Motion Systems Applications Handbook

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November 2015

Motion

Systems

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Precision Gearboxes for Servomotors SureGear Precision Servo Gearboxes ®

$674.00

The SureGear series of high-precision servo gear reducers is an excellent choice for applications that require accuracy and reliability at an exceptional value.

(PGB070-05A1)

These planetary gearboxes, available in right-angle, inline, and now hub-style versions, have a thread-in mounting style, along with precision and torque capacity that is best in class.

• NEW hub-style models are perfect for applications requiring high-speed, high-precision indexing movement • Industry-standard mounting dimensions • Best-in-class backlash • Multiple gear ratios available (5, 10, 15, 25, 35, 50:1) • Uncaged needle roller bearings for high rigidity and torque • Maintenance free: no need to replace the grease for the life of the unit • At nominal speed, service life is 20,000 hours • Can be positioned in any orientation • 5-year warranty • Starting at: $398.00 (70mm Frame - PGA070-05A1)

$398.00

(PGA070-05A1)

Use SureGear with our practical SureServo systems start under $1,000**

The SureServo family of brushless servo systems from AutomationDirect is fully digital and offers a rich set of features at dynamite prices.

Beginners to experienced users can take advantage of this easy-to-use family for as little as $986.00** (100W system). ** All components sold separately.

• Eight standard systems from 100 W to 3 kW • Use with most AutomationDirect PLCs or any other host control • Drives feature on-board indexer and adaptive tuning modes • Free set-up software • 2 year warranty

Example models shown

$722.00

(PGD047-05A1)

Mates easily to SureServo motors

Research, price, buy at: www.automationdirect.com/motion-control AutomationDirect Price/Part Number

Servo Systems

Allen-Bradley Price/Part Number

Digital Servo Drive

$488.00

$1,340.00

100W Servo Motor with connectorized Leads

$325.00 SVL-201

$558.00 TLY-A130T-HK62AA

Breakout Board Kit for CN1 Control Interface

$94.00 ASD-BM-50A

$263.00 2090-U3BK-D4401

10’ Motor Feedback Cable

$49.50 SVC-EFL-010

$90.00 2090-CFBM6DF-CBAA03

10’ Motor Power Cable

$29.50 SVC-PFL-010

$101.00 2090-CPBM6DF-16AA03

Configuration Software

FREE

$82.00 2098-UWCPRG

SVA-2040

SV-PRO*

2098-DSD-005

*SureServo Pro software is FREE when downloaded and is also available for $9.00 on a CD

Complete 1-axis 100W System

$986.00

$2,434.00

All prices are U.S. list prices, AutomationDirect prices as of October 2015.

The Allen-Bradley 100W system consists of part numbers shown in table above with prices from www.wernerelectric.com, www.rexelusa.com 5/25/2015.

Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.

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the #1 value in automation

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HERO

BEI Sensors rotary encoders are well-sealed, shock and vibration resistant and built with heavy duty bearings for unmatched performance. Put a working class hero on the job and see what a difference real reliability can make.

800-350-2727

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SENSORS FOR EXTREME ENVIRONMENTS

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CASE

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Aerospace: Showcasing motion excellence

NASA

LISA EITEL @DW_LisaEitel

This NASA Robonaut uses 26 Harmonic Drive component sets in its arm, leg, head and torso joints.

engineers and scientists saw years of design work come to fruition when the Mars rover Curiosity, a 2,000-lb feat of excellence, settled onto the red planet in a gentle touchdown of glory.

But it wasn’t just the efforts of NASA personnel that gave humanity that moment—and every other win in the thousand-plus days that Curiosity has successfully documented Mars terrain. Scores of suppliers (among them many motion-component manufacturers) also saw their designs succeed.

In our inaugural edition of this Design World Motion Casebook, we profile applications that showcase this kind of engineering excellence. Read through this Casebook, and you’ll discover how smart bearings could soon improve rail and wind-turbine applications ... and how customengineered conveyors and robots are leading warehouse automation in packaging.

You’ll also see how smart

motors power next-generation peristaltic pumps to circulate blood without pulsations.

Reconsider Curiosity. As details about its design (including some of its bearings, actuators, and software) continue to go public, we cover the technical details.

For example, we now know that tubular piezo stacks from Physik Instrumente (PI) are on the rover and still working perfectly, currently helping in the collection of soil samples from the red planet’s Gale Crater. The solid-state actuators go on a Chemistry & Mineralogy (CheMin) instrument to help scoop Mars dirt into test chambers and dump it out when tests are done.

Conventional polymer-insulated piezo actuators would’ve been too sensitive to humidity and temperature extremes on Mars. But PI’s ceramic encapsulation (cofiring that puts piezo-elements in monolithic blocks) makes the actuators more durable. In fact, PI PICMA actuators with the same design now work for nanopositioning systems in

This is the recovery of SpaceX’s Dragon spacecraft off the coast of southern California in early 2015 after a parachute-assisted splashdown. Thanks to durable components, Dragon can repeatedly return supplies and experiments back to Earth.

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FOR MOTION CONTROL INNOVATION, SOLUTION CITY NEVER SLEEPS.

Whatever keeps you up at night, we’ve got a solution—the largest selection of motors, pumps and air-moving devices available. Plus, one-of-a-kind solutions ready to be custom-engineered for your precision industrial, commercial, combustion or transportation application. If you can dream it, you’ll find it at Solution City.

100 East Erie Street Kent, OH 44240 ametekdfs.com

© 2015 by AMETEK Inc. All rights reserved.

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AEROSPACE SHOWCASES MOTION EXCELLENCE MR encoders from maxon motor work in Curiosity’s electromechanical joints. The magnetic sensors mount on the drive shafts and help drives control motors.

After passing extensive NASA tests, PI’s PICMA actuators got into Curiosity and still work in the sample-analysis system of the CheMin sample-collection instrument. (The tests confirmed PICMA actuators deliver 96% of their original stroke after 100 billion cycles.)

Starring in The Martian are Matt Damon ... and emerging aerospace technologies. In fact, many of the movie’s dramatized rover, camera, and solar-panel actuating systems incorporating motion components already exist. Photo courtesy Aidan Monaghan and Fox Films

semiconductor test and inspection, super-resolution microscopy, and bionanotechnology.

Even simpler power-transmission components on Curiosity demonstrate design merit. Consider the DU metalpolymer bearings in Curiosity’s soil drill.

GGB Bearing Technology made the self-lubricating bearings to function in Mars temperatures from -328° to +536° F. That’s important because DU bearing segments function as the main drillspindle component.

Curiosity engineers tapped motionindustry resources on the software side as 4

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DU metal-polymer bearings from GGB Bearing Technology go into the spindle of Curiosity’s soil-grinding drill, which the rover uses in getting samples.

well. They used Adams multi-body dynamics software from MSC to design Curiosity’s descent and landing. Simulating of touchdown details helped them prevent flight hardware from banging during breakaway of a Descent Rate Limiter and bridle deployment.

Other aerospace projects exhibit motion-design brilliance. Just turn to page 61 of this Casebook, where we detail how encoders on a Sentinel-1A satellite support inter-satellite laser communications. Or consider how the European space probe Rosetta recently landed on the comet Chury, and an array of dc motors from maxon motor helped the craft do its job.

Even seemingly futuristic technologies in recent Hollywood blockbuster The Martian already exist. The movie dramatizes a Mars habitat that strongly resembles the real Human Exploration Research Analog (HERA) at NASA’s Johnson Space Center. HERA is a simulated deepspace habitat for ISS-bound astronauts. It’s complete with two stories of living quarters, hygiene module, workspaces and airlock. Other technologies in the movie for water recovery, rovers, space farming, oxygen generation and ion propulsion also exist.

To be sure, aerospace applications are challenging, so are subject to failures. An experimental NASA cubesat recently showed altitude-control issues; the SpaceX CRS-7 mission earlier this year (to resupply the ISS) failed after an explosion originating from a liquid oxygen tank; defective pressure gauges recently delayed the launch of the European Space Agency’s ExoMars 2016 mission.

Despite such challenges and in celebration of those averted, may we let today’s applications in aerospace and other motion industries bring us inspiration, and let us welcome the technologies they kindle tomorrow.

NASA’s Curiosity rover took of itself with its robotic Mars Hand Lens Imager camera arm on October 5, 2015 (its 1,126th in service). In the background is Mars’ Gale Crater. Image courtesy NASA

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WHEN SPEED MATTERS THE MOST. And More than 1,000 motion solutions to choose from, most with same-day shipping option. Design your own, today!

• Brushed and Brushless DC motors • Planetary and Worm gearboxes options • Integral All-in-One BLDC • Diameter from 30 to 75mm • Power from 10 to 450 Watts • Motor stall torque up to 400Ncm (580 oz.in) • Gearbox output torque up to 160Nm (120 ft.lb)

dunkermotor.com/express

Dunkermotor is a leading manufacturer of customized rotary and linear motion solutions providing low-risk product development, lower total system cost and faster time to market for original equipment manufacturers in the automation, medical, solar, packaging, semiconductor and transportation industry segments.

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1500 Bishop Ct - Mt Prospect, IL 60056 Call: 773-289-5555 www.dunkermotor.com info@dunkermotor.com

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Aerospace showcases Motion excellence

Actuators......................................................... 10

Human machine interface (HMI) hardware...... 76

Ballscrews.........................................................16

Human machine interface (HMI) software....... 78

Bearings..........................................................20

Leadscrews......................................................82

Brakes, clutches & torque limiters................... 24

Linear guides, rails, slides & ways...................84

Cable management......................................... 26

Motors • AC....................................................90

Cabling............................................................30

Motors • DC.................................................... 93

Chain............................................................... 32

Motors • Integrated........................................ 97

Compression springs....................................... 34

Motors • Linear...............................................98

Controllers • Motion, servo & PLC.................. 35

Servomotors.................................................. 102

Conveyors.......................................................40

Stepper motors............................................. 106

Couplings........................................................ 42

Networks....................................................... 108

Drives • AC......................................................48

Positioning stages & tables............................112

Drives • DC..................................................... 52

Retaining rings...............................................114

Encoders......................................................... 56

Shaft collars • Locking devices.......................116

Gears • Speed reducers,

Shocks & vibration-damping components.....118

gearboxes & servo gearing................ 62

Wave springs................................................. 122

Gearmotors .................................................... 72

2015 PTDA Summit recap:

Grippers.......................................................... 74

The industry’s future....................................... 124

WORLD A DESIGN WORLD RESOURCE

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A warm-up.

Nothing moves air with more rock-solid reliability than AMETEK® Rotron regenerative blowers.

Fifteen years’ service life is not unusual. These low-pressure, high-volume blowers feature rugged, compact construction and quiet operation. Their proven design makes them ideal in applications from chemicals, wastewater and furnaces to vapor recovery and more. Plus, they’re backed by the industry’s most knowledgeable engineering experts. AMETEK can customize your blower for harsh environments, high voltage and specialized applications, too. So make your next air-moving challenge a breeze.

Call us at +1 330-673-3452 or visit our website to get started.

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© 2015 by AMETEK Inc. All rights reserved.

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M O T I O N CASEBOOK

EDITORIAL

GRAPHICS

VIDEO

Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor

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

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Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_LeeTeschler

Graphic Designer/ Production Coordinator Margaret Schneider mschneider@wtwhmedia.com @Meg_CLE

Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_Motion Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_LisaEitel Associate Editor Mike Santora msantora@wtwhmedia.com @DW_MikeSantora Assistant Editor Michelle DiFrangia mdifrangia@wtwhmedia.com @wtwh_Michelle

Traffic Manager Mary Heideloff mheideloff@wtwhmedia.com MARKETING Marketing Manager Stacy Combest scombest@wtwhmedia.com @wtwh_Stacy Marketing & Event Coordinator Nicole Loepp nloepp@wtwhmedia.com @wtwh_Nicole Marketing & Event Coordinator Jen Kolasky jkolasky@wtwhmedia.com @wtwh_jen

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2011, 2012, 2013, 2014

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Your Catalyst to Innovative Motion Control Solutions A single single resource resource for for integrated integratedmechanical, mechanical,electronics, electronics,drives drivesand and software, with software, with experienced experiencedcustomer customersupport support forforthe the development development of simple-to-sophisticated simple-to-sophisticatedautomation automation systems. systems.

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At Catalyst Motion Group, Group we are able to configure motion systems by utilizing our own component level supply. What this means for our clients is full accountability for customized solutions while realizing the improved efficiencies of a reduced supplier count and receiving fully tested and delivered solutions.

We can provide you with the ultimate solution for almost any application, while managing scheduling demands, technical requirements and financial considerations.

We are able to accomplish this through coordinated utilization of our extensive engineering resources and vertically integrated manufacturing resources.

We put it all together – customized motion systems that include stepper motors, brush and brushless DC motors, linear mechanics, drives, electronics and an the entire entire process, process, extensive array of peripheral system components. Our considerable and wide-ranging in-house manufacturing capabilities allow us full control of the from development of prototypes to delivery of fully tested production units.

And, with our engineering capability, if we don't have it ...we can develop it!

We have successfully developed and taken to production fully customized motion solutions for a wide variety of advanced technologies including: • Medical devices for diagnostics, surgical procedures, therapeutics and pharmaceuticals • Laboratory and analytical instrumentation and equipment • Industrial automation including robotics and production line processing operations MO M OTTI IOON NG RGORUOP U P We are innovative, flexible and most importantly a secure, reliable, and knowledgeable resource ready to respond to your most challenging motion control needs.

CATALYST CATALYST

www.catalystmotiongroup.com www.catalystmotiongroup.com Call Call 1 1 203 203725 725 3852 3852

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1500 Meriden Road • Waterbury, CT 06705 U.S.A.

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CASE

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Electric actuators: Versatility in motion

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lectric actuators range from syringe-sized units in medical applications to those that drive truck-sized industrial presses. These ubiquitous muscles of precision motion usually incorporate an electric motor and rotary-to-linear device for conversion of torque to linear force.

No matter the application, electric actuators deliver precision and repeatability—indispensible for repeatedly moving loads to a given location or locations. In some cases, they’re also more controllable than fluid-power options, giving engineers a viable way to shape the speed, force and acceleration of machine-axis moves.

Another benefit for applications that must deliver different outputs over time is that many electric actuators are programmable, so can adapt to changing conditions. Exceptions abound, but

Series SE slide

Series SD slide

Series SFP slide

applications with similar dynamics generally make use of similar actuators— those that pair motors with ballscrews; incorporate brushless dc motors; use leadscrews; come in a rod style; integrate belt-and-pulley setups; use motors paired with planetary roller screws; or are fully integrated actuators with built-in guides.

Note that electric actuators that work closed-loop or with a micro-stepping motor can match force and speed output commands best using feedback to overcome most of the mechanical limitations of rotary-to-linear devices.

Some application tips: No matter the application, establish the design’s power draw. Determine if the machine needs continuous or intermittent power draw, as that will dictate actuator size and type. Remember that overly large electric actuators can be less responsive than properly sized units.

On the other hand, appropriate safety factors ensure that electric actuators run coolly. Plus, lighter loads on the mechanical components can extend life. Halving load on a leadscrew can extend its life eightfold, for example.

Also account for the application environment and any dirt, chemicals and liquids that will contact the actuator. O-rings and seals must be made of materials that withstand the application’s suite of contaminants.

Finally, ensure that the electric actuator can handle the application’s side, radial and axial loads.

In this conveyor setup, SFP, SD and SE slides from PHD, Inc. route products off a conveyor line, while optical sensing identifies routed pieces. Such setups quickly and effectively separate product for packaging and distribution.

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What’s Inside Your Matters Catalyst to Innovative Motion Control Solutions The PITTMAN Difference ®

A single resource for integrated mechanical, electronics, drives and software, with experienced customer support for the development of simple-to-sophisticated automation systems.

On the outside, this looks like an ordinary DC motor. In fact, this particular motor is not a standard off-the-shelf part, but designed exactly to a customer’s specific technical requirements. PITTMAN provided an experienced team of engineers to work directly with the customer to design the perfect motor to meet a demanding motion application…

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• Special brush formulation for use in a very low humidity environment • Bearing system to handle higher than normal axial loads • Very tight balancing spec to minimize audible noise and vibration at high speeds • Unique magnet charge pattern to minimize cogging at low speeds At •Catalyst Motion Group Specially chosen surface-mount components inside the motor to meet an aggressive EMC requirement We are able to accomplish this through coordinated utilization of our extensive engineering resources and vertically integrated manufacturing resources.

We put it all together – customized motion systems that include stepper motors, brush and brushless DC motors, linear mechanics, drives, electronics and an extensive array of peripheral system components. Our considerable and wide-ranging in-house manufacturing capabilities allow us full control of the entire process, from development of prototypes to delivery of fully tested production units.

And, with our engineering capability, if we don't have it ...we can develop it!

We have successfully developed and taken to production fully customized motion solutions for a wide variety of advanced technologies including: • Medical devices for diagnostics, surgical procedures, therapeutics and pharmaceuticals • Laboratory and analytical instrumentation and equipment • Industrial automation including robotics and production line processing operations

When evaluating DC motor choices, it’s what’s inside that matters.

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resource ready to respond to your most challenging motion control needs.

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MOTION GROUP

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www.catalystmotiongroup.com

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ACTUATORS

Matching actuators to design demands

This five-axis CNC foam-cutting gantry system was designed and built by a faculty and student project team at the University of California, Davis Engineering. It’s for the fabrication of aerostructures, such as foam-core wings, and for the production of forms for composite layup.

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The machine was built from standard configurations of Bishop-Wisecarver LoPro linear actuators featuring ballscrew drive mechanisms. The designers configured the actuators in to an X-X’-Y gantry using T-slot aluminum framing members and aluminum brackets to create a work envelope of 1 x 2 x 0.7 m.

The fourth and fifth axes are custom designed and fabricated to accommodate the cutting spindle.

More specifically, on the X axis, there are two aluminum-beam-mounted LoPro actuators with Size2 ballscrews and a basic wheel plate with lubricators for 1,000 mm of travel. The Y Axis has one LoPro with a Size-4 ballscrew for 2,000 mm of travel. The Z axis has a LoPro Size-2 ballscrew and travels 700 mm.

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Electric actuators for automation applications must deliver set levels of speed and force requirements.

Here, better feedback and controls can increase responsiveness to overcome any mechanical limitations while boosting output-motion accuracy. OEMs and end users can pick from a vast array of actuators to get the right level of accuracy—for everything from lumberprocessing machines to those medical applications that need accuracy to a few micrometers. Electric-motor actuators that use belts and acme screws for rotaryto-linear conversion of motion abound. That said, the majority of general motion applications (including positioning tables, workpiece-pivoting stations, robotic end effectors and machining axes) make use of actuators that integrate ballscrews. With precision of down to micrometers, these satisfy designs that need thrust to thousands of pounds-force or linear positioning speeds to several feet per second.

Elsewhere, on injection-molding applications, packaging machines, machine presses and other setups that need high thrust, actuators that pair the electric motor with a roller screw (sporting a nut loaded with roller bearings that work like planetary gears around the screw) is a newer and increasingly common option.

Typical stroke is 2 m with acceleration to a few gs.

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Complete Motion Solutions Pneumatic, Electric & Hydraulic Actuators

PHD offers an extensive line of pneumatic actuators that are known for long life and high quality. Over our 55 years of innovation, we have extended our product offerings to include built-to-need components, price alternative components, electric actuators, specialty workholding clamps, and motion control robots.

From single actuator solutions, to multi-unit systems, PHD and Yamaha Robotics can provide complete solutions for practically any application requirement.

To order a catalog, visit

phdinc.com/dws1115 • 1-800-624-8511

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ACTUATORS

CASE

Robot controller

ION

7th-axis resolver or encoder feedback enclosed within protective housing

MOT

Actuator for welding

Welder controller

This is one example of how manufacturers often build actuators to specific requirements—here, an actuator on a spot-welding robot used in automotive body-in-white spot welding applications.

These GSWA ServoWeld actuators from Tolomatic, one of a myriad of job-specific offerings from the company, offer faster spot weld cycles and higher quality, more repeatable welds than pneumatic robotic spot welding equipment. The lightweight actuators have an enclosed anti-rotate assembly and are ideal for P (pinch), C, X, or Euro guns, offering superior performance and lower lifetime costs. A hollow-core servomotor pairs with either a ball or roller screw to output efficient, repeatable high force, lasting more than 10 million cycles and eliminating the need for couplings, adapters, belts and gears.

Common actuator types

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Benefits and potential limitations

Typical uses

Actuators pairing motors with ballscrews

• High axial output force for given torque input (mechanical advantage) • Speed and stroke limits

Industrial, transportation, aerospace and defense

Actuators with brushless dc motors

• None of the wear of brush motors; long life • More costly initially and potentially complicated drive

General-purpose applications; axes run at high speed; appliances; factory automation

Actuators with leadscrews (or Acme screws)

• Simplicity and (in some versions) integration of guide function • Variable life due to sliding wear

Ruggedized equipment; lower-cost consumer products; machine-tool transport

Rod-style actuators

• High force output (especially screw-driven types); hygienic • Seals can increase cost

Medical applications needing sealed motion components; sorting and food processing

Actuators with belt-and-pulley setups

• Extremely high speeds and long strokes; short design lead times • Limited precision without guides

Horizontal and vertical designs; small conveying to large SCARA transport

Fully integrated actuators (with built-in guides)

• Simple installation • Less design freedom

Consumer products to medium-volume industrial machines

Linear motors

• Fast and accurate • More costly than alternatives

Ultra-high-precision applications in semiconductor, medical and more

Motor paired with planetary roller screw

• Fast, accurate and precise • More demanding installation requirements

Precision applications in aerospace and semiconductor

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Want us to make you a hero?

Electric rod actuators

Power and economy

Low-cost ERD electric rod cylinder • Replace pneumatic cylinders, automate manual processes • USDA- and 3A-approved hygienic design • IP69K/IP67 options • Force range to 4,500 lbf (20 kN)

High-force RSA actuator • High performance • Mounting flexibility • High thrust up to 12,900 lbf (57 kN)

Heavy-duty IMA linear servo actuator

Powerful linear motion solutions that help you save the day (and simplify your machine design).

Build your next machine exactly as you envision it. With Tolomatic’s broad line of electric linear actuators and motion control systems, you can conquer virtually any application adversity with ease. You’ll find the speed, force and accuracy that precisely fit your machine goals, plus expert specification help through our online tools and customer support.

• Forces up to 6,875 lbf (30 kN)

Face your linear motion challenges with Tolomatic at your side.

Contact us to find out how easy it is to get the job done.

Visit www.tolomatic.com or call 877-385-2234.

Visit www.tolomatic.com/ electric-rod

Be heroic! Sign up to receive Tolomatic’s blog and register to win a GoPro® HERO camera. www.tolomatic.com/Heroic

• Compact package • Ball and roller screw

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Ballscrew applications: From mainstream to extreme

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allscrews are a tried and true linear motion component.

They best suit applications needing light, smooth motion; applications requiring precise positioning; and when heavy loads must be moved. Examples include machine tools, assembly devices, X-Y motion and robotics.

Ballscrews are usually classified according to factors such as lead accuracy, axial play and preload, and life/load relationship.

Lead accuracy refers to the degree to which the shaft’s rotational movements are translated into linear movement. With lead accuracy and axial play determined by the manufacturing method of the ballscrew shaft and the assembly of the nut, high lead accuracy and zero axial play is generally associated with relatively higher-cost, precision ground ballscrews, while lower lead accuracy and some axial play is associated with lower-cost, rolled ballscrews.

Fabricated by rolling or other means, these ballscrew shafts yield a less precise, but mechanically efficient and less expensive ballscrew.

When specifying a ballscrew, understanding the application criteria that the component needs to satisfy is essential. There are several factors to consider and each one plays a role in the decision-making process. The most important factors to consider when selecting a ballscrew are: • load—including the mass being moved and the forces involved in the machine’s processes • orientation—for example, horizontal or vertical, which affects the need for load-bearing support • speed—velocity and acceleration • travel—the stroke length • precision—including positional accuracy and requirements for repeatability • environment—special considerations for rugged or unique environments • duty cycle—cycle rate

Shown here is a Skyfire SVM-0 CNC milling machine. It has linear rails from HIWIN for all three axes of motion; the ballscrews that drive the axes are P7 single or double-nut rolled or C3class ground ballscrews.

Recently, advances in manufacturing and materials have improved ballscrew performance so machine designers today can get better linear motion at lower cost. Some improvements include the fact that the latest generation of ballscrews has more load density than ever, giving designers higher capacity from a smaller package.

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MAINTENANCEfREE OPERATION. WORRy-fREE DESIGN.

nsk k1TM lubricaTion uniT Experience long-term, maintenance-free operation with NSK K1™ Lubrication Units. These patented units provide fresh, continuous oil flow onto the rail or shaft during operation, making them ideal for environments where grease replenishment is undesirable or where grease is easily washed away.

Available on NSK linear guides, ball screws, Monocarrier™ actuators and Robot Modules, K1™ Lubrication Units prolong life for up to 5 years or 10,000 km operational distance.

1.800.255.4773

www.nskamericas.com

BALL BEARINGS | ROLLER BEARINGS | LINEAR MOTION PRODUCTS | TECHNICAL SERVICES

NPA-SL-020 Design NSK 8-15.indd 17 World ad_K1 Unit[250314]v1.indd 1

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BALLSCREWS

Motion Systems Corp.’s 1,000-lb-rated Model 85199 Ball Drive actuator is efficient and takes less energy to move a given load.

ballscrews using both rolled and ground screw manufacturing methods.

In addition to higher load capacities and miniaturization, there is also a move toward more integration.

For example, ballscrew-based linear actuators are readily available as all-in-one packages. The benefit here is that such integrated packages significantly reduce design time as well as time required for assembling a system and programming the actuator itself.

Actuator stabilizes world’s fastest motorcycle

The Top 1 Ack Attack Streamliner Motorcycle could become the first bike to exceed 400 mph. Actuators are key to its safe operation.

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A recent example illustrates how ballscrew-based actuators play a key role in stabilizing the world’s fastest motorcycle called the Top 1 ACK Attack Streamliner. Since it broke the motorcycle land-speed record in 2006, engineer Mike Akatiff and his design team have been working to make the Top 1 ACK Attack Streamliner surpass 400 mph, setting a new motorcycle land-speed record.

Training-wheel-type stabilizers for starts and stops, as well as rear stabilizing flaps for coast-down, are critical safety features. To move these safety components, Akatiff and his team chose Motion Systems’ 1,000-lb-rated Model 85199 actuator.

Ballscrew-based actuators have better efficiency than those with acme screws, so they consume less energy to move the same amount of load.

This in turn lets engineers use smaller power supplies, which reduce size and weight, critical parameters when attempting to break a land-speed record. Ballscrew-based actuators also have better speed characteristics.

For the motorcycle, engineers modified the 0.979-in.-diameter 85199 to withstand g forces during acceleration and deceleration.

So the actuator freewheels at stroke ends to eliminate limit switches and prevention of overtravel at stroke ends. Initiating freewheeling and linear advance stops is a ball cage within the nut ID that hits stop pins at each travel end. Factory-installed top pins mount in the screw thread for the specified stroke, which eliminates the need for limit switches. Screw, nut and ball cage are made of heat-treated alloy steel to resist wear. These mechanical design elements keep the motorcycle rider and others safe.

designworldonline.com

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StepSERVOTM combines the best features of stepper and servo systems.

Free samples for qualifying OEMS

Applied-Motion.com/StepSERVO

StepSERVOTM

Servo performance at step motor prices Closed loop for faster response, ideal for high throughput machines 50% more torque Runs cooler, saves power, lasts longer

866-916-6379 www.Applied-Motion.com Email: StepSERVO@applied-motion.com

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Search or shop online today.

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Bearings abound in myriad applications

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earings are ubiquitous and essential components for reducing friction between moving parts. Their primary function is to give moving parts something to roll on rather than slide over. Their secondary function is to transmit loads. Bearing loads are either radial (perpendicular to the shaft), axial (parallel) or a combination of the two. Depending on the type of loads expected and the likelihood of extreme temperature, pressure and contaminant exposure, there are different bearings specialized for certain applications.

Consider the bearings and slewing rings in wind turbines. These can reach 2 m in diameter and must, in some cases, bear hundreds of tons.

At the opposite end of the size spectrum (but only slightly less demanding) are bearings for medical applications. These often take the form of compact equipment necessitating bearings of just a couple millimeters in diameter, with rollers that are smaller. Some going into equipment subject to washdown have treated steel subcomponents; others for disposable or quiet designs are made of plastic. Likewise, industrial machines that are particularly hot, fast, or starved of lubrication under normal design conditions benefit from the use of hybrid bearings, which are those that use steel raceways and rollers or balls made from ceramic. No matter the design, each bearing type satisfies specific parameters.

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Ball bearings use balls to provide a low-friction means of motion between two bearing races. Ball bearings are usually inexpensive and, when selected properly, require little maintenance. These characteristics, along with limited heat generation make them one of the most common types of bearings. They are found in everything from skateboard wheels to turbine engines in aerospace applications, medical equipment and home appliances.

Roller bearings use rollers of varying shape (spherical, spherical thrust, cylindrical) instead of balls to transmit loads and reduce friction. Thanks to this shape, roller bearings have greater surface contact than ball bearings, so handle larger loads without deforming. Their shape also allows for a moderate amount of thrust load because the weight is distributed across cylinder line contacts instead of sphere point contacts.They are common in conveyor belt rollers, turbine engines, transmissions and gearboxes, as well as the mining, food and beverage, pulp and paper, waste-water and marine industries.

A needle roller bearing is a roller bearing with rollers whose length is at least four times their diameter. The large surface area of a needle roller bearing allows them to accommodate high radial loads in a limited ammount of space. Needle bearings often go in compressors, rocker-arm pivots, pumps, transmissions and other automotive designs.

Some applications excel with custom bearing designs. Shown here is the bearing in a blade pitch control on a wind turbine. Designed by Plymouth Machine Integration, it includes two concentric bearing rings fitted with one-way sprag clutches oriented in opposite directions. Small relative oscillatory motions of the inner race alternately lock and unlock the two clutches, in opposite phase. The middle (common) race is advanced in a single direction by an angle equal to the amplitude of the oscillatory motion. The average motion within each bearing is non-zero, promoting movement of the lubricant within the rolling elements.

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Robolink D Low cost, lightweight, modular robotic system

Affordable, lightweight, and modular in design, with motorized self-lubricating slewing ring joint technology. For robotics manufacturers, automation engineers, and a multitude of applications.

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Timken pinion bearings were selected for the opener hubs on this P51C Mustang opener because of their ability to handle extreme radial and axial loading. Common double Timken pinion bearings are rated at 3,300 lb. Image courtesy of Timken

The drive shaft of a rear-wheel drive vehicle typically has at least eight needle bearings (four in each U joint) and often more if it is particularly long, or operates on steep slopes. They are also found in construction and agricultural equipment, two-cycle engines, outboard engines and paper moving equipment.

Thrust ball bearings go in applications with mostly axial loads and can handle shaft misalignment. These bearings also excel in high-speed applications in aerospace, automotive, and oil and gas industries. Thrust ball bearings are also often found in machine tool tables, fluid control valves and spindles.

Thrust roller bearings transmit load from one raceway to the other to accommodate radial loads. Bearings like these also have a self-aligning capability that makes them immune to shaft deflection and alignment errors. Typical applications include: crane hooks, pulverizers, cone crushers and other heavy-load, medium-speed applications.

Tapered roller bearings have tapered inner and outer ring raceways with tapered rollers between them. The rollers are angled so their surfaces converge at the bearing’s axis. These bearings are unique in that, unlike most bearings that can handle either axial or radial loads, they can handle large amounts of load in both directions. Common applications include helicopter transmissions, fuel pumps and agricultural uses.

The principle difference between plain bearings and roller bearings is that plain bearings do not have any rolling elements.

Plain bearings are usually compact, lower-cost bearings that are relatively simple in design. They can be found in many applications, but automotive and construction are some of the most common.

Plain bearings are used in steering cylinders, front and rear struts, dump cylinders and on hydraulic excavators.

Split roller bearings, like this one from Revolvo SRB, are completely split to the shaft. This design feature makes installation easier and is an alternative to solid bearing replacement.

Intelligent bearing technology trialed in railway and wind energy sectors

SKF is now using a bearing health-management technology called Insight in several industry applications. The design puts a self-powered intelligent wireless sensor in a bearing to get condition-monitoring data through the Internet. In fact, the setup is already undergoing trials in challenging wind-turbine and railway applications.

“It goes beyond current sensorised bearing technology by integrating more sensors and ... self-powering and wireless technology,” said Ronnie Spolidoro, business development manager, SKF Insight. “These bearings connect to the Cloud, giving customers access to a range of diagnostic and support services.”

SKF Insight monitors dynamic parameters such as temperature, lubrication condition, vibration and load, and informs operators when conditions are abnormal or threatening. When launched at Hannover 2013, SKF Insight was a just a concept for maintenance engineers to track bearing health. But now it’s a functioning

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BEARINGS

In this image we see True-Tech technicians installing low-speed gear, shaft and bearing assembly into a lower housing bearing bore in a Valmet/Bonus Model SL3H-500 wind turbine gearbox. Image courtesy of True-Tech Industries Co.

After a bearing failure in the rotating element of this sludge thickener tank, engineers chose this custom cross roller slewing ring from Revolvo. This bearing is over 1,800 mm in diameter and is designed for long term reliability in harsh conditions.

solution running in customer pilots to supply data directly to diagnostic centers for condition monitoring using SKF aptitude. From here, dashboards and reports go to plant operators, machine manufacturers, SKF and anyone else authorized online. Users can even access the data on mobile devices.

Now using dynamic bearing data provided by SKF Insight, bearing health management will let operators see how actual conditions are affecting bearing health and spur corrective action— automatic lubricant application or shifting speed, for example.

One promising application for SKF Insight is wind-turbine monitoring.

Sometimes changing a turbine’s main bearing is so expensive that it negates the turbine’s overall viability. Here, Insight could monitor loads and lubrication conditions in service, giving plenty of time to prevent damaging conditions.

In fact, SKF is already helping a wind turbine customer develop such a system to measure dynamic bearing information in the true operating state, then wirelessly communicate it to monitoring centers and maintenance crews. Ultimately, the system will monitor bearing speed,

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Here, a True-Tech technician installs a high-speed pinion/bearing assembly in Valmet/Bonus Model SL3H-500 wind turbine gearbox.

vibration, temperature and lubrication— even as a retrofit to enhance operational potential of thousands of turbines already in operation worldwide.

The company is developing a similar solution in the railway sector for wheel-end bearings—critical components usually changed at set intervals, regardless of condition. Here, Insight could soon let operators change the bearings based on real conditions.

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Brakes, clutches and torque limiters in motion

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rakes, clutches and torque limiters serve similar functions in packaging machinery, medical equipment, industrial hoists and installations.

Essentially, brakes stop and hold loads while clutches and torque limiters disengage and engage power-transmission outputs to transfer torque from an input. Torque limiters usually modulate power transmission to protect mechanical equipment from overload.

When selecting brakes, clutches and torque limiters for a given application, engineers must pick between mechanical, electric, fluidic or self-actuation. Electric brakes are easy to control and cycle, even to a couple thousand cycles per minute. In contrast, common air-actuated brakes and clutches run coolly and maintain hold with minimal power. Friction brakes with disc, drum and cone morphologies work well as emergency brakes because of their failsafe holding—essential on conveyors, escalators, airport-baggage handlers, elevators and other safetycritical designs.

The size and type of brake most suitable for a given design depend on whether the machine needs emergency stops or softer stops that sacrifice brakes to protect loads from shock. Then, other application criteria (including the machine envelope, thermal capacity, cycle rates, and inspection and repair schedules) dictate the final selection.

In other machines, it’s more important that brakes prevent shifting loads and misalignment.

In most cases, it’s best to size brakes and clutches to the motor torque of the machine axis. But especially for axes where the brake must stop a vertical load, engineers should account for the fact that motors can temporarily draw added current to output more than their rated torque. Helpful resources include published performance curves from brake and clutch manufacturers. These list dynamic torque ratings for various operating speeds to help engineers match brakes and clutches to peak motor-output torque.

Beyond these general guidelines, fast, hot and other extreme applications require extra evaluation. Some tips: • Spring-set brakes benefit motion designs that slow loads with the motor before the brake engages; they’re also suitable as holding mechanisms.

• Machinery that runs beyond a few hundred cycles per minute may require brakes and clutches that are larger than performance curves indicate.

• Industrial designs that operate in hot environments may benefit from friction brakes with specialty frictionsurface geometries and materials (such as phenolic resin or ceramic). Motion applications that don’t get a lot of maintenance also benefit from the longer life these friction materials get.

• Brakes that use permanent magnets for operation automatically adjust for wear, so they excel in industrial machines subject to slow but steady on-and-off cycling.

Here, a ROBA guidestop on a carriage clamps directly to a profiled rail.

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BRAKES, CLUTCHES & TORQUE LIMITERS

One brake example: Safety for linear motion

Backlash-free safety brakes (as this ROBA-guidestop from Mayr Corp.) maximize functional safety while boosting the rigidity of an NC axis and overall machine performance.

Mayr’s safety brake applies stopping force directly to moving vertical-axis masses. This makes for safer operation—with the right controls, minimizing the hazard risk to people, according to safety standard DIN EN ISO 13849-1.

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In machine tools and machining centers, rail brakes can boost safety while improving accuracy and performance.

Consider how suspended loads present a hazard in machines and systems, especially if people are below.

During falls or crashes, the design must stop the load as quickly as possible to protect people and the machine.

So, some safety brakes (in the form of clamping units that engage profiled rail guides) brake movements safely and quickly by rigidly clamping the axes while running. Case in point: Backlash-free ROBAguidestop profiled rail brakes from Mayr Corp. now come in eight sizes for nominal holding forces from 5 to 34 kN. The designs are dimensioned for four rail sizes made by established linear guide manufacturers. A short constructional design and the integrated switching-condition monitoring use a contactless proximity switch.

The guidestop brakes mount directly to masses, which is especially useful for gravity-loaded axes that pose a risk to nearby workers. Drive elements between the motor and moving mass (spindles and nuts, shaft couplings or gearboxes) don’t affect overall machine safety as in motor brakes that rely on drive elements to transmit braking torque to the load. Another drawback of the motorbrake setup (not to mention pole brakes or band brakes) is that everything between the brake and carriage degrades rigidity. ROBA-guidestop safety brakes avoid this issue.

The ROBA-guidestop safety brakes work as fail-safes, as they close when de-energized. Tensioned cup springs press brake shoes onto the profiled rail’s middle (to clamp it). Then hydraulics release the ROBA-guidestop with nominal pressure of 70 bar—low compared to the holding force. The brake mechanism is for relatively long stroke paths, so compensates for profiled rails’ manufacturing tolerances without losing braking force. Two brake circuits work independently to either double holding forces or provide redundancy.

The backlash-free clamping of guidestops directly onto profiled rails also boosts the rigidity of the NC axis (for more accuracy) and minimizes vibrations (for better workpiece surface quality). What’s more, when the axis is at a standstill during machining, the ROBA-guidestop brake takes over the load, so the drive motor switches off and disconnects from the controls. This eliminates the control movements and relieves the ballscrew spindle; the closed brake absorbs axial forces.

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Cable and hose carriers in use

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able and hose carriers may be installed as a component on new or existing equipment, but it is often possible to simplify and expedite their installation with a complete turnkey assembly from the manufacturer. Such an assembly may incorporate other system components that include the hoses or cables, fittings, manifolds and special brackets, which add value by simplifying installation and minimizing errors.

Instead of having to install the cables or hoses into a carrier on-site, the end user often can obtain preloaded carrier assemblies or complete harnesses with connectors and fittings from the carrier manufacturer for plug-and-play installation.

Cables, hoses and fittings can either be furnished to specifications or drop-shipped to the carrier

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manufacturer from a customer’s supplier and installed before shipping. The end result is a drop-in assembly, ready for quick installation when it arrives.

A turnkey engineered carrier assembly may integrate a range of other system components to meet specific application requirements. Some examples include special mounting brackets to allow drop-in replacement, as well as manifolds, junction boxes, tow-arm assemblies, guidance and support systems, safety mechanisms, shrouds and enclosures, or other associated components.

Nylatrac NP Series cable carriers are installed on a gantry crane designed to offload product to an automated cart-shuttling system.

Photo courtesy of Dynatect Manufacturing

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Move cables, hoses, and more with ease

Rol E-Chain

速

All media in one chain & from one source: power, hoses, data, and more. Corrosion-free and resistant against chemicals and other liquid media. Long travels up to 2,700 ft. and speeds up to 20 ft./s possible with up to 57% lower required drive force. Light and modular.

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Dynatect Manufacturing supplied Gortrac steel-nested cable carriers for this Universal 360 Vertical Drill Rig developed by Robbins HDD, one of the first companies to pioneer this type of equipment.

This Nylatrac carrier system from the Gortrac Division of Dynatect Manufacturing is preloaded on reels for easier shipping, handling, storage and quick installation.

This value-added system from the Gortrac Division of Dynatect Manufacturing for a military dynamometer includes multiple cable and hose carriers and a structural support.

Cable and hose carrier applications

For a military application on a dynamometer carrying cables and hoses, the manufacturer furnished a structural support system on which multiple carriers ride. The metal Gortrac carriers, which hold a total of 10 cables and hoses, are approximately 40 ft long. As a result, the end user was able to simply bolt the system in place instead of building the support system.

Cable carriers made for an offshore oil rig were shipped on storage reels so they were easier to ship, handle, store and install. In this case, cables specified by the customer were included, and brackets also were included for easy assembly. The Nylatrac carriers for this application were 54 ft long and carried eight cables.

For a pontoon bridge at the Hood Canal on Puget Sound, the supplier of the Nylatrac carrier system designed and manufactured a stainless-steel support and guide tray system for the carrier. Other value-added components included the cables, clamps, auto-alignment brackets and fixed-end mounting structure. Stainless steel was used for the support and tray system to resist corrosion in the salt air environment. The cable carrier was constructed of a 28

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heavy-duty, fiber-reinforced nylon. The self-aligning brackets were designed to accommodate lateral misalignment up to ±2 in. over more than 300 ft of travel to reduce stress on the carrier.

When it’s necessary to provide optimum cable separation and ensure that cables ride on the neutral axis of the carrier, machined bars with a series of holes through which the cables pass can be added to a carrier design. This helps reduce stress on the cables and extend their life.

A hose carrier for a Las Vegas water show was supplied with a stainless-steel water manifold, as well as hoses and PVC guides, so it could be installed as a complete system. The large Nylatrac carrier handles four 5-in. diameter hoses and is 48 ft long. Cable or hose carriers with long travel requirements can be supplied with a carriage system equipped with rollers to support the carrier and allow it to extend smoothly beyond its self-supported travel limits. End brackets, clamps and other components also can be furnished to provide a complete bolt-in-place system. designworldonline.com

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CABLE MANAGEMENT

CUSTOM BALL SCREWS DESIGNED IN REAL TIME



Dynatect precision-ground ball screws can be quickly designed to your exact specifications with our automated CAD system.

A manufacturer also may be able to incorporate other items into a turnkey package customized for the application.

These may include such diverse products as protective expanding/telescoping covers, roll-up doors, slip clutches and motors, and ball- or leadscrews.

Discussion with the manufacturer’s application engineers may open up new possibilities for saving time and reducing costs by combining multiple components into complete turnkey assemblies.

Along with turnkey solutions, the carrier manufacturer also may be able to help minimize inventory requirements for OEM users by customizing a Kanban or JIT program. Another possibility is a vendor-managed inventory and tool crib replenishment program that integrates directly into the manufacturing process.

Thank you to Mark Cunningham, Sales Manager at the Gortrac Division and Mark Zanolla, Engineering Manager at the Gortrac Division of Dynatect Manufacturing for this information.

• High precision, up to ANSI class 2/JIN Class 1 spec.

• Virtually any length (longest to date: 54 feet) • Screw diameters from 1/2" to 6" • Designed to minimize backlash and eliminate deadband • We take into account: load, speed and accuracy, for optimal performance and long life

• Manufactured from your specifications, or print, or sample unit • When required, CAD models delivered quickly • Full repair, analysis and replacement services • Economical whirled ball screws available for non-precision applications

VISIT US ONLINE OR CONTACT US FOR OUR FULL-LINE CATALOG.

sales@dynatect.com / 262-786-1500

VISIT US AT DYNATECT.COM FOR MORE CUSTOM-ENGINEERED PRODUCTS AND SERVICES. GORTITE® PROTECTIVE COVERINGS

GORTRAC® CABLE/HOSE CARRIERS

Customized bellows; steel covers, roll-up covers and doors; walk-on covers; way wipers

Metal, plastic & hybrid; open- and enclosed-styles; modular and custom designs

POLYCLUTCH®

Continuous mechanical and pneumatic slip clutches

(800) 298-2066 / dynatect.com 11 • 2015

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Cables in motion: Common applications

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ore than any other component, cables come in customized versions to satisfy specific application requirements. The number of conductors and strands to transmit power to motors and feedback to and from sensors and controllers are just a couple cable features designers match to designs.

Usually requiring UL listing, cables in motioncontrol applications must be able to handle tight bending radii, abrasion, flexing and possibly even torsional movements. Some must also isolate the effects of strands conducting power. In VFD cables, for instance, a symmetrical ground design with three grounds and three power conductors offers a small outer diameter and less EMI. However, a fourconductor design with three power conductors and one ground is better for continuous flex applications.

The latter are common in machine tools, assembly lines and industrial-production applications.

Jacket material must also be compatible with the application. The cable jacket protects conductors and insulation and may also provide a level of shielding.

For example, cables used in harsh environments, such as on mobile machinery and machine tools, require special jacketing to withstand chemicals such as cutting fluids and oils and abrasion. Cables used in these tough environments or in welding applications may also require a flame-retardant jacket or lowsmoke, zero-Halogen design.

Cables used in flexing and rotating applications, such

as those on robots, must have high tensile strength and abrasion and flammability resistance. These are most often manufactured of polyvinyl chloride (PVC), chlorinated polyethylene (CPE), polyurethane (PUR) and thermoplastic elastomer (TPE).

On the other hand, cables used in medical applications must be biocompatible. The most common material used in cables for medical equipment is silicone, as it is durable and can be easily sterilized, disinfected and cleaned without disintegrating. Other medical-grade materials include thermoplastic elastomers, thermoplastic polyurethanes and PVC. Still other cables are manufactured with anti-microbial jacket materials to prevent bacterial growth.

As mentioned, shielding and insulation are also application-specific. Shielding protects the cables from outside electromagnetic interference, but also protects users and machines from voltage spikes and other internal interferences. For cables that will be inside cabinets or machines, or those with light to medium loads, unshielded designs may be used, as they usually are smaller and offer a tighter bend radius.

But cables installed on machines that are in motion require shielding, especially when they connect to a motor or drive enclosure.

Cables used on robotic arms, left, must have high tensile strength, abrasion and flammability resistance. At right, cables are tested for abrasion resistance, a critical feature required of any industrial motion cable. Photos courtesy of igus

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窶イABLING

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Chains for every environment

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ith recent advances in precision, designers can use chains in more applications than ever, including remote installations thanks to lubrication technology.

Chains are versatile and reliable components used primarily to transmit power in machinery or convey products. Roller chains are mainly used with drives. But they can also be found in applications with harsh environments that subject chain to weather, water or chemicals, where other options would fail. Most drive applications use an ASME/ANSI roller chain wrapped around a driver sprocket that is connected directly to the motor or reducer. This sprocket is usually connected to a machine’s conveyor head-shaft.

Conveyor chains are used in applications that require moving product horizontally, vertically or around curved radii. Most common conveyor chains are ASME-style (ANSI-style) attachment chains. Types include single-pitch attachment chain, double-pitch attachment chain, hollow-pin

chain, curved-attachment chain and plastic-sleeve chain. The attachments accommodate special fixtures or blocks for specific conveyor functions.

Accumulating conveyors are one subtype of conveyor chain that suit applications that need more control over product flow, such as packaging or assembly.

Self-lubricating chains excel in harsh environments or where regular maintenance is difficult. They are useful in applications in food and beverage, paper product or wood-processing industries where traditional lubrication presents too much of a contamination or clogging risk.

Chains are also available with specialty coatings for rugged environments. Stainless steel is a good choice in applications exposed to corrosion, but because this material cannot be hardened in the same manner as carbon steel, it doesn’t have the same load carrying capacity. Nickelplated chains are another alternative, providing some protection for mildly corrosive environments.

Factors that can limit chain life are corrosion, wear and fatigue. If a chain application requires long life without contamination, pick chain with selflubricating subcomponents. If the roller chain application requires high precision, pick chain with precision roller bearings at each link connection.

Shown here is a mobile chain application, a trencher from Shelton Sportsturf Drainage. Its digging chain runs off the tractor power takeoff; twin augers flanking the chain move dirt away.

Called the Shelton CT150, the vehicle uses laserguided grading to evenly install drainage pipes.

Hydraulics control trench depth; a pipe layer lifts out of the ground for easy starts.

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AN UNBEATABLE PACKAGE:

QUALITY, DEPENDABILITY, & ENGINEERING SUPPORT.

Crafted to excel in the toughest environments, including high-speed, wash down, vacuum sealing, high-temperature, food grade and many more. From standard chains to highly customized solutions, Tsubaki has the right chain for your packaging industry application. We understand the importance of your line’s uptime so save time and money by trusting in Tsubaki. And don’t forget Tsubaki’s full line-up of complementary products. Bundling options provide the flexibility to ensure optimum quality along your entire production line. At Tsubaki, we’ve got you covered.

ROLLER CHAINS • ENGINEERING CLASS CHAINS • BACKSTOPS • SPROCKETS • CABLE & HOSE CARRIERS • POWER TRANSMISSION PRODUCTS ROLLER CHAINS • ENGINEERING CLASS CHAINS • CAM CLUTCHES • SPROCKETS • CABLE & HOSE CARRIERS • PT COMPONENTS

Total Package USTSUBAKI.COM

©2015 U.S. Tsubaki Power Transmission, LLC All Rights Reserved.

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Compression springs in motion

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ompression springs are typically used to resist linear compressing forces (such as a push force) where space is limited, where uniform bearing pressures are required, or to reduce buckling. Thus, they are ubiquitous motion components. In the automotive industry, they are common in seats, pedals, transmission springs and windshield wipers. Building automation uses compression springs for industrial doors, fasteners and

dampers. In electric-distribution applications, they are indispensible for the function of contact switches and other electromechanical components. Medical uses for compression springs also abound—in simple mechanical equipment, such as beds, to those in advanced actuators for precision medical devices. In consumer devices, they are found in major appliances, lawn mowers, cell phones and so on.

This application example from Jacquemet Group shows compression springs in an engine.

Shown here is a compression spring inside the ball of a Dyson vacuum cleaner. The spring helps a flexible changeover valve-hose assembly engage with the floor-vacuuming mechanism or the wand, depending on how the user moves the handle.

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Compression springs are also common in shocks and runaway bumpers on high-speed trains. Image courtesy Jacquemet Group

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otion controllers range from single-axis smarts to programmable automation controllers (PACs) that synchronize hundreds of axes and plant IT. These brains of precision motion are at the heart of today’s motion-system innovation. But controls are increasingly advanced in mobile applications as well.

Consider just one example: Trust Automation Inc., known for standard and custom motion and motor controls, is helping design and develop a multi-mission launcher (MML) for a U.S. Army Indirect Fire Protection Capability program. The Development and Engineering Center of the U.S. Army Aviation and Missile Research is leading the project.

The design is a truck-based system that’s fixed or semi-fixed. It holds 15 launch tubes that can fire simultaneously at threats, for 360° protection against unmanned aircraft, cruise missiles, artillery, mortars and rockets. Trust Automation is developing elevation controllers for the MML to give them precise positioning. The controller interfaces with heavy-duty electro-mechanical actuators for motion control to the

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Controllers in motion: Applications advance MML elevation axis. In short, digital signal processing and advanced algorithms enable synchronous control of twin actuators that raise and lower the MML’s pallet.

“These platforms are critically important to national defense,” said Craig Von Ilten, business-development VP for the defense industry at Trust Automation.

Food and beverage example: Controllers make it simple

Consider another example: Opelka’s new continuous pastry fryer is more versatile and easier to clean and service than its predecessor. Called the MagicBaker CleanFlex, it uses B&R automation components for a modular architecture—so end users can use the machine without programming, even after a shutdown to replace parts.

PowerLink allows line or star topology on the equipment, and users can remove networked components without disconnecting the power or worrying about disrupting bus communication. Central data storage speeds up commissioning.

This gabletop case packer is one version of a line of stainless-steel case packers from Schneider Packaging Equipment that allows for sanitation washdown. There’s even an additional sleeve around open spaces in the support frame between the bolts and frame interior.

“The extra sleeve makes a more hygienic environment by preventing contamination from microbiotic organisms inside the frame itself,” said Pete Squires, VP of Schneider Packaging.

Quick changeovers let the machine go from two-pack convenience cases to three, four, six and eight-pack cases. Similar Schneider machines accommodate half-pint, pint, quart and gallon sizes. A complete end-of-line automation solution is easy thanks to simple integration with accumulator sand loaders for gabletop cartons, carton lane-dividing and transport conveyors, and robotic palletizers. Standard features include touchscreen operation and Allen Bradley Logix controls.

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Opelka’s new continuous pastry fryer, the MagicBaker CleanFlex, uses a B&R controller.

Here, a ROBA-guidestop on a carriage clamps directly to a profiled rail.

Data coding, motion control, PLC tasks and HMI functions are all on a single CompactFlash card in the controller. When the equipment restarts after maintenance, the controller automatically copies the software (including changes) to related B&R components. More specifically, Opelka leverages integrated PLC/HMI functionality from the B&R Power Panel 500, which has a 10.4-in. touch screen, X20 I/O and ACOPOSmulti drives.

The fryer’s versatility arises from the new control architecture, which allows changes through the HMI panel to accommodate different configurations for different bakers, said Stefan Weng of Opelka. ACOPOSmulti servodrives replaced pneumatic drives on the previous version to eliminate design and operation constraints. Here, a key advantage over pneumatics is that controls can implement new paths during operation at the push of a button without major modifications.

So now, pastries go through the machine more gently and with greater precision. That in turn means that users can customize the machine for different pastry types ... simply by picking recipes on the HMI. So the machine can now float or tip pastries into the oil bath.

The new machine’s drives are synchronized electrically, which means the oil bath can extend as needed without making the engineers modify the power-transmission system.

There’s also a Power Panel 500 in a control cabinet within the machine body. The drives for other machine modules (including one for loading separate raw-dough forms into rows and another at the end of the line that injects jelly into the pastries) are in distributed control cabinets.

All of the automated functions on the new MagicBaker CleanFlex from Opelka use B&R technology, and Opelka set up the PLC and HMI in B&R’s Automation Studio software.

Seamless integration makes programming, diagnostics and maintenance more efficient.

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What if you never had to worry about servo tuning?

You wouldn’t believe the things we do.

Mitsubishi Electric’s One-Touch Auto-tuning for the MR-J4 Series Servo System ensures every servo in a machine is always perfectly tuned from commissioning to end-of-life. Maintain peak performance and accuracy and reduce downtime, even as equipment wears. That is the beauty of One-Touch Auto-tuning: one click, one time.

No tweaking, no maintenance, just the sweet sound of productivity.

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“Space is limited in the distributed cabinets, so the compactness of the ACOPOSmulti and X20 modules was key,” said Weng. A two-axis variant of the ACOPOSmulti was the biggest space saver of all. Opelka saved even more cabinet space by replacing dedicated power supplies with 24-V modules from the X20 system. The X20 system also provided digital and analog I/O slices, as well as PT100 input terminals for PID temperature control.

The X20 modules also control stepper motors that move pushers and other small machine axes. “The X20’s three-part construction has a terminal block, electronics module and bus module. This simplifies installation and allows electronic-module replacements without the hassle of rewiring,” said Weng.

X20 modules and drives communicate with each other and the central controller through PowerLink.

Another improvement is that the user can configure components without needing to connect each to a PC first.

To prepare the components for bus communication, the engineer just sets their node numbers with DIP switches before install.

During operation, PowerLink and the electronic drives also make decoupling machine modules easier.

The user simply disconnects the power and PowerLink cables, both of which handle repeated plugging and unplugging much better than compressed air hoses.

Then machine modules can go to a washdown room for cleaning.

PLCs control San Fran hangar doors

Door motors, controls and gear drives of the Superbay Maintenance Hangar at the San Francisco International Airport needed a retrofit. Previous controls were built in 1969 with relays, contactors, timers, antiquated power tracks and miles of wiring requiring continuous maintenance. The massive hangar has two 130-x-90-ft doors, weighing 74,000 lb, on either side. Each door consists of an inner and outer panel for a total of eight independently functioning doors. The door sections mounted on rails offset so that adjacent doors can open and close without interfering with neighboring ones.

MicroSmart Pentra PLCs from IDEC now control and monitor the doors, letting airplanes as large as a 747-400s in and out of the hangar. Engineers from San Francisco International Airport’s Design and Construction Dept. used IDEC PLC programming and PLCs for their simplicity and expandability. Twin drives power the doors’ halves. A VFD drives each motor door, in turn capable of moving the entire door (though airport engineers made each drive redundant).

An IDEC MicroSmart Pentra PLC connects to each doors’ two VFDs through Modbus, and communicates in ASCII through an RS485 connection. The PLC also has inputs for switches and sensors for preventing operation when people or objects are in the way. From the IDEC HG4G’s HMI, operators open and close the doors.

In this defense application, controllers from Trust Automation synchronize actuators that position a multi-mission launcher (MML). The design is part of an Indirect Fire Protection Capability (IFPC) program led by the U.S. Army.

An IDEC Pentra PLC controls two VFD drives that open and close a hangar door. The hangar has eight doors, each with its own PLC controller.

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CONTROLLERS

IDEC PLCs control 37-ton hangar doors to let airplanes in and out of the hangar.

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The eight centralized PLCs controlling the eight doors simplify operation; soon a master PLC could control all the doors and command the PLCs as slaves. Wireless connection will soon provide fire control. In the current design, anytime a door stops, its PLC analyzes the problem and displays a troubleshooting protocol on the HMI. The IDEC MicroSmart Pentra PLC has floating-point math functions, supports 32bit processing, Modbus master and slave capabilities, up to 512 digital I/O and 56 analog I/O. The PLC also connects to the Internet (to allow for mobile access). IDEC Automation Organizer software comes in WindLDR for programming in ladder logic and function blocks (and online editing and simulation) or WindO/INV2 for programming HMIs. WindO/I-NV2 has tools for programming HMIs with a 5,000-symbol library (to save design time).

The hangar engineers used Automation Organizer to program touch-screen controls, status and troubleshooting displays, alarms, feedback processing and drive operating hours for maintenance purposes.

Simulation with the IDEC system let the engineers start and fine-tune the first door’s operation in less than a day (with the others in operation within a few hours). It also let the engineers add interlocking man-doors to the giant hangar doors—standard doors are embedded in the hangar doors for aircraft mechanics to enter and leave the hangar. Then the engineers programmed the PLC and HMI to interlock these man-doors with the larger hangar doors. If any man-doors are open, the HMI indicates that and prevents operation.

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Conveyors: A variety of uses

Collectors buy and sell coin proof sets to enjoy the currencies’ precise level of detail and overall presentation in durable packaging. Here’s a robot and Dorner conveyor that help automate the exacting packaging process.

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anging from discrete product transport to bulk-material carriage, conveyor functions are as varied as the places in which they work.

Engineers make conveyors meet specific applications by tailoring about a dozen conveyor design elements: belt or chain size, morphology and material; bases and support frames; controller, drive, and motor or motors; mode of belt or chain engagement with the drive; encoder, vision, and switch feedback; tracks, bumpers, and gates; and HMIs and plant-level IT integration.

Consider the warehouse-automation industry. Sorting and tracking tasks are paramount, but speed is often critical. Such applications need conveyors with servomotor functionality integrated with inspection stations fitted with machine vision. Or consider pharmaceutical manufacturing. It’s grown to a trillion-dollar industry, even while standards such as the FDA’s Current Good Manufacturing Practice (CGMP) regulations are more stringent than ever. Here, conveyors must have all the functions of those for warehouse-automation, plus need to be stainless and aluminum, posing no risk of contamination, while quickly and cleanly transporting expensive pharmaceutical products to and from stations for bottle filling, pill compressing, sorting and inspection.

In the same way, the manufacture of medical devices must adhere to FDA regulations that dictate equipment-sterilization schedules and methods. Here, only conveyors withstanding regular harsh cleaning last.

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CONVEYORS

2200 and 3200 Series belt conveyors from Dorner work in lightweight to heavyweight industrial applications like this one with Farason because they’re low profile and can slowly move with precision. The conveyors also work with robotics and indexing applications, as they are easily programmable to operate drive and control options and integrate into larger systems.

Packaging application: Conveyors support coordinated robot tasks

Mounting coin proof sets into hobbyist commemorative cases sounds easy, but it’s challenging when the application calls for precisely placing several thousand coins on moving inserts every day. This was a challenge engineers at Farason Corp. recently solved with conveyors from Dorner Manufacturing and vision-guided robots.

Farason designs and builds custom machinery for assembly, manufacturing and packaging processes (mostly in cosmetics, food and confections, medical, pharmaceutical and manufacturing industries).

For the coin-setting application, a system picks and orients coins in case inserts, then encloses the inserts with top and bottom lenses, said Joe Hurley, president, Farason.

The automated system uses 13 vision-guided robots and 22 Dorner conveyors purchased from Stokes Material Handling Systems. First coins enter the machine in trays for indexing. Six Dorner 2200 Series conveyors feed stacks of trays containing the different coins to unloading robots.

These robots remove rows of coins from their respective trays and place them onto one of six servo-driven Dorner timingbelt conveyors. Each 2-in.-wide conveyor indexes coins downstream to where a camera logs the coins’ rotational orientation. A placing robot tends each conveyor and takes coins and places them (properly oriented) into coin wells.

After depleting a tray, these robots then put empties on a Dorner 2200 Series conveyor for transfer out of the machine.

Upstream robots pick coin inserts from a stack, present them to a camera (which checks for smudges, scratches and other imperfections) and then place them onto a 10-in.-wide Dorner 3200 Series conveyor. This conveyor transfers the coin inserts past six coin-placing robots.

Next, a flipper robot puts completed coin inserts into a device that overturns the inserts 180° for downstream assembly. Top and bottom cameras inspect the insert to ensure all coins are present and properly orientated.

Inserts that pass inspection go to a robot that picks top lenses from a stack, presents them to the camera for inspection, and then places them down onto a Dorner 3200 Series conveyor. The flipper robot puts the inserts into the top lenses; then the conveyor takes the partial assemblies to a station where (after another inspection) a robot presses the cases’ bottom lenses in place. Then the conveyor takes the final packages to a trolley-loading robot that gathers them in three-up operation for shipment preparation.

All other Farason-built coin-picking systems use This is a conveyor that simplifies self-stacking. Called the DirectDrive Self-Stacker Dorner conveyors. This latest design took about System from Intralox, it uses a lightweight, hygienic, modular, plastic solution to a year from initial specification to delivery and save floor space, allow horizontal airflow and minimize destacking. commissioning in April.

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Different coupling styles require different applications

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ouplings are simple yet precisely engineered devices that connect shafts to transmit torque and compensate for misalignments. But many variations of coupling designs exist to complement machine dynamics and meet specific application criteria.

Couplings are either torsionally rigid or flexible. Flexible couplings compensate for misalignments, while rigid designs handle drive components already in alignment.

Temperature, misalignment potential, mechanical resonance and several other factors make some couplings better than others for given applications. Here are just a few different coupling types and the applications where they’re most common.

Rigid couplings are torsionally stiff and used when shafts are already in alignment. These couplings have two drawbacks: They fail if parallel shaft misalignment exceeds one thousandth of an inch, and they are susceptible to vibration and cannot run at high speeds.

Clamp or compression couplings provide high torsional strength. Their two-piece design lets engineers easily remove these couplings for maintenance. Rigid couplings go in servo systems that require high torque capacity, moderate speed and low cost.

Some engineers see flexible couplings as the most compliant components in mechanical motion systems. This attribute makes torsional stiffness critical in

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Zero-Max offset couplings like those in this high-speed slitting line can handle shaft displacements of 0.156 to 17.29 in.

maintaining positional control. Many designs need a shaft to start and stop multiple times per second, a dynamic requirement that necessitates a torsionally stiff coupling to reduce settling time between cycles. Regardless, flexible couplings frequently win out because of their torque capacity. Flexible couplings damp vibrations in both continuous-motion and intermittent applications.

Flexible bellows couplings are common in motion applications that need precision control and misalignment compensation. There are three components: a metal bellows and two hubs. One hub connects to the driving element; the designworldonline.com

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In this diagram we see the space reduction after the installation of the Zero-Max coupling.

Schmidt offset couplings from Zero-Max, like the one used in this coating system, compensate for radial misalignments while transmitting torque and constant angular velocity misalignments. They handle torque capacities up to 459,000 in-lb.

other hub connects to the driven element. The bellows connects the two hubs. The bellows element of this coupling compensates for all three types of misalignment.

Because of this design, metal bellows couplings are suitable for most applications. Bellows couplings are found in CNC machines, robotics and encoders.

Jaw couplings have two metal hubs that engage through a spider insert made of elastomer customizable to meet specific design needs. Because they’re less stiff than other couplings, flexible-jaw couplings work best in constant motion applications— including those in oil and gas, water and waste management, construction and aerospace.

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versatile and offer long life, even in designs that exhibit significant misalignment. Their three-piece design—two hubs and a torque-transmitting center—makes them easy to install and disassemble.

Oldham couplings are manufactured in a variety of materials to satisfy different application demands—the need for zero backlash or vibration reduction, for example.

They address parallel misalignment and limit axial motion.

Disc couplings work with servomotor and demanding applications because they transmit high torque, operate at high or changing speeds and handle misalignments. Disc couplings are often selected for automotive, construction and aerospace applications.

No matter the material or subtype, the one-piece design of beam couplings makes them easy to maintain.

The couplings are also zero backlash with spiral cuts to

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transmit torque over spaces with significant angular, parallel or axial misalignment. Beam couplings are often selected in motion control applications for robotics, for attaching servomotors to leadscrews and attaching shafts to encoders.

Offset couplings require less space when connecting offset shafts in large systems. With these couplings designers can create smaller and more efficient machines.

Engineers can mount the offset couplings to shaft hubs or directly to existing machine flanges. They are available for shaft displacements of 0.156 to 17.29 in. and torque capacities to 50 to 460,000 in.-lb.

Design configurations abound.

One option is to comb couplings with zero-maintenance bearings to boost uptimes and eliminate the need for lubrication. Such sealed bearings don’t have lube fittings, so make for a streamlined coupling setup—one that sheds contaminants and lets the couplings work in tight spaces and challenging environments.

Offset couplings work in embossing systems, presses, paper industry equipment and pharmaceutical machinery.

In this multi roll press, Zero-Max offset couplings help keep out contaminants and foreign matter, letting the couplings work in tight spaces and in less than ideal operating environments.

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窶イOUPLINGS

THE SURVIVOR

FOR EXTREME DUTY POWER TRANSMISSION: OUR ZERO MAINTENANCE DISC PACK COUPLINGS.

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Common applications for ac drives

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ll ac drives (including those known as variable frequency drives or VFDs) must satisfy specific application demands. The most common of these ac drives differ from those typical for precision motion control found in robotics, semiconductor fabrication, certain types of machining, and medical instruments to output motion to sub-mm to µm and even nm scales.

That’s because common servo systems use feedback and an array of dc drives to control motor-driven axes, but the most common ac drives control induction and ac synchronous motors.

Common applications include conveyor applications; lift and hoist machinery; grinding, fan, pump and compressor operations; and large machinery installations.

The most common ac drives run applications that need speed control ... everything from basic functions to VFDs paired with (as mentioned) induction motors or synchronous permanent-magnet types. Such ac drives first convert ac to dc and then use switching techniques to vary voltage and frequency to the motor. Constant-voltage VFDs (which use pulse width modulation or PWM) are most common; these feed a train of dc pulses with different widths into the motor windings with a shaped current waveform.

Machine builders often use VFDs to boost energy. Controlling current drawn by the motor can reduce energy bills because it prevents the motor from constantly running at full load. But VFDs help boost efficiency in other ways, too.

With three-phase motors, they outperform single-phase induction motors (common in industrial washers and similar applications).

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This is a converting line built in-house by Sealed Air to produce bubble wrap with paper wrap for Amazon shipping.

It uses VFDs for speed control.

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CELEBRATING 100 YEARS Thank you to our customers, associates and partners for 10 decades of success.

Celebrating 100 years of proven performance, Yaskawa is the world’s largest manufacturer of ac drives, motion control, and robotics.

YA S K A W A A M E R I C A , I N C .

DRIVES & MOTION DIVISION 1 - 8 0 0 - YA S K A W A | YA S K A W A . C O M For more info: http://Ez.com/yai834

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This is a new line built with drives (including VFDs for speed control), motors, and an operational HMI from Siemens. Sealed Air engineered it with automation partner Axis Inc.

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In a similar way, VFD setups also outperform pairings of triac control with universal motors.

Some applications (including vertical arrangements and those with frequent stopping and starting) benefit from regenerative braking possible with VFDs. Here, the drive’s solid-state components (that control motor voltage) channel energy back into the ac mains or braking resistor. That boosts design efficiency and lets machinery axes slow down faster than they would if left to coast down.

Induction-motor-based motion designs that incorporate VFDs also avoid high in-rush current at startup.

That’s because VFDs make it so the motor’s input starts with low voltage and frequency. There’s also less mechanical wear, as eliminating startup in-rush currents prevents excessive torque and renders throttles, dampers and louvers unnecessary.

No matter the application, all ac drives must meet key parameters, including the power-supply configuration and input voltage (and whether input is 60 or 50 Hz).

Compatibility with the motor’s voltage, current rating and horsepower, as well as what speed control the application needs (closed-loop vector, openloop vector or volts/Hz), are other considerations. Note that VFDs can introduce harmonic distortion, which degrades power quality and machine performance. However, some new VFDs address this issue.

Besides that, many common acdrive applications benefit from ac drives that deliver safety features (brake controls and stops, for example) and acceleration or speed monitoring and limiting.

One last application parameter is that ac drives must, in some cases, withstand exposure to dust, extreme temperature and humidity. Here, drives with rated enclosures (NEMA 1 or NEMA 12 ventilated, for example) simplify selection. designworldonline.com

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DRIVES • AC

The drives cabinet is 50% smaller than previous setups thanks to compact Sinamics drives and Simotion motion controllers.

Drive-motor-control boosts production by 50%

Sealed Air’s Saddle Brook, N.J., facility was both an OEM converting-line builder and equipment end user. Recently, it migrated its converting lines from an older control, motor-and-drive arrangement to boost line production.

“There was some resistance from our team, but we worked with our automation partner Axis Inc. who showed us a better way,” said Tom Kimble, director of specialty equipment. Axis is a local industrial automation specialist.

On this project, the challenge was to boost production of Jiffy-Lite papersleeve (laminated bubble wrap mailers for an online retailer) from 120 to 180 bags per minute. The aim to increase output demanded more horsepower and better controls and drives. Axes had to run faster, yet with more accuracy and a smaller machine footprint to address material-handling and plant-space challenges, said Joe Pitera, motion products manager of Axis Inc. Several previous converting lines featured a reliable motor, drive and motion control package, but the new line had to perform at levels not possible with old hardware and software.

Ultimately, Axis recommended motors, drives and integrated motion controllers in a cabinet 50% smaller than the previous design.

Siemens TIA Portal programming and commissioning software simplified controller integration.

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screens for design and subsequent runout on the devices used,” said Pitera.

“I fought the idea of a whole new engineering platform,” Kimble said. “It was so different from our previous protocols and even previous generations of Siemens products we’d used on successful Sealed Air lines. But Joe showed us the demo and how the TIA Portal pulls everything together and runs the HMI from one touchscreen with tagging, interconnects, an option-screen library and access tracking to all cable runs in the line.”

Kimble anticipated pushback. So, Pitera spent a day each week for several months at Sealed Air showing engineers multiple functions—how to copy and paste values for the entire temperature zone of the line, for example.

Implementing Sinamics S120 ac drives and Simotion motion controllers with Sinamics V20 plus using the integration features of the TIA Portal from Siemens helped Sealed Air increase line speed by 50% (from 120 to 180 packages per minute) and shrunk the control-cabinet footprint by 50%.

The new design controls 13 axes of servo motion with three simple VFDs for speed control; 16 heater zones with solid-state control and automation through the HMI; integration of 32 analog and 64 digital signals; and circuit control, safety devices and terminal blocks.

Building the design (including blocks) took less than six months. In fact, this system follows a recent build of a co-extrusion line at a Sealed Air facility in Chicago, which uses Siemens products for 43 axes of motion, 91 zones of heating, hundreds of I/O points and an HMI and controller.

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DC drives excel in an array of applications

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he array of machines that incorporate ac motors and drives makes them the industry standard, but dc-drives are widely used for good reason.

Many applications benefit from dc drives and the distinct characteristics they offer—including simple speed control, cost-effective integration and long life.

Common dc-drive applications include the movement of axes on wire-drawing machinery, hoists and elevators, paper-web handing, magnetic grabbers, extruding applications, spindle drives, and material handling.

Traditional machine setups that use dc drives paired with brush motors for speed control incorporate a silicon controller rectifier (SCR) for power conversion. This SCR, or thyristor, converts ac power input to adjustablevoltage output that goes to the motor armature. SCRs provide controllable power output by phase-angle control, named for how the firing angle synchronizes with the ac source’s phase rotation.

When dc drives pair with brushless (electronically commutated) dc motors, they offer an alternative to conventional dc drives and ac inverters, marketed as dc-drive replacements.

Brushless dc motors have windings on the stator

and permanent magnets on the rotor; rotor-position feedback from an encoder or Hall-effect sensor feeds speed information back to a controller for facilitating adjustment of electronic commutation on the fly.

So, dc drives offer distinct advantages, including those mentioned ... as well as wide speed ranges, good speed regulation, and starting and accelerating torques that exceed rated toque by 400% or more.

Matching a dc drive to a given application ultimately depends on the application’s starting torque; input power factor; need for dynamic braking; speed regulation, range, and need for high speed; and conduciveness to energy regeneration for boosting design efficiency.

Engineers at the Terminal de Contenedores de Yucatán (TCY) in Progreso, Mexico, used advanced dc drives from Emerson Control Techniques in America to modernize the control system on an aging ship-to-shore crane.

The hoist has a 373-kW motor rated at 50 tons to move 45 m/min, and it uses a 120-A Mentor MP dc drive. A 55-kW trolley (which moves 120 m/ min) and the 55-kW boom (moving to 6 m/min) share a 210-A Mentor MP that switches between them. Four 105-A Mentor MP dc drives serve eight 14-kW gantry motors.

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This iPCBRM100 is Air-Vac’s solder-rework machine that removes defective parts from circuit boards after the initial build. In the machine (inset)is AllMotion’s 1.6 x 1.6 in.

EZSV17 controller plus drive that works with brushed or brushless dc motors.

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DRIVES • DC

Motion controller + drive improves PCB repairs

Air-Vac, a manufacturer of flexible machines for printed circuit board (PCB) rework, adheres to the International Electronics Manufacturing Initiative 2013 Technology Roadmap mandating leadfree rework of plated-through-hole (PTH) components on large assemblies.

The company’s PCBRM100 machine removes and replaces through-hole components on 26 x 26 in. boards.

It uses an EZSV17 motion controller and drive from AllMotion, a controller needing little to no tuning when pairing with most miniature (2-in. diameter or smaller) motors. The controller also speeds implementation of brushless dc motors or brushed dc motors in automation.

The motion system for the PCBRM100 also has linear encoders and rotary motors switched back and forth between being belt driven and running as direct drives. Linear motors would have been too expensive for such a large system.

Features include 485 communications at 115,200 baud to quicken operations; software flexibility to let the machine send commands and get them instantly executed; and direct-drive joystick control. Additional controller features are a single fourwire bus that can link up to 16 stepper or servomotors; a 2-A motor drive; 20 to 40-V input, RS232, RS485, or USB based communications; on-board EEPROM for user program storage; and stand-alone operation.

The PCBRM100 is totally automatic.

The EZSV17 controller runs the carrier along X and Y axes using linearencoder feedback. It moves to a taught position where a downward-scanning digital camera with zoom lens presents images to the operator, superimposing the image of the solder stack over the board top. Then the operator can align the part using an X-Y joystick-based designworldonline.com

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control. Target rework position can be taught on the fly or stored in the program. After alignment, the board moves into the oven for focusedconvective heating to about 150° C. Then it returns to taught alignment and lowers to 15 mm above the flowing solder. Finally, an additional nozzle comes to 5 mm above the part. The part is heated to 217° C and lowered into the solder for removal.

Once inside the solder flow, either a vacuum comes on and the upper nozzle removes the loosened component or the operator manually takes the part out. Next, the board moves to 25 mm above the solder flow for solder removal with a scavenger nozzle. With a joystick control, an operator moves the nozzle over the board barrels to remove any leftover solder. (Or during automated execution, the machine can perform the removal.) Then the board returns to the unload position for removal.

The board can now accept a new component and the machine can help here, too (this time, to solder in the new component).

Machine accuracy is 0.001 in. The PCBRM100 is an open machine, so low speed isn’t a problem. A joystick gives operators an accurate and easy-to-use machine interface. The machine’s software is also user-friendly.

Originally, the engineer programming the machine had to perform most of the work needed for operation ... including setup of board and part thicknesses and locations and other data based on the particular board being serviced. But now, after initial setup for a particular component, parameters easily copy and paste in the software for similar parts or boards.

The 120-x-52-x-77-in. machine has a solder-pot capacity of 90 lb, the top and bottom preheater sizes are 28 x 28 in., with a clearance of 3 in. on the top and bottom.

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Customized encoders satisfy design objectives

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bsolute and incremental, rotary and linear, optical and magnetic, TTL compatible, multiturn, and application-specific integrated-circuit (ASIC) magnetic encoders: These are all encoder subtypes to suit specific design objectives.

Rotary encoders go into industrial applications that range from from speed monitoring on conveyor systems to position control on automated machine axes. When encoders provide position feedback, it’s common to specify encoder resolution exceeding what the application requires as a way to address partial count uncertainty shared by all digital measurement systems. Where EMI is an issue, optical encoders excel.

Especially in heavy industrial equipment and metal stamping, wind turbine, printing, and steel processing, it’s common to see machinery that necessitates high-speed

rotary encoders—those that can run and reliably track speed and position even to 40,000 rpm.

Scale is also relevant. Miniature applications (especially in medical designs) benefit from reflective encoders with built-in interpolation for high-resolution measurement on miniature motors (in many cases, closed-loop steppers) that drive axes on consumer products such as printers.

In contrast, some applications depend on rugged and rated encoders (with oversized bearings, specialty seals, metal and not glass or plastic read disks, and reinforced housings) to last. Industrial-rated encoders work in interior elevators, automated process machinery and robot joints.

In contrast, applications that expose encoders to liquid submersion, washdown, contaminants, shock and vibration or EMI noise necessitate still more rugged versions. These applications include designs for off-road equipment, A Renishaw encoder works on the Optical Communications Payload (OCP) of the European Space Agency Sentinel-1A satellite. Its reference marks let a laser-communication terminal track the absolute position of a coarse pointing assembly with minimal rotation.

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This Model TR1 TruTrac from Encoder Products Co. (EPC) is an integrated design with an encoder, measuring wheel and torsion arm. It provides linear-measurement feedback for New Tech Machinery’s mobile steel-roll form-and-cut machine.

cranes, wind turbines, food-and-beverage machinery and some medical devices. Usually, it’s either the failure of the encoder’s bearing (in the case of rotary setups) or contamination and signal loss that causes encoder failure.

For example, ingress of dust from wood processing or steam from food-application cleaning cycles can quickly render encoders useless if they breach the housing.

In applications where the design must track position along a linear axis, linear encoders are often the most suitable choice. These track location without intermediate mechanical components, even registering errors from rotary-to-linear linkages, so help controls correct for machine errors. One industry that makes copious use of linear encoders is the machine-tool industry ... especially for the manufacture of aerospace parts that necessitates precision milling and finishing.

Encoders at work in metal cutting

New Tech Machinery (NTM) makes a portable SSQ Multipro roof-panel machine for metal roofing contractors, installers and fabricators. Users can take the machine to jobsites and quickly cut metal roofing panels to any length. It works like this: A metal coil feeds into

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one end of the machine and gets one of 15 different profiles. Then the machine automatically cuts the metal to length. A rotary encoder tells the controller how much material has fed through, which activates the shear mechanism at the right time.

NTM needed an incremental encoder to provide accurate linear measurement and withstand the rigors of outdoor operation. The encoder had to be small and (to get feedback directly from the metal surface) sport a measuring wheel. After testing and evaluation, NTM picked a Model TR1 TruTrac from Encoder Products Co. (EPC) and bought it from a local distributor.

The compact TR1 encoder has an integrated measuring wheel and spring-loaded torsion arm. It operates in any orientation; it’s fully configurable with up to 10,000 CPR resolution; and it accommodates line speed to 3,000 ft per min. On the SSQ, constant spring tension keeps the measuring wheel in contact with the metal, and the pivot arm accommodates any panel movement. To date there have been no TR1 failures on any SSQs; NTM recently released a simplified (less costly) roofing machine and it also uses a Model TR1 TruTrac.

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Encoder solutions for a world in motion Advanced Opto-ASIC circuitry and intelligently designed, robust mechanical packaging combine to deliver reliable, high-performance rotary motion feedback. Made in the USA, and backed by an industry-best three year warranty, fast delivery and global support, Encoder Products Company rotary encoders work when it counts – which is all the time.

1-800-366-5412 www.encoder.com

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An ElectroPuls component-fatigue test machine from Instron uses a linear synchronous motor, so needs good velocity feedback (due to the challenge of driving linear motors with lower inherent damping than traditional rotary designs). LVDT technology was insufficient.

So instead, the machine uses Renishaw’s RESOLUTE encoder with linear resolution of 1 nm and speeds exceeding 20 m/sec.

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ENCODERS

Encoders at work in space

Now, Renishaw encoder technology works on the optical-communications payload of the European Space Agency Sentinel1A satellite to support inter-satellite laser communications.

The optical-communications payload allows communication between lowEarth-orbit and geostationary-Earth orbit craft through twin laser-communication terminals (LCTs)—essentially telescopes with coherent receiver and transmitter hardware from space-telecommunications company Tesat-Spacecom. The rotary encoders help track the position of the LCTs’ coarse pointing assemblies.They go on both of the assemblies’ rotary axes (and will integrate into LCTs of future space platforms, including Sentinels and European Data Relay Satellites EDRS-A and EDRS-C. Space is a harsh environment, but aerospace components must be reliable, because repair in orbit is economically unfeasible. That complicates selection of qualified technology—so the LCT’s core encoder technology borrowed from Renishaw’s TONiC encoder range but development went through collaboration with Tesat.

The resulting encoder withstands bombardment by solar and cosmic radiation as well as high mechanical loads during rocket launch. Radiation hardening and robust optical detection let the encoder qualify for 15 years of service in a geostationary Earth orbit.

Inside, the encoder has a stainlesssteel ring with ablated graduations on the periphery and a custom readhead.

INTRAC reference marks on the incremental channel are arranged so the distance between any two marks is unique. That means even small rotations let the encoder get absolute position.

There’s also no contact between the rotary ring and static readhead, which eliminates friction ... in turn preventing hysteresis error, wear and need for lubrication. The system gets resolution better than 0.5 µrad, with a short-range error of less than 0.5 µrad and longrange error of less than 5 µrad.

Left: Duff Norton uses Encoder Products Co. (EPC) encoders on heavy railcar jacks to track the position of gearmotor-driven screw jacks that let a controller perfectly synchronize multiple jacks and lift 80-ton railcars without tilting.

Right: EPC customized a Model 15T through-bore encoder for In-Line Labeling Equipment’s Paradigm machine—in this case, on an axis to orient bottles before label application.

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Gears in motion: Choosing the right gear for the right application

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otion applications for gearing are as varied as the motors with which these power-transmission devices pair. Just consider how designs ranging from amusement rides to consumer-grade beard trimmers make use of spur gears. These mostly roll through meshing, so can be 98% or more efficient per reduction, though with tooth sliding. They can be noisy, too, because of initial tooth-to-tooth contact along the whole tooth width, causing audible shock loads.

In contrast, helical reducers excel in applications that need higher horsepower and efficiency, even if they’re more costly initially. Conveyor drives, textile-manufacturing machinery, rolling mills and elevators are some examples.

That’s because helical gear teeth engage gradually over their tooth faces for smooth operation and higher load capacity. Here, the machine setup must include a frame to resolve thrust loads that originate from the gears.

Non-parallel and right-angle gearsets often go into designs for material handling, aerospace and defense, packaging equipment and food-processing machinery.

Industrial robots from KUKA use a new KL 100 linear robot-transfer unit (RTU). This track helps to boost speed and manufacturing quality, even in tight spaces. Engineers used Graessner USA’s Gearfox software to develop and optimize its drivetrain.

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GEARS • SPEED REDUCERS, GEARBOXES & SERVO GEARING

According to engineers at MICROMO (FAULHABER Group), in robot-guided surgery, even a millimeter of error can drastically affect patient outcome. In some cases, using zerobacklash actuators with encoder-equipped gearheads at the robot end effectors lets surgeons position their equipment with absolute accuracy.

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This is a Sawyer Hero collaborative robot.

Harmonic Drive component sets go in all of Sawyer’s rotary joints.

Tile and carpet-cleaning machines from Rotovac are self-propelled with high-torque dc motors that move scrubbers to 200 rpm.

The original had motor-armature shaft failures. So in a redesign, Groschopp changed the armature shaft’s steel and specified heat-treating. Groschopp also improved the gearbox and gave it a hardened shaft and synthetic oil. Better controls now feed cleaner dc power to the motor to boost efficiency and prevent overheating as well. The revised cleaner delivers more torque and performance.

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Input and output shafts protrude in different directions; gear teeth are worm, hypoid, bevel (straight, spiral or zerol), skew or crossed-axis helical.

Common bevel gearsets go into an array of materialhandling and packaging equipment. Hypoid gears (useful for hightoque applications) are like spiral-bevel gearsets, but output and input shaft axes don’t intersect, which simplifies the integration of supports.

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

Gear reducers or speed reducers work with an array of motors.

These are gears or sets that alter the torque of a motor—usually as an increase proportional to rpm reduction.

Especially common in material-handling setups, shaft-mounted gear reducers come in truly shaft-mounted 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.

According to the American Gear Manufacturers Association (AGMA), the term speed reducer applies to those with pitch-line velocities not exceeding 5,000 fpm or pinion speeds not exceeding 3,600 rpm.

Consider worm-gear reducers. These typically go into low- to moderate-horsepower applications (largely because they have high ratios and high output torque, but are compact and cost effective). Most worm gears are cylindrical with teeth of consistent size; some wormbased reducers have double-enveloping tooth geometry (in which pitch diameter goes from deep to short and back) to boost teeth 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 resist shock and withstand extreme acceleration. The low inertia of this gearing also lets presses start and stop more quickly than those with multi-stage gearing.

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GEARS • SPEED REDUCERS, GEARBOXES & SERVO GEARING

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 harmonic gearheads, all exceling in select applications.

The latter (also called strain-wave gearing) is for special speed-reduction applications. More specifically, this gearing is indispensible in robotarm articulation, medical equipment and offshore drilling. (Strain-wave gearing sets are called Harmonic Drives, a registered trademark term of Harmonic Drive Systems.) Strain-wave gearing helps designs with zero backlash and high-torque operation from a small package.

Much machinery integrates servogears 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 are particularly common 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 the planet gears.

In fact, planetary gearsets offer applications several advantages over other gearsets—multiple kinematic combinations, power density, big reductions from volume compact setup and pure torsional reactions. Planetary gearboxes also boost overall design efficiency. Losses never exceed 3% per stage, so transmit most energy for productive motion output. Planetary gearboxes distribute load efficiently as well.

In applications driven by servo systems, gearboxes also reduce settling time (which is a problem when load inertia is high compared to motor inertia).

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The ReWalk portable support is a battery-powered frame to help paraplegics move. It has motion sensors, a central controller, and integrated drive motors at the joints. The design uses MS Graessner precision bevel gears.

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GEARS • SPEED REDUCERS, GEARBOXES & SERVO GEARING

This KHK USA ratcheting set shows how some rack-and-pinion gearing works in miniature designs.

Gear-selection tool helps robot-maker KUKA

Consider one specific application.

Now, KUKA’s KR AGILUS industrial robot uses a new KL 100 linear robottransfer unit (RTU). This track helps to boost speed and manufacturing quality, even in tight spaces. Core to the development and optimization of the drivetrain was Graessner USA’s Gearfox software.

In short, KUKA needed an efficient, extremely compact gearbox for its KUKA KL 100 RTU. So, company engineers used Gearfox to incorporate relevant operating conditions. The software even helped the engineers simulate the gearbox thermal balance. Engineers also used

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the software to identify and analyze the next smaller and next bigger gearbox variants possibly viable for the application. In the end, they picked a DynaGear set.

The internet-based software gave KUKA engineers assurance that the DynaGear gearbox would fulfill all design requirements (dynamics, durability and thermal stability) before physical testing.

No matter the application, MS-Graessner Gearfox software helps designers consider each design task as a challenge with multiple viable solutions. These include variations with different drive elements, including gearboxes. First, the software profiles the application

needs, including definition of product requirements and variations in the application itself. Then it analyzes different gear-design permutations and culminates with iterative gearbox optimization. Factors that Gearfox uses in calculations and permutation simulations include application speeds and torques, bearing durability, gearing forces and efficiencies, moments of inertia, axial and radial forces, square, cubic, quartic and quintic motion cycles, and the profiles of an array of servomotors.

The software also uses profiles of seven predefined application types and five predefined gear types in its calculations.

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Gearing up for the medical market

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earmotors are most common in applications that need a lot of force to move heavy objects. Most industrial gearmotors incorporate fixed-speed ac motors. However, some gearmotors use dc motors, which are common in automotive applications in adjustable side-view mirrors and automatic seat adjustments.

Though it’s possible to combine many different motors and gearsets, not just any one will work for every application because certain combinations are more efficient and cost-effective than others. This is why knowing the application and getting an accurate estimation of its required torque and operating speeds is the foundation for successfully integrating a gearmotor into a system.

Typically, gearmotors outperform other motorgear combinations. More importantly, gearmotors simplify design implementation because they save engineers from integrating motors with gears, which in turn reduces engineering costs. If the application requirements are known, engineers can order the right gearmotor from a supplier directly.

What’s more, if a gearmotor is sized properly, having the right combination of motor and gearing can prolong design life and boost overall design

This dual output planetary gearmotor was custombuilt by Groschopp for an application involving a surgical table with two hinged arms that needed synchronized alignment and movement.

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efficiency. Gearmotors can also eliminate the need for couplings and potential alignment problems that come with those components. Such problems are common when a design includes the connection of a separate motor and gear reducer—which in turn increases the potential for misalignment and bearing failure.

As applications for gearmotors expand, manufacturers are seeing a change in expectations

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from end users. For instance, end users have an increased expectation for more integrated designs. Meanwhile, other companies are reporting that the design requests they’re receiving are becoming more complex, requiring more customization and creative thinking.

Dual output gearmotor delivers quiet, synchronized motion

One such challenging application comes from the medical industry. Specifically, tables for surgical procedures that have extremely accurate positioning demands.

Highly specialized surgical procedures, such as those focusing on spinal, joint replacement and orthopedic trauma, require automated operating room tables that can be positioned with extreme accuracy. This is best achieved using a compact gearmotor with a high torque output— intermittent duty loads up to 500 lb—and quiet operation.

Recently, Groschopp partnered with one of the world’s leading designers and manufacturers of medical products to build the best solution for their surgical tables.

This particular table had two hinged arms that needed to be driven simultaneously so the alignment and movement would be synchronized. Rather than following the traditional method of link chains, belts and pulleys, which have greater margins of operation error, Groschopp thought that a single motor with two outputs would provide greater accuracy and be more cost effective. Due to the intermittent operation, Groschopp’s design engineers were able to meet the 24-V power supply specification. The high efficiency of the planetary reducers made it possible to achieve the needed torque while staying below the 20 A current limit. Because the same motor drives both outputs, there is both mechanical and electrical linkage, allowing for a more common control scheme.

Once the dual planetary dc gearmotor was approved, Groschopp’s team went into extensive prototyping and testing to reduce noise through various techniques and product customizations. The motor, gearbox and gearmotor assembly each contributed to the gearmotor’s noise. By analyzing and addressing each component individually, they were able to minimize the overall noise. Also, using a special speed reducer component configuration and alignment further minimized noise. designworldonline.com

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Grippers: Where they work

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n robotics and material handling, end effectors are tools or devices connected to the end of a robot arm. End effectors can include cutting tools and drills, welding tools, brushes, screwdrivers, vacuum cups and grippers.

Grippers are devices often used in robotic systems to pick up or place an object on an assembly line, conveyor system or other automated system.

Fingered tooling or jaws are attached to grippers to grip or hold the object.

Grippers come in a variety of styles and powered designs. Three common types are parallel, threefinger and angled designs. The most common are parallel designs with two fingers that close on a workpiece to grip it or open it out by creating pressure on the inside. Three-finger designs hold the workpiece in the center, and have three fingers offset by 120°. Finally, angled designs feature jaws that work at a variety of different angle openings.

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Ultimately, it’s the size, force and shape of the parts in an application that the machine must grip that dictate the most suitable gripper style. In today’s industrial applications, gripper designs are increasingly diverse. Other grippers that don’t fall into neat categories include single-jaw grippers, bladder grippers that inflate against part ODs and IDs, and magnetic grippers.

Typically, three choices of power are available, the most common being pneumatic power and the least common being hydraulic designs. Traditional pneumatic grippers still dominate industrial-assembly and robotic applications. That’s because pneumatic grippers are reliable, come in myriad sizes and grip quickly.

Shown here are PB swing-arm and PEC arm over-clamps from PHD, Inc. working to hold ATV frame components together in a roboticwelding application.

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 GRIPPERS

Electromechanical designs are another common option. These grippers use ballscrews, belts or racks and pinions to connect to the jaw or finger that is touching or gripping the part. They are driven by a motor for tasks like loading and unloading machines to assembly lines. They can grip small parts, like an IC chip, up to large pieces, such as a railroad wheel assembly greater than 3,000 lb. They are also ideal when tight precision is needed or when lifting larger, heavier items.

Normally, electromechanical grippers are made of aluminum and steel components, but some designs can be manufactured from composites like carbon fiber and other plastics.

Traditionally, one of the biggest drivers of industrial gripper innovation has been the automotive industry. Auto companies use grippers in various stages of the manufacturing process to manipulate parts and panels for everything from painting to final assembly.

Besides the automotive industry, another industry spurring changes in robotic gripper design is electronics, especially consumer applications. That’s because manufacturers must adapt quickly, with product lifecycles shorter than ever. For non-industrial applications, a growing area of specialized devices are prosthetic grippers.

These grippers are by far the most sophisticated, with designs aiming to replicate the movement and functionality of a human hand.

Here, a sensor-feedback flange from KEBA Corp. (called the Active Contact Flange) helps a robot arm buff an auto body with enough precision to ready the surface for a smooth coat of paint. Such end-effector fixtures are increasingly common on six-axis robot arms.

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HMI hardware and PLCs together in motion

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MI (human-machine interface) technology has seen significant changes in recent years, with increasingly affordable multi-touch screens, a shift from resistive displays to projectedcapacitive displays, and displacement of proprietary design platforms by web-based HTML5 platforms.

The spread of capacitive displays has expanded HMI use in industries needing bezel-free designs. This is because they help machinery meet cleanliness and sterility requirements, such as those in food and beverage processing and medical equipment, for instance. What’s more, HMIs with capacitive displays have multi-touch capabilities that make industrial displays feel more like personal mobile devices, helping machine builders leverage the familiarity many users already have with such interfaces.

The consumer mobile-device market is improving HMIs for industrial applications.

With smartphones and tablets having wireless communications capabilities, large and bright displays and portable processing power, these devices themselves can function as HMIs. Another reality of modern manufacturing is the need to swiftly upgrade machines or changeover from one manufacturing operation to another. Modular hardware The Unitronics Vision350 PLC + HMI mounts on a Vapor Systems Technologies nozzle tester.

meets this challenge by letting users make on-the-fly changes to machine operations to keep up with varied production requirements.

Other high-tech industries, such as pharmaceutical and medical, often incorporate the latest HMI designs to differentiate them in the marketplace. These OEMs push for more complex features like multi-touch panels.

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PLC/HMI combo helps streamline machine testing When flammable gasoline is in play, no container failures are acceptable.

Now, one manufacturer tests its gas-pump hoses with equipment sporting advanced PLCs. Vapor Systems Technologies makes breakaways, whip hoses, gas nozzles and other gas-dispenser hardware. The manufacturer wanted to test its nozzles to 1,000,000 cycles, the equivalent of about 17 years of normal operating service. But the testing equipment Vapor Systems was using couldn’t test for that long and could only test one nozzle at a time.

“It was extremely slow, and very un-reliable,” said Patrick Elam of Vapor Systems. “We would only run it during business hours for fear of breaking down. The old tester was also big, bulky and difficult to move. I wanted a new tester to be smaller and more compact, so if the sales department wanted to take it with them to a petroleum show, they could.”

The compact all-in-one design of the Vision350 allowed Vapor System Technologies to reduce the size of their tester; the controller, HMI and I/O are all incorporated into the new portable design.

The old tester also used 120 Vac to operate. “It would burn up relays, sensors and blow fuses regularly. We were always afraid to let it run past business hours because if it failed under load, it could burn up a pump.”

The test setup Vapor Systems uses now has a Unitronics V350-35-TR20 PLC, which runs on 24 Vdc, and is reliable and safe. The palm-size PLC simplified the testing design by consolidating several functions. Its 3.5-in. color-TFT touchscreen clearly displays images and fonts; its onboard and expansion modules support 512 I/Os. Users can set up and label two keys on the PLC to suit the application. The all-inone design of the Vision350 let Vapor System Technologies reduce the tester size by incorporating the controller, HMI and I/O. Once programing was complete, the Vapor Systems team ran the new tester for more than two months straight with zero failures and zero damage to any of the electronic components. The 1-MB Ladder code application memory (plus 3 MB for images and 512 K for fonts) designworldonline.com

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HUMAN MACHINE INTERFACE (HMI) HARDWARE

Running on 24-Vdc power, the Vision350 safely operates 24 hours a day without blowing a fuse.

The new tester has space to test multiple nozzles at one. Vapor Systems’ previous setup only accommodated one nozzle at a time.

helped the Vision350 run these complex control and automation tasks. Within three months Vapor Systems hit its 1,000,000-cycle mark.

“The amount of money we saved from R&D time and not having to replace burned up components regularly justified the cost of the V350-35-TR20,” Elam said. Plus by reaching our 1,000,000 cycle target, we exceeded our qualification test and put the finished product out in the market faster.”

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Using a Unitronics PLC + HMI in their test setup lets Vapor System Technologies run tests without stoppages or delays.

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12.1” HMI5121XL

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HMI software simplifies motion applications

EHT’s MultiCut series of power squaring shears, featuring an ECS touch screen controller, is designed for one-off and series production of parts of all sizes.

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uman machine interface (HMI) software gives machine operators a way to interact with and manage a system. This interaction is through a graphical user interface (GUI), which facilitates information exchange and communication between two types of HMIs: a supervisory level and a machine level.

Generally, HMI software is designed for either machine level or supervisory level, with applications suitable for both types. These software applications are expensive at the outset, but can lower long-term costs and reduce redundancies in the long run.

Choosing the right HMI software for an application starts with an analysis of product specifications and features.

The key considerations can include the system architecture, performance requirements, integration and cost of procurement and operations.

The HMI system typically presents the information to the operator through some sort of GUI. More advanced HMI

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systems allow operators to view diagrams, digital photos and detailed system schematics. For motion control applications, the visual GUI can range from simple text displays to color monitors with touchscreen controls. HMI display screens come in standard, advanced, compact and high-performance versions. The latter can be customized based on the operator’s requirements. The standard version is normally used on low-cost systems that are not task-intensive.

More sophisticated HMI software is structured around mobile, portable platforms such as the Microsoft Windows CE platform, a scalable version of the Windows operating system for handheld devices. This presents a cost-saving value as the operating systems are distributed on machinelevel embedded HMI, solid-state open HMI machines, distributed HMI servers and portable HMI devices. Also, some applications, such as pharmaceutical and medical machinery, use the latest HMI features to differentiate themselves from competitive offerings.

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HUMAN MACHINE INTERFACE (HMI) SOFTWARE

Red Lion’s industrial Graphite HMIs feature a resistive analog touchscreen display that can be operated with gloves in harsh manufacturing environments. Thanks to accommodating hardware and software, the HMIs also seamlessly connect, monitor and control multi-vendor processes with more than 300 industrial protocols.

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HMI software improves sharing machine design

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EHT, a manufacturer of sheet-metal forming and cutting technology, recently transitioned from a disjointed patchwork system with a conventional controller to a fully integrated controller solution from B&R Automation.

EHT was also able to step up the shears’ performance while simultaneously reducing the cost of producing both standard and specialty machines.

EHT developed the software for the new ECS-Touch controller used in its VarioCut and MultiCut series of power squaring shears entirely in Automation Studio. The openness of the engineering environment is essential for the company, giving it unlimited access to make software adjustments on their own at any time. The full integration and centralized data management have allowed EHT to reduce development and commissioning times and minimize customer downtime.

“Since switching to B&R, we need considerably

“It’s just as easy to get our machines back up and running after a component failure,” added Alexander Eirich, who developed the new EHT controller. “Replace the defective part, insert the CF card and set the POWERLINK address—then switch it on and you’re done.”

Yet the time saved during commissioning and maintenance doesn’t fully explain EHT’s substantial reduction in costs compared to its previous control solution. The greatly simplified architecture played an important role as well, as Eirich explained: “Since we’re able to control our hydraulic proportional valves with an X20 motor module that we were already using for I/O, we’ve been able to do away with the separate upstream modules.” The X20 module allows for more precise ramp settings, and in turn more dynamic hydraulic movements, so EHT was able to increase the cut count as well. The motor module also functions as a counter card for the shear’s motorized back-gauge.

less time to commission our systems,” said EHT’s sales manager, Holger Ebin. “What used to take us three days is now done in two hours.”

With the control and HMI software as well as all motion control parameters stored on a CompactFlash card, inserting the card in the slot on the controller starts up the machine. The B&R system then automatically copies the software to the respective automation components and configures them. All that’s left to do is home the machine, and it’s ready to go.

The simplification was even more pronounced with the VarioCut series. Like the MultiCut series, these highprecision swing beam shears are available in a range of varieties with a host of options. What sets them apart is that EHT customizes them to user specifications and optionally integrates them into the production line. Due to the rigidly limited functionality of the old standard controller, the additional tasks that arose through customization and integration had to be handled by a second, higher-level controller.

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HUMAN MACHINE INTERFACE (HMI) SOFTWARE

With B&R’s Power Panel 520, a single controller handles the automation of the entire line. With its 10.4-in. screen, the controller has plenty of resources left over to serve as an HMI operator panel.

All of the machine’s software, including the HMI application, was created using Automation Studio. The open environment lets EHT maintain, adapt and expand the software without any outside assistance. B&R delivered the basic framework, shortening the development phase and freeing up EHT’s programmers to implement new functions. The libraries provided in Automation Studio inspired Eirich to integrate a function that allows machine operators to generate analytical data and save it on a flash drive. “We’re then able to use this data—which they can send us directly by FTP—to provide them with an updated software image that preserves all of the operator’s settings,” explained Eirich. “Machine updates are completed in no time and with minimal impact on production.”

The new control solution also minimizes downtime in the event of an error. “Before we switched to B&R technology, the task of troubleshooting alone was problematic,” said Ebin. “Now we have a complete and homogeneous automation solution that also allows remote VNC access—so we can quickly identify and correct errors without ever setting foot on site.”

In a hotly contested market like sheet metal cutting, where profit margins are extremely thin, this is a significant cost advantage.

EHT’s new ECS-Touch controller is based on a Power Panel 520 from B&R. In addition to controlling all of the machine’s processes, it also serves as an HMI platform and operator interface.

EHT’s MultiCut series of power squaring shears has an extensive selection of sophisticated options that make it especially efficient and ergonomic to use.

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Applications for leadscrews expand into new markets

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hen it comes to translating rotary motion to linear motion, one of the most common methods is to use a leadscrew. A leadscrew, also known as a power screw, is a threaded rod or bar that translates rotational motion into linear motion. Leadscrews generate sliding rather than rolling friction between a nut and the screw. Consequently, higher friction means a lower overall efficiency. And efficiency, when talking about leadscrews, is simply the ability to convert torque to thrust while minimizing mechanical losses.

Leadscrews are common in many motion designs, driving axes on machines big and small. They usually sport higher ratings than comparable ballscrews thanks to more contact between the nut and screw load surfaces. Recently, innovations in materials and helix geometry address old issues associated with leadscrew friction, bringing it down to better than 0.10 in some cases; making them a good fit for fast and dynamic applications. In fact, there’s also been an uptick in leadscrew use in machines for 3D printing, manufacturing and medical applications.

Industries across the board are adopting new leadscrew components and linear systems. Designers of kiosk and automated retail applications, for instance, are looking for ways to simplify machines, reduce design weight and simplify assembly and maintenance. In a similar way, both additive manufacturing (3D printing) and traditional subtractive processes (plasma cutter, laser and waterjet manufacturing) are driving new leadscrew uses. The same holds true for factory automation.

SIMO Series linear actuators from PBC Linear use leadscrews with Constant Force Technology, which applies a uniform pressure to the nut at all stages of a motion profile and throughout its life. The nuts are self-lubricating, maintenance free and, for most applications, do not require any external lubrication.

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Choosing the right leadscrew for a linear motion application involves several considerations including screw pitch and lead, thrust, speed, accuracy and repeatability.

The two most important factors in determining the performance of a leadscrew are the screw pitch and lead.

The pitch is the linear distance between the threads, while the lead is the linear distance the nut travels. Speed is another critical parameter. Leadscrews have a critical velocity, which is the rotational velocity limit of the screw.

Reaching this limit induces vibrations in the leadscrew.

Accuracy and repeatability are also important factors to consider. The accuracy of a leadscrew is a measure of how close to a desired end point the assembly can move a load to within a given tolerance. The accuracy of the leadscrew will mostly determine the system’s accuracy. On the other hand, repeatability is a measure of how well a leadscrew assembly can repeatedly move a load to the same position.

When it comes to the kinds of leadscrews engineers are specifying in their designs, there are more integrated or pre-engineered systems being used. Choosing these types of systems can reduce engineering costs as well as design time.

Miniature or micro leadscrews and nuts are also seeing an uptick in demand, especially in medical applications. For instance, a line of micro leadscrews with diameters of 2 mm from Haydon Kerk Motion Solutions features customized leadscrew nut materials for specialized medical applications.

Specifically, the company has years of experience working with medical device manufacturers developing insulin and drug delivery pumps. Now, companies can use Haydon Kerk’s custom thread rolling, in-house plastic injection molding and tooling departments to develop customized solutions to meet the challenges involved with engineering the next generation of insulin patch pumps and other personal drug delivery systems.

Using Kerkite engineered polymers or customer specified materials (including PEEK), Haydon Kerk can help design and manufacture a leadscrew nut that delivers smooth, efficient rotary to linear motion conversion. Using Kerkote TFE coating can effectively reduce the amount of torque required to actuate the plunger. This can lead to longer battery life and a possible reduction in motor size.

designworldonline.com

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Let’s solve this.

Together.

Having a linear automation issue? Not sure what product to select for your application? You’re not alone.

Just pick up the phone and we’ll connect you with some of the most seasoned application engineers in the industry.

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Linear guide rail and slide applications on target

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inear guide systems can include guide rails, slides and ways. They can also be categorized into a few basic types including profile rails, drawer slides, linear bearings, guide wheels and plain bearings. A typical arrangement includes a rail or shaft, and carriages and runner blocks. They can also be distinguished by the method of contact, either sliding or rolling.

A major function of rolling guides is to reduce friction in machines.

They’re used in various applications ranging from advanced semiconductor manufacturing devices to large machine tools and construction equipment.

Semiconductor manufacturing equipment or inspection apparatus that requires high precision positioning is a good application for linear guides. In the case of a machine tool for cutting, linear guides are used instead of slidingcontact linear-motion bearings to cope with temperature rise and durability issues associated with ever-increasing feed speeds.

The classic application for profile rails is in the machine tool industry where load capacity, stiffness and accuracy are paramount. In medical equipment such as CAT scan, MRI and x-ray machines, square rails are more common.

On the other hand, round rails can offer several advantages, one of which is the ability to run smoothly when mounted to less than perfect

surfaces—defined as having a flatness error of over 150 μm/m.

For cleanroom and food processing applications, where low contamination is a necessary requirement, linear guide systems that are rolling-element based are generally not a good choice because of the lubrication requirements.

Likewise with plain bearing systems.

For applications demanding extremely high precision and accuracy, so-called fluid-floated bearing systems offer the highest levels of accuracy and precision.

Usually these are hydrostatic or aerostatic bearings, meaning that a high-pressure fluid serves as the bearing between the rail and carriage. Generally more expensive and harder to manufacture, they nonetheless provide some of the highest levels of precision and accuracy.

The switching station for the rail system at NASA’s indoor radar range is shown here.

Targets atop track sections are moved on and off the turntable, which aligns track sections with the 110-ft-long track that brings them into the radar range.

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When Precision Linear Motion is required, Medical Equipment Designers Choose

Del-Tron!

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Del-Tron’s new product line of Non-Magnetic ball slides provides the ideal solution for applications where magnetic interference cannot be tolerated. These lightweight Non-Magnetic ball slides are the perfect solution for medical, semiconductor, military and laser applications, just to name a few. Manufactured in the USA, these Ball Slides are constructed using silicon nitride ceramic ball bearings, titanium shafts, aluminum carriages, bases, and end caps, along with brass fasteners, making them the perfect solution for your Non-Magnetic linear motion slide requirement.

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• Factory preload minimizes side play and provides low friction.

• Self-cleaning ball bearing design offers long life and requires no lubrication.

• Metric ball slides are also available.

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LINEAR GUIDES, RAILS, SLIDES & WAYS

NB TOPBALL slide units include a clear anodized, corrosion-resistant aluminum block and a TOPBALL self-aligning slide bushing. The closed and adjustable clearance styles incorporate machined snap ring grooves with standard retaining rings for slide bush retention.

Important considerations for choosing a linear-motion rolling guide include the loading (both static as well as applied), the stroke and speed, as well as the desired precision and accuracy and the required life. Pre-loading may also be required depending on the application requirements. Lubrication is another important consideration, as is any method to minimize contamination of the linear guide system from environmental factors such as dust and other contaminants using bellows or special seals.

Linear rails help guide targets at NASA radar range

Recently, NASA wanted to refurbish and upgrade an old indoor radar range by clearing it out and replacing it with newer, better-designed equipment. When ADC USA received the request for a quote from NASA, the requirement was to design, build and install the major components for a 40 x 40 x 40 ft indoor radar range.

What NASA wanted was “to put multiple targets inside the radar range without having to get a forklift to bring them in and out,” said Eric Van Every, director of operations for ADC USA. “Not only things such as an airplane but really anything that is detected by radar.”

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The indoor range measures RCS, or radar cross section, and antenna measurement range. RCS is a strong function of the orientation of the radar and target. So orienting the target— positioning it accurately within the radar range—is crucial to the whole measurement process. ADC’s most critical requirement was to build a transportation system into and out of the radar range that provided absolutely accurate positioning.

To bring targets in and out of the radar range, they proposed building railroad tracks approximately 110 ft long that would be all metal welded. Two rails would be positioned about 4 ft apart and would traverse the distance to and through the indoor radar range.

Because NASA wanted to put multiple targets inside the radar range without having to get a forklift to bring them in and out, ADC developed the design of a switching station outside the perimeter of the range.

The switching station would actually be a turntable similar to switching stations for railroad trains. Targets atop track sections could be moved on and off the turntable, which would then turn to align that track section with the 110-ft-long track that would bring them into the radar range.

The Experimental Test Range rail system begins in the model prep area of the facility and ends 10 ft past the center of the test chamber. The total length of the rail system is 112 ft with laser position encoding for the final section of the rail system. Linear guide rails are used to support the carriages and each carriage is positioned with a rack and pinion drive. Rails mount to steel weldments that are supported with 8-in. diameter feet, and the capacity of the rail system is 7,300 lb.

The design includes a place to dock positioning components when they are not in use. Curved linear guide rails support the switching station so that the platform can be rotated manually. Hardened tapered pins align the switching

designworldonline.com

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CUSTOM ENGINEERED SPINDLES & SLIDES DESIGNED & MANUFACTURED TO YOUR SPECIFICATIONS

www.setco.com/design Let Us Help You

1-800-543-0470

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LINEAR GUIDES, RAILS, SLIDES & WAYS

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the railroad tracks the target is, we station with mating rail segments. use a WayCon, LLD-150-Profibus NB Corporation of America laser encoder. It’s accurate to 0.05 machined the custom rails. They in., which is approximately 1.27 are case hardened steel shafts that mm. That’s the accuracy over the have tapered ends to improve approximately 110 ft.” transfer across the switching The slide units are the NB station platform; the rail diameter TOPBALL series, which include a is 2 in. The rails are supported clear anodized, corrosion-resistant

by NB shaft supports, which are aluminum block and a TOPBALL precision-machined aluminum self-aligning slide bushing. Closed extrusions available with or without pre-drilled mounting holes. and adjustable clearance styles incorporate machined snap ring Spacing between sections is equal grooves in combination with standard to the pitch of the rack so that retaining rings for slide bush retention. transfer is completely motorized.

ADC was particularly concerned Their open style incorporates bottom plates and mounting screws to retain about the positioning accuracy bushings in the proper position. requirements. They tested several Van Every added that the most vendors’ linear guides and blocks challenging part of the project that would carry the target was the engineering, especially platforms. Van Every said, “Speed ”mechanically engineering it to was not as important as accuracy. handle the load and meet the NASA We have more than 4,000 lb that’s requirements. In particular, the one going to be moved on these rails. It thing that had never been built this had to have laser encoded tracking way is that switching station. That accuracy. To find out where down

was unexpected. But, when I got into it, even talking to NB and talking to other vendors, no one has done something like that before—not with this capacity and this accuracy. So, that was all new ground.”

ADC will also be assembling the radar range for NASA. They’ll travel with it from their facility in Lansing, New York, down to NASA Langley Research Center in Hampden, Virginia.

Special thanks to Larry Hansen at NB Corp. of America

This is a Cartesian robot built of linear slides and actuators from PHD, Inc. More specifically, it uses Series ESFX electric linear-actuator slides for high speed and load carrying in a saddle geometry. Particularly common in the packaging industry, such setups are increasingly modular.

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Mechatronics Enabled

™

Bring mechanical design & electronic motion control together with an optimized solution from PBC Linear®.

PBC Linear’s full range of linear slides and actuators are easily integrated for a complete mechatronics solution.

See all Mechatronics Enabled motion systems at www.pbclinear.com.

Solutions are just a click away!

1-800-962-8979 • www.pbclinear.com • 6402 Rockton Road, Roscoe, IL 61073 USA

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AC motors aid in bottling production

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lectric motors can be either dc or ac. Ac motors, especially induction motors, are common in many industrial applications, heating and ventilation systems, and refrigeration, as well as many household appliances. Their speed can be varied and controlled fairly easily and they are more reliable and require less maintenance compared with brush dc motors.

There are some basic guidelines for selecting the right ac motor for an application. Important parameters include knowing the operating speed, load torque and inertia of the system based on the motion requirements. There are many online calculators that can help determine the right motor based on these specific application parameters. Other important factors to consider may include the available input voltage, required functions, features and user preferences.

Aside from well-established industrial applications, medical equipment is driving new demand for ac motors that are smaller, lighter, more powerful and efficient and generate less noise.

Regardless of application, however, designs incorporating ac motors are seeking smaller footprints to continue to decrease sizes of machines and systems as well as better efficiencies that can improve manufacturing production rates.

Together with improved drives and motion controllers, complete integrated systems with drives, controllers, motors and HMIs can simplify designs and improve production throughput on manufacturing or packaging lines as well as simplify overall operation.

Case in point; Nicolas Feuillatte, a globally recognized Champagne producer, improved its bottling line by going with an upgraded system from Emerson.

A Unidrive M700 drive is paired with a geared servomotor with reduced backlash. The combination uses real-time Ethernet and an integrated PLC to control movement sequences.

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MOTORS • AC

The bottling line at Champagne producer Nicolas Feuillatte can run at a rate of 4,000 to 6,000 bottles per hour.

The Centre Vinicole - Champagne Nicolas Feuillatte (CV-CNF) is the leading Champagne producers’ union. It comprises 80 cooperatives and represents over 5,000 wine-growers. Its facility in Chouilly, in the Marne region, is one of the most automated plants of its type, with a workforce of 235 people, half of whom are involved in production. The company output reaches 23 million bottles a year, making it one of the world’s leading Champagne producers.

Frédéric Lopez, automation manager CV-CNF, said: “We needed to replace a series of drive systems in a gradual process … we also wanted to establish a partnership with a company able to deliver the level of service we needed. This is why we selected Emerson.”

The first step was to replace one conveyor drive system. It sits at the start of the line to position the empty bottles accurately before cleaning and filling. The bottles are loaded onto the conveyor from 1,200 x 1,200 pallets, and then lifted in rows of 4 to 12 (depending on their size) onto a perpendicular conveyor.

“This line runs at a rate of 4,000 to 6,000 bottles an hour and has to offer maximum availability in operation.

Emerson designed the most appropriate solution for us as well as to program the variable-speed drives,” said Lopez.

The existing drive system consisted of an automatic controller, an alignment controller, a variable speed drive and a motor. The solution from Emerson removes the need for the alignment controller, reducing the 92

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overall complexity of the system. It consists of a Control Techniques Unidrive M700 variable speed drive, connected to the automatic controller and combined with a Leroy-Somer DYNABLOC Pjn1102 low-backlash servogear. This offers high overload tolerance, high torsion strength and great accuracy. Emerson’s MCi200 machine control option module has been added to Unidrive M to manage positioning. The Unidrive M700 drive is especially suited to this type of application, with a cycle time of 250 µsec, synchronised communications through real-time Ethernet, and an integrated PLC for controlling movement sequences.

The entire application is simple to program using Engineering Control Studio. The system uses Unidrive M’s embedded Advanced Motion Controller. In the final configuration, 15 different configurations have been defined to suit the various bottle shapes. Each cycle has a coarse pitch with a specific movement profile (position, speed, acceleration and deceleration), a fine pitch with a second movement profile (position, speed, acceleration and deceleration) and the number of short pitches to be carried out.

The required configuration is selected using logic inputs, which automatically starts the chosen cycle. The coarse pitch is performed, then the fine pitches are chained together while the path is free. Signals for “end of long movement” and “cycle completed” are sent by the drive’s logic outputs to the client’s system. designworldonline.com

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c motors are the oldest style of motor and among the most common still in use today.

The two major types of dc motors are brush and brushless. Even with the known drawback of brush motors exhibiting wear at their brush-and-commutator interface, they are still widely used because of their high peak torques and the fact that they can be controlled by simple speed controllers. Plus, they are often less costly than other options, especially in large volumes.

They also have a linear torque-speed relationship, which makes them easier to control. These characteristics make them suitable for applications in consumer appliances, personal home goods and toys, and automotive designs.

In fact, permanent-magnet brush dc motors are the most common electric motor in passenger vehicles where they’re used for driving windshield wipers, power windows and power seat positioners.

On the other hand, wound-field dc motors are common in household appliances such as vacuum cleaners, cordless power tools and food mixers. The only drawbacks are that they produce more audible noise and exhibit wear (at the brushes) so don’t work well in applications with high duty cycles.

In general though, many industry trends are pushing dc motors to be lighter, more powerful and portable. So, for example, more and more miniature applications are using dc motors. Because of the need for power and precision in a small package, miniature dc motors are finding their way into medical applications such as remote surgical robots.

A number of different applications are spurring changes in the design of dc motors— for example, drones and unmanned aircraft.

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DC motors: Modern applications

In one specific application for the U.S. Air Force, Boston Engineering will work to enhance UAV capabilities and reduce drone noise. Essentially, the company is bridging a market gap between commercial motor control products that don’t meet the U.S. Air Force’s rigorous UAV requirements and the technical expertise required for custom embedded control systems.

In the UAV project, Boston Engineering will build an embedded motor-control platform to accelerate U.S. Air Force UAV research and development initiatives. Embedded motor controllers underpin critical UAV operations including drone propulsion and sensors for applications including surveillance. The company received the Phase I award from the U.S. Air Force’s Small Business Innovation Research (SBIR)/Small Business Technology Transfer (STTR) program.

“We’re providing a motor-control framework to accelerate nextgeneration UAV development without the need to have extensive embedded control-systems experience,” said Guy Fichera, director of the Industrial and Commercial practice at Boston Engineering.

Complementing the motion control and product-development consulting is the company’s FlexMC Motor Control Development Platform, a rapid-development system for any motor control. Global FlexMC Kit adoption includes Analog Devices, which has selected Boston Engineering as its exclusive motor control design partner in North America and Europe. The FlexMC Kit combines hardware and software with out-of-the-box functionality for a brushless dc motor with a hall sensor, encoder or sensorless feedback.

Turntable applications need precision control of the tone arm for quality sound. The DCX motor from maxon, together with a spur gearhead, offers a 76:1 ratio for positioning.

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maxon motor control

Maintaining control has never been easier.

If decentralized drive intelligence is called for, maxon motor control provides the answer: All speed and positioning controllers are designed to match with brushed and brushless DC motors up to 700 watts power. The EPOS2 positioning controller enables you to connect quickly through the CANopen network and, using the Interpolated Position Mode, to synchronously run a preset path specified by interpolating points in real time.

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maxon motor is the world’s leading supplier of high-precision drives and systems of up to 500 watts power output. maxon motor stands for customer specific solutions, high quality, innovation, competitive prices and a worldwide distribution network. See what we can do for you: www.maxonmotorusa.com

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MOTORS • DC

Ironless dc motors help audio application

A fair number of audiophiles agree that music sounds better on vinyl, but motor noise, speed control and tonearm tracking can degrade even turntable performance.

These were the concerns of Expressimo Audio when they began the design process for their latest audio turntables.

Now, their latest turntable incorporates two motors from maxon precision motors. One motor spins the turntable while the other raises and lowers the tone arm.

The audio company needed a motor that was quiet and wouldn’t cog at low speeds, as the tone arm must move smoothly and accurately or it distorts the sound.

Ironless dc motors were the perfect fit, thanks to their lightweight design with good acceleration, quick reaction time, quiet performance and acceptable thermal dissipation, all properties desirable in a turntable application. For the tone arm motion, a spur gearhead was attached to the motor for a 76:1 ratio for precision positioning. The turntable application requires two precision speeds—33.3300 and 45.0000 rpm. The motor pulley is only 0.400 in. in diameter and spins at 940.5 rpm, spinning the 12-in. diameter platter that weighs about 30 lb at a speed of 33.3300 rpm. When the motor

spins at 1,260.4 rpm, it spins the platter at 45.0000 rpm. This motor, while in operation, draws about 0.03 A, and speed is accurate to ±0.001 rpm. The DCX motor uses rare-earth magnets to maximize the torque. Efficiency is 86% depending on the winding. All in all, the motor gave the design team a component that weighed less than 4 oz. with zero cogging and operation from -20 to 100° C. The second motor, an A-max 16, is used inside the remote control movement system for the variable tone arm operation. The VTA moves at 0.001 in. at a time, with full indication through a precision indicator.

Different versions of the motor use metal or graphite brushes and single or double shafts, while power ranges from 4 to 11 W. Maximum continuous torque is up to 19.8 mNm, and the motors weigh about 100 g.

A word of caution about ironless motors and heat.

While not a concern in turntables, ironless motors tend to overheat if maximum load is exceeded for an extended period of time. With no metal core to handle the heat, adhesives holding the rotor windings together can become damaged. Cored motors are still the better choice if an application has overload concerns.

Shown here are the motion components from maxon and the machined turntable components by Expressimo Audio.

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Typical applications for integrated motors

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ore applications than ever include integrated motors. Also called smart motors, these setups include a motor rotor and stator (in a brushless dc, servomotor or stepper motor form) paired with other motion components. About half of all integrated motors incorporate a brushless motor with permanent magnets on the rotors, though other formats exist. The most basic integrated motors consist of just a motor and drive or a motor and controller.

Other add-ons can include feedback (such as that from encoders), power supplies, cabling, and communication ports. For the latter, common communication options include serial communication links such as RS232 or RS485 and advanced network topologies for complex motion control tasks—CANopen, DeviceNet or Ethernet protocols.

The pre-engineered nature of smart motors lets application engineers more easily design motor-based motion control. Fewer parts also means these motors boost reliability and minimize cabling, wiring and overall design cost. Most integrated motors also program easily and quickly, which cuts development time.

For machine builders, integrated motors help reduce machine size and complexity. That’s because the motors significantly reduce the amount of needed space for a machine by consolidating components and (in some cases) nix enclosures. Integrated motors can also eliminate external controllers such as PLCs. Applications using integrated motors have only proliferated with the increased use of decentralized motioncontrol architectures. As an alternative to centralized motion control, decentralized architectures distribute motion control to individual motion axes (in this case, to individual integrated motors), which eliminates the need for a central controller. This means that individual motors can execute the control closer to the actual axis of motion or load, thereby taking the computational burden off a central controller and distributing it to individual integrated motors.

When selecting a smart motor for an application, note that the most important step is determining the design’s load characteristics. Here, properly calculating the load torque is paramount. Also keep actual operating conditions below published limits of the motor to extend motor operation.

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Burchfield Automation makes pan-and-tilt camera positioners that mount to ATVs. They must stay steady even on bumpy rides, so the company uses Moog Animatics SmartMotors and its phase-offset function to damp vibration. Phase offset makes a differential velocity between the external gyroscopic measurement of the pan-and-tilt and the motor’s internal encoder. That way, servo controls can use gyroscopic position-sensor measurements for corrections ... and keep the camera steady, even over rough terrain. Application image courtesy Burchfield Automation

Integrated motors work in medical applications. Here, a Lexium MDrive series 23 motor from Schneider Electric powers a Watson-Marlow 313 peristaltic pump (depicted with a red cover) to circulate blood in heart-lung machines and during bypass surgery. One peristaltic-pump challenge is that the pumps can cause pulsations as internal rollers move on and off pressure shoes. To address this issue, the Lexium MDrive starts each dispensing cycle with a roller in a preset starting position. Controls use external valves to make the pump dispense fluid volumes from multiple and partial revolutions. The Lexium MDrive controls these valves so the rollers start at the same position for all dispensing and non-dispensing cycles.

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Applications that benefit from linear motors

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ore than half of all linear motors go into applications for machine tools or the manufacture and assembly of semiconductor components and electronics. It’s no wonder: Linear motors are the precise but generally costly option to which other linear devices are compared. In fact, applications for these relatively new motion components also include those that need fast and precise positioning, or slow and extremely steady axis traversing.

Depending on the type, linear motor speeds range from a few inches to thousands of inches per second.

They’re capable of unlimited strokes and (with an encoder) accuracy to ±1 μm/100 mm. For this reason, a variety of medical, inspection and material-handling applications use linear motors to boost throughput.

Unlike rotary motors (which need mechanical rotaryto-linear devices to get straight strokes) linear motors are direct drive. So, they avoid the gradual wear of traditional rack-and-pinion sets. Linear motors also avoid the drawbacks of rotary motors with belts and pulleys for translation ... more specifically, limited thrust because of tensile-strength limits; lengthy settling times; belt stretching, backlash and mechanical windup; and typical speed limits of 15 ft/sec or so. In the same way, linear motors avoid lead- and ballscrew efficiencies (of 50 and 90%, respectively), as well as whip and vibration. They don’t force engineers to sacrifice speed (with higher pitches) for lower resolution, either.

Multi-axis stages that use linear motors on each axis are more compact than traditional setups, so fit into smaller spaces. Their lower component count also boosts reliability.

Here, the motors connect to regular drives, and (in servo operation) a motion controller closes the position loop.

Linear stepper motors deliver speeds to 70 in./sec, suitable for relatively quick-acting pick-andplace and inspection machines. Other applications include part-transfer stations. Some manufacturers sell twin linear steppers with a common forcer to form X-Y stages. These stages mount in any orientation and have high stiffness and flatness to a few nanometers for every hundred millimeters to output accurate moves.

Some cost-sensitive applications benefit from hybrid linear motors, as they have inexpensive ferromagnetic platens. Much like linear stepper motors, they vary magnetic saturation from the platen to shape opposition to magnetic flow; feedback plus a PID loop with positioning control helps the motor output servo-grade performance.

The only catch is that hybrid motors have limited output and exhibit cogging from coupling between the forcer and platen. Two solutions here are phase-teeth offset or driving to get partial saturation of platen teeth and sections of forcer teeth. Some hybrid motors also use external cooling to boost output during continuous operation.

Linear ac induction motors that run to 2,000 in./sec work for people movers, roller coasters and large aerospace applications. General-purpose types

KUKA’s PULSE system, which boosts design flexibility and adapts to different assembly plants, uses linear motors. “We’re sure PULSE will become a preferred technology in plant retoolings,” said Kevin J. Laurence, the design-concept’s developer and advanced engineering manager at KUKA Systems North America.

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MOTORS • LINEAR

These robots (in a KUKA PULSE line) use linear motors to move large automobile parts. KUKA Systems began developing PULSE for an R&D project in 2009. It went into laboratory testing in 2013 and is now commercially available.

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can move a few inches to 150 ft/sec or faster. Cylindrical linear motors have steel rods and a moving coil or rods filled with stacked magnets, so work in myriad machines that need quick and accurate strokes. In a similar way, ironless-core (or air-core) linear motors output up to 3,000 N and speeds exceeding 230 in./sec.

These capabilities make this linear-motor subtype indispensable in long-stroke pickand-place applications, flying-shear setups, and laser and waterjet cutting.

Linear ac synchronous motors can output 7,000 N or more. Some use watercooling to boost force output—enough to let the motors drive large baggage handling and amusement-ride axes. Ironcore motors are also suitable for select machine tool and robotics applications.

Just consider one specific robotics use: KUKA Systems North America

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recently began selling PULSE carrier conveyance systems for automotive car-body assembly lines. The design from KUKA in the U.S. uses linear synchronous motors from MagneMotion to move body sections through robotic workstations of assembly lines as other machinery does joining.

PULSE setups are flexible and 30% faster than conventional friction-based transfer systems. That lets plants get more use out of process equipment (and reduce production-line footprint). With solid-state linear motors, the PULSE lines have fewer components (sensors, connectors and cables) that wear and fail. Quick-stop axes boost safety. One PULSE line handles up to four models and adding functions to handle a second model is cheaper than with a conventional transfer system.

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Film wrapper uses direct-drive motors

Getting consistent packaging despite constant product variations is a challenge. Alpenland Maschinenbau (ALPMA) aimed to overcome it with its new MultiSAN film-wrapping machine, which packages round and rectangular soft cheeses, karospar-wrapped cheeses, and cheeses shaped in cylinders and half moons.

“Some cheese makers today only make a few cheeses, but change production every few hours to produce custom orders by the truckload,” said Helmut Eitermoser, MultiSAN designer. The reasons for smaller batches are like those in other industries: shorter product life cycles, customer-specific product requirements and more product variety.

Until now, cheese makers used packaging machines in which a mechanical master shaft studded with cam drives the synchronous motion of individual mechanisms.

“These cam machines work for packaging just one product type, because they’re precise, cost-effective and durable,” said Eitermoser. These can even package similar shapes—round and half-moon—and different sizes. But this takes compromise, as the packages for each product version are suboptimal. It’s impossible for cam-based machines to wrap several different products

in a folded or wrapped package with rapid changeovers.

Such tasks take reconfiguration or even machine replacement before product changeover.

For the MultiSAN, the ALPMA design team used directdrive technology with a virtual master shaft and electronic cams to completely replace mechanical versions.

The envelope folds under the cheese; the machine makes them with four LinMot linear motors horizontally mounted ... each driving a shutter blade through a linkage. Once the machine wraps the cheese in film and fixes it in place on a round plate with a gripper, the shutters press the protruding film together on the bottom of the product in rapid succession. That makes the fold pattern. Another linear motor pushes the cheese off the round plate and onto a conveyor.

For this application, the design team initially suspected that only linear motors would have the required power density. “Tests showed that rotary servomotors are unsuited for this task because they take up too much space,” said Eitermoser. Instead, he chose PS01-23x160H-HP-R motors for the MultiSan. The motors have 23-mm (stator) diameters not including the plug connection on the end—but can still output peak force to 130 N when coupled with an E1130DP-HC controller. Matching sliders come in versions for

With the help of direct-drive motors, the MultiSAN can mechanically decouple so sensitive components can fold back and out of the foam cleaning area.

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MOTORS • LINEAR

ALPMA’s MultiSAN film wrapping machine can process myriad products with no changeover (thanks to LinMot linear motors).

strokes from 20 to 780 mm. The version in the MultiSAN has a 120-mm stroke.

The space-saving form factor of the linear motor also lets the new design take up the same floor space as comparable mechanical-cam-based versions ... and cycle times of the two machine types are the same.

But differences abound. To create a modular construction, the ALPMA design team combined the mechanical unit with shutter drives for a subsystem working several machine functions. It is designed

to function as a heat sink for the linear motors as well. These machine features help get product with consistent and repeatable packaging.

“We’ve also leveraged the linear motors’ sensitivity and direct reactions to give operators a way to address productconsistency variations,” said Eitermoser.

So, onsite parties can set their own parameters for various consistencies, and the machine operator can adapt machine settings to product changes with a push of a button.

Here’s a custom twin carriage linear motor, the TCLM from Mechatronic Techniques. The relatively lowcost linear motor uses two Yaskawa coils and a Yaskawa linear magnet track. The motor also has two THK SHS linear guides, Yaskawa SGLFW-35A iron core coils and a SIKO analog (SIN/COS) linear encoder.

Travel lengths abound, but start at 300-mm stroke. Connectors are standard; potted in the carriage base for protection are all the servo and power cables.

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Servomotors: Small size, big impact

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ncreasing globalization and industrialization are spurring high-capacity manufacturing with even less tolerance for errors than ever before. These applications are leveraging servomotors and drives in their quest to achieve better efficiency with automation. This is because servomotors are one of the most commonly used motors for precision positioning and load-responsive motion.

Servomotors power applications in a wide range of industries, though are most suited for controlling the movement of machines in packaging, textile production, semiconductor manufacturing, as well as medical equipment and food and beverage production. Other common applications include robotics, positioning systems and tracking systems for solar panels. Here and elsewhere, servomotor technology can help boost accuracy and output.

Selecting the right servomotor for an application involves three important parameters: load, speed and torque.

Not only must acceleration, deceleration and running torque be taken into account, but also the ability of the servomotor to tightly control the load’s speed, position or torque. This means the peak torque measurements must be calculated, usually during acceleration or deceleration, along with the running/normal torque.

Also, the inertia of the system (the load’s resistance to change in speed) must be calculated to ensure that the motor/drive system will be able to control the load.

A motor’s continuous torque is its ability to produce the rated torque and speed without overheating. Intermittent torque indicates how much torque a motor can produce in a short period of time based on current limits of the drive and motor. The intermittent (or peak) torque of a motor can be much higher than its rated torque, and servo systems are usually designed to operate within that peak torque range when accelerating or decelerating the load.

Small size makes big difference for micro-machining innovator

Microlution builds equipment that can create machined components of an exceptionally small size at extremely high levels of precision. Tiny parts are cut, milled, drilled and turned on equipment that achieves a positional accuracy of ±0.00004 in. (1 micron). Precisely controlled high-speed spindles operating at more than 50,000 rpm offer high volume production of intricate micro components for end users in the automotive, medical, aerospace and consumer products industries.

Near-microscopic output isn’t the only size advantage the company offers.

Today’s manufacturers are increasingly concerned over the scarcity of space on the production floor. Microlution responds with machines that pack an abundance of high-precision capability into a footprint as small as 2 ft wide, and a height of less than 5 ft.

Company founders Anthony Honegger and Andy Phillip have had to search for components that deliver exceptionally precise and highly consistent movement, with a form factor that fits within a fraction of the space occupied by standard industry products.

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SERVOMOTORS

Yaskawa’s direct-drive servomotor, 2 in. high and 5.3 in. in diameter, delivers 4 Nm of torque in the small footprint necessary for Microlution’s micro machining application.

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Development of rotary tables has been a particular challenge. “The solution we need doesn’t exist from existing CNC rotary table builders,” Honegger said. “Geardriven solutions are fairly compact, but they don’t offer the performance we need. There is also the issue of backlash with mechanical tables. Direct-drive servo tables have the precision and the speed, but they are far too large. Some of them are as big as our entire machine.”

After a thorough investigation, the Microlution team decided it would be wisest to design and build a rotary table on their own. Success demanded a direct-drive servomotor that would fit in the available 104

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space in a Microlution machine, yet provide the torque required to rotate parts for a high-throughput machining process. An extensive search uncovered the Yaskawa SGMCV-04, a direct-drive servo with a height of only 53 mm (2 in.) and a diameter of 135 mm (5.3 in.). Even though the size is a fraction of the footprint required for comparable direct-drive servos, the SGMCV-04 has a torque output of 4 Nm and a power output of 126 W. This level of performance proved to be enough for Microlution’s fine cutting applications.

The direct-drive motor’s rotor couples directly to the chuck, eliminating gears and other mechanical transmissions

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SERVOMOTORS An interior view of a Microlution machining center shows the custom rotary table and the user interface and control center.

and yielding a big improvement in accuracy and responsiveness. Eliminating mechanical compliance enables accurate and immediate response to position, velocity and acceleration demands. “An improvement of fractions of a second could give you a 10% increase in tact time,” Honegger said. “At these rates, the benefits of direct-drive technology become obvious pretty quickly.” He also noted that a direct-drive rotor table removes the mechanical backlash that leads to poor positioning of the part being machined. “When you’re machining parts that are smaller than a fingernail, even a small lack of compliance can be a big issue,” he added.

The table’s mechanism needed to be well protected from chips, dust and cutting fluids to function reliably. The engineers at Microlutions chose to encase the Yaskawa servo in a sealed enclosure, with a liquid-cooled bottom plate to maintain the proper operating temperature. “In our applications, temperature control is critical,” said Honegger. “With precision like this, a degree of temperature variation here or there could ruin our accuracy.” designworldonline.com

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The native precision of the Yaskawa direct-drive servo was further reinforced by augmenting the servo’s existing bearing with a cross roller bearing at the top of the enclosure, adding rigidity and minimizing the possibility of off-axis motion during the indexing process. The Microlution engineering team also chose to implement linear servos to control some of the machine’s other axes. By moving from mechanical transmission components like ballscrews, belt drives and mechanical gearing toward a completely servocontrolled mechanism, a Microlution machine eliminates the mechanical compliance issues that diminish system speed and accuracy.

As a bonus, the Yaskawa direct drive meets Microlution’s need to comply with the safety standards of customers worldwide. The Safe Limited Speed function built into the Yaskawa servo’s amplifier helps the machines meet CE safety standards for delivery into the EU. “Having both the STO to turn the unit off and the safety limited speed was a big advantage for us,” Honegger said. “Having that capability built into the amp meant we didn’t need to develop a solution on our own. We were CE compliant right out of the box, which saved us a lot of time.”

The new rotary table design is now a standard part of Microlution’s high-volume machines. It also holds the potential to be a successful retrofit for existing Microlution products now in place. “The time savings is significant. Customers can probably gain a big improvement in speed and a 10% improvement in throughput,” said Honegger. “At another company where we have four machines, we’ve estimated that a retrofit could increase throughput by 20%.”

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ne of the most common motors used in motion applications is the stepper motor. They’re used mostly in positioning applications and have the advantage of being able to be accurately controlled, down to fractions of a degree without the use of feedback devices such as encoders or resolvers. They operate in open-loop (not closed-loop), without the need for tuning parameters as in closed-loop systems. Stepper motors are also relatively inexpensive. And because speed is proportional to the frequency of the input pulses, they can attain a wide range of speeds.

However, while stepper motors are capable of producing high torque at low speeds, they generally are well suited for lower power applications not for applications requiring lots of torque to move heavier loads. They are best for applications requiring the control of rotation angle, speed and position. Some other drawbacks are that not properly controlling the motor can produce undesired resonance in the system. Also, stepper motors are generally not easy to operate at extremely high speeds. And as the motor speed increases, torque decreases.

Applications for stepper motors are diverse. However, most uses take advantage of their superior positioning capabilities. For example, in optical systems and electronics assembly, accurate positioning is critical for maintaining high production standards.

What’s more, using hollow-shaft stepper motors lets machine

designers route wires and cables through the center of the shaft, which in turn saves valuable space and can reduce cable fatigue.

Other applications include surgical robots, some pick-and-place gantry systems as well as solar cell positioning and 3D printing.

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STEPPER MOTORS

SMART Intelligent Motion Control

The MPPV has a linear travel of 0.005 in. per step for high-flow resolution and a sealing-force of up to 16 lb of thrust at 100 steps/sec. Standard sized pinch valves accommodate 1⁄8-, 1⁄4-, 3⁄8- and 1⁄2-in. tubes.

Stepper motors have long been common in biomedical applications as well. However, with the rise of integrated motors with industrial strength connectors and hefty IP ratings and the ability to easily connect to common fieldbuses, they are becoming more prevalent in harsher industrial applications such as packaging and food and beverage.

A recent unique application involves a flow-control valve.

Stepper actuator drives mini proportional pinch valve

Resolution Air in Cincinnati recently came out with a new line of miniature proportional pinch valves (MPPVs). The valves are designed to deliver tight specifications for high-resolution flow control for integration into portable and handheld equipment in a variety of industries, including bio-chemical, food and beverage, and healthcare. The valves are used to pinch a fluid-filled, low durometer tube with varying amounts of pressure to regulate the flow of the fluid (liquid or gas) through the tube. It uses a stepper linear actuator (stepper motor and leadscrew) and a custom piston in a miniature aluminum valve body.

During the evaluation process, the company used a stepper controller from AllMotion. “Our extensive research for the right component led us to the discovery of the StepperStick controller, manufactured by AllMotion,” said designworldonline.com

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Brad Thompson, Resloution Air owner and chief engineer on the project. The StepperStick eliminated the complexity of the control system by simplifying the wiring, the power supply requirements and the programming needed for evaluation. “In under ten minutes, our customer can be evaluating the MPPV, compared to the days it would take if the control system was built from scratch—even more time if the company doesn’t employ control engineers specifically.”

The StepperStick uses a wiring harness that connects to the stepper motor mounted on the MPPV. The device then plugs into the USB port of a computer to provide communications with Allmotion’s Windows-based programming language. The computer also provides the power needed for both the controller and stepper motor.

The controller supplies up to 0.5 A of current to the stepper motor. The device also has a current adjustment, which allows users to reduce the current output to match the valve’s requirements (0.385 W). Plus, the MPPV only requires power to adjust position, not maintain position, resulting in power savings.

Housed in a USB stick measuring only 2 x 1 x 0.5-in. thick, the StepperStick works on any stepper motor that is 1.7 in. (size 17) or smaller. Commands for the controller are sent through ASCII text from any serial terminal program or from AllMotion’s EZCommander application.

The MPPV features linear travel of 0.005 in. per step for high-flow resolution, as well as high sealing force of up to 16 lb of thrust at 100 steps/ sec. The valve also features a locking leadscrew.

Standard sized pinch valves accommodate 1⁄8-, 1⁄4-, 3 ⁄8- and 1⁄2-in. tubes.

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Networks in motion promise greater efficiency

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arious versions of Ethernet are common in motors, drives and controls such as PLCs. The applications are everywhere, from simple pick and place assembly all the way to a lights-out facility.

And they will continue to gain in importance thanks to the Internet of Things (IoT). The gathering of data is the new application for networks in motion, courtesy of all the smart chips going into virtually every motion component.

The hope is that all of the new and analyzed data will help improve motion. Many motion applications require tight coordination between axes to maximize quality and throughput. The manufacture of flat-panel displays and batteries, for example, is increasingly complex as the demand for lower prices requires increased efficiency at every step. Coordinated motion, courtesy of networks and

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controls, delivers the needed efficiency. With access to more process data, it might be possible for engineers to use analyzed information to develop even more efficient operations.

In the area of hydraulic-based motion control, the industry has found that it is simpler and more precise to synchronize multiple hydraulic actuators using a communication protocol like Sercos than by conventional means.

Applications such as injection molding or metal forming presses use networks as the nervous system for centralized multiple input/multiple output (MIMO) control systems.

The IoT makes it possible to collect and integrate much more information than ever before. The question is, what will that lead to going forward? It’s still early to predict, but there are many exciting opportunities.

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Networked drives ensure smooth tunnel construction

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Even in a tunnel building application, networks play a critical role. The Long Island Railroad tunnel project in New York City, for example, uses conveyors to remove debris churned by the Tunnel Boring Machines (TBMs).

Without tight coordination among the conveyor motors, the conveyor belts can break or the conveyor carts can jump the track or flip. If a motor stops, it creates an overload and imbalance on the other motors. Thus, communication plays a key role in motor coordination.

The project requires using TBMs to hollow out multiple tunnels 200 ft below the surface. All totaled, 12.4 km of rock must be bored and all of the associated debris must be removed. The conveyor system includes every type of commonly recognized conveyor— including belt conveyors, TBM conveyors, transfer conveyors, a serpentine conveyor to continuously extend the conveyor to follow the boring machine, an extensible crown-mounted conveyor, a pocket belt vertical conveyor, two cascading overland conveyors, and one radial stacker.

Variable frequency drives (VFDs), from Mitsubishi Electric, control the conveyor motors. The VFDs use CC-Link to communicate to the motors to control the various conveyor systems under a load-sharing scheme. In past systems, other communication networks were tried, but due to the required length of the tunnel boring operation as well as the harsh environmental conditions, those other networks could not meet the stringent requirements of the job and the communication system failed regularly.

The communication system consists of three interconnected CC-Link networks working in conjunction. These networks control more than 70 stations, including the conveyors, pumps, fans and EECS, as well as HMI inputs and outputs to control other various functions within the tunnel construction system.

Communication key to fast produce processing

How many applications involve equipment and systems from multiple vendors? Quite a few. Communication can play a key role, connecting all of these disparate systems together into a coordinated whole. For one produce processor, communication was critical.

Communication ensures coordinated motion for a produce processor. CC-Link was chosen for its ability to work equipment from a number of different vendors, including 31 VFDs.

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NETWORKS

The rail-mounted Tunnel Boring Machine

In addition to more than 100 drives operating various conveyors and other machines, a number of ultra-sonic welders were used in the facility. This equipment created an operating environment that was electrically noisy and not friendly to high-speed communications. The selection of CC-Link as the network made it easier to operate equipment from many different manufacturers for coordinated control, as well as handle an electrically noisy environment.

Locally grown lettuce is shipped to the produce facility where it is separated and sorted using incline conveyors. The belt in the sorter moves at 600 ft/min.

Then, the lettuce is washed and dried.

Two lines are used to handle the produce volume. Each system is controlled through CC-Link, using a Mitsubishi Q-Series PLC Rack and a CC-Link Master station, all communicating with 35 CC-Link slave stations. These stations consist of 31 VFDs—including three spare VFDs, and four Wago Remote I/O blocks. designworldonline.com

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Improving cycle time in injection molding

To fully realize the promise of IoT, disparate systems need to securely connect, interoperate and communicate. Many manufacturing facilities still have “islands of automation,” points where there is little to no communication between components and equipment. Often, the communication system and the control work together to ensure smooth operation.

Husky Injection Molding Systems makes equipment that is used to manufacture a range of plastic products, including bottles and closures for beverages and parts for the medical industry. A major trend in the industry is reducing raw material costs, while ensuring quality.

Working with Husky, Beckhoff developed an IPC that serves as a multitasking centralized controller running all PLC, motion control and measurement communication to auxiliary devices and the HMI software. By using one IPC processor to run PLC tasks and another to run the HMI software, Husky decreased scan times while improving overall quality by establishing real-time control and repeatability of every axis of motion.

The system improved productivity and cycle time from 3 to 12%, depending on the application. Automation technology, such as consolidating workloads to strike the best balance between quality and efficient use of plastic resources, is a major reason companies choose Husky. The HyPET HPP5 system built on Beckhoff IPCs equipped with Intel Core i7 processors is perfectly positioned to extend this trend.

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Positioning stages go custom

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ositioning stages currently lead the general move to integrated designs in all kinds of applications. Just consider the way challenging fiberoptic, test-and-measurement and semiconductor applications, such as assembly and wet-bench setups, use precision stages (and their integrated mechatronics) as systems to improve throughput and product quality. Custom setups rule: For example, the manufacture of flat-panel displays has spurred ever-larger motion-stage formats with linear-motor actuation and air-bearing load carrying. Elsewhere, belt-driven stages satisfy the need for long strokes, but avoid ballscrew support challenges and the cost of linear motors.

Another growing industry using positioning stages is additive manufacturing. Here, ever-improving materials and layup techniques demand new stages at all performance levels. Many basic maker-level machines use stages with synchronous belt-driven axes. More demanding applications (from researching and prototyping to medical and smallbatch manufacturing) commonly use positioning stages with motor-driven ballscrews to coordinate motion.

Still other medical and life-research applications make use of ultra-precision stages that deliver performance motion profiles impossible a decade ago. Here, piezomotors, miniature linear supports and coarse-and-fine tandem actuators are increasingly common options.

The packaging industry tends toward pre-engineered positioning stages, as this industry often forces integrators to satisfy design schedules that bar design and set up of multi-axis functions in house.

Likewise, the machine-tool industry is making more use of custom-built positioning stages—in laser-cutting and similar machines, for example. These and the stages for CNC applications are increasingly customized to specific

motion tasks. That helps them deliver on dynamic parameters at lower cost and without the hassle of reformatting or retrofitting stock setups. Enabling this newer approach are proliferating software tools that let OEMs and end users manipulate initial design iterations within virtual environments that have accurate models of realworld stage components.

Assembly is different. Here, semi-custom Cartesian stages excel for pick-and-place and inspection via machine vision. More typical in these setups are traditional rotary motors paired with rotary-to-linear devices (ballscrews, for example) and controllers that compensate for system dynamics to get accuracy to a few micrometers or better.

Automotive applications vary widely. For example, the large scale of sheet metal and body-assembly tasks present unique challenges that, in some cases, only overhead stages (or those with rack-and-pinion sets) satisfy. At the opposite end of the spectrum, stages that carry inspection instrumentation to detect part features on a nanometer scale often take the form of direct-drive axis assemblies driven by a precision controller that even corrects for environmental fluctuations.

Here’s a large stage application. ATI Industrial Automation’s Rail Tool Changers allow for quick and reliable swapping of press transfer tooling. ATI designed custom Tool Changers for Güdel transfer lines to withstand the high speed, high-inertialoading environment of the process. This coupler upgrade mitigates problems that make other exchangeable rails get stuck between die changes. With numerous production runs and die changes every day by the end user, this is a significant productivity booster.

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Aerotech Cartesian Robots Maximize Your Application Throughput

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Ph: 412-963-7470 Email: sales@aerotech.com www.aerotech.com AF1114D-PMG

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Retaining rings— a motion mainstay

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achine assemblies and subassemblies make copious use of retaining rings in everything from electric motors and gear retainers to solenoids to aircraft to door handles and sports equipment. These fasteners hold together components on a shaft or in a housing when installed in a groove. In fact, the automotive industry may make the most use of retaining rings, especially for assemblies in air bags, timing-belt pulleys, radiator hoses, turbo chargers, door locks, carburetor assemblies, drive shafts, and brakes.

Used in an array of oil-and-gas and other industrial designs, tapered-section rings have decreasing thickness from center to ends.

They mount axially or radially, and the taper keeps full contact with the installation groove.

Common in assemblies for lawn mowers, hand and power tools, agricultural machinery, electronics, and even nuclear equipment, constant-section retaining rings have a constant width around the ring circumference. When installed, these rings don’t maintain uniform contact with the entire component. They take on an elliptical shape and make contact with the groove at three points. Spiral retaining rings go into housings or on shafts with full contact with the groove or component. Their grooves are shallow, so they have less load bearing capability.

So, spiral rings often go into applications that prioritize full contact with the retained component or lower axial profile.

Spiral rings find use in torque converters, speed reducers, lamp assemblies, clutches, hinge pins, home appliances, robotic

Spiral retaining rings (as this one from Smalley Steel Ring Co. in an assembly) don’t need special tools for removal. Notches make extraction easier.

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This assembly shows a single-turn wave spring from Rotor Clip helping to retain a bearing on a shaft. The ring can be a replacement that fits into a preexisting groove.

toys, pumps, couplings, valves, hydraulic equipment, and photography equipment. They don’t have protruding ears to interfere with mating components; they also eliminate the need for machining and threading.

Spiral retaining rings don’t need special tools for removal and come standard with removal notches for extraction.

When selecting a retaining ring for an application, factors that dictate which is most suitable include application environment (temperature and thrust), critical dimensions (including the assembly’s housing or shaft diameter) and the installation groove’s dimensions.

Note that maximum thrust is a particularly critical application parameter, as it dictates whether there’s risk of groove deformation or ring shear. Another note: Applications in corrosive environments may also need retaining rings made of specialty material. designworldonline.com

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IS EDGEWINDING THE NEXT BIG THING? Ask Smalley. Edgewinding is our precision forming operation that offers unique advantages. Unlike the conventional stamping process, Smalley edgewinding delivers maximum strength, effectively eliminates material waste, and offers No Tooling Charges™ to make prototyping or custom designs easier and affordable.

Our experienced engineers can show you how edgewinding gives our wave springs, Spirolox® retaining rings and constant section rings a real performance edge. It’s a combination of manufacturing innovation and technical expertise that only Smalley delivers.

Spirolox® Retaining Ring

Stamped Ring

The edgewinding process coils pretempered flat wire on edge to give Smalley products strength and stability far superior to stamped retaining rings.

Visit smalley.com for your no-charge test samples.

THE ENGINEER’S CHOICE™

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Shaft-collars: Where they work

Some Ruland shaft collars (as the one shown here) attach encoders to shafts. Clamp-style collars need precise face-to-bore mating to meet the demands of medical equipment. Ruland makes their clamp shaft collars with smooth or threaded bores from 3 to 150 mm.

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haft collars are part of nearly all types of moving machinery—including designs for mechanical, medical, aerospace, automotive and industrial industries. In electricmotor-driven designs, they’re most common at the gearbox and motor assemblies. Shaft collars satisfy three basic functions: • set shaft position • space components on shafts • limit shaft movement As such, they commonly work as mechanical stops on actuators and cylinders, as locating components for gearboxes and motors, and for keeping sprockets and bearings on shafts. Some shaft-collar variations are more suitable for given applications than others.

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clamping collars (with distinct benefits over setscrew designs) have been around for some time. Yet, setscrew shaft collars are still common in today’s applications that don’t need post-installation adjustments and where cost is a concern.

CLAMP-STYLE SHAFT COLLARS Clamp-style collars use compressive forces to secure components to shafts without marring them like setscrews. These collars distribute clamping force uniformly around the shaft (and not at one point) so users can easily adjust them without damaging the shaft. Clamp-style shaft collars are either one-piece or two-piece collars; the two-piece collar most evenly distributes force and creates the strongest hold.

While these types of collars are found in nearly any industry where power transmissions are present, they are increasing in medical applications. designworldonline.com

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SHAFT COLLARS • LOCKING DEVICES

Some Ruland collars function as mechanical stops

Clamp-style shaft collars for medical equipment

Clamp-style shaft collars work as guides, spacers, and stops on medical equipment, but only collars with tightly controlled face-to-bore perpendicularity (with a TIR of less than or equal to 0.05 mm) satisfy the design requirements in these critical designs—especially where the collar functions as a load-bearing face or aligns critical motion components such as bearings or gears. Clamp-style shaft collars distribute compressive forces evenly around the shaft for strong hold.

Two-piece collars have more holding

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power than one-piece designs and install in place. In fact, machine integrators can add these collars to a design at any point in the manufacturing process.

Some shaft collars use fastening hardware that tests beyond industry standards for maximum torque capabilities and holding power. For example, some stainless-steel shaft collars sport hardware that can also resist

corrosion and satisfy regulatory standards; the stainless hardware undergoes surface treatment to prevent galling. Other clamp-style shaft collars come in steel with a black oxide or zinc finish, aluminum, titanium, and engineered plastic. Black-oxide on steel resists corrosion and smoothens screw installation to boost the transfer of screw clamping forces to the collarshaft interface while preventing stick-slip.

In this image we see a hygienic clamping assembly from Ruland on a mozzarella production machine. The collar is located on the outside of the machine and holds the shaft in place in the event of failure. This component is made of a 303 stainless steel shaft collar and other FDA compliant materials. It has none of the surface irregularities, like saw cuts and screw pockets that allow bacterial contamination in other types of shaft collars. This uniform surface allows for easy clean-up around the moving parts of the machine. The collar is also IP69K rated for dust and water up to 176°F/80°C with 10 MPa of pressure.

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Shock and vibration-damping components at work

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hock and vibration-damping components are as varied as the designs in which they work. That ranges from heavy-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 smaller-bore 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 Teflon-coated piston rings and piston rod seals formulated to withstand heat.

Shocks and vibration dampers excel in designs that are engineered to 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 Outside the enormous mouth of NASA’s giant thermal vacuum chamber at Johnson Space Center in Houston, engineers and technicians prepare to test the James Webb Space Telescope. Minus K Technology supplied five negativestiffness vibration isolators to keep the test setup properly positioned.

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With a shock and vibration isolation system that includes highly tuned dampers from ITT’s Control Technologies, this design absorbs impact energy several times greater than past designs.

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 general rule of thumb, isolators should shift a design’s natural frequency so it’s no more than onethird of the excitation frequency.

One caveat is that overly compliant isolators can actually 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-of-phase frequency.

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One such design is a negativestiffness mechanism from Minus K, which adjusts horizontal and vertical resonant frequencies separately.

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 electricmotor-driven machinery to those that run off internal-combustion setups.

As mentioned, one semi-active product to damp vibrations is magneto-rheologic fluid from Lord Corp., a blend of magnetic powder in oil, water or glycol that reversibly

changes from free-flowing to semisolid under an electromagnetic field.

Particularly useful in automotive applications that must accommodate changing road and driving conditions, magneto-rheologic components can replace traditional hydraulic fluid in shock absorbers.

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.

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SHOCKS & VIBRATION-DAMPING COMPONENTS

Isolation system manages cargo kinetic energy

Norwegian oil company Statoil’s Gudrun Platform operates in the North Sea’s Gudrun field. The platform operates cranes for around-the-clock cargo handling. As crane operators hoist supplies from ships to the platform, containers (some weighing as much as 8,000 kg) can move toward the Gudron Platform at 3 m/sec.

“Moving equipment from a supply ship onto an offshore platform in difficult conditions requires a highly engineered system of shocks and dampers,” said Tomm Kuran, sales manager for pneumatics at Servi Hydranor AS, a Norwegian distributor of hydraulic and hydraulic-related products. “The Gudrun’s crane operators move food and heavy, expensive equipment for drilling. If an operator mishandles a container, people can be hurt or equipment destroyed.”

“A mishandled container can also halt drilling operations,” said Peter Bauer, managing director for ITT Control Technologies EMEA. Flexible barriers have been used for approximately 10 years on offshore platforms in the North Sea, but they often sustain damage from containers slamming into them.

Engineers came to Servi Hydranor and ITT’s Control Technologies early in the design process of the Gudron Platform with a set of specifications (including

environmental conditions) and space limitations. While offshore rig builders know how to to stabilize cranes, engineers saw challenges in designing a dampening system for its cargo barrier.

So, the two companies engineered a shock and vibration isolation system that includes highly tuned dampers that absorb the cargo’s kinetic energy. Because of the design, the barrier system handles impact energy several times higher than traditional designs. The companies completed the shock and isolation design work in 2013, and the Gudrun Platform is now in operation.

Linear modules must endure high speeds and loads in automation, handling, and pick-andplace operations, so safety dampers can be used to provide reliable insurance against impact damage. This long-stroke Omega module from Bosch Rexroth uses safety dampers from ACE Controls in its end positions. ACE’s SCS33 to SCS64 safety dampers provide true linear deceleration while protecting the Z-axis against uncontrolled motion. ACE safety dampers are specifically designed for emergency use only and offer reliable protection at an affordable cost.

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Wave springs in motion

Here is a basic formula to narrow down the wave-spring type, shape and size that best suit an application. Note that wave springs are helping today’s push toward design miniaturization. Smaller designs need shorter and small-diameter wave springs. That’s spurred some developers to make wave springs less than 0.250 in. in diameter.

Formulas: Operating Stress: S = (3πPDm)/4bt2 N2

A

lthough often out of sight, wave springs are essential in many motion-control applications, ranging from gear assemblies, actuators, rotary unions and different kinds of clutches, to many consumer products.

Wave springs operate as load bearing devices.

Thus, they suit applications with special space needs, such as taking up play, or compensating for dimensional variations within assemblies. They suit applications that need loads to move either gradually or abruptly to reach a predetermined working height.

A wave spring always applies its load in an axial direction. Wave springs also apply consistent loads within a small tolerance range at different work heights.

These capabilities let design engineers easily adjust the application to meet given requirements when needed.

One type of wave spring is the single-turn.

Versions with overlapping ends save axial space so that more space is given for travel. The spring clings to the bore, which saves radial space.

Nested wave springs suit applications requiring higher forces to meet safety regulations, such as those in government or military applications. A nested-wave spring provides a higher load than a single-turn wave spring (a stamped wave washer) and uses the same radial space as a single-turn design.

Use of a multiple-turn wave spring can save 50% in axial space compared to a traditional coil spring. What’s more, these springs eliminate the risk of torsional movements during compression to work height.

One advantage of wave springs is that they save space. Because the springs have shorter operating heights, they can fit into smaller spring cavities. That lets engineers make assemblies lighter and more compact, which in turn reduces overall design cost.

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Where: S = operating stress P = load in pounds Dm = mean diameter in inches b = radial width of material in inches t = thickness of material in inches N = number of waves per turn Fatigue Stress Ratio: x = s-s1/s-s2 Where: s = Material tensile strength s1 = Calculated operating stress at lower working height (must be less than s) s2 = Calculated operating stress at upper working height Deflection: f = ((PKZDm3)/(Ebt3N4)) x (ID/OD) Where: f = deflection in inches P = load in pounds K = multiple wave factor Dm = mean diameter in inches Z = number of turns E = modulus of elasticity b = radial width of material in inches t = thickness of material in inches N = number of waves per turn Spring Rate: R = (P/f) = (Ebt3N4)/(KZDm3) x (ID/OD) Where: R = Spring rate in pounds/inch P = load in pounds f = deflection in inches E = modulus of elasticity b = radial width of material in inches t = thickness of material in inches N = number of waves per turn K = multiple wave factor Dm = mean diameter in inches Z = number of turns

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M O T I O N CASEBOOK

Ad Index ACE Controls Inc........................................................................... 121 Aerotech, Inc................................................................................. 113 AllMotion........................................................................................... 8 AMETEK Catalyst Motion Group....................................................... 9 AMETEK PMC/Dynamic Fluid Solutions........................................ 3, 7 Applied Motion Products, Inc.......................................................... 19 AutomationDirect.......................................................................... IFC Beckhoff Automation..................................................................... 109 BEI Sensors........................................................................................ 1 BellowsTech, LLC ............................................................................ 45 Bishop-Wisecarver Corp................................................................ IBC CGI, Inc. .......................................................................................... 71 Chieftek Precision Co., LTD........................................... 101, 103, 105 Crouzet Motors...................................................................... 106, 107 Del-Tron Precision, Inc..................................................................... 85 Dunkermotoren, part of AMETEK..................................................... 5 Dynatect Manufacturing Inc............................................................ 29 Encoder Products Co...................................................................... 59 FESTO............................................................................................ BC Groschopp, Inc................................................................................ 69 Harmonic Drive LLC........................................................................ 63 Helical Products Co......................................................................... 43 igus, Inc..................................................................................... 21, 27 ITT Enidine.................................................................................... 119

KHK Kohara Gear Industry Co., Ltd. ............................................... 67 Kuebler Inc...................................................................................... 57 LinMot USA, Inc............................................................................... 99 Maple Systems, Inc.......................................................................... 77 maxon precision motor, inc............................................................. 94 MICROMO........................................................................ COVER, 96 Mitsubishi Motors North America, Inc............................................. 37 Moog Inc., Animatics..................................................................... 104 NOOK Industries, Inc...................................................................... 83 NSK Precision America.................................................................... 17 PBC Linear....................................................................................... 89 PHD, Inc.......................................................................................... 13 PITTMAN......................................................................................... 11 R+W America.................................................................................. 47 Schneider Electric............................................................................ 91 Servometer...................................................................................... 45 Setco Inc.......................................................................................... 87 SEW Eurodrive................................................................................. 73 Siemens Industry............................................................................. 53 Smalley Steel Ring Co................................................................... 115 Tolomatic, Inc.................................................................................. 15 U.S. Tsubaki Power Transmission, LLC............................................. 33 Yaskawa America, Inc...................................................................... 49

LEADERSHIP TEAM

SALES VP of EE Product Development Mike Caruso mcaruso@wtwhmedia.com 469.855.7344 Vice President, Publisher Michael Ference mference@wtwhmedia.com 408.769.1188 @mrference General Manager Todd Christenson tchristenson@wtwhmedia.com 440.381.9048 @wtwh_todd VP, Business Development David Geltman dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david

Key Account Manager Jim Powers jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

Regional Sales Manager Neel Gleason ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

Publisher Mike Emich memich@wtwhmedia.com 508.446.1823 @wtwh_memich

Regional Sales Manager Tom Lazar tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom

Regional Sales Manager Megan Hollis mhollis@wtwhmedia.com 440.821.2941 @wtwh_Megan

Managing Director Scott McCafferty smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty

Regional Sales Manager Courtney Seel cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

Business Development Michelle Flando mflando@wtwhmedia.com 440.670.4772 @mflando

EVP Marshall Matheson mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

Regional Sales Manager Jessica East jeast@wtwhmedia.com 330-319-1253 @wtwh_MsMedia

CONNECT WITH US!

Follow the whole team on twitter @DesignWorld

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PTDA 2015 Summit recap: Connecting young talent & industry veterans

SPARK

a Movement: Inspire.

All of these presentations worked well as preamble for Motivate. Lead. The economic expert Alan Beaulieu’s summit closing talk the tagline for the annual PTDA Industry Summit, held following day. Covering the big picture, Beaulieu wasted little in Chicago last month, doesn’t explicitly say here time before addressing what he thinks will be a bleak outlook in come the Millenials. But the tectonic plate shift in the next decade and a half. Graciously, Beaulieu tempered his the global workforce was of real interest at the event. prediction of an economic doomsday in 2030 with a brighter In an industry densely populated with Boomers, the outlook for the next 5 years—adding that it’s important to take PTDA seemed well aware of the transitionary period advantage of the growth we can expect to see before 2020. on the horizon.

“Spend money on people, processes, and then spend some Several featured speakers at least touched on more,” he said. Beaulieu finished his presentation by assuring how a new generation is affecting the work they the audience that planning for the future during this period of do. Artist Phil Hansen, a Gen Y/Millennial himself, growth will mean companies should be just fine. delivered an expanded version of his TED talk on It’s an obstacle as old as industry itself—young new embracing inevitable change. Marketing maestro talent must blend with industry veteran wisdom. But whether Ryan Estis explained how we are now entering “the we learn to adapt through old-school summit presentations, era of the customer,” essentially a new period or the live tweets that come from it, the torch is getting of radicalized but widely accepted consumer passed just the same. expectations. And lastly, technology speaker Scott Klosocky quoted Klaus Schwab in saying “Capitalism is being replaced by talentism.” So what does this all mean for the power transmission industry?

Alan Beaulieu presented attendees with his economic forecast for the next 15 years.

The International Ballroom at the Hilton Chicago held many of the events at the 2015 PTDA Industry Summit.

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