12 wedges depicting a figure from the Chinese zodiac. The wedges open like an iris to reveal an LED screen; each 14,000-pound wedge has a built-in 7.5-hp gearmotor and linear guide for actuation, along with an Andantex Module 4.0 rackand-pinion assembly. The motor holds the integrated pinion; the rack installs next to the track.

The atrium’s Dragon of Fortune and Tree of Prosperity animated sculptures employ a wagon and trolley, 42,000-lb-rated lift, and Andantex rack and pinions (Module 10.0 systems in pairs) for actuation of various elements. The drive systems link four 180-hp motors with gearboxes to deliver up to 372,000 lb-in. The rack and pinions easily meet the speed requirement for raising and lowering the Dragon of Fortune and Tree of Prosperity sculptures — three feet per second. In fact, the rackand-pinion sets are especially appealing for specialized applications such as theatrical lifts and other kinetic architecture.

Compared to other technologies such as wire rope, roller chains, and push chains that typically need replacing every decade, the rack-and-pinion sets usually last up to 20 years in Show Canada equipment and often outlast the life of the production.

DESIGN WORLD — MOTION

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automation in agriculture

“Vertically grown microgreens are one of the keys to solving the challenges of global nutrition in the future,” says cofounder and CEO of Ultragreens Cristian Tudor.

Ultragreens partnered with HELUKABEL for their designs’ cabling in part because their team required a responsive partner with local presence.

SATISFYING THE DEMANDS OF VERTICAL FARMING

Automated greenhouses (especially those taking the form of vertical farming) offer space savings and grow-environment controls that (according to the U.S. Department of Agriculture) can produce twenty times the yield of traditional farming. Here, a sensor-fitted robot evaluates the quality of tomato seedlings.

Image: Dreamstime

Vertical farming — the cultivation of food in multi-story greenhouses — is a rapidly growing approach to food production. After all, ensuring a sustainable food supply with new farming approaches is key to ensuring humanity thrives in the coming decades. Experts estimate that the world’s population will grow to 9.7B people by 2050, and food demand with it. Unfortunately, many traditional approaches to food production contribute to environmental issues; climate change is causing more frequent crop failures; and political conflicts regularly affect supply chains around the globe.

Addressing many of these issues is vertical farming — the cultivation of plantbased foods within closed multi-story greenhouses. Vertical farming requires less land than traditional approaches for massive efficiencies and the ability to farm even in urban areas. What’s more, plants are protected from extreme weather and pests.

A pioneer in this industry, Romanian startup Ultragreens relies on wire and cable systems from HELUKABEL for the reliable transmission of power, signals, and data in their automated indoor farms. Founded in 2014, the company supports the growth of food closer to its points of sale. To

motioncontroltips.com | designworldonline.com

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DESIGN WORLD — MOTION

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automation in agriculture Vegetables, salads, herbs, and seedlings (microgreens) can grow in vertical greenhouses: These are young vegetables that grow up to ten centimeters high and can only be harvested after one to two weeks. Their high vitamin and mineral content make these plants real superfoods. In addition, the short production process enables consistently high yields at any time of year.

do this, Ultragreens relies on compact greenhouses that can be directly placed in supermarkets, for example. In fact, Ultragreens also plans and implements so-called green hubs — huge vertical indoor farms to be operated by nationwide wholesalers and retail chains. To optimize transport costs and reduce environmental impacts, the green hubs are often located in the immediate vicinity of retailers’ logistics centers.

Several green hubs are already operating successfully in Romania, and Ultragreens recently announced its entry into the Bulgarian market. The vertical greenhouses are modern and fully automated: The plants grow under precisely calibrated LED light and without soil in so-called hydroponics, where they are supplied with all the necessary nutrients through special substrates.

Irrigation, ventilation, temperature, and many other factors are precisely regulated by computer systems and continuously monitored with comprehensive sensor technology. If a limit value is exceeded

or not reached, the system adjusts itself automatically so that optimal growing conditions always prevail.

“The extensive technical equipment with sensors, control and monitoring systems is of course essential for the operation of our vertical farms,” says cofounder and CEO of Ultragreens Cristian Tudor. “On the other hand, it also means that malfunctions or failures of individual components can affect the entire harvest.”

To avoid this, Ultragreens only equips its systems with high-quality, reliable components that have been extensively tested beforehand. For the cabling, the company has relied on HELUKABEL since the very beginning: The electrical connection technology specialist supplies the connection, control and data cables required for the operation of the vertical greenhouses. Tried and tested solutions such as the JZ-500 and JZ-600 cable types, the H07V-K single conductors or the TRONIC-CY data cable are applied.

“For us, quality was the most important criterion when selecting

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The vertical greenhouses are fully automated.

our suppliers,” reports Cristian Tudor.

“HELUKABEL was recommended to us by one of our technical service partners … and met our high expectations.” The HELUKABEL Romania team (led by managing director Ionut Nica) thoroughly examined the application and selected the optimal solutions for the special operating environment. “Importantly, the cables used must be resistant to moisture, and they must also be sufficiently bendable to allow for a flexible installation even in tight spaces,” explains Nica.

All cables supplied by HELUKABEL are certified according to the standards and regulations applicable to local markets.

“HELUKABEL is more than a supplier to us; they are a partner for the joint development of our product portfolio,” says Tudor. Further projects are already being planned — for example, the largest vertical greenhouse in Europe to date, with a cultivation area of 6,500 m² on 12 levels.

Other motion components found in automated greenhouses

In contrast with approaches to optimize the traditional farming of fields, automated greenhouses solutions eliminate issues associated with tight labor markets, guarding delicate or valuable crops, and the need to apply pesticides and herbicides to plants grown outdoors. Such automated greenhouses often employ building automation with HVAC controls to hold temperature, humidity, air composition, and light to grow-stage setpoints; automated circuits to keep watering and nutrient formulations at comparable setpoints; and linear-motion systems as well as collaborative robots (cobots) and six-axis robots to transport plant flats, camera

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equipment, harvesting robotics, and other systems around greenhouse facilities.

For example, multi-axis cartesian robots consisting of pre-engineered linear actuators in some cases move light and fan towers along rows of plants to optimize crop growth while reducing the number of plant-tending units required.

Elsewhere, the approach is reversed: AGVs move racks of plants to workcells where greenhouse personnel can more readily reach and tend or even harvest the crop.

Or such AGVs might take racks of plants to cartesian workcells employing vision-based inspection routines to catalog plant size and health. Then end effectors might test, spray, prune, and even harvest the crop.

The latter arrangement adapts automated storage and retrieval system (AS/RS) iterations to greenhouses making efficient use of three-dimensional spaces with stacked crop rows stretching dozens of feet.

Where crop-tending equipment to maneuver around racks, pots, and tubs is shuttled along long crop rows, the linear motion components (due to the way they’re often exposed to dirt and moisture) must have rugged sealing and high load ratings — especially if operating near or transporting flats of plants or moisture-laden dirt, for example. Track-roller linear guides (in contrast with profile-rail linear guides) may be most suitable for their ability to bulldoze dirt aside upon each stroke. Especially long crop rows may also require linear motion assemblies having butt-joined linear rails to essentially form seventh-axis linear systems akin to those so common in automotive manufacture.

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applications casebook

End effectors also contain damping elements to process delicate circuit boards without damaging them. Image: Dreamstime

APPLICATIONS FOR SHOCK AND VIBRATION MITIGATION

The bulk of industrial automation systems incorporate motion on some level. This means that stopping or changing the direction of motion releases kinetic energy which in turn can produce shock and vibration in the system. Sudden shocks can damage the machine or the components being manufactured or processed.

Likewise, vibration can damage a machine over time, causing fatigue which can lead to premature failure.

Shock and vibration mitigation components help systems reduce the impact of these disturbances and prolong system life.

Shock and vibration-damping components are as varied as the designs in which they work. That ranges from heavy-

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duty machine tools to delicate designs that assemble semiconductor components.

Addressing these oscillations lets machines run faster, for more throughput and higher-quality (more accurate) moves. For example, the automotive manufacturing and packaging industries make copious use of mid-bore and smallerbore hydraulic dampers.

Consider how bottle-blowing machine builders use adjustable shock absorbers instead of rubber bumpers or springs to increase glass and plastic bottle production. The shock absorbers protect the bottle’s neck and opening against stress fracture during manufacturing, even in hot and dirty environments. The shock absorbers in this application sport reinforced bodies to withstand more energy per second as well as Tefloncoated piston rings and piston rod seals formulated to withstand heat.

Shocks and vibration dampers excel in designs that are engineered to motioncontroltips.com

|

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shock & vibration mitigation

Bumper arms in this carton-forming machine feature damping elements. Image: Dreamstime

avoid the structures’ natural frequencies during operation. Adding mass with heavy bases or mounting machines into steel or concrete flooring is one approach. In applications where this is not possible or sufficient, vibration-isolating components and other passive dampers can absorb or attenuate vibrations. Here, the components bear the whole machine weight to shift excitation off the natural frequency.

As a rule of thumb, isolators should shift a design’s natural frequency so it’s no more than one-third of the excitation frequency. One caveat is that overly compliant isolators can actually act to increase the magnitude of motion. One solution where this is an issue is hydraulic or magneto-rheological setups that damp at system natural frequency but isolate like undamped designs.

In contrast, active vibration controls use actuators and sensors to counteract vibrations with motion having an out-ofphase frequency. Certain negative-stiffness mechanisms separately adjust horizontal and vertical resonant frequencies. Such technology is particularly useful in aerospace and semiconductor applications with nanometer-level and better accuracy demands.

Mechanical subcomponents in the form of wave springs and compliant couplings are still other options to isolate vibrations in everything from precision electric-motor-driven machinery to those that run off internal-combustion setups.

As mentioned, one semi-active product to damp vibrations is magneto-rheologic fluid — a blend of magnetic powder in oil,

water or glycol that reversibly changes from free-flowing to semi-solid under an electromagnetic field. Particularly useful in automotive applications that must accommodate changing road and driving conditions, magneto-rheologic components

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No matter the subtype, shocks and vibration-damping components have a reputation for being a commodity component. In fact, these devices are highly engineered and customized to very specific loads, impacts and machine geometries, and affect overall equipment performance.

Particularly for transportation applications, in days past when everything was made out of heavy steel, if one wanted to take out some vibration, the simple solution was to just make it heavier. Today, that’s no longer the thought process. Now, the requirement in many industries is to make systems lighter and faster, and that creates a whole new set of conditions for engineers to tackle as they attempt to best isolate vibration in smaller, lighter, and faster products.

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applications casebook

Food-industry pick-and-place Image: John6863373

Automated labeling machine Image: Baloncici

THREE APPLICATIONS IN THE PACKAGING INDUSTRY

Packaging machinery uses cutting-edge automation, and it’s no wonder. Facilities that parcel products need to deliver high throughput, but modern consumers demand smart packaging in the form of nofuss containers that protect everything from M&Ms to patio furniture. What’s more, there’s a continuous drive to customize packages and let consumerfacing companies wrap products for bulk distribution, single-item sales, and everything in between.

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To satisfy these design objectives, packaging machinery over the last decade has become increasingly adaptive. That’s been evident in a range of motion components and fully integrated designs at recent Pack Expo events.

Pick-and-place functions in packaging operations Pick and place in the context of machines for packing typically involves the handling of discrete products (from the size of a cookie to the size of a sportsdrink skid) by fixed cartesian arrangements, delta robots, or SCARA robotic arms. In fact, pick-and-place operations are excellent candidates for automation, as the work (if

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packaging

done manually) tends to be quite dull and monotonous and therefore prone to error.

Consider box loaders — those machine designs that stack filled, wrapped, and in many cases cartoned goods into larger cases to transport.

The motion workcell orients and queues each unit on the infeed conveyor, and then a pick-and-place machine flanking this conveyor (and outfitted with machine vision) loads the units into boxes. Once filled, the box travels on an outfeed conveyor to make way for the next empty case — and ride onward to taping and labeling stations.

Now consider a four-axis (X-Y-Z and base rotation) pick-and-place motion system for loading pallets for shipping. Here, linear systems that are preassembled by the motion-component supplier are increasingly common, as these can be furnished preprogrammed as well.

Though linear axes based on ballscrews (flanked by linear guides) driven by a gearhead-fitted servomotor are most common, linear-motor-based solutions are employed on particularly demanding or challenging axes.

Servomotors with low inertia support the quick accelerations needed by pick-and-place operations.

Rotary direct-drive servomotors increasingly drive rotary axes at the base and end effort of the system.

Such motors help pick-and-place operations achieve the exceptionally high precision and speed required by highthroughput workcells — especially those associated with the processing of foods and other consumer goods.

Labelers include several coordinated motion axes.

motion profiles are key to achieving these smooth and efficient trajectories.

Perhaps no other industry has more preprogrammed software modules than packaging … and options abound from motion suppliers that sell or offer as a value-add an array of pick-and-place modules adhering to both proprietary and industry-conforming standards (such as Packaging

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Pick-place software considerations: High-speed networking (increasingly Ethernet-based) can further boost machine speeds as well as simplify motor drive and controls configuration upon startup. Smooth motions (with accelerations and decelerations free of impulse and jerk) can keep delicate or liquid-based end product intact (and firmly grasped) during lifting, lowering, and traversing — and also helps machines and support assemblies minimize mechanical wear to achieve their expected life.

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The S-Carriage InstaThread Pre-stretch Film Carriage from Orion Packaging Systems can help packaging facilities save up to 15% on film per load — a substantial savings to help offset the rising cost of film seen over the past year.

At the heart of the carriage design are two pre-stretched rollers. Film travels in an S pattern around the rollers, providing over 180˚ of film contact to reduce slippage and neckdown. The result is a consistent prestretch of 260% at different tensions and 1 in. less neckdown.

Machine Language or PackML) as well as templates. Segmented programming roughly associated with separate machine sections as well as HMI accessibility render routines and tags easy to understand and reuse.

Label printing and scanning One of the most common forms of labeling in the packaging industry involves affixing self-adhesive branding and designation stickers to discrete end units off a spool off said stickers. Though the applications for food and beverage products are most visible, this type of labeling is used in the pharmaceutical, petrochemical, electronics, and home goods industries as well.

In this spool-based automated labeling operation, discrete products ride on a conveyor into a separating station that evenly spaces them out. Then the products travel onward to the label-station proper.

Here, a three wheels work in conjunction to intermittently drag the unwound and peeled back portion of the label spool across product surface … sometimes processing 100 feet per minute or more of labels. A belt stops and starts the web to synchronize the labeling-wheel stroke with that of the conveyor upon which the discrete products are riding.

Either closed or open-loop control of the label-wheel axle position maintains proper web tension.

To ensure straight and centered placement, a machine-vision camera or other sensor reads a mark on each sticker to inform the controls of any slight drive-wheel adjustments required during deceleration and final application.

Sizing motion components for this application often requires separate consideration of the label-web feed axle (axis), take-up web-tensioning reel, and

11 • 2023

DESIGN WORLD — MOTION

spent web backing axle (axis). The forces and speeds as well as the continually changing spool geometries and inertias are primary considerations.

Stretch wrapping applications Stretch wrapping is essential to bundling cut film off a web at exceptionally high a wide array of goods into transportable rates. Rotary and linear motion designs and salable units. Such packing also (including three-axis gantry systems) serves to protect the discrete items in the complement the core conveyor and pack … and simplify distribution. Where machine-vision systems that enable this consumers will see the shrink wrapping, it application. must be especially attractive and rugged.

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MATCHING JAW COUPLINGS TO APPLICATION REQUIREMENTS Consider how standard jaw couplings deftly handle shock loads. If the application at hand requires the coupled axis to quickly start and stop, a rigid coupling (or one without cushioning or damping characteristics — such as a zero-backlash jaw coupling) will transmit that shock and can actually accelerate the destruction of the assembly’s bearings on the ballscrew input or motor. In contrast, compliant jaw couplings handle shock loads quite well — even on axes with frequent stops and starts to maintain high throughput.

Here, requiring that the axis decelerate more gently or run softened move profiles just to accommodate a bellows coupling or a rigid coupling is unacceptable. Jaw couplings here impart excellent protection for the life of the design’s motor or actuator — and lets the axis run aggressive move profiles without sustaining damage.

Spider materials and spider hardnesses abound.

For example, there’s 98 Shore A, 92 Shore A, and 85 Shore A — sometimes more casually expressed as just 85 durometer. Depending on the amount of cushioning or damping the axis needs, design engineers can fine tune the coupling behavior to suit by strategically choosing from these different spider materials.

Jaw couplings are an inherently fail-safe design: If the jaw coupling’s spider is catastrophically damaged, its arms tear off ... and the coupling will go metal-to-metal and still drive. This is useful on applications where it’s important to have a

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DESIGN WORLD — MOTION

fail-safe design or positive drive. Even zero-backlash jaw couplings work in this manner.

Case in point: The vertical (Z axis) of a semiconductor handling machine might be responsible for lifting and lowering an expensive boat of wafers for wafer processing. Here, suddenly dropping the valuable load could be an expensive error.

So to prevent dropping that load in case of failure (and having the screw back drive) a jaw coupling here will act as the positive drive.

One drawback of jaw couplings is that they have fairly low misalignment capabilities ... so require requires precision alignment at installation.

They do impart a bit of forgiveness, but nothing like beam couplings or other couplings.

So if an axis’ halves

are misaligned beyond what the jaw coupling is capable of accommodating, that coupling’s will hubs will go in shear, and the spider will degrade ... which in turn results in excessive loading on the axis’ bearings.

That’s especially true if the spider fails. If this occurs while the system is still running, the assembly will run through a metal-to-metal coupling engagement — potentially outputting bad product until it’s discovered the coupling’s spider has disintegrated.

Jaw couplings for electrical isolation: Jaw couplings do impart a modest level of electrical isolation that is sufficient for lowvoltage applications. That’s because spider (usually made of polyurethane or some other polymer) prevents the coupling’s metal jaws from touching the face of the hub on the other side. Manufacturers don’t usually recommend jaw couplings for electrically isolating high-voltage applications.

In fact, preventing low-voltage signals from jumping over the coupling (and potentially interfering with processes by traveling into other components) is possible with jaw couplings, Oldham couplings, and disc couplings with nonmetallic center members.

Have quick reversals? No worries. There are multiple spider materials to match jaw couplings to application needs.

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• Optional pre-designed kits make it easier to select the right system for your application.

• 8 material options.

VIBRATION ISOLATING COMPONENTS

QUICK CLAMPING COLLARS

• Rubber bumpers are ideal as end stops or mounting feet.

• No tools required to install, remove, and adjust.

• Vibration isolation mounts can be sandwiched between components to dampen shock loads.

• Best suited for systems that require frequent adjustments.

• Both types can have studs or tapped holes.

ruland.com | sales@ruland.com

Created for the Most Demanding Environments Harsh Environments

Vibration Damping

Extreme Heat +200°C

Welding

Extreme Cold -240°C

Dust Metal Debris

Washdown

PBC Linear Simplicity® Plain Bearings and Shafts Maintenance-Free • Wide Temp Range • Vibration Damping • Quiet Operation • Chemical Resistant

Request a FREE Sample at: bit.ly/SampleDW2021

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