Motion System Applications 2021

NOVEMBER 2021

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MOTION SYSTEM APPLICATIONS

Hollow Shaft Meets Solid Stepper Performance

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THINK INSIDE THE BOX Exceptional designs deserve superior components.

The developer of the original world-class linear motion systems, THK continues to redefine industry standards and to meet an ever-growing range of needs. From aerospace and machine tool to packaging and medical, THK products play a vital role in the advancement of technology and capability.

To learn more, call us at 1-800-763-5459 or visit www.thk.com.

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COVID-19 AND THE GREAT RESIGNATION SPUR AUTOMATION ADOPTION

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ith no end to COVID-19-related supply-chain and labor woes in sight, myriad industries — from semiconductor manufacture to fast food and retail — have increased adoption of factory and process automation. It’s a response first observed to lesser extents during the past decade’s SARS and Ebola outbreaks, and predominantly employed by larger companies with the means to institute new and ambitiously innovative systems in daily operations. We cover just a few of these new applications in this, our seventh annual Design World Motion Casebook.

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One burgeoning application in manufacturing and processing facilities has been the use of robotics to execute tasks that otherwise require workers to eschew social distancing to do their work.

Just consider the case of the meatpacking industry, where workers must do their jobs in proximity closer than any other. Work associated with the slaughter and processing of chickens, cattle, sheep, and pigs is inherently grueling and grisly work that can inflict physical and psychological harm on abattoir employees, and leave animals exposed to unintended cruelties.

But making this work even more treacherous last year was the way in which COVID-19 infections tore through meatpacking facilities — disproportionately affecting the most socioeconomically vulnerable personnel. No wonder the $200B U.S. meatpacking industry has increased testing and adoption of automation technologies such as that from Germany slaughter-equipment company BANSS, for example. Here, the main challenges to roboticized equipment are the unlimited variability of animal-carcass morphologies along with cold and flesh-spattered factory settings requiring regular washdown.

Automation is a suitable fit for this space, as many abattoir jobs are “dangerous, dirty, and dull” indeed. Here, new motion technologies could help improve the physical and psychological welfare of employees by allowing more manageable pacing of tasks as well as better spacing of employees to reduce the spread of illness.

The caveat is that only large-scale social programs can ensure such workers aren’t completely disenfranchised by such technology. In contrast with Western European countries that have well-established job-training and retention programs on national levels, such protections in the U.S. would necessitate the institution of new solutions to support less-skilled workers in their efforts to maintain employability. In contrast with Asian countries, adoption of robotics automation in the U.S. is still in its early days, so still accelerating — making the need for reskilling and vocational programs in the U.S. particularly urgent.

As underscored by the Great Resignation currently driving millions of mid-level employees in the U.S. to quit their jobs each month, humans need dignity and respect in work as well as reasonable (sustainable) workloads and employment terms. These basic needs demand earnest dialog with and support of those in less mobile positions who (sooner rather than later) will be affected by automation in their industries.

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CONTENTS V O L U M E

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EDITORIAL ON THE COVER ACTUATORS BALL SCREWS BEARINGS BRAKES & CLUTCHES CONTROLS CONVEYORS COUPLINGS DRIVES ENCODERS GEARING LINEAR SLIDES & GUIDES MOTORS PULLEYS/BELTS SENSORS VIBRATION & SHOCK MITIGATION SPRINGS

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DESIGN WORLD — MOTION

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MOTION SYSTEM APPLICATIONS THIS IS THE FOURTH TIME NEW ZEALAND HAS WON THE AMERICA’S CUP.

MOTION CONTROL ON AC75 BOAT KEY TO WINNING AMERICA’S CUP T

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he America’s Cup international competition (named for its winners’ trophy of the same moniker) has been the premier sailing competition since its founding in 1851 — with a format that culminates in a match race between two sailing yachts every several years.

control electronics, sensors, fluid power, electric motors, and high-speed networking that helped ensure the precision driving of foil canting, steering, sail trimming, and other rudder functions.

Such technology is necessary for keeping the 75-ft-long boats under control, as their speeds can exceed 100 kph.

The most recent America’s Cup was held this year in March (with just a slight delay due to COVID-19) on the inner Hauraki Gulf off Auckland in New Zealand. The Royal New Zealand Yacht Squadron on their AC75 class foiling monohull boat Te Rehutai triumphed over the Italian Circolo della Vela Sicilia team on a boat of the same design.

Though wind serves as the primary motive force for these performance carbon-fiber vessels, it was batteries, copious

ETHERCAT TECHNOLOGY GROUP ON EMIRATES TEAM NEW ZEALAND BOAT

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Emirates Team New Zealand is an EtherCAT Technology Group (ETG) member and used EtherCAT on controls for its hydraulically driven canting hydrofoils with dynamic flaps. Emirates Team New Zealand chose EtherCAT as the central onboard bus system for the network’s fast response times and acceptance of other systems into the EtherCAT network via gateways.

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ON THE COVER MOTORS FROM MAXON ON EMIRATES TEAM NEW ZEALAND BOAT Initiual boat design through simulations and the use of AI technology were big risks for Emirates Team New Zealand, who were frank about the lack of racing experience in this new AC75 class. It leant the team had to learn fast during regattas.

The risks paid off for the Kiwis who ultimately won seven out of 10 races with the Italian team in the final Cup series.

Back in 2018 maxon joined Emirates Team New Zealand as an Official Supplier, providing 480-W dc motors with 42-mm gearbox combinations and EPOS motor controllers to the sailing team.

This particular dc motor combination was selected because of its outstanding power density and ability within even the harshest of environments. The America’s Cup AC75 Class Rule allows the use of electric motors to operate hydraulic valves, drive clutches, rudders, and foils. Teams may also use motors for driving simulator platforms and numerous test jigs.

“We’ve been watching the races globally across our offices — cheering on Emirates Team New Zealand,” says maxon motor Australia managing director Brett Motum. We’re proud to have supported Emirates Team New Zealand as an Official Supplier and see them cement their place in history winning this 36th America’s Cup match.”

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THE NEWEST NEW CLASS OF AMERICA’S CUP BOATS CAN REACH MORE THAN 100 KPH ON THE WATER.

11 • 2021

DESIGN WORLD — MOTION

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MOTION SYSTEM APPLICATIONS

QUICK UPDATE ON INTEGRATED MOTOR-SCREW DESIGNS B

all and lead screw assemblies are often driven by a motor connected in-line with the screw shaft via a coupling. While this mounting arrangement is simple and easy to service, the addition of a non-rigid mechanical component (the coupling) can introduce windup, backlash, and hysteresis — all of which affect positioning accuracy and repeatability. The coupling also adds length, reduces rigidity, and increases the inertia of the system. One way to eliminate these potential problems is to do away with the external coupling and integrate the screw directly into the motor.

Integrated motor and screw assemblies are available in various configurations and designs. The motor can be either a servo or a stepper type, and the screw can be a ball screw or a lead screw, although the most common configurations pair a lead screw with a stepper motor or a ball screw with a servo motor.

One of the most popular integrated designs uses a motor with a hollow shaft and integrates the lead screw directly into the motor. The screw is machined so that one end that mates to the hollow bore of the motor, and the machined end is either permanently fixed to the motor bore via welding or an adhesive or secured with a fastener. Connecting the screw shaft to the motor bore via a fastener allows the components to be disassembled for maintenance and makes it possible to replace either component (rather than replacing the entire assembly), but this method can also experience loss of alignment and rigidity over time.

Regardless of which method is used to connect the screw shaft to the motor, this method of motorscrew integration is typically called an “external” design because the ball or lead screw nut remains external to the motor. Like a traditional screw-motor setup, the motor’s rotation causes the screw to turn, which advances the nut (and the load) along the length of the screw shaft.

Although applications with short strokes and light loads can sometimes operate without additional support for the screw (essentially a fixed-free arrangement) or without linear guides, most applications will require support for the opposite end of the screw and the use of linear guides to prevent radial loads on the screw.

In the non-captive method of integration, the ball or lead screw nut is integrated into the motor (or mounted to the face of the motor) and does not travel along the screw. Instead, the screw is prevented from rotating (typically by the attached load) and when the motor and nut turn, the screw travels linearly, back-and-forth through

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the motor-nut combination. In this configuration, the non-captive design provides a better stroke-to-overall length ratio, provided the design allows space for the screw to extend beyond the back of the motor.

Alternatively, if the screw is fixed so that it doesn’t travel, the assembly essentially becomes a driven nut design — for which the motor’s rotation causes the motor-nut assembly to travel back and forth along the stationary screw. Like a conventional driven nut assembly, this configuration allows higher travel speeds because screw whip is almost eliminated. It also allows multiple motor-nut combinations to be mounted to the same screw shaft and driven independently.

A variation of the above motor-screw combination is the captive design. Like the non-captive design, the nut is integrated directly into the motor, but a spline shaft is attached to the screw, preventing the screw from rotating and creating linear motion when the motor turns. In this design, the screw extends and retracts from one end of the assembly and is not supported. The captive design is essentially a more compact version of the thrust rod style actuator, making it best suited for pushing or pressing applications where the load is guided and there is no radial force on the screw.

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MOTION SYSTEM APPLICATIONS

BALL SCREW SEALS ENSURE SMOOTH OPERATION IN CLEAN ENVIRONMENTS B

all screws are used in a wide range of applications, many of which expose the screw and nut assembly to harmful contamination in the form of dust, chips, or liquids. And like any bearing that uses metal balls (or rollers) on metal raceways, ball screws can experience abrasive wear when exposed to solid contaminants, while liquid contaminants can interfere with proper lubrication — with both conditions reducing the expected life of the assembly and potentially causing catastrophic failure.

One way to protect ball screws from contamination is to completely enclose them in a bellows or telescoping-style enclosure.

But the suitability of bellows or telescoping covers should be carefully evaluated, because the negative and positive air pressure caused by their contraction and expansion can act to “suck in” particulates. This air flow can also cause otherwise stationary particles in the environment to become airborne, essentially “stirring up” harmful dust and chips.

Manufacturers use different terminology to describe various ball screw sealing options, but most offer three fundamental types of seals: non-contacting, full-contact, and highperformance versions.

liquids to enter the ball nut, so they’re primarily used in environments where contaminants are in the form of larger, solid particles.

FULL-CONTACT BALL SCREW SEALS There are several forms of seals that make contact with the outer diameter of the ball screw shaft. The simplest is the brush seal. Although brushes don’t provide a tight, continuous seal with the screw shaft, they are effective at wiping, or brushing away, larger contaminants and preventing them from entering the ball nut.

Brushes are often used in conjunction with other types of full-contact seals, such as lip seals or segmented seals with preloaded “fingers.”

Lip seals and segmented seals are both

designed to make full contact with the raceway of the screw shaft, providing excellent sealing against both fine particulates, such as ceramic dust, and liquids. Segmented seals typically use a spring mechanism to preload protruding “fingers” against the screw shaft. Lip seals are molded in a profile that matches that of the screw cross-section, ensuring there are no gaps between the seal and the screw shaft.

It’s important to note that although fullcontact seals offer the best protection against fine particulates and liquids, they do increase friction and drag torque, which should be taken into account when sizing and selecting the motor. This additional friction also causes heat generation, which can affect lubrication.

NON-CONTACTING BALL SCREW SEALS As their name implies, non-contacting seals leave a small gap between the seal and the screw shaft, with the most common design being plastic labyrinth seals. The lack of contact between the seal and the screw shaft means these designs don’t increase friction and running torque.

However, they can allow smaller particulates and

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AMONG THE OPTIONS AVAILABLE FOR NEW SLA ACTUATORS FROM SCHNEEBERGER ARE COVERS FOR CONTAMINATION PROTECTION IN CLEAN ROOM APPLICATIONS.

11 • 2021

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BALL SCREWS HIGH-PERFORMANCE BALL SCREW SEALS

LABYRINTH SEALS LEAVE A SLIGHT GAP BETWEEN THE SEAL AND THE SCREW SHAFT, SO THEY DON’T INCREASE FRICTION OR DRIVE TORQUE. COURTESY THK

Each manufacturer has its own offering of high-performance seals or seals for special conditions. These range from double- and triple-lipped seals, to combinations of two or more seal types, to full-contact seals specially designed for low-friction operation. And although standard ball screw seals are typically made of Viton (a type of FKM made by Chemours), manufacturers offer other materials, such as EPDM, that can withstand high- and low-temperature extremes and protect against specific chemicals.

As an example, consider the new SLA actuators from Schneeberger, which use recirculating ball linear guides that ensure smooth motion and high load capacity. These actuators can be customized to meet the requirements of a range of precision linear motion application and arexs offered in both a lead-screw design as well as a ball-screw version for higher speeds and duty cycles.

In addition to features such as a wide base for maximum stiffness, custom lengths, and an anti-backlash leadscrew nut, other options include different motor flanges, brake options, a linear encoder option, as well as a cover option for contamination protection for use in applications in clean room environments.

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MOTION SYSTEM APPLICATIONS

HOW TO PREVENT BEARING COUNTERFEITING WITH MARKING SOLUTIONS T

he bearing market has been facing an ongoing scourge of counterfeiting for many years leading to significant challenges for manufacturers and consumers alike. No less than 5.4 million jobs are at stake, as well as a loss of 36 billion euros for the global economy (figures from the World Bearing Association). These figures are prompting major bearing manufacturers around the world to mark their components.

This step helps facilitate internal traceability, maintenance actions, and it improves their corporate identity by offering distinctive and aesthetic signs.

VARIOUS MARKING REQUIREMENTS Every year, millions of bearings are manufactured for numerous sectors such as the automotive and aerospace industries, and the energy and medical sectors. This significant demand generates a wide variety of products, in terms of used materials (steel, ceramic,

or other treated metals) but also in terms of dimensions (larger or smaller diameters or widths). As a result, marking solutions must easily adapt to these differences.

The marking type is also different. The bearings are marked with various information, ranging from alphanumeric production codes or product data (site or date of manufacture) to Datamatrix codes or logos. The inscriptions must be clear, readable, and unalterable. This last point is especially true if the bearings are subject to significant mechanical or thermal stress.

In addition to their great modularity, marking solutions must adapt to different parts’ shapes. Consisting of an inner and an outer ring, bearings commonly have both components engraved. This need for multiplecomponent marking involves flat, circular, concave, and convex markings. All of this while considering cycle times that can sometimes be in the order of a second.

LASER MARKING SIC MARKING, specialists in industrial traceability, has spent over 30 years providing the most appropriate marking solutions to meet industry challenges. Its experience has enabled the French group to offer a technically superior range of laser

SIC MARKING’S INTEGRATED LASERS ARE PARTICULARLY WELL-SUITED TO MARKING BALL BEARINGS, PROVIDING CLEAN AND PERMANENT RESULTS ON ALL MATERIALS, FROM PLASTICS TO CERAMICS TO HARD METALS.

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CONSISTING, AMONG OTHER THINGS, OF AN OUTER AND INNER RING, IT IS COMMON TO ENGRAVE BOTH COMPONENTS IN THE BEARING. marking machines and various automatic reading solutions (Datamatrix).

SIC MARKING’s integrated lasers are particularly well-suited to marking ball bearings, providing clean and permanent results on all materials, from plastics to ceramics to hard metals. The various options available, including the 3D function and Autofocus, ensure perfect marking on all bearing surfaces (outer or inner ring).

The range is completed by three workstations (L-BOX, XL-BOX, and XXL-BOX), allowing a dedicated marking station. This can be integrated into a production line or used as a stand-alone marking station. The production of a small, medium, and even large series is possible. The resizing of the boxes, the creation of specific tooling, and the addition of additional movements (Z-axis, rotary axis) are options available on request.

What makes the strength of the 300

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BEARINGS

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

THE BEARINGS ARE MARKED WITH VARIOUS INFORMATION, RANGING FROM ALPHANUMERIC PRODUCTION CODES OR PRODUCT DATA (SITE OR DATE OF MANUFACTURE) TO DATAMATRIX CODES OR LOGOS.

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employees’ company, apart from its product quality, is its ability to adapt to the different needs of its customers, illustrating its knowledge of tailor-made solutions.

SIC MARKING has 3 competence centers in Europe, America, and Asia, offering specific solutions developed and studied locally.

Thus, the team dedicated to the end-users’ needs is perfectly capable of adapting to the various contacts, whether they are multi-site, process, workshop, or line managers. The particulars of the different sites are carefully studied, whether it’s the surface area available, the technologies for conveying parts, or the environmental constraints.

The laser marking specialist had the opportunity to prove the qualities of its solutions by taking up the challenges proposed by a major Swedish ball bearing manufacturer with a presence in Germany.

The manufacturer wanted to mark an alphanumeric and Datamatrix code on steel bearings with diameters ranging from 150 to 600 mm.

In addition to adapting to the different part sizes, the solution had to be integrated directly into the production line and be able to mark the bearings in two places simultaneously while ensuring that the Datamatrix was read back.

Calling on its many years of experience, the SIC MARKING team offered a customized station, equipped with an IPG 50-W laser, marking on the bearing face, and an IPG 3D laser, automatically controlled on two axes, capable of marking on the part radius. A proofreading system was also integrated to proofread the marking directly, and a conveyor belt, allowing the machine to be integrated into the production line.

In addition to a solution that perfectly met the specifications, SIC MARKING convinced the user thanks to its dedicated organization, local support via its German subsidiary, and a major marking test campaign that mobilized its Laser experts.

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DESIGN WORLD — MOTION

BEARLOK

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MOTION SYSTEM APPLICATIONS

WHAT ARE ELECTROMAGNETIC POWER-OFF BRAKES, AND WHERE ARE THEY USED? P

ower-off brakes are commonly used in motion control applications to stop or hold a load (or both), especially on vertical axes or emergency stop functionality in servo applications. Power-off brakes are so named because the brake is engaged when power is removed from the system — either intentionally or accidentally. (Power-off brakes are also sometimes referred to as fail-safe brakes.)

BRAKE ENGAGED WITH POWER OFF PERMANENT-MAGNET FLUX PATH

While there are many types of power-off brakes, electromagnetic versions are typically used in servo applications. Two designs of electromagnetic power-off brakes — springengaged and permanent magnet — are preferred for applications that require high torque, low backlash, and the ability to be customized to the application.

SPRING-ENGAGED POWER-OFF BRAKES Spring-engaged (also referred to as springapplied) brakes are disengaged electrically via electromagnetic force when power is applied and engaged mechanically via spring force when power is removed. Their construction is

PERMANENT MAGNET BRAKE. COURTESY KENDRION

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ON OFF

ENERGIZED COIL FLUX PATH relatively simple, with a coil, an armature plate, a friction disc, a pressure plate, springs, and a hub. The hub is connected to the shaft of the motor or component to be braked.

To disengage the brake, for normal operation, voltage is applied to the coil. The coil creates an electromagnetic field, and the magnetic flux from this field attracts the armature plate to the coil, which compresses the springs. This releases the friction disc and allows it to rotate, along with the hub and the connected load.

To engage the brake, for stopping or holding, power is removed from the coil. The electromagnetic (attractive) force dissipates, and the armature plate moves away from the coil.

This decompresses the springs, pushing the armature plate against the friction disc, trapping the friction disc between the armature plate and the pressure plate. This stops (or holds stationary) the friction disc, hub, and load.

Spring-engaged electromagnetic power-off brakes are highly customizable, 11 • 2021

BRAKE DISENGAGED WITH POWER ON PERMANENT-MAGNET FLUX PATH with the ability to use different spring forces, friction materials, and operating voltages.

Some manufacturers of spring-engaged electromagnetic brakes tout their high efficiency since the amount of power supplied to the brake can be reduced once the armature plate is engaged. (It takes much less power to hold the armature plate in place once it has been attracted to the coil and the springs have been compressed.) It’s also possible, for brakes that have been appropriately sized, to use over-excitation — the momentary application of voltage higher than rated voltage — to reduce the brake’s response time. However, spring-engaged designs typically exhibit some backlash, so they may not suit applications where precise stopping or holding is critical.

PERMANENT MAGNET POWER-OFF BRAKES Permanent magnet power-off brakes are disengaged electrically with the application motioncontroltips.com

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BRAKES & CLUTCHES

SPRING-APPLIED BRAKE FOR SERVO MOTORS. COURTESY KENDRION

You don’t need to be an expert in clutches, brakes or torque limiters.

of power and engaged magnetically when power is removed. These designs incorporate both an electromagnetic coil and permanent magnets, and an armature plate and a hub.

The key to permanent magnet brake operation is the use of magnetic forces from both the coil and the permanent magnets. When voltage is applied to the coil — to disengage the brake for normal operation — an electromagnetic field is created. This field opposes and negates the field of the permanent magnets. Since there is no magnetic field to attract the armature to the coil, an air gap is created between them. And with no contact (and, therefore, no friction) between the armature and the coil, the armature, hub, and connected load are free to rotate.

To engage the brake — for stopping or holding a load — power is removed. With no power to create an electromagnetic field to counteract that of the permanent magnets, the field produced by the permanent magnets acts on and attracts the armature to the coil, and this metal-on-metal contact creates the braking force.

Permanent magnet electromagnetic poweroff brakes have a strong torque-to-size ratio and can operate at the high speeds servo motors often require, since there are no moving parts.

Permanent magnet versions also don’t exhibit backlash and are typically preferred in highprecision positioning applications. However, these brakes require a consistent, narrow range of current (and, therefore, voltage) to counteract the force of the permanent magnets and release the brake. Conditions that could cause fluctuations in current, such as temperature changes or extreme temperatures, aren’t suitable for permanent magnet power-off brakes.

Because we are.

We Are Your One-Stop Shop For Motion Control Solutions.

When it comes to high-performance, custom-made clutches, brakes and torque limiters, we aim to please. Which is why you’ll find Engineering, Production, Sales, and Product Support all under one roof. All to put you at ease, knowing that we’ll deliver the perfect solution for your applications.

The Mach III Advantage: Rapid Custom Solutions From slight design modifications to unique, clean-sheet creations, we can present you with a customized design solution in about 48 hours.

Built To Order We specialize in high variation, low quantity production. All products are built-to-order, allowing even catalog models to be bored to fit the exact shaft and key size required.

Reliable Ship Dates Every purchase order we receive is confirmed with a ship date that we meet or beat 98% of the time. Lead times for Standard Products: 2–5 weeks and Custom: 3–6 weeks.

To learn more, contact us at 859–291–0849 or email us at engineering@machiii.com DESIGN WORLD — MOTION

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MACH III_1/2 Page ISLAND Ad_FINAL_12.21.20.indd 1

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MOTION SYSTEM APPLICATIONS

THIS PRE-ASSEMBLED MULTI-AXIS MECHATRONIC SYSTEM FROM BOSCH REXROTH INCLUDES A MOTOR, CABLE, AND ALL ATTACHED PARTS AS WELL AS A REXROTH CTRLX SERVO DRIVE WITH A CONTROLLER, ALL IN ONE PACKAGE.

INTEGRATED CONTROLS SIMPLIFY MECHATRONIC DESIGNS M

anufacturing and automation is seeing technology advancements at a steady clip these days, a lot of it centered around Industry 4.0 innovations. These include the latest class of smart technologies that combine digital electronics with communication interfaces, offering more functionality and simplifying the end-user experience.

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DESIGN WORLD — MOTION

One area in which this change has been notable is in mechatronic systems. Mechatronics systems and subassemblies combine mechanical and electrical components into a single system dedicated to a specific task. In the world of motion control, examples include applications in product assembly and transport where mechatronic linear motion systems and

11 • 2021

Cartesian robots are employed. The key to any successful mechatronics application is tight integration of the motors, controls, sensors and linear components.

To that end, Bosch Rexroth recently expanded its Smart MechatroniX platform by adding a new subsystem. The Smart Function Kit for Handling joins the existing kit for Pressing

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CONTROLS and Joining and can be used in a variety of ways, including for production handling, machine assembly and packaging. A Cartesian multi-axis system for packages of different sizes, weights and formats handles pick-andplace tasks. With the new mechatronic kit, users can save time when engineering multi-axis systems. In addition to the preassembled multi-axis system, which includes a motor, cable and all attached parts, a suitable Rexroth ctrlX servo drive and controller is included in the package.

Engineering and runtime apps are also preinstalled.

A story of a successful implementation of such a mechatronic system comes from a sensor manufacturer setting up an assembly line operation to produce rotary encoders. The line was designed to be flexible with the ability to make different products in small batches. It also required exact pressing and joining processes as well as automatic documentation of the process data for quality assurance. The company selected a Smart Function Kit for Pressing, which was delivered as a preconfigured package with no programming knowledge required, which meant that the sensor manufacturer could set up the line quickly before starting operation.

One of the critical production steps involves pressing a small lid precisely onto a sensor housing with high precision. The Smart Function Kit was up to the task, being suitable for forces from 2 to 30 kN and

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combining standard components such as an EMC electromechanical cylinder, force sensor, servo motor, drive controller and industrial PC. Plus, the browser-based HMI software can also be operated via tablet.

Instead of laboriously writing code for the pressing processes, programming takes place visually. Select the software blocks via dragand-drop, combine them, enter the parameters and the workflow is complete. The drive controller parameterizes itself automatically, and a wizard guides the user intuitively through the commissioning process.

In addition, the process data can be shown live and is considered along with the force displacement curve in the IT system for quality assurance management and analysis purposes.

11 • 2021

DESIGN WORLD — MOTION

21

Design World’s Motion Control Classroom An online reference series

for design engineers. Each

motion installment features current trends, videos, typical and emerging

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MC² installments include • Ball Screws • Cable Carriers • Conveyors • Couplings • DC Motors • Gearing • Integrated Motors • Linear Guides • + More

stay up-to-date MC² Classroom installments cover topics including essential power-transmission and motion-control technologies for an array of OEM machines, powered end-user products, servo drives, and automated installations.

learn more at: www.designworldonline.com/mc2

CONVEYORS

CONVEYOR SYSTEM HELPS MODERNIZE 326-YEAR-OLD TEA COMPANY Y

amamotoyama was founded in Tokyo in 1690 when its founder created a new way of steaming green tea leaves, making the product more accessible to the public. Since that time, the company has expanded its operations around the globe while staying current with modern manufacturing methods.

EXPANDED PRODUCTION IN THE U.S. REQUIRES CONVEYOR SYSTEM Yamamotoyama of America sought to improve its Pomona, CA, production operations to achieve greater productivity and flexibility in producing multiple products. The facility operates multiple IMA teabag manufacturing and carton machines, each of which can produce 300 teabags (18 full cartons of teabags) per minute. Once cartons are produced, the next step is packing the full tea cartons into shipper cases, then labeling the cases and palletizing them for shipment. As management at Yamamotoyama planned to expand production, they needed to add more automated case packers, which needed to be sourced from the tea cartoning machines. A carton delivery conveyor system from the tea cartoners to the case packers was required, with the ability to organize multiple flavors to the case packers in the proper grouping of 12 cartons per flavor.

REXROTH’S VARIOFLOW PLUS ALLOWS YAMAMOTOYAMA TO MOVE PRODUCTS HORIZONTALLY, VERTICALLY, ON INCLINE OR DECLINE, OVERHEAD, SUB-FLOOR, AROUND OBSTACLES, AND OVER LONG DISTANCES.

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11 • 2021

DESIGN WORLD — MOTION

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MOTION SYSTEM APPLICATIONS

REXROTH’S VARIOFLOW PLUS INCREASES PRODUCTIVITY AND FLEXIBILITY TO IMPROVE YAMAMOTOYAMA’S ABILITY TO PRODUCE MULTIPLE PRODUCTS.

THE FLEXIBILITY OF VARIOFLOW PLUS IS A BIG PLUS FOR TEA-MAKER

Bosch Rexroth’s VarioFlow plus is a flexible, modular plastic chain conveyor system used for moving high-volume packaged goods and other consumer goods, such as packaged foods, pharmaceuticals, and healthcare products. It can be used to move products horizontally, vertically, on incline or decline, overhead, sub-floor, around obstacles, and over long distances. Workpiece pallets can be used to convey products in applications where positioning or higher precision is needed. The management at Yamamotoyama was interested in VarioFlow plus because of its smooth-

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DESIGN WORLD — MOTION

running belt, low profile channel, tight radius curve wheel, and ability to create a “stacked” conveyor configuration with vertical curves.

MULTIPLE FLAVORS IN A SINGLE CASE PACKER Yamamotoyama of America needed the flexibility to source multiple flavors of tea products from multiple IMA cartoners into a single IMA case packer. Each IMA machine can produce just one flavor of tea at any given time; however, the Yamamotoyama plant is arranged such that the machines are in groups, each producing 18 cartons per minute.

This meant that the conveyor system had to accommodate this volume of tea cartons per

11 • 2021

minute and accurately merge/induct groups of 12 cartons into the case packer without error. A second requirement was to protect the carton surface. The tea product is packaged in glossy, shelf-ready cartons, and the appearance of the carton needs to remain neat and unscratched.

Therefore, a smooth-surface conveyor belt would be required. The third challenge was one of space. The plant equipment spacing is very compact, with minimal lateral distance between production equipment, so the conveyor system needed a small footprint.

CASES SOLVED The mechanical design of the VarioFlow plus

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CONVEYORS

better products. better solutions.

CONVEYOR EXPERTS. You’re an expert in what you do. So it only makes sense to work with an expert in conveyors. Whether it’s a single conveyor or a complete conveyor system, mk has the answer.

VARIOFLOW PLUS’S SMOOTH CONVEYOR BELT ALLOWS YAMAMOTOYAMA TO PRODUCE SHELF-READY CARTONS THAT REMAIN NEAT AND UNSCRATCHED.

mk North America is the conveyor expert you need. mk provides not only a better product, but also a better solution.

conveyor needed to be complemented with custom mechanical devices for controlling product groups of cartons and further integrated with an electronic controls system.

Yamamotoyama system receives the output of the IMA cartoners onto individual takeaway conveyor runs. The Bosch Rexroth conveyor elevations were varied via vertical inclines and lateral offsets to achieve a stacked configuration, allowing for a narrow footprint. At the terminus of the system, the product travels in a vertical incline onto the trunk conveyor via Bosch Rexroth vertical curve declines.

CONVEYORS

PALLET-HANDLING SYSTEMS

FLEXIBLE CHAIN CONVEYORS

www.mknorthamerica.com/DW

DESIGN WORLD — MOTION

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(860) 769-5500 info@mknorthamerica.com

MOTION SYSTEM APPLICATIONS

A STROMAG 2IN1 PERIFLEX VN/MWU COUPLING/CLUTCH ASSEMBLY WAS RECENTLY INSTALLED ON THE HYBRID PROPULSION SYSTEM ON BOARD SWITZERLAND’S FIRST CLIMATE-NEUTRAL CRUISE SHIP WITH ENERGY CONSUMPTION THAT IS 20% LESS THAN A CONVENTIONAL SHIP.

TWO-IN-ONE COMBINATION COUPLING/CLUTCH SIMPLIFIES DESIGNS E

quipment and machinery OEMs worldwide are continually challenged to design cost-effective drivetrains that fit in ever-shrinking spaces. For mobile equipment designers, reducing overall system weight is also a critically important consideration.

Sourcing individual drivetrain couplings and clutches can be time-consuming as engineers hold interface clarification meetings with elastic coupling and clutch suppliers while also ensuring that quality, reliability, efficiency, vibration, footprint, weight, and cost requirements are met.

As the only major power transmission component manufacturer in the world to offer both couplings and clutches, Stromag is uniquely positioned to respond to the growing demand for new drivetrain solutions.

The company’s engineering team recently designed a new line of unique, modular 2in1 coupling/clutch combination assemblies. The pre-engineered combinations have an existing Stromag flexible coupling configured with an existing switchable clutch model for a compact, single-piece solution.

Depending on the application, various models from the line up of Stromag couplings and clutches are combined for electric, hydraulic, or pneumatic actuation. Suitable 2in1 solutions are available for nearly every combination between drive electric motors or diesel engines and pumps, generators, and belt drives.

The power spectrum of the 2in1 clutch/coupling combinations ranges from a few hundred to several ten thousand Newton meters.

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DESIGN WORLD — MOTION

11 • 2021

motioncontroltips.com | designworldonline.com

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All products available directly All products All products available available directly directly All products available directly on RULAND.COM on RULAND.COM on RULAND.COM on RULAND.COM Introductory offer:10% 10% off 10% off •• Introductory • Introductory offer: offer: off your next web order with code • your Introductory 10% off TOOL-LESS ADJUSTMENT COMPONENTS nextyour weboffer: next orderweb with order code with code TOOL-LESS TOOL-LESS ADJUSTMENT ADJUSTMENT COMPONENTS COMPONENTS DW202003 your nextDW202003 web order with code DW202003 ADJUSTMENT COMPONENTS •TOOL-LESS Adjustable handles and knobs replace standard hardware • Adjustable • Adjustable handles and handles knobs and replace knobs standard replacehardware standard hardware DW202003 can bebe used to torque components without tools.

• and Adjustable handles and knobs replace standard hardware and can and used can to be torque used components to torque components without tools. without tools.•• Free Free 2-day 2-day shipping onall alldomestic domestic • Free shipping 2-day on shipping on all domestic can be used to torque components without tools.

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Free orders 2-day shipping on all domestic Levers can • Levers be used can with be Ruland used with shaft Ruland collars shaft for quick collars for quick• web web - no orders minimum - no minimum value. value. and adjustment.

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Ruland Manufacturing is proud installation videos. the FIRST Robotics Competition Largestock stock onhand hand inour our ••support Large • Large on stock in on hand in our asMarlborough, a Gold Supplier ofUSA precision shaft MA USA location.

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ROBOTIC FOR SYSTEMS

EXPANDED COUPLING LINE EXPANDED EXPANDED COUPLING COUPLING LINE LINE PRECISION COUPLINGS COUPLING LINE •Stainless Stainless •steel Stainless oldham steel couplings oldham couplings high temperature for high temperature •EXPANDED steel oldham couplings forfor high temperature

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• and Stainless steel oldham couplings for high misalignment temperature acBeam couplings for light weight & high Controlflex • couplings Controlflex couplings couplings encoders forsingle inencoders single in single doubleand double corrosion resistance.

• •and Controlflex forfor encoders in andand double commodation. insert styles insert and speeds styles and up to speeds 25,000 up RPM. to 25,000 RPM. insert styles and speeds up to 25,000 RPM. Zero-backlash jaw couplings for vibration • Controlflex couplings for encoders in singledampening and double couplings • of Slit with couplings bores with starting bores at starting 1.5mm at 1.5mm speeds styles and speeds up to 25,000 RPM. • •insert Slit with bores starting at 1.5mm andand speeds upand speeds &Slit acouplings variety performance options. up to 70,000 upRPM. to 70,000 RPM. to 70,000 RPM. Bellows couplings for high size to torque ratio.

• Slit couplings with bores starting at 1.5mm and speeds up

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MODULAR MODULAR MOUNTING MOUNTING MODULAR MOUNTING SYSTEMS SYSTEMS SYSTEMS MOUNTING MODULAR •• Assortment • Assortment of of components SYSTEMS Assortment ofcomponents components

to 70,000 RPM.

that that allow to users small to build small thatallow allowusers users tobuild build small • assemblies Assortment ofmounting components for assemblies forsensors, mounting sensors, assemblies for mounting sensors, that allow users to build small conveyor rails, conveyor machine rails, guards, machine guards, conveyor rails, machine guards, assemblies for mounting sensors, and more. and more. and more.rails, machine guards, conveyor • Optional •pre-designed Optional pre-designed kits make kits make and more.pre-designed kits make • Optional UNIVERSAL UNIVERSAL JOINTS JOINTS it easier to select it easier thetoright select system the right system UNIVERSAL JOINTS it easier to select the right • for Optional pre-designed kits system make your application. for your application.

• Friction bearing • Friction forbearing high torque. for high torque. for your to application.

JOINTS SHAFT •UNIVERSAL FrictionCOLLARS bearing for high torque. it easier select the right system • Needle bearing • Needle forbearing accuracy forand accuracy and for your application.

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8 material

VIBRATION VIBRATION ISOLATING ISOLATING COMPONENTS COMPONENTS VIBRATION ISOLATING COMPONENTS • Rubber bumpers • Rubberare bumpers ideal asare end ideal stops as end stops ISOLATING •VIBRATION Rubber bumpers are idealCOMPONENTS as end stops or mounting or mounting feet. feet. mounting feet.are ideal as end stops • •or Rubber bumpers Vibration • isolation Vibration mounts isolation can mounts be can be or mounting feet.

• Vibration isolation mounts can be components sandwiched sandwiched between components between between components to dampen toshock dampen loads. shock • sandwiched Vibration isolation mounts can loads. be to dampen shock loads. components •sandwiched Both types • between Both can have types studs can have or tapped studs holes. or tapped holes. dampen shock loads.

• to Both types can have studs or tapped holes.

• Both types can have studs or tapped holes.

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INDEXINGINDEXING PLUNGERS PLUNGERS INDEXING PLUNGERS • Spring-loaded • Spring-loaded indexing indexing QUICK CLAMPING COLLARS PLUNGERS •INDEXING Spring-loaded plugers with plugers or indexing without with or without

plugers with orindexing without lock-out. lock-out.

Hand operated: no Spring-loaded lock-out. plugers with orto without tools required install, Designed •toDesigned lock devices to lock devices lock-out.for Designed lock devices remove, &to adjust. in-place in-place adjustable for adjustable in-place for adjustable positioning.

• positioning.

Designed to lock devices Best suited for robotic positioning. in-place for systems thatadjustable require positioning. frequent adjustments.

• • •

MOTION SYSTEM APPLICATIONS

“Instead of designing “from scratch” to meet specific customer requirements, the 2in1 modular “smart” design concept allows our engineers to select from a carefully preconfigured family of paired flexible couplings and clutches. These compact pre-engineered combinations can then be quickly modified to meet particular customer needs,” said Ralph Breuer, director of engineering and product management at Stromag.

This modular design approach can significantly reduce costs and lead times. OEMs can experience cost-saving advantages while more easily meeting tighter delivery schedules.

Plus, time-consuming meetings between elastic coupling and clutch suppliers to ensure component compatibility are no longer necessary.

Stromag couplings, including plug-in, highly flexible Periflex VN disc couplings, TRI-R couplings with a combination ring element and diaphragm, and highly elastic SSC steel spring couplings, are all precisely calculated to dampen torsional vibrations to an absolute minimum.

Breuer explained, “Stromag‘s know-how in Torsional Vibration Analysis (TVA) constitutes the core of each coupling design. It provides a comprehensive analysis of loads in the crankshaft, coupling and driven side to ensure that no critical speeds occur during operation.”

Unevenly rotating systems can severely degrade product quality and cause great harm to the powertrain. The TVA experts at Stromag work daily on the challenge of detecting such

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DESIGN WORLD — MOTION

deviations by measuring them and protecting the entire powertrain with accurate product selection. Stromag calculates stationary and transient operating conditions while considering the stiffness and damping of a particular coupling’s elastomers.

These flexible couplings also accommodate various radial, axial, and angular misalignment levels, depending on the model. All couplings meet the following industry classifications: ABS, Lloyd’s, CCS, Bureau Veritas, and DNV-GL. Since the 2in1 combinations are configured into a single piece, there is no need for individual housings, bushings, or keyways. These part reductions combine to provide weight savings which are especially important for marine and mobile equipment applications.

Stromag combination assemblies are provided as an open-running solution required for resiliently mounted engines and rigidly arranged drive lines. However, if desired, the combination units can be integrated into a single SAE housing for direct mounting to diesel engines. Stands and IIoT options are also available.

The unique 2in1 coupling/clutch combination units can be incorporated in many applications across many industries. However, they are particularly popular for marine applications. “We have seen increased demand for these compact 2in1 assemblies partially due to the growing usage of marine hybrid drive systems or alternative drive train solutions due to ecological restrictions in or near harbor areas,” Breuer said.

11 • 2021

DEPENDING ON THE APPLICATION, VARIOUS MODELS FROM THE LINEUP OF STROMAG COUPLINGS AND CLUTCHES ARE COMBINED FOR ELECTRIC (LEFT), HYDRAULIC, (CENTER) OR PNEUMATIC (RIGHT) ACTUATION.

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COUPLINGS Various 2in1 combination assemblies are also well-suited for use on a range of off-highway construction and agricultural machinery, including asphalt milling machines, dozers, excavators, tractors, and combines.

In these construction and agriculture applications, enclosed units for direct mounting on internal combustion engines according to the SAE standard are used on air compressors, and hydraulic fluid pump drives. Units can also be used on belted drives applications such as asphalt milling machines. Output-side is designed for easy “Plug & Play” connection to work machines.

Stromag www.stromag.com

STROMAG’S MODULAR, 2IN1 PRE-ENGINEERED COMBINATIONS HAVE AN EXISTING STROMAG FLEXIBLE COUPLING CONFIGURED WITH AN EXISTING SWITCHABLE CLUTCH MODEL FOR A COMPACT, SINGLE-PIECE SOLUTION.

DESIGN WORLD — MOTION

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LIGHTING YOUR WAY L E D R I N G D I S P L AY F O R E A S Y S TAT U S R E V I E W

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00

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Easy to install. Simplistic design. Minimal installation requirements. Highly reliable. The Yaskawa GA500 will give you confidence that it will stay up and running after you leave the job.

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YAI-DW_11.2021.indd 1

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DRIVES

DRIVES EXCEL IN CONVEYING APPLICATIONS

AS

the pace of automation continues to accelerate, key automation and control components such as controls and drives are evolving to meet new challenges and provide more functions to designers and end-users. Broader industry trends such as the rise of the IoT and the related industrial IoT (IIoT), with its emphasis on data and connectivity, as well as an increased emphasis on safety have driven recent design improvements.

motioncontroltips.com | designworldonline.com

Such improvements can benefit a range of industrial uses, including packing and conveying applications. One recent example comes from Siemens. The company’s Sinamics G115D is a new compact and powerful drive system specifically designed for horizontal conveyor applications. The drive system comprises the motor, drive and gearbox in one unit and is offered in two versions — wallmounted and motor-mounted.

The Sinamics G115D drive system

11 • 2021

THE SINAMICS G115D DRIVE SYSTEM FROM SIEMENS IS COMPACT AND POWERFUL AND SPECIFICALLY DESIGNED FOR HORIZONTAL CONVEYOR APPLICATIONS.

DESIGN WORLD — MOTION

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ISO 9001:2015 | AS9100D ITAR Compliant - DDTC Registered DFARS Compliant NIST SP 800-171 Compliant We deliver precision gears, high-quality machined parts, and molded components for thousands of applications.

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DRIVES

features a robust design with a high IP protection class (up to IP66 / UL Type 4X) and is suitable for use in harsh environments. Its compact dimensions allow it to be installed in confined areas. The drive system can also be operated reliably over a wide temperature range of -30 to 55 °C (-22 to 131 °F), enabling operation in extreme environments such as deep freezing applications.

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

To be prepared for digital transformation and to enable cloud-based analysis, Sinamics G115D is integrated into the entire MindConnect portfolio and is compatible with MindSphere applications such as Analyze MyDrives. With respect to safety features, thanks to Profisafe, the Sinamics G115D has Safety Integrated in the form of STO (Safe Torque Off) SIL2, which standardizes and facilitates the certification process. For flexibility in terms of installation, service and maintenance, it’s equipped with a plug-in connector and flexible connection possibilities. The device is particularly suitable for interaction with Simatic controllers such as the Simatic S7-1200 or Simatic ET200 for motion control.

motioncontroltips.com | designworldonline.com

THE SINAMICS DRIVE SYSTEM COMBINES A MOTOR, DRIVE, AND GEARBOX INTO ONE UNIT, AND IS SHOWN HERE WITH A SMART-ACCESS WIRELESS MODULE.

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DESIGN WORLD — MOTION

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MOTION SYSTEM APPLICATIONS

THE MULTI-DOF ENCODER LINE FROM HEIDENHAIN ALLOWS MACHINE MANUFACTURERS TO IMPLEMENT METROLOGY DESIGNS TO OBTAIN MULTIPLE MEASUREMENTS SIMULTANEOUSLY.

ENCODERS OFFER PROGRAMMABILITY, MULTI-DIMENSIONAL MEASUREMENTS E

ncoders are employed in all kinds of motion systems to measure position as well as speed, providing feedback to increase system accuracy and reliability.

They’re typically grouped by a number of distinguishing features including operating principle, whether they are linear or rotary, or whether they are absolute or incremental encoders. And just as other components in motion systems evolve, encoder manufacturers are making sure that their offerings keep pace with these broader technological changes.

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Encoders — Motion System Applications 11-21.indd 34

One way that encoders have evolved is by offering more connectivity options, which in turn means added features such as selfdiagnosis and better programmability. For example, industrial networks like Ethernet IP or ProfiNet can collect data in real time while also letting operators fine tune sensor and encoder performance via adjusting software parameters.

Machines and systems used in the packaging industry are one application area where programmability can provide a huge advantage. The challenge: getting exactly the right position sensor for a specific packaging 11 • 2021

application. This is where sensors and encoders from companies like POSITAL can make a difference. The company’s programmable rotary encoders give designers a cost-effective and convenient way of configuring sensors to deliver exactly what’s needed.

With the company’s programmable IXARC encoders, key performance characteristics such as resolution, communications interfaces and measurement ranges can be set up through firmware updates, with no need for mechanical changes. This helps designers fine tune their devices for optimal performance. It also motioncontroltips.com | designworldonline.com

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ENCODERS benefits distributors and machine builders who can reduce parts inventories while still offering a wide range of performance characteristics.

POSITAL’s UBIFAST programming tool provides an easy-to-use wireless interface for making software updates.

For POSITAL’s programmable incremental encoders, resolution (anywhere between one to 16,384 pulses per revolution), direction and communications interface driver (HTL or TTL) can all be defined through software parameters. In the case of absolute encoders with analog interfaces, their outputs – current or voltage - can be ‘scaled’ so that a predetermined range of mechanical motion (anything from a fraction of a turn to several hundred rotations) can be set to span the full electrical output range, significantly improving accuracy for simple analog control systems.

The company’s encoders offer more versatility with the addition of accessories such as measurement wheels and draw-wire

mechanisms. These can transform rotary encoders into accurate linear measurement tools. For conveyer belt systems, for example, wheel-equipped encoders can take measurements directly from the moving surface to provide precise speed and position feedback. For cut-to-length applications, wheel/encoder assemblies can measure position directly from the surface of materials such as fabric, paper, wire, or sheet metal. Accuracy in this operation improves productivity and reduces scrap losses.

ENCODERS OFFER MULTI-DIMENSIONAL MEASUREMENT CAPABILITY Traditionally, an encoder is only able to measure deviations along a single axis and although these can be corrected via some controllers, they can still be blind to common but unavoidable effects of guideway error or thermal linear expansion (to name a few) which would cause deflection along multiple axes.

Using multiple reader heads allows for the detection of these deflections, allowing for the necessary compensation at the inception and ensuring the integrity of the machine.

One example of this multi-dimensional measurement capability comes from HEIDENHAIN’s MULTI Degrees of Freedom (or MULTI-DOF) encoder line. It offers machine manufacturers a better way to implement metrology designs to obtain multiple measurements simultaneously and the capability of correcting deviations on the fly. Conventional encoders offer one degree of motion, but these encoders do more to serve the demanding requirements of machines in the semiconductor and electronics industry, among others.

The three new encoders include the LIP 6031 Dplus, the GAP 1081, and the MKV 1/9x30. The LIP 6031 Dplus is based on the standard HEIDENHAIN LIP 6000 linear encoder. In essence, two LIP 6000 encoders

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have been integrated into a single device to read two graduation tracks on a measuring scale angled at ± 45° relative to each other, thereby making it possible to measure in both the main direction and orthogonally to the main direction at a measuring length of ±2 mm.

The GAP 1081 is the first gap encoder from HEIDENHAIN. Rather than using interferometry for gap measurement, it uses HEIDENHAIN’s own encoder technology enabling measurement of the gap between a mirrored scale and the scanning head. Out-of-plane measurement is thus easy to implement in a metrology design.

Lastly, the MKV electronics enables the bus capabilities of EnDat 3 interface by reading the position values of up to four 1-VPP scanning heads. This is useful for multi-dimensional encoders where the readings from each head can be calculated and sent to the controller on just a single cable. This also allows a reduction in the number of cables required and prevents the controller from needing to make such calculations.

www.posital.com 36

DESIGN WORLD — MOTION

11 • 2021

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GEARING & GEAR DRIVES

SHOWN HERE IS AN AC INDUCTION GEARMOTOR WITH OFFSET GEARING CUSTOMIZED FOR USE IN COMMERCIAL ICE-MAKING EQUIPMENT. POWER ELECTRIC’S SOLUTION UTILIZES PROVEN MOTOR AND GEARING TECHNOLOGY IN A CUSTOMIZED FORM-FACTOR TO LET THE MACHINE BUILDER DROP IT INTO THEIR EXISTING MACHINE DESIGN. COURTESY POWER ELECTRIC

GEARS IN MOTION APPLICATIONS G

ears complement electric motors in industrial and consumer designs. Consider some examples: Amusement rides to consumer-grade beard trimmers make use of spur gears.

These roll through meshing for up to 98% or higher efficiency per reduction. The only caveat is that they exhibit tooth sliding and noise due to initial tooth-to-tooth contact and audible shock loads.

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

Non-parallel and right-angle gears go into motion applications for material handling, aerospace and defense, packaging equipment and food-processing machinery.

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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 often go into material-handling and packaging equipment. Hypoid gears (useful for high-toque applications) are like spiralbevel gearsets, but output and input shaft axes don’t intersect — and that simplifies integration of supports. Common in aerospace, zerol gearsets have curved teeth that align with the shaft to minimize thrust 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. Common in material-handling setups, shaftmounted gear reducers come in truly shaft-mounted designs that use special couplings to address reactionary torque. Other shaft-mounted reducers mount to the machine housing (especially in machine setups with surrounding enclosures) so the input shaft doesn’t support the reducer.

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

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DESIGN WORLD — MOTION

39

GEARING & GEAR DRIVES Consider worm-gear reducers. These typically go into low to moderate-horsepower motion applications because they have high ratios and high output torque but are cost effective and compact. Most worm gears are cylindrical with teeth of consistent size; some worm-based reducers have double-enveloping tooth geometry (in which pitch diameter is deep and short and then deep again) to boost tooth engagement.

Metal cutting and forming machinery, construction equipment, and packaging machinery all benefit from the low backlash of this gearing type. To illustrate, printing-press rolls hold tight print registration at high speeds thanks to the ability of double-enveloping worm gearing to 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.

Gearheads, much like gear reducers, are useful where applications call for high torque at low speed. They reduce a load’s reflected mass inertia, so ease the acceleration of big loads ... which in some cases, even lets

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machines run off smaller motors. Gearheads range from basic spur gearheads to complex planetary gearheads and strain-wave gearheads, all exceling in select applications.

The latter (also called strain-wave gearing) is for special speed-reduction applications. More specifically, this gearing is indispensable in robot-arm articulation, medical equipment, and offshore drilling.

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

11 • 2021

AS AUTOMATION BECOMES MORE INTEGRATED INTO MEDIUM AND HEAVY-LOAD ACCUMULATION AND ASSEMBLY APPLICATIONS, THERE’S MORE NEED FOR CONVEYORS HAVING ZONING CAPABILITIES. NOW AN EDGE ROLLER TECHNOLOGY (ERT250) PRECISION PALLET AND TRAY-HANDLING DESIGN FROM DORNER CAN HANDLE ZONE FUNCTIONALITY FOR PRODUCT ACCUMULATION WITHOUT HAVING PALLETS BUMP INTO EACH OTHER DURING CONVEYOR BACK-PRESSURE SITUATIONS. A LINEAR GEARBOX DRIVE SYSTEM CREATES ZONES BY REMOVING A LOWER GEAR TO LOCATE A SPLIT BETWEEN ZONES. EACH ZONE ACTS INDEPENDENTLY OF OTHERS VIA A BRUSHLESS DC GEARMOTOR. PALLET SENSORS AND CONTROL LOGIC DETERMINE WHEN A PALLET IS FREE TO ADVANCE OR IF A PALLET IS STOPPED DOWNSTREAM. IF A PALLET MUST STOP, IT STOPS IN THE NEXT ZONE. MOTORS OPERATE ONLY WHEN PALLETS ADVANCE FORWARD OR REVERSE.

COURTESY DORNER

DESIGN WORLD — MOTION

41

MOTION SYSTEM APPLICATIONS 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.

CYCLOIDAL-REDUCER DESIGN APPLICATIONS The eccentric rolling-mechanism gearheads known as cycloidal reducers are a type of servo gearing that has an input shaft that drives a bearing assembly. This in turn drives a cycloidal disc (sometimes called a cam) that connects to an output shaft. The cam has lobes or teeth that engage with a cam follower — typically with pin or needle bearings. The eccentric cam rotation

induces rotation of an output shaft at a lower speed and higher torque than the input.

The main advantage of cycloidal reducers is their property of zero or near-zero backlash (to 1 arc-min.) which makes for high precision and high accuracy. This is especially in demand where highly precise and accurate positioning is required, for instance in robotic applications, machine tools, and similar applications. Cycloidal reducers also feature rolling as opposed to sliding contact, thus experiencing less overall wear. Some cycloidal speed reducers offer zero backlash by combining a compound reduction cam with a full complement of needle-bearing cam followers.

Because of the pin-and-gear structure, cycloidal gearing maintains continuous and distributed power-transmission contact for higher shock resistance than traditional reducers. In fact, some variations can withstand transitory exposure to quadruple their rated torque. High torque density makes for ratios to 185:1 in reasonable gearbox footprints.

THIS IS A SPINEA HIGH-PRECISION CYCLOIDAL REDUCER FROM DIEQUA CORP. SPINEA TWINSPIN (TS) REDUCERS HAVE A UNIQUE SPEED-REDUCTION MECHANISM AND RADIALAXIAL BEARINGS TO OUTPUT PRECISION MOTION. THE REDUCERS ARE ALSO MORE COMPACT THAN OTHER CYCLOIDAL REDUCERS ON THE MARKET. IN SMALLER SIZES THEY EVEN COMPETE WITH FLEX-SPLINE GEARING WITH HIGH TORQUE DENSITY AND RIGIDITY.

STRAIN-WAVE GEARING EXCELS IN COMPACT AUTOMATION AND ROBOTICS APPLICATIONS NEEDING HIGH RATIOS AND TOP EFFICIENCY. SHOWN HERE ARE NEW SUREGEAR HIGHPRECISION INLINE STRAIN WAVE GEARBOXES FROM AUTOMATIONDIRECT — DESIGNED TO WORK WITH SURESERVO AND SURESTEP MOTORS AND DELIVER RATIOS TO 200:1.

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DESIGN WORLD — MOTION

11 • 2021

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MOTION SYSTEM APPLICATIONS

NEW DESIGNS WITH LINEAR GUIDES

L

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 sliding-contact 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 that can’t tolerate contamination, linear guides that use rolling elements (as well as plain bearing systems) are unsuitable because of their need for lubrication requirements.

ONE NEWER APPLICATION OF LINEAR GUIDES IS ON LINEAR-MOTOR CONVEYORS, ALSO CALLED INTELLIGENT TRANSPORT SYSTEMS. “USING ECOSTRUXURE MACHINES FROM SCHNEIDER ELECTRIC, INCLUDING THE NEXT-GENERATION LEXIUM MC12 MULTI CARRIER SYSTEM, MAKES OUR OPERATIONS MORE EASILY INTEGRATED,” SAYS FEDERICO SCORNAIENCHI, EXPORT MANAGER FOR MACHINE BUILDER LIVETECH.

COURTESY SCHNEIDER ELECTRIC

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DESIGN WORLD — MOTION

inear guide systems include guide rails, slides, and ways. Industry categorizes them into a few basic types as well. A typical arrangement includes a rail or shaft, and carriages and runner blocks.

11 • 2021

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MOTION SYSTEM APPLICATIONS Some applications demanding extremely high precision and accuracy use fluidfloated bearings for the highest accuracy and precision possible. These are hydrostatic or aerostatic bearings using a high-pressure fluid between the rail and carriage. They’re more expensive and harder to manufacture than other linear options but get top precision and accuracy.

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. Preloading is sometimes needed as well depending on 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.

Consider how automated storage and retrieval systems (AS/RS) make copious use of linear systems. AS/RS BEND-TECH — A WISCONSIN COMPANY installations contrast with traditional SPECIALIZING IN CNC TUBE AND PIPE CUTTING warehouses that use forklifts with MACHINES, TUBING, AND PIPE BENDING limited height, as they make far more SYSTEMS — RELIES ON THOMSON LINEAR efficient use of vertical space. The only ACTUATORS FOR CONSISTENT AND ACCURATE caveat is that the expansive volumes MOTION CONTROL ON ITS PLASMA CUTTING, preclude regular access by personnel MARKING, AND ENGRAVING SYSTEMS. for operations or maintenance — so necessitate particularly reliable linear ONE MOTION CONTROL ASSEMBLY THAT guides, slides, and actuators for THOMSON CUSTOMIZED FOR BEND-TECH automation.

INTEGRATED A STEPPER-MOTOR-DRIVEN In some cases, these linear systems LEADSCREW INTO PREVIOUSLY BALLSCREWtake the form of aluminum components DRIVEN LINEAR SLIDE. THE THOMSON (in areas where the motion design must handle moderate loads) or steel SLIDES BOLT TOGETHER IN A CROSS-LIKE components where payloads exceed FORMATION TO MOVE A PLASMA-CUTTING 100 kg or so. Consider an automatedTORCH AND MARKING TOOLS. warehousing shuttle arm that uses

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DESIGN WORLD — MOTION

11 • 2021

LINEAR SLIDES & GUIDES

inductively hardened raceways (paired with carriages) and telescopic rails to prevent deflection under load, even when extended.

One such installation serves the medical industry by moving test-tube samples around a refrigerated warehouse for tests. In this application, a robot moves along rails to reach shelves running along warehouse corridors. Quick directional changes and rail irregularities are two main challenges because the robot must go from track to perpendicular track with speed and precision. Various rail profiles with hardened raceways (and sliders that mate with theses profiles) help these linear systems compensate for any framing surface misalignments.

WHEN TO USE TRACK-ROLLER LINEAR GUIDES FOR A GIVEN APPLICATION With so many linear guide choices, deciding which technology to specify for a given application can be difficult. On one hand, not every application requires machine tool rigidity and the ability to move a small car. On the other hand, most applications

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require a guide that can withstand high duty cycles in an industrial environment. Among linear-guide technologies that excel in more challenging motion applications are trackroller linear guides. Linear guides based on track rollers often serve in two challenging application types: Long-stroke linear-motion axes such as those driven by belts or rack-and-pinion sets Linear systems in harsh environments subject to hot and humid conditions, extremely cold temperatures, washdowns, abrasive materials, extreme loading, and corrosive chemicals.

However, other uses abound. Here we list five benefits that track-roller linear guides offer for applications ranging from light industrial off-highway designs to large-scale material handling.

Speed of track-roller linear guides: Because track rollers are based on radial rather than recirculating bearing elements, they can travel at higher speeds than ball or roller-based profiled-rail guides. Track-roller linear guides can commonly reach speeds

11 • 2021

GRIFFITH TEXTILE MACHINE IS A MANUFACTURER OF LUXURY CARPETS THAT USES ITS MACHINERY TO PRODUCE MORE THAN 250,000 M 2 OF CARPET PER YEAR FOR HOTELS, MUSEUMS, GOLF COURSES, AND RESTAURANTS. HEPCOMOTION GV3 VEE-BASED LINEAR MOTION OFFERINGS FROM BISHOPWISECARVER WITHSTAND THE CHALLENGES POSED BY THE DUST AND FIBER GENERATION ASSOCIATED WITH CARPET WEAVING, WHICH IS WHY GRIFFITH TEXTILE MACHINE USES HEPCOMOTION LINEAR PRODUCTS ON BOTH ITS FAST AX2 CARPET WEAVING MACHINES.

DESIGN WORLD — MOTION

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MOTION SYSTEM APPLICATIONS TRACK-ROLLER LINEAR GUIDE ERROR ABSORPTION

ADMISSIBLE TANDEM-TRACK HEIGHT DIFFERENTIAL (MM)

100

50

0

-50

-100

ERROR FROM MOUNTING-PLANE MISALIGNMENT 0

250

500

1,000

1,500

2,000

2,500

DISTANCE BETWEEN TWIN TRACKS ON A TANDEM-SUPPORTED AXIS (mm) beyond 10 m/sec. Standard acceleration limits are 50 m/sec2 although higher accelerations are possible by increasing the preload of the trackroller wheels to avoid slipping. For applications such as pick-and-place or assembly, track-roller linear guides offer the highest speeds of virtually any linear guide.

Weight of track-roller linear guides: Trackroller assemblies benefit from weight that’s far lower than that of other linear-guide options. As mentioned, one typical track-roller linear guide construction consists of an aluminum rail with steel guide inserts and an aluminum carriage block with steel rollers. In contrast, recirculating bearing carriages and rails must be made almost entirely of steel for higher load carrying capacities, which improves rigidity … but greatly increases weight.

The lower weight of track-roller linear guides enables the increased acceleration limits already discussed and is beneficial in highly dynamic applications — especially those with multiple axes.

Robustness of track-roller linear guides: Contamination that destroy the recirculating bearings of profiled rail is less detrimental to track-roller linear guides, so even the harshest environments rarely call for special sealing or protective coverings. That said, harsh washdown or corrosive applications benefit from guide rails

48

DESIGN WORLD — MOTION

and carriage bodies constructed of noncorrosive materials or coatings for additional protection.

Also: While recirculating bearings live and die though proper lubrication, the radial bearings that support track-roller linear guides are oftentimes fully sealed and lubricated for life — especially smaller variations. Manufacturers may recommend a light oil or grease application between the trackroller wheels and the guide rail or offer lubrication ports or wipers to extend relubrication intervals … though in almost all cases, the lubrication requirements are far less stringent than those for profiled rail. That’s another benefit of having the working load-bearing elements encased within the track-roller wheels.

Track-roller linear guide servicing: Unlike recirculating bearings having a set preload typically determined by ball or roller selection, most track-roller linear guides accept preloading adjustments by the user during installation. That means as application conditions fluctuate or components wear, preload can be further adjusted to maintain rigidity, speed, and performance. This also simplifies replacement because adjustable preload means that bearing blocks and guide rails are interchangeable.

Mounting track-roller linear guides: For profiled rails with recirculating bearing elements, 11 • 2021

TRACK-ROLLER LINEAR GUIDES ARE INDISPENSABLE ON EXTENDED-STROKE APPLICATIONS, WHERE THEY CAN COMPENSATE FOR SLIGHT GEOMETRICAL INCONSISTENCIES THAT ARE QUICKLY MAGNIFIED INTO SIGNIFICANT ERRORS BY LENGTHY AXIS STRETCHES.

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LINEAR SLIDES & GUIDES error in alignment degrades bearing preload accuracy and induces uneven loading as well as premature wear. This is not the case for track-roller linear guides, because carriage preload is adjustable — making mounting requirements for track-roller assemblies much less stringent than those for profiled rails.

In most cases, mounting a track-roller linear guides rail doesn’t require a reference edge, even when mounting two guide rails in parallel.

Because many track-roller linear guide rails are aluminum, mounting them to aluminum substructures (such as extruded profiles, requires no special preparation or machining for flatness or straightness. This makes trackroller linear guides a good choice for selfassembled linear actuators.

Taking this forgiving mounting feature a step further are some track-roller linear guides in large-scale printing and slicing applications. Many of these can even

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accommodate imperfect machine-frame geometry. Here, track-roller linear guide pairs with complementary geometry accommodate the changing direction of the force vectors resulting from machine-frame misalignments.

More specifically, such track-roller linear guide pairs might include: One guide with a C-shaped track having a flat raceway surface — to impart lateral freedom to a couple millimeters or more Another guide with a track that constrains the track-roller wheels on one flank while permitting slight rotation on the other flank — to impart angular freedom to a couple degrees or more Together the linear guides work well even on nonmachined out-of-parallel surfaces for linear strokes sans excessive friction. In contrast, traditional linear guides in such applications register misalignment as additional load that (due to no DOFs in the

11 • 2021

mounting surface or linear guides) causes tensile force within the guide assembly — even to the point of binding. That’s an especially distinct possibility on very long machine axes where even small assembly errors cause rather dramatic effects over the course of strokes that are multiple meters long.

DESIGN WORLD — MOTION

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MOTION SYSTEM APPLICATIONS

MOTORS MEET DESIGN CHALLENGES IN MEDICAL EQUIPMENT, AGVs I

t’s no secret that smaller motors pack more of a punch these days than ever before.

Design improvements have lead to motors packing more power and torque into smaller footprints, and they’ve also gotten quieter, making them more suitable for applications where excessive noise is an issue.

Case in point; a new series of brushless dc motors that are used in medical equipment where the minimization of noise is a key requirement. The compact brushless dc motors, called the Silencer, are from Moog and are used to help medical equipment makers reduce the size and sound of devices like oxygen concentrators and ventilators.

For patients reliant on oxygen therapy for a severe lung disease, oxygen concentrators offer more mobility than heavy, bulky oxygen tanks. But patients say even smaller devices weighing as little as five pounds and measuring less than 12 in. wide and tall can be noisy and tiring to carry. To meet these challenges, Moog Industrial Controls segment, a division of Moog Inc., offers designers and makers of medical equipment the Silencer BN Series Brushless DC Motors for oxygen concentrators. The smallest Silencer motor, including housing, measures 1.2 in. in diameter and 1.3 in. long.

The Silencer series motors have a continuous torque ranging from 2.4 to 519 oz/in., speeds up to 20,000 rpm and range-rated power up to 874 W. “By using the compact Silencer motor series in an oxygen concentrator’s compressor system, designers can make these systems far smaller and more easily carried,” said Michael Starks, Moog’s Design Engineering Manager in Murphy, NC, “The smoothrunning Silencer means low noise—hardly perceptible acoustically—for patients requiring an oxygen concentrator throughout their daily activities and at night while sleeping.”

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DESIGN WORLD — MOTION

BX4 MOTORS FROM FAULHABER OFFER HIGH RELIABILITY AND HIGH TORQUE FOR APPLICATIONS IN ROBOTICS AND MEDICAL DEVICES. THE MOTORS CAN BE USED IN COMBINATION WITH ENCODERS AND GEARHEADS, AND OPTIONS ARE AVAILABLE FOR SPEED AND MOTION CONTROLLERS AS WELL.

The Silencer’s high level of efficiency also ensures a longer battery operating life for oxygen concentrators, whether running in a pulse-flow or continuous mode. Moog also designed the Silencer with high-energy magnets and exceptional winding density to not only reduce the motor’s size but also generate nearly twice as much torque as conventional stator technology.

“Along with oxygen concentrators, ventilators are an application in which medical equipment makers successfully use Silencer motors,” added Moog’s Robbie Queen, Sales Manager at Moog Murphy. “We supply the entire air blower, consisting of both motor and integrated fan.”

MOTORS DRIVE AGVs IN IIoT MANUFACTURING One of the goals of Industry 4.0 and the Industrial Internet of Things (IIoT) is that individual products should be designed and equipped according to customer requirements – with the highest possible level of automation. This requires flexibility in manufacturing processes that is not compatible with the permanently installed path of a conveyor belt. In the Adaptive Machine Platform Prolynk, manufacturing machinery and assembly stations can be configured and combined with complete flexibility. The parts move individually from station to station, in a mini-taxi so to speak. FAULHABER supplies the drive technology for the small AGVs. With the Prolynk technology, the configuration of the “assembly line” can

11 • 2021

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MOTION SYSTEM APPLICATIONS

be freely adapted or reconfigured, following changing requirements. The components no longer travel on a predetermined path, but instead take a taxi in the form of a small driverless transport unit (automated guided vehicle, or AGV). “The part to be processed is reliably transported to all required stations,” explains Antonio Sanchez, Chief Commercial Officer of Prolynk. “The processing steps, whether performed manually or by robots, can occur completely individually. Yet, the sequence is still automated.” A platform made of standardized table-shaped modules serves as the physical basis of the system. It consists of standardized plates and can be designed freely with respect to size and shape. Simple metal plates form the base unit and serve as movement surface. A variant of the base plate is equipped with fastening indexing units. For production steps that require high precision or for which a larger application of force needs to be compensated, they hold the vehicle and component in position. Here, the plate element also has an opening in the middle. This can be used to perform processing from below as well, as it corresponds exactly to the shape of the opening in the AGV. The Prolynk AGV is available in two sizes (325 x 230 and 450 x350 mm); the maximum load is between 5 and 35 kg depending on the model.

The component to be processed is secured for travel to the individual assembly stations via the opening in the middle. These stations can be freely attached, including manual jobs as well as tasks performed automatically by machines or robots. The MC 5004 P motion controller and the IE3-1024 series encoders from FAULHABER play a key role here. They detect the rotation of the brushless motors of the BX4 series, which is used by the Prolynk electronic motherboard to do the odometry, calculate AGV position and manage motion control. The motor’s force is transferred to the drive belts of the wheels by planetary gearheads of the 32/3 design. “If a company decides on the Prolynk solution, the small AGVs become the heart of a production process. They must, thus, function completely reliably and with a low level of maintenance, over as long a time as possible, securing a low total cost of ownership” says Antonio Sanchez, explaining the priorities for selecting the AGV components.

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DESIGN WORLD — MOTION

THE SILENCER MOTOR SERIES FROM MOOG FEATURES LOW NOISE — AT LEFT WITH HOUSING, AND RIGHT WITH STATOR-ROTOR SET. “With the drive unit, the quality of the products had top priority for us.”

The vehicle has little space to spare, but even so a great deal of motor power is needed to move what are often heavy parts at the required speed. The BX4 motors have a power density that can handle the job and is a key factor in both the reliability and flexibility of the AGV. The combination of reliability and flexibility gives users of the Prolynk solution maximum flexibility in designing their production processes. They can theoretically get started with a small platform consisting of just a few plates and a single mini-AGV. The system can be freely expanded or reorganized, with high flexibility and machine adaptability. Smart functions are available and the Prolynk technology is easy to integrate into PLC architecture. New products, new processes and technologies can also be easily integrated; the existing modules can be rearranged depending on circumstances.

11 • 2021

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MOTION SYSTEM APPLICATIONS

MANY BELT SPROCKETS ARE MADE OF IRON THOUGH STEEL PULLEYS CAN BE SUITABLE IN DESIGNS THAT RUN AT HIGH SPEEDS — TO 20,000 FPM. ALUMINUM PULLEYS ARE ANOTHER LOW-INERTIA OPTION THAT RUN HIGH-FPM BELT DRIVES.

BELT DRIVES COMPLEMENT ELECTRONICS MANUFACTURE M

otion applications make wide use of belts and sprockets of urethane, double-sided, mini-pitch, and made-to-order (MTO) designs. Double-sided belts have covered teeth to transfer up to 100% of the maximum rated load from one or both belt sides. These come in trapezoidal timing-belt configurations and HTD curvilinear tooth profiles. Some can run to 14,000 rpm with speed ratios to 10:1, which is enough to replace gearsets in some cases.

Double-sided belts also excel as serpentine drives in riding mowers with counter-rotating blades, printing presses, and textile machines. Urethane belts maximize motion transfer, especially when incorporating polyester or aramid tensile members. Their tooth profile is a miniature version of belt with standard 40° angle teeth. Speed ratios reach 8:1 and torque output is to a couple lb-in. These belts excel on positioning axes, thanks to their low torque and minimal backlash — especially in printers and copiers that need clean operation.

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SHOWN HERE ARE SERVOMOTOR-DRIVEN AXES FITTED WITH SYNCHRONOUS BELTS ON A MACHINE INVOLVED IN ELECTRONICS MANUFACTURE.

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Custom Mach ine & Tool Co., 301 Winter Inc. Street P.O. Box 298 Hanover, MA 02339

Manufacturers Motion Cont of Power Transmission and rol Compone nts

Email or call to get your CMT Stock Products Catalog.

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Manufacturers of Power Transmission and Motion Control Components

Custom Machine & Tool Co., Inc. 800-355-5949 sales@cmtco.com www.cmtco.com

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CMT - MSA 11-21.indd 55

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MOTION SYSTEM APPLICATIONS

TYPICALLY, TOOTHED TIMING BELTS USED FOR MATERIAL HANDLING (CONVEYING) TASKS ARE VERY LONG. THE BELT’S LOAD SIDE LIES IN A FRICTION-INDUCING SUPPORT RAIL. THE BRECOROLL BELT SHOWN HERE HAS ROLLERS INTEGRATED INTO THE BELT TEETH TO AVOID SLIDING FRICTION — AND INSTEAD RELY ON ROLLING FRICTION FOR LESS STRESS ON THE BELT AND MOTOR. COURTESY BRECOFLEX

POWER TRANSMISSION-PART CONVEYING

Long belting (usually with L or H trapezoidal tooth or HTD profiles) can exceed 500 feet in some cases. They work for power transmission and axis synchronization — doing double duty as conveyors in many cases. Such belts complete with rack-and-pinion sets in machine tools and X-ray equipment as a viable drive for linear strokes. One caveat: These belts spliced transmit a quarter less horsepower than a comparable endless belt.

Made-to-order (MTO) belts take myriad forms, but most are trapezoidal and HTD. Those that go into applications involving the assembly or transport of electronics or explosive substances include a body and tooth-facing fabric made of conductive material such as carbon to prevent static discharge. In contrast, belts for power tools and appliances are often made of non-conductive materials that insulate internal components. Belts that run in harsh environments incorporate oil-resistant and temperature-resistant compounds. Elsewhere, tensile members made of aramid withstand shock loads, and steel members help belts maintain positioning accuracy. Engineers can even customize the twist of members to alternate or go left or right to satisfy tracking requirements.

Another option is thick or backed belts to convey or grip objects in tandem with mating belt drives. Backings can also extend belt life and address vibration.

For industrial applications, most belt sprockets are made of either cast or ductile iron. That said, steel excels in designs that run at speeds exceeding those safe for iron pulleys — to 20,000 fpm. Likewise, aluminum pulleys run at high speed and have low inertia to boot. Another lightweight option is nonmetallic pulleys — common in lawn equipment and power tools that transmit little torque and have relatively short design life. Other synchronous-sprocket options include specialty tooth profiles for better positioning accuracy or custom hub mounts and flanges.

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SENSORS

SENSORS ENSURE ACCURATE POSITIONING OF AUTOMOTIVE ROBOTS I

n all kinds of machinery, sensors play a central role in providing vital information on machine operation. More often than not they are the unseen elements that make complex machines and systems perform at their optimal level. Perhaps nowhere is this more evident than in robotic applications. The sensors used in robots provide an interface to the external world the robot interacts with, providing data on speed, light, force, or position among others.

One example of position sensors comes from robots used in automotive manufacturing. In particular, rotary position sensors from Newtek, the company’s RV series, ensure performance accuracy of industrial robotic systems used throughout automotive assembly plants.

Car factory robots perform a variety of assembly tasks, such as picking and placing for example. They’re typically used to pick and place heavy components such as doors, engines, windshields, and motors, relieving human workers from having to perform such dangerous lifting tasks. Other robots used in automotive manufacturing perform tasks including arc and spot welding in attaching chassis components on an assembly line and painting, sealing, and coating automotive bodies. In all of these applications, rotary position sensors provide highly accurate angular displacement measurements to ensure the correct positioning of robotic arms.

The RV series sensors from Newtek feature a shaft that rotates 360° with no stops, and can measure shaft angle position over a nominal range of ±30°.

motioncontroltips.com | designworldonline.com

Without internal components to wear or degrade, this RVDT (rotary variable differential transformer) technology offers long mechanical life even in the harsh, wet, and dirty locations of automotive assembly. Non-contact measurement also offers greater accuracy in measurement feedback.

The RVDT-based sensors are reliable and rugged, operating with higher accuracy and longevity in areas with high temperatures, vibration, and shock. In this case, a wide operating temperature range of -65 to 221°F (-55 to 105°C) ensures long-term reliability in the hot environments of automotive production.

Shock and vibration tolerant, these ac-operated RVDTs also offer good noise performance.

The units are available in both a size 8 (0.75-in.) and size 11 (1.06-in.) diameter. As the ac-operated rotary position sensor requires external excitation, NewTek NTC-6000 LVDT Signal Conditioner powers the sensor while converting its position output into 4-20 mA, 0-5 V, 0-10 V, or RS-485 format for robotic control systems.

THE RV SERIES ROTARY POSITION SENSORS FROM NEWTEK ARE DESIGNED TO OPERATE RELIABLY IN APPLICATIONS SUBJECT TO HIGH TEMPERATURES, VIBRATION, AND SHOCK.

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MOTION SYSTEM APPLICATIONS

NEW SHOCK AND DAMPER USES S

hocks 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 and other passive dampers can absorb or attenuate vibrations. Here, the components bear the whole machine weight to shift excitation off the natural frequency.

Shock and vibration-damping components range from heavy-duty machine tools to delicate designs that assemble semiconductor components.

Addressing oscillations lets machines run faster for more throughput and more accurate moves.

Isolators should usually shift a design’s natural frequency so it’s no more than one-third of the excitation frequency. One caveat is that overly compliant isolators can increase the magnitude of motion. One solution

SHOWN ABOVE IS A SOFT-DAMPING MINIATURE SHOCK ABSORBER FROM ACE CONTROLS. THESE ARE SUITABLE FOR USE ON LARGE DRIVEWAY GATES THAT NEED TO OPERATE QUICKLY BUT SAFELY, EVEN AT THE ENDS OF STROKE.

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motioncontroltips.com | designworldonline.com

SHOCK & VIBRATION MITIGATION

Buy a Solution Fast with ACE Motion & Vibration Control Products Industrial shock absorbers

SHOWN HERE ARE ISOLATION HEMISPHERES FROM SORBOTHANE. THESE ARE STANDARD STOCK PRODUCTS THAT ARE USEFUL FOR ISOLATING TEST-BENCH EQUIPMENT THAT EXHIBIT 20 TO 30% DEFLECTION WHEN STATICALLY LOADED. ALL SIZES ARE AVAILABLE WITH PRESSURE SENSITIVE ADHESIVE.

Industrial gas springs Vibration isolation

where this is an issue is hydraulic or magnetorheological 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. 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 nanometerlevel and better accuracy demands.

VIBRATION ISOLATION EXAMPLE ON DRIVEWAY GATES Consider this application example from ACE Controls — that of hydraulic driveway gates.

Upon deceleration to their open or closed positions, these gates can vibrate or twist. One solution to prevent such movement distortion is to slow the gate’s swing speed … though that can degrade endusers’ experience with the gate. Another option is servo deceleration, which can add costly and complex electrical controls to the gate system. A third and better option is end-of-stroke damping.

Recently, a gate builder asked ACE Controls to design two shock absorbers for installation close to the gate pivot. This

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arrangement created a couple of inches of deceleration near the pivot, resulting in roughly two feet of deceleration at the gate end positions. The shock absorbers also manage a high effective weight — nearly all of it being a product of the hydraulic driving force.

The miniature shock absorbers used in this swing gate application are the ACE Controls SC650s — suitable for soft damping with an energy capacity of 650 lb-in. per cycle and 600,000 lb-in. per hour. With a stroke length of 1 in., this series is available with soft-contact minimal effective weights from 24 to 800 lb and maximum effective weights from 80 to 2,400 lb. In addition, these selfcompensating units can react to changing energy conditions without adjustment.

Additional features and specifications include a maintenance-free, ready-to-install design; an integrated positive stop; and impact angles up to 25° when used with a side load adapter.

Thanks to these attributes, the SC650 shock absorbers effectively decelerate moving gate energy … a small portion of the overall system energy. Because most of the energy is from the hydraulics, the shock absorber can be considered a varying-velocity flow control, because as the shock absorber gradually slows, the hydraulic system slowly DESIGN WORLD — MOTION

59

Standard products available to buy online Tools Sizing & specification ▪ Online calculations & product selection

▪ One-on-one

application assistance

Resources Online & downloadable ▪ ACE CAD database ▪ ACETips video tutorials ▪ Technical blog & case studies

800-521-3320 www.acecontrols.com

MOTION SYSTEM APPLICATIONS

VIA DREAMSTIME

increases flow across the relief valves as if it has servo-controlled deceleration.

In addition to driveway gates, the softcontact miniature shock absorbers are wellsuited for industrial, automation and machine engineering applications — especially when it comes to parts and materials handling.

PROVEN SHOCK, VIBRATION & NOISE REDUCING SOLUTIONS

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OTHER OPTIONS FOR MITIGATION OF VIBRATION No matter the subtype, shocks and vibrationdamping 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.

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

Another product to damp vibrations is magnetorheological fluid from Lord Corp.

This is a blend of magnetic powder in oil, water, or glycol that reversibly changes from free-flowing to semi-solid when subject to an electromagnetic field. Particularly useful in automotive applications that must accommodate changing road and driving conditions, magnetorheological components can replace traditional hydraulic fluid in shock absorbers.

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SHOCK & VIBRATION MITIGATION Yet another option is gas springs — sometimes called gas dampers, tension springs, gas-pressure springs depending on the setup and application. These compressed-air or oil cylinders install in motion designs to damp forces and return kinematic linkages and more complicated assemblies to default positions.

Gas springs work through a piston on the end of a rod that protrudes from a steel cylinder body; usually compressed gas (often nitrogen) within the cylinder exerts force on this piston to reassume and maintain set positions. Nitrogen is common here because it’s inert and nonflammable. In such designs, oil or grease between the piston and other contacting parts minimize friction.

QUANTIFYING APPLICATION VIBRATION CRITERIA WITH VC CURVES Precision manufacturing and testing processes are highly sensitive to vibrations, which often result from both internal sources such as foot traffic, fans, and pumps, and external ambient sources such as outside traffic, construction, and other nearby industrial activities.

To address these concerns, a set of generic vibration criteria was created in the 1980s by Eric Ungar and Colin Gordon, providing a guide for designers of vibration-sensitive manufacturing facilities and equipment.

Note: The vibration criteria (VC) are often represented as velocity spectra in 1/3-octave bands. The original criteria included four levels labeled VC-A through VC-D. In 1994, a fifth level was developed (VC-E) and the vibration criteria were standardized by the Institute for Environmental Sciences and Technology or IEST. Through additional testing and analysis, the criteria have been expanded to now span levels VC-A to VC-M. A 1/3-octave band is a frequency band that, rather than covering an entire octave, has a width defined by an upper band frequency (f2) that is equal to the lower band frequency (f1) times the cube root of 2.

To develop the vibration criteria (VC) curves, vibrations are measured in the vertical and two horizontal directions. Vibration can be expressed as displacement, velocity, or acceleration, but it’s important to note that for the VC curves, the original developers chose to express vibration in terms of root-mean square (RMS) velocity. This is because studies have shown that while different types of equipment exhibit maximum sensitivity to vibration at different frequencies, these points often lie on a curve of constant velocity.

The vibration criteria (VC) curves also use a proportional bandwidth — in other words, bandwidth is proportional to frequency — rather than a fixed bandwidth. The proportional bandwidth was chosen because experience demonstrates that in most environments, vibration is dominated by broadband, or random, energy rather than tonal, or periodic energy. With a proportional bandwidth, the center frequencies of the individual bands are standardized, and the bandwidth of each band is 23% of its center frequency.

Often depicted with VC curves are the four ISO guidelines related to the effects of vibration on people in various types of buildings or environments. And some vibration charts also

motioncontroltips.com | designworldonline.com

depict the NIST-A criterion — originally developed for metrology applications — alongside the VC curves.

In conjunction with the VC curves, a table was developed to define the maximum level, or amplitude, for each criterium and to describe how and where each criterium is deemed to be most applicable. For example, the VC-C criterium allows an amplitude of 12.5 μm/sec and is deemed to be appropriate for “optical microscopes to 1000X, inspection and lithography inspection equipment (including moderately sensitive electron microscopes) to 1 μm detail size, and TFT-LCD stepper/scanner processes.”

The table often includes a specification labeled detail size.

According to the original developers, this refers to the “line width in the case of microelectronics fabrication, the particle (cell) size in the case of medical and pharmaceutical research” — another indication of the VC curves’ original focus on the microelectronics, medical, and biopharmaceutical industries. But despite being developed with these three industries’ needs in minds, the vibration criteria have now been accepted and adopted by many industries that use vibration-sensitive equipment, as the basis for designing facilities, mounts, and vibration-dampening systems to meet required vibration levels.

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SPRINGS

THE BASICS OF SPRINGS IN MOTION APPLICATIONS T

ypically mounted deep inside an assembly of moving parts, industrial springs often go unnoticed, despite their importance to motion control and industrial equipment. In fact, they’re found in everything from door closing mechanisms on machine tools to mechanical seals in rotary unions. While springs are readily available in custom designs and variations, there are three primary types used in industrial applications: compression springs, extension springs, and torsion springs. Knowing the basics about each type of spring can help in selecting the right one for an application.

COMPRESSION SPRINGS Springs that resist axial compressive forces are categorized as compression springs. They’re one of the most common types of springs and one of the most efficient at storing energy. When force is applied to a compression spring, it compresses, or shortens, and stores energy. As the spring tries to return to its original length, it releases this energy and “pushes back” against the load.

Wave springs are a type of compression spring made of flat wire with waves added to each turn of the wire. The addition of waves in the spring results in a high spring force with a lower working height than traditional round-wire

compression springs. Industrial applications for wave springs include vibration isolators and bearing retention for rotating equipment.

EXTENSION SPRINGS Springs that resist tensile forces — forces that attempt to pull them apart — are known as extension springs or tension springs. Extension springs are coiled with an initial tension, and when the spring is lengthened, it creates a “pulling” force as it tries to return to its original shape. These springs have loops or hooks on the ends so they can be easily attached to components that need to be held together via the spring’s force.

One way to describe the primary difference between compression and extension springs is their load at zero deflection.

Compression springs have zero load at zero deflection. Extension

COMPRESSION SPRINGS ARE OPEN-COIL HELICAL SPRINGS WOUND OR CONSTRUCTED TO OPPOSE COMPRESSION ALONG THE AXIS OF WIND.

motioncontroltips.com | designworldonline.com

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PICTURED HERE ARE A RANGE OF TORSION SPRINGS FROM NEWCOMB SPRING CORP. TORSION SPRINGS RESIST TWISTING (TORSIONAL) FORCES AND COME IN A WIDE RANGE OF SIZES AND LEG DESIGNS. springs, on the other hand, experience a load at zero deflection due to their initial tension.

A common example of extension springs are those used on trampolines. Industrial uses include medical devices and door mechanisms on automated equipment.

Unlike a compression spring, which can only be compressed to its solid height, an extension spring has no mechanism to prevent overloading.

TORSION SPRINGS Torsion springs are designed for applications that need resistance to twisting forces (torque), rather than axial tension or compression forces.

Torsion springs are helically wound springs with arms on the ends that rotate about the spring’s central axis. The arms are connected to the external components, which apply a load to the spring. It’s important to note that the load on a torsion spring should only be applied in the direction that causes the spring’s diameter to decrease. A common example of torsion springs are those used in clothespins.

For applications that require high torque, two torsion springs can be combined, with a space between them, to create what is known as a double torsion spring.

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AD INDEX MOTION SYSTEM APPLICATIONS 2021

Ace Controls................................................................... 59 AllMotion.......................................................................... 4 Beckhoff Automation....................................................... 7 CGI Inc............................................................................ 38 Chieftek Precision.......................................................... 49 CMT ............................................................................... 55 Del-tron.......................................................................... 45 Diequa............................................................................ 43 Digi-Key Corporation....................................................... 3 Encoder Products Company.......................................... 35 Ewellix............................................................................ 15 FAULHABER MICROMO.........................................53, IBC Festo................................................................................. 9 Harmonic Drive............................................................. BC Intech.............................................................................. 46 Lee Spring Company...................................................... 62 Mach III........................................................................... 19 maxon ............................................................................ 51

mk North America, Inc................................................... 25 NBK America LLC........................................................... 29 Parvalux.......................................................................... 40 PBC Linear...................................................................... 13 PM B.V............................................................................ 21 POSITAL FRABA............................................................. 36 Pyramid Inc..................................................................... 56 Renishaw........................................................................ 37 Ruland Manufacturing Co., Inc....................................... 27 SEW Eurodrive................................................................. 1 Sorbothane..................................................................... 60 Stock Drive Products/Sterling Instrument...................... 32 THK America, Inc...........................................................IFC Ultra Motion................................................................... 11 WAGO Corporation......................................................... 5 Whittet-Higgins.............................................................. 17 Yaskawa Electric America............................................... 30 Zero-Max, Inc................................................................... 2

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motioncontroltips.com | designworldonline.com

Miniature Actuator with Integrated Servo Drive

The Servo Drive is Inside!

The compact RSF-5 miniature actuator with a zero backlash Harmonic Drive® gear delivers high torque with exceptional accuracy and repeatability. The actuator features an integrated servo drive utilizing CANopen® communication. This evolutionary product eliminates the need for an external drive and greatly improves wiring while retaining high-positional accuracy and torsional stiffness in a compact housing. This new miniature actuator is ideal for use in robotics.

• Actuator + Integrated Servo Drive utilizing CANopen communication conforming to DS402 and DS301 • 24VDC Nominal +7 to +30VDC Supply Voltage Range • Single Axis BLDC Motor Controller/Driver with CAN & TTL-UART Interface • Field Oriented Control • Single Cable with only 4 conductors needed: CANH, CANL, +24VDC, 0VDC

• Zero Backlash • Pigtail Connectors with 2 exit options • 14bit (16384 cpr) resolution motor encoder • Control Modes Including Torque, Velocity, and Position Control, CSP, CSV, CST • Harmonic Drive HDL Software for initial tuning, commissioning, and analysis • Homing modes include: single-ended, doubleended, double-ended with 16bit autoscale hardstop homing or teachable position

42 Dunham Ridge, Beverly, MA 01915 | 800.921.3332 | www.HarmonicDrive.net Harmonic Drive is a registered trademark of Harmonic Drive LLC. CANopen is a registered trademark of CAN in Automation.

DW RSF-5 Integrated Ad 9x10.875.indd 1

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