Motion System Applications 2018

NOVEMBER 2018

DE S I GNWOR LDONLI NE . COM

M OTIO N CO N TRO LTIPS.CO M

MOTION SYSTEM

APPLICATIONS

A Solution for Every Motion Application

final cover – motion casebook 11-18.indd 1

11/21/18 11:42 AM

Step-Up for Savings ®

With SureStep integrated stepper motors and drives INTEGRATED MOTORS/DRIVES STARTING AT

$97.00 (STP-MTRD-17038)

SureStep® Integrated Steppers Starting at $97.00 (STP-MTRD-17038)

Integrated stepper motors and drives save panel space, require less wiring and are less expensive than traditional stepper motor and drive separates.

Standard models include: • Pulse/Direction or CW Pulse/CCW Pulse input • Externally-wireable encoder included on select models for feedback to an external controller • Three optically isolated digital inputs, 5 to 24 volts • Optional step input signal smoothing • Dynamic smoothing reduces jerk, limiting system resonance • Electronic damping eliminates midrange resonance • Idle current reduction option saves energy when system is idle • Configurable hardware digital noise filter, software noise filter • Non-volatile storage, configurations are saved in FLASH memory on-board the DSP • Dynamic current control provides smoother motion and allows the motor to run cooler

Advanced models ALSO include: • Pulse/Direction or CW Pulse/CCW Pulse or A/B Quadrature input • Velocity (oscillator) and position mode (internal indexing) • Control via streaming SCL commands over RS-485 • RS-485 ASCII (2- or 4-wire) communications • Internal encoder included on select models for improved position and speed control • Four “Variable I/O” points, 5 to 24 volts (NEMA 24 models) • Analog input for speed and position, 0 to 5 VDC

Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2018 AutomationDirect, Cumming, GA USA. All rights reserved.

automation direct – motion systems applications 11.18.indd 1811-DesignWorld(2)-IntegratedSteppers-MAG.indd 1 1

FREE! SureMotion Pro Configuration Software • Provides easy configuration and setup of the drive, including: motion control modes, I/O and motor • Open, Save, Upload and Download configuration files • Status Monitor screen aids troubleshooting • Self Test Mode verifies motor wiring and functionality • SCL Terminal window allows testing/verification of SCL (serial ASCII) commands before programming begins • Comprehensive Help Files include technical data, application information, advanced setup and serial command instructions • Used for advanced models only (standard models configured via simple DIP switches)

Also Available Traditional Stepper Systems (separates)

SureGear® Precision NEMA gearboxes

Linear Motion Slides and Actuators

Research, price, buy at:

www.automationdirect.com/stepper-systems

1-800-633-0405

the #1 value in automation

11/16/18 3:23 PM 10/2/2018 11:42:33 AM

ONE SYSTEM, UNLIMITED POSSIBILITIES

ETHERLINE®: Data Communication Systems for Ethernet Technology LAPP’s ETHERLINE® cables and connectors provide fast, secure and reliable network connectivity in demanding industrial and process control environments— guaranteeing the long-term success of your automation efforts.

• • • • • • • •

High data transmission rate Company-wide access to data Better process monitoring and control EMI protection Category 5, 5e, 6, 6a or 7 Fast assembly—RJ45 or M12 connectors Stationary, continuous flex and torsion options Supports common Industrial Ethernet protocols, including PROFINET, EtherNet/IP and EtherCAT

To learn more, visit https://lappusa.lappgroup.com/etherline-cables-and-wires.html ETHERLINE ® ETHERNET DATA SYSTEMS

lappusa.com

lapp group usa – motion systems applications 11.18.indd 1

11/16/18 3:26 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Want to be a better problem solver?

Step away from the workbench

EACH YEAR, our special Motion System Applications issue shines a spotlight on the many new and creative ways engineers are solving the design challenges they face.

Leaving aside for the moment the engineering end of the equation, I wondered about the process of problem solving itself – what makes an engineer a good problem solver?

What characteristics do such engineers possess?

Executive editor Lee Teschler addressed similar themes in a recent editorial by asking whether the best engineers were born or made.

What some of the most recent studies pointed to was the importance of unstructured play and discovery in early childhood, allowing one’s natural curiosity to be awakened and nurtured.

Another perspective comes from the field of medicine. I recently attended a lecture by Dr. Salvatore Mangione, a medical doctor who also teaches at Jefferson University Hospitals in Philadelphia. His question; “does medicine need the humanities?” (Spoiler alert: his answer is yes.)

Dr. Mangione told the audience how almost half of a doctor’s time with patients is spent in front of a screen of some kind (laptop computer, tablet, or monitor) and only around 12 % actually interacting with the patient in front of them. A growing number of doctor’s lament this fact because they believe it adversely affects the quality of patient care.

As an antidote to doctors becoming mere screen-addicted cogs in a medical technocracy, he stressed the importance of a complementary humanities education in the arts, music, and literature to foster creativity, visual thinking, and empathy. He cited growing awareness of how such an educational experience translates into better one-on-one care by having an ability to see problems from multiple perspectives in order to better understand and ultimately treat patients. His medical students are encouraged to learn to draw or play a musical instrument, act or write plays and visit museums.

2

DESIGN WORLD — MOTION

editorial MILES – motion casebook 11-18.indd 2

Two notable examples of creative problem solvers Dr. Mangione cited were Leonardo DaVinci and Albert Einstein. DaVinci was a polymath who broke the rules by being a creative visual thinker, but also an outsider who, in his words, was an ignoramus and an idler. Being able to view things from an outsider’s perspective allowed him to see situations differently and invent solutions that others couldn’t. As for Einstein, a well-known anecdote recounts that when stuck on a problem he would stop working, pick up his violin and play for a bit until the solution came to him. In reflecting on his work, he said "When I examine myself and my methods of thought, I come close to the conclusion that the gift of imagination has meant more to me than any talent for absorbing absolute knowledge."

Which brings us back to engineering problem solving and how it may well involve the two factors of play and diversity of interests.

Both factors can make us attuned to our innate playfulness and creativity and how we can use those in constructive ways to solve problems. Most of us already know that when stuck on a problem it helps to step away and focus on something other than the immediate problem at hand.

Doing so gives one part of the brain a break while engaging another where answers often arise unbidden.

So the message for engineers may be to widen their horizons, to expand the scope of their interests, to re-awaken a dormant passion or hobby. Learn a new skill – a foreign language, a musical instrument, take up painting or scuba diving. Combined with your technical knowledge, chances are these added skills will only make you MILES BUDIMIR a better problem solver.

11 • 2018

SENIOR EDITOR

motioncontroltips.com | designworldonline.com

11/20/18 2:12 PM

Raise Your Predictivity iQ

Manage your production maintenance proactively.

Wear and tear of mechanical systems is inevitable, but having advance notice of impending breakdowns can mitigate production losses and scrap. Ensure you can meet production demands and maintain mechanical integrity with Mitsubishi Electric’s advanced analytic algorithms, remote monitoring, and diagnostics of your installations.

Protect and predict with Mitsubishi Electric Pak/iQ ™. www.mitsubishipackaging.com

AD-VH-00102

mitsubishi – motion systems applications 11.18.indd 3

11/16/18 3:26 PM

NEW!

M O T I O N S Y S T E M A P P L I C AT I O N S

4 AXIS SERVO from

Lots of lip service about science,

2.25”

but little action

IT HAS BECOME TRENDY for scientists to run for political office. The Huffington Post reports hundreds of scientists in the U.S. had their names on ballots in the recent midterm elections. The reason seems to be widespread worries about a downplaying of scientific conclusions in political mandates.

Yet recent statistics indicate these scientifically educated nouveau politicians might be worrying about the wrong data set.

It could be argued that the funding of science in private industry rather than the government policies surrounding it are of most concern.

That’s the feeling you get from economists who say the days of big U.S. investments in science are over. The OECD (Organization for Economic Co-operation and Development ) estimates that China now spends about 45% as much as the U.S. on R&D, but that figure is really equivalent to 88% of what the U.S. spends if purchasing power is factored in. R&D funding is rising rapidly in China. In the U.S., not so much, particularly among manufacturers.

The disparity is hard to figure given all the recent emphasis in the U.S. on economic growth. It’s become a truism that increases in national output are based largely on advances in science. And some of the biggest scientific advances have come not just from universities but also from prominent manufacturing firms – say the words “Nobel Prize” and institutions such as Bell Labs and IBM spring to mind.

But since the 1990s, large industrial U.S. firms slashed budgets for big corporate labs.

There are claims that small research-intensive start-ups have taken up some of the slack. But by some measures, industry just doesn’t put as much value on science work as it did in the heyday of Xerox’s Palo Alto Research Center and General Electric’s labs.

So say researchers from Duke University and the University of East Anglia in the UK who recently studied the changing nature of corporate R&D. Writing for the National Bureau of Economic Research, they concluded that companies generally are devaluing basic research while simultaneously boosting their patenting efforts. One telling statistic:

- brushed or bldc motors - 5 amps per axis - 16 analog inputs - 16 on/off drivers - home and limit in - live tech support - made in the USA See the

EZQUAD SERVO in action!

WWW.ALLMOTION.COM

(510) 471-4000 30097 Ahern Avenue Union City, CA 94587 Te c h n i c a l S u p p o r t

(408) 460-1345

4

editorial LEE – Motion Control HB 08.18 V1.indd 4

DESIGN WORLD — MOTION

Whereas Fortune 500 firms garnered 41% of the prestigious R&D 100 awards in 1971, they accounted for only 6% of those awards in 2006.

Meanwhile, the implied value of patents in the marketplace, including the premium paid for patents in merger and acquisition activities, has remained stable. The implication is that the work that goes into patenting – which is largely in the category of development rather than research – has a higher value in the eyes of company managers. That companies spend less on science but emphasize patenting suggests there’s more incentive to protect what you have rather than do fundamental work that could lead to new ideas, says the NBER team.

One culprit, the researchers argue, is global competition as measured by changes in the amount of Chinese imports. A growing Chinese import stream is correlated with diminishing investments in U.S. science, R&D, and in physical equipment. All in all, low-cost competition may encourage incremental and patentable research, but may discourage more long-term, basic research, according to the NBER researchers.

Interestingly, there’s no evidence that patent applications draw less from scientific discoveries these days, nor reason to think company managers see scientific discoveries as becoming less useful, the NBER team says.

All in all, if scientists-turned-politicians really want to make an impact, perhaps they ought to do more hand-wringing about why corporations don’t bother to fund science and less about bending it for political reasons.

LEE TESCHLER

EXECUTIVE EDITOR

11 • 2018

11/20/18 1:51 PM

s

n

High HighPerformance PerformanceStep StepMotor MotorSystems Systems STR STRand andSTRAC STRACSeries SeriesStepper StepperDrives Drivesare are compact, compact,powerful, powerful,digital digitalstep step&&direction direction drives drivesideally ideallysuited suitedtotodrive drive2-phase 2-phasehybrid hybrid step stepmotors. motors.

HT HTStep StepMotors Motorsare areoptimized optimizedfor for microstepping microsteppingand andcome comewith withnumerous numerous options optionsincluding includingencoders, encoders,gearheads, gearheads,and and holding holdingbrakes. brakes.

Industrial Industrial Strength Strength atat Competitive Competitive Prices: Prices: • DC-powered • DC-poweredSTR STRdrives drivesstart startatat$75 $75 • AC-powered • AC-poweredSTRAC STRACdrives drivesstart startatat$325 $325 • HT • HTstep stepmotors motorsstart startatat$28 $28 • STM-R • STM-Rintegrated integratedsteppers steppersstart startatat$98 $98

Features FeaturesInclude: Include: • Dip • Dipswitch switchsetup setup- No - Nosoftware softwarerequired required • Step • Step&&direction direction(digital (digitalpulse) pulse)control control

STM-R STM-RIntegrated IntegratedSteppers Steppersput putour ourstepper stepper drive drivetechnology technologydirectly directlyinto intothe themotor motortoto create createa auser-friendly user-friendlyand andpowerful powerfulintegrated integrated stepper steppermotor. motor.

• Advanced • Advancedmicrostepping microsteppingperformance performance

AllAllthis thistotohelp helpyou youMake MakeititMove.

Move.

• Encoder • Encoderoptions options– –Optical Opticalororcapacitive capacitive incremental incrementalencoders, encoders,absolute absoluteencoders encoders

• Sophisticated • Sophisticatedcurrent currentcontrol control • Anti-resonance • Anti-resonancealgorithm algorithmelectronically electronicallydamps damps resonance resonancefrequencies frequenciestotocreate createsmooth smoothmotion motion and andoptimize optimizethe thedynamic dynamictorque torqueoutput output

• Holding • Holdingbrake brakeoptions options • Planetary • Planetarygearheads gearheadsinina awide widerange rangeofofratios ratios 800-525-1609 800-525-1609 www.Applied-Motion.com www.Applied-Motion.com Email: Email:sales@applied-motion.com sales@applied-motion.com

Applied Motion — MC Handbook 8-18.indd 5

11/16/18 3:28 PM

Design World FOLLOW THE WHOLE TEAM ON TWITTER @DESIGNWORLD

Editorial

Creative Services

VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_Editor

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

Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3Dprinting

Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer

Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_LeeTeschler

Graphic Designer Allison Washko awashko@wtwhmedia.com

Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_Motion

Videography Services

Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_MaryGannon Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_LisaEitel Associate Editor Mike Santora msantora@wtwhmedia.com @dw_MikeSantora

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

Videographer Derek Little dlittle@wtwhmedia.com Videographer Graham Smith gsmith@wtwhmedia.com

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

Events

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

Events Manager Jen Kolasky jkolasky@wtwhmedia.com @wtwh_Jen

Webinar Manager Lisa Rosen lrosen@wtwhmedia.com

Events Marketing Specialist Christina Lograsso clograsso@wtwhmedia.com @wtwh_christina

Webinar Coordinator Halle Kirsh hkirsh@wtwhmedia.com Digital Marketing Coordinator Lexi Korsok lkorsok@wtwhmedia.com @wtwh_Lexi Leadlift Onboarding Specialist Mike Ulanski mulanski@wtwhmedia.com @wtwh_mike

Digital Media/Web/ Development Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_WebDave

Senior Digital Media Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick

Production Services Customer Service Manasger Stephanie Hulett shulett@wtwhmedia.com Customer Service Representative Tracy Powers tpowers@wtwhmedia.com Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com Customer Service Representative Julie Ritchie jritchie@wtwhmedia.com

Digital Production Manager Reggie Hall rhall@wtwhmedia.com Digital Production Specialist Brian Furda bfurda@wtwhmedia.com Multimedia Specialist Jaeden Froese jfroese@wtwhmedia.com

2011 - 2018

2014 Winner

6

Videographer Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh

Digital Marketing

DESIGN WORLD — MOTION

staff page – motion CASEBOOK 11.18.indd 6

11 • 2018

motioncontroltips.com | designworldonline.com

11/20/18 1:59 PM

festo – motion systems applications 11.18.indd 7

11/16/18 3:29 PM

Inside MOTION SYSTEM

A P P L I C A T I O N S

EDITORIAL:

Actuators .. .............................................................10 Bearings .. ............................................................... 14

Want to be a better problem solver? Step away from the workbench

Belts & Pulleys . . .................................................... 18 Brakes & Clutches . . ............................................. 20

BY MILES BUDIMIR | PAGE 02

Cables.................................................................... 22 Chain ..................................................................... 24

Lots of lip service about science, but little action

Controllers .. .......................................................... 25 Conveyors ............................................................ 30

BY LEE TESCHLER | PAGE 04

Couplings .. ............................................................ 36 Damping Springs . . ................................................ 41 Drives .................................................................... 43 Encoders .............................................................. 52 Gearing ................................................................. 56 Gearmotors .......................................................... 62

14

22

HMI . . ....................................................................... 66 Linear Guides, Slides & Ways . . ......................... 69 Motors DC .................................................................. 76

ON THE COVER:

Linear ............................................................ 78

Brixel walls (including the mirrored variation shown) can serve as animated facades, railings, dividers, and fences based on arrays of independently actuated bricks. Within each brick, a stepper motor drives commanded rotations through a geartrain.

Image courtesy Breakfast LLC

Stepper.......................................................... 80 Positioning Stages, Gantries & XY Tables ..... 85 Seals . . .................................................................... 90 Shocks & Vibration Damping.............................. 91 Transducers & Sensors . . .................................... 94

8

DESIGN WORLD — MOTION

contents – motion CASEBOOK 11-18.indd 8

11 • 2018

motioncontroltips.com | designworldonline.com

11/20/18 2:59 PM

— ABB servo motors precise control in a compact design

ABB’s AC servo motors were created for industrial, automated applications that require precise control for positioning, speed and acceleration such as packaging, labeling, wrapping, and cutting.

Designed for durability, we also offer a wide choice of inertia, winding, and feedback options.

More torque. Less cogging. Superior performance.

479-646-4711 new.abb.com/motors-generators

abb motors – motion systems applications 11.18.indd 9 ABB DW Servo Motors Ad_0718.indd 1

11/16/18 3:29 PM 10/11/18 4:36 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Linearin actuators medical sit-to-stand lifts BY 2050 there will be two billion people older than 60, according to the WHO … and 2035 will see a 12.9 million shortage of healthcare professionals. Fortunately, some new technologies could help satisfy the growing need for healthcare, especially in the segment of the industry dedicated to patient rehabilitation.

Consider one relatively new assistive technology — sit-to-stand patient lifts. These let patients work on recovery with less help from nursing or other staff. In some cases, they even let patients recover at home with more independence. In contrast with traditional patient lifts operated by a caregiver, sit-to-stand lifts let the patient control the machine (with help from a caregiver) to increase the feeling of self-reliance.

Linear actuators from LINAK include an array of safety features to work in such patient lifts. The manufacturer leverages experience to satisfy country and international standards … and ensure patient safety and healthcare-professional ergonomics. Some actuators are built to specific standards — such as EN10535 for the prevention of overload and abuse, for example.

Patient-lift actuators for both traditional and sit-to-stand lifts are heavily tested. Consider the LA40 PL — an actuator capable of smooth output of 8,000 N for its full stroke, even with significant side load. Combining it with a BAJL Li-Ion battery, design engineers can impart eco-friendliness to lift designs.

For safety, the LA40 PL also includes an end-stop switch and a ratchet spline to ensure the patient won’t fall or get squeezed while operating the lift.

Visit linearmotiontips.com for more on this application.

10

DESIGN WORLD — MOTION

Actuators – Motion Control HB 08.18 V6 FINAL.indd 10

11 • 2018

linearmotiontips.com | designworldonline.com

11/20/18 4:07 PM

A C T U ATO R S

ELECTRIC! LA40 PL image courtesy LINAK

!

NEW

FIVE CONSIDERATIONS FOR ACTUATING VERTICAL AXES Mounting orientation is one of the core considerations when sizing and selecting a linear actuator. Depending on the type of linear guides used, some actuators can support higher downward or lift-off loads than side loads, or can handle pitch and yaw moments better than roll moments — all important factors when evaluating an actuator for vertical duty. The type of drive mechanism also influences an actuator’s suitability for vertical operation. Screws, whether ball screws or lead screws, are generally preferred over belts or linear motors for carrying loads vertically, but they do have some limitations.

The unique challenges of working against (and sometimes with) gravity go beyond just loading. Below are five factors that designers and engineers should consider when choosing a linear actuator for vertical duty.

Loading: While load placement and orientation is one of the first parameters to examine in any application, it is worth emphasizing for actuators mounted in a vertical orientation. Because the actuator will be working against gravity during the upward stroke, and will be assisted by gravity on the down stroke, the loads in each case will be different, regardless of the process (pressing, pulling, or transporting, for example).

11 • 2018

DESIGN WORLD — MOTION

Actuators – Motion Control HB 08.18 V5 OK.LE.indd 11

Series EGRR Electric High Capacity Grippers

Series ECVA/ECVR Rail Screw Electric Cylinders

Series ESFX Modular Electric Slides

Series ESK/ESL Electric Thruster Slides

USDA Certified for CIP YOUR MOTOR

Series ESG Electric Gantry Slides

• Electrically-powered units built on the foundation of PHD’s proven pneumatic product technology • Electromechanical actuators offer flexibility to use the motor of your choice

Series ECP IP69K Cylinders

Your Motor, Your Way! With PHD Plus, you can use the motor of your choice.

• High thrust and speed capacities

Call 800-624-8511 or visit phdplus.phdinc.com/plusad

P.O. Box 9070 • Fort Wayne, IN 46899 USA

11

11/19/18 2:39 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Applications needing the force of a hydraulic cylinder but compactness benefit from the roller-screw-driven Tolomatic RSX 080 actuator. Forces are to 18,000 lbf; a 100% duty cycle make the actuator work in pressing, punching, stamping, riveting, fastening, joining, injection molding, and sawmilling.

Rated IP65 with an IP67 option, the actuator resists water from a light washdown and dust from outdoor environments. A food-grade version is made of 316 stainless steel and includes food-grade white epoxy to meet USDA specifications.

dual output servo gearheads

This will affect not only the bearing life of the guides and drive mechanism, but also the required motor torque. In addition, the force of gravity on the load when starting and stopping will influence the inertia of the system, which also plays a role both actuator selection and motor sizing.

In a vertical application, it is generally recommended to use two bearing blocks on each guide rail. This ensures that the assembly can support the pitch and yaw moment loads that arise during acceleration and deceleration. Similarly using an actuator with two guide rails in parallel will enable the actuator to handle any roll moments that arise from a load that is not even distributed, or from external forces due to the process. The best scenario, if space allows, is to choose an actuator that uses two guide rails with two bearing blocks each.

Buckling load: When using a ball screw or lead screw in a vertical application, the full load is experienced as an axial force, which can cause the screw to bend and, eventually, buckle under the load. The buckling load is determined by the screw’s root diameter, unsupported length, and end bearing arrangement.



Did you mean: DieQua Corporation?

The end bearing arrangement has a significant influence on buckling load. The more rigidly fixed the screw assembly is, the higher its permissible buckling load will be. For example, a screw with a fixed-fixed bearing arrangement has 16 times the permissible buckling load than a screw with fixed-free end mounting.

Where Fc = Maximum compressive load (N); fb = End bearing factor; d1 = Root diameter of screw m); and L = Unsupported length (mm) Arranging the screw with the fixed bearing on the top will put the screw in tension, avoiding excessive compressive forces on the screw. Most ball or lead screw actuators are constructed with the fixed bearing on the driven (motor) end, but it’s important to check the bearing arrangement and ensure the actuator is mounted in such a way that the fixed bearing is on the top.

Back driving: For safety reasons, screws are preferred over belts or linear motors in vertical applications, as they help prevent a load from catastrophically crashing if there’s

The search is over!

The Tandler high precision right angle servo gearheads provide unmatched performance, durability, and design flexibility. Look no further than DieQua. • Backlash to ≤ 3 arcmin • Torque capacities up to 1250 Nm • Single or DUAL output options include solid shaft, hollow bore, or shrink disk • Peak torque up to 2800 Nm To find what you’re looking for, check us out on the web, or give us a call.

diequa.com/dw 800-430-1439

half page ad 2018.indd 2 Actuators – Motion Control HB 08.18 V6 FINAL.indd 12

4/24/18 3:03 PM 11/20/18 3:33 PM

Thomson smart actuators including heavy-duty Electrak HD actuators are suitable for agriculture, construction, and other off-highway vehicles. Their integrated electronics can be programmed to deliver feedback on position via a J1939 CAN bus network.

A C T U ATO R S

When standard catalog products don’t meet your requirements

Ask An Expert

We’ve been designing and manufacturing customized products for more than 80 years. a loss of power to the motor. However, they can (and often will) back drive, depending on the screw’s friction, lead angle, and efficiency. (In general, lead screws have a lower tendency to back drive, due to their lower efficiencies.) The likelihood of a screw assembly to back drive can be determined by calculating the back driving torque and comparing it to the friction force of the assembly (drag torque of the nut, friction from the seals, and friction from the end bearings). If the back driving torque is less than the assembly’s friction, the load is unlikely to cause back driving.

Where Tb = back driving torque (Nm); F = Axial load (N); P = Screw lead (m); and η2 = Reverse efficiency (0.8 to 0.9 for ball screws) Note on the latter that efficiency when back driving is typically less than the efficiency for normal operation.

Be sure to check the manufacturer’s specification for the back driving efficiency.

Lubrication: Most bearings and actuators have lubrication ports on all four sides to accommodate access in case there are obstacles that block 11 • 2018

Actuators – Motion Control HB 08.18 V6 FINAL.indd 13

one or more ports. For some designs, the design orientation also dictates which lubrication ports should be used.

Because gravity is a hindrance to lubricating the upper tracks of a linear guide or the uppermost raceways of a screw, follow lubrication guidelines for vertical mounting. In many cases, manufacturers recommend against using oil. With grease, the assembly will often have specially metered lubrication pathways to ensure lubrication reaches all critical surfaces.

Contamination: Actuators in a vertical orientation have the benefit that liquid contamination will typically drain away, reducing the risk of corrosion.

However, very fine, light particulates, such as fiberglass and ceramic powder, are more likely to adhere to bearing surfaces and simply be “pushed” along by end seals, causing a build-up of contamination and increasing the risk of entry into the bearings.

To ensure the best protection in vertical applications, linear guides with both front and side seals should be used. Also choosing an actuator with its own sealing or covering mechanism (preferably a full-contact seal rather than just a cover plate) provides additional protection against both airborne and liquid contamination.

DESIGN WORLD — MOTION

13

Available options include: – motor voltage windings – custom windings – shaft modifications – custom connectors – lead wire assemblies – gear boxes – encoders – brakes Large quantities not required.

USA: Europe: Asia: Email:

+ 1 267 933 2105 + 33 2 40 92 87 51 + 86 21 5763 1258 info.pittman-motors@ametek.com

haydonkerkpittman.com

© 2018 by AMETEK Inc. All rights reserved.

MCM2018_009_DesignWorld_1118_DisplayAd.indd 1

9/24/2018 11:24:31 AM 11/20/18 3:33 PM

M O T I O N S Y S T E M A P P L I C AT I O N S Image courtesy of SoftWheel

Bearings improve wheelchair suspension and more ENGINEERS AT SOFTWHEEL were recently looking to improve wheelrim suspension to make wheelchair riding significantly more comfortable and efficient for users. The company developed four technologies for its SoftWheels suspension to absorb bumps and vibrations and isolate them from the rider’s body.

The biggest challenge in designing the SoftWheel was developing a suspension. Engineers carefully analyzed wheelchair dynamics to identify key requirements. “We knew we couldn’t put the suspension in the chair … so we put it in the wheel,” said CEO Daniel Barel.

The wheel includes three suspension arms equidistant around a central hub.

The arms are inside the rim and absorb shock from any direction.

SoftWheel’s Adaptive Rigidity means the suspension arms are rigid but

automatically compress when needed.

In other words, the in-wheel suspension activates only when needed to let the wheel to act as a rigid wheel over flat surfaces and conserve rider energy and forward momentum with less bounce on flat runs.

With its Rapid Shock-Reset technology, the suspension arms are ready to go after one-third of a turn — outperforming a common chair wheel.

In a drop of 15 cm with a 110-lb load, the common wheel returns to a stable position in 10 sec. A SoftWheel takes just two seconds to become stable. Its singlepiece Rigid Rims offer as much stability as regular rims on the market.

Plastic components manufactured by igus complete the SoftWheels design.

Engineered plastic L280 bushings called the Marathon Runner install on the triangular component of the wheels. The plastic bushings provide wear resistance in harsh environments or when mated to rough shafts with a low coefficient of dynamic friction and high wear resistance. The L280 bushings also have a compressive strength of 8,847 psi and at 68° a tensile strength of 18,130.

Read more about the SoftWheel design at www.bearingtips.com.

Shown here is a common bearing use ... for cam following. This IKO follower is based on needle-roller bearings and a stud enclosed in an outer ring that rotates. IKO followers maintain high rigidity and accuracy for cam mechanisms as well as guide rollers on linear-motion assemblies in office-automation equipment, machine tools, industrial robots, and electronics. A hexagon socket on the stud head allows for secure tightening; the lubrication system allows servicing from multiple locations — even from a center grease nipple (here in bronze).

14

DESIGN WORLD — MOTION

Bearings – Motion Control HB 08.18 V6 FINAL.indd 14

11 • 2018

CONSOLIDATED PARTS IN A BEARING ASSEMBLY Consider another application. CCTY Bearing is a manufacturer that recently helped one utility-vehicle OEM address sourcing, quality, and assembly issues with some of its front-suspension ball-joint components. Ultimately, CCTY Bearing consolidated three part numbers for a more cost-effective and reliable setup.

The traditional ball joint, retaining plate, and rubber shroud needed assembly and greasing during production — and then regular maintenance by the end user. CCTY eliminated the regreasing issue by designing a maintenance-free ball joint assembly. This also let engineers eliminate the grease fitting and machining operations needed to provide a path of travel for the grease into the ball joint from the mating part. That also let the OEM remove maintenance instructions from the vehicle owner’s manual.

The new bearing design is backwards compatible with current and previous UVs … though with a positive seal (that the previous design’s rubber shroud couldn’t support) and a corrected taper on the stud (eliminating the need for an additional washer).

“During a conference call the OEM project engineer said, ‘Most suppliers don’t ask the kind of questions you guys do … and I like the questions,” noted senior engineer Rich Pearlberg.

motioncontroltips.com | designworldonline.com

11/20/18 3:34 PM

Replace your metal bearings...

...in all applications and environments

iglide® Q2: high strength, dirt and corrosion resistant

iglide® A181: FDA compliant, resistant against washdowns

iglide® P: high load capacity, very low moisture absorption

iglide® J: vibration dampening, reliable and long-lasting

Make the switch to iglide

®

Reduce cost and increase technology with iglide

®

• 100% self-lubricating • maintenance free • high strength and wear-resistant • corrosion and moisture resistant • lightweight • More than 40 materials available • lifetime calculator • shipped from stock in 24h • CAD file downloads • online selection tools

igus -- Motion System Casebook 11.17.indd 15

www.igus.com 1.800.521.2747

11/16/18 3:35 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

One vegetable-processing company was having ball-bearing failures on a large conveyor subject to frequent washdown to maintain hygienic conditions. In fact, the bearings only lasted about two weeks before needing replacement.

NSK Precision America determined that copious water was entering the bearings and washing out grease, so suggested the use of sealed corrosion-resistant NSK Molded-Oil bearings. That helped the bearings contain their grease for better performance and longer life.

In fact, the NSK solution eliminated the conveyor’s recurring annual $6,955 bearing-lubrication cost and the $3,204 cost for the regular dismounting and remounting of bearings. Bearing life went from two weeks to more than nine months.

OTHER INDUSTRIAL BEARING USES Bearing variations abound to satisfy an array of loads, environments, speeds, expected design life, and more.

Consider the bearings and slewing rings in wind turbines.

These can reach 2 m in diameter and must sometimes bear hundreds of tons. In contract are miniature bearings for medical applications. These often go into tiny handheld devices and other compact equipment necessitating bearings of just a couple millimeters in diameter (with rollers that are even smaller).

Some going into equipment subject to washdown have treated steel subcomponents; others for disposable or quiet designs are made of plastic. Industrial machines that endure hot, fast, or lubrication-starved conditions pose their own bearing-design challenges.

Some of these benefit from the use of hybrid bearings — those with steel raceways and rollers or balls made from ceramic. No matter the design, each bearing type satisfies specific parameters.

Ball bearings use balls to provide lowfriction motion between bearing races. When selected properly, they require little maintenance.

This is an igus L280 This feature and their limited heat generation make plastic bushing.

16

DESIGN WORLD — MOTION

Bearings – Motion Control HB 08.18 V6 FINAL.indd 16

11 • 2018

them indispensable. They go in everything from skateboard wheels to turbine engines — in aerospace applications, medical equipment, and home appliances.

Roller bearings have cylindrical rollers instead of balls to transmit loads and reduce friction. Thanks to this shape, roller bearings have greater surface contact than ball bearings, so handle larger loads. Their shape also allows for a moderate amount of thrust load because weight is distributed across cylinder line contacts instead of point contacts. These bearings are common in conveyor belt rollers, turbine engines, transmissions and gearboxes, as well as the mining, food and beverage, pulp and paper, waste-water and marine industries.

Needle roller bearings have rollers with lengths at least four times their diameter. The large surface area accommodates high radial loads even in compact designs.

Needle bearings often go in compressors, rocker-arm pivots, pumps, transmissions, and other automotive designs. Needle bearings are also common in construction and agricultural equipment, two-cycle engines, outboard engines, and papermoving equipment.

Thrust ball bearings go in applications with axial loads and (in some cases) shaft misalignment. They excel in high-speed aerospace, automotive, and oil and gas applications. Thrust ball bearings also work in machine tools, fluid-control valves, and spindles.

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

Tapered roller bearings have tapered inner and outer ring raceways with rollers between them. The rollers are angled so the direction of their long axes converge at the center of the shaft accommodating the bearing. These bearings can handle axial and radial loads and are common in helicopter transmissions, fuel pumps, and agricultural equipment.

Plain bearings don’t have rolling elements. They’re compact and lower-cost bearings for many applications, but automotive and construction are particularly common.

Plain bearings go in steering cylinders, hydraulic excavators, and more.

motioncontroltips.com | designworldonline.com

11/19/18 11:37 AM

PRECISE. ROBUST. AVAILABLE. These new generation CD® Couplings feature zero backlash precision and high torsional stiffness. They answer today’s demanding needs in servo motor applications with high reverse loads and positioning requirements. New clamp style hubs handle increased torque on shafts without using keyways.

Manufactured of RoHS compliant materials.

Now size, select and see the right CD® Coupling solution for your coupling application with Zero-Max 3D CAD files.

Check our FAST deliveries.

www.zero-max.com 800.533.1731

Zero Max 3-18.indd 17 Zero-Max_CD Coupling A1C r4 Design World.indd 1

11/16/18 3:35 PM 1/15/16 1:46 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

The R.A Jones Autoprod CF-400 is an inline cup-filling machine available in five, six, or eight-lane configurations with production speeds to 900 cups per minute. One innovative feature on the machine is a sealed rotary drive mechanism for sanitary station movement. Another is its use of a long endless synchronous belt (in blue) instead of a chain drive.

belt

POWER TRANSMISSION-PART CONVEYING

PYRATHANE® BELTS With Lifetime Warranty Against Manufacturing Defects

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

Endless boosts precision of packaging machine LONG BELTING (usually with L or H trapezoidal tooth or HTD profiles) can exceed 500 feet in some cases. Such belts 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.

SAMPLES AVAILABLE

Try our Pyrathane Belts

®

on your conveyor ...

the standard of the industry!

AN ISO 9001 CERTIFIED COMPANY

Consider one application of an endless belt — on the R.A Jones Autoprod CF-400 cup-filling machine for the food and beverage industry. It has a belt drive for pockets instead of a traditional chain design. The belt drive boosts precision while reducing maintenance and the number of adjustments needed to stations.

pyramidbelts.com • 641.792.2405 • sales@pyramidbelts.com 18 201702_Pyramid4x475_lineshaftR2.indd 1 belts & pulleys – Motion Control HB 08.18 V2.cut.LE.indd 18

DESIGN WORLD — MOTION

11 • 2018

2/9/2017 10:43:58 AM 11/19/18 11:46 AM

THINK INSIDE THE BOX Exceptional designs deserve superior components.

The developer of the original world-class linear motion systems, THK continues to redeďŹ ne 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.

thk – motion systems applications 11.18.indd 19

11/16/18 3:36 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Highest Torque in the Smallest Space ... or the largest.

Maxitorq® clutches and brakes deliver power, reliability and are customized to meet your exact needs. Land, sea and air – CJM is everywhere.

AS9100C:2009/Certified

Brakes & clutches

for guaranteed actuator protection

Clutches, Brakes & Power Transmission Products • electrical, mechanical, pneumatic & hydraulic models • system design and integration • expert engineers working on every order

Engineering Solutions for Clutches & Brakes

www.cjmco.com Phone: 860-643-1531 291 Boston Tpke, Bolton, CT 06043

BRAKES AND CLUTCHES are sometimes pre-integrated into designs.

Case in point: The new Warner Linear B-Track K4x dc-motor-driven ballscrew actuator (which delivers 4,000 lb load capacity) includes a ball-detent overload clutch. The actuators excel where designs can’t use fluid-power cylinders — on solar panels, off-highway equipment, scissor and dump box lifts, and mower and tractor lifts, for example.

Its overload clutch setting is at 25% over the actuator’s rated dynamic load.

No wonder that these and other overload clutches are called torque limiters in some contexts. Main strengths here are simple and accurate disengagement at a preset torque.

Here’s how the simplest versions work: Rollers (usually balls) are sandwiched between two component halves — and rest in mirror-image detents machined into these halves. Usually springs hold the halves together. The

20

brakes & clutches – Motion Control HB 08.18 V4 FINAL.indd 20

DESIGN WORLD — MOTION

motor-driven side transmits torque to the load half called the thrust or pressure flange, and the whole assembly rotates in unison unless there’s an overload.

In such situations, the overload-clutch halves overcome the axial spring force and repel apart. The rollers come free of their detents and roll to continue onward or resettle into the next detent pair when the jam or other overload is removed.

OTHER APPLICATIONS Brakes, clutches and torque limiters work in medical equipment, packaging machinery, industrial hoists, and installations. Recall that brakes stop and hold loads. Clutches and torque limiters disengage and engage powertransmission outputs to transfer torque from an input. Torque limiters modulate power transmission to protect mechanical equipment from overload.

When selecting clutches, brakes, and torque limiters for an application,

motioncontroltips.com | designworldonline.com

11/19/18 11:57 AM

CUP OVERFLOWING? B R A K E S , C L U T C H E S & TO R Q U E L I M I T E R S

options include mechanical, electric, fluidic or self-actuation.

Electric brakes are easy to control and cycle, even to a couple thousand cycles per minute. In contrast, common airactuated brakes and clutches run coolly and maintain hold with minimal power.

Friction brakes with disc, drum and cone morphologies work well as emergency brakes because of their failsafe holding— essential on conveyors, escalators, airport-baggage handlers, elevators and other safety-critical designs.

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

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

Beyond these general guidelines, fast, hot and other extreme applications require extra evaluation. Some tips:

Spring-set brakes benefit motion designs that slow loads with the motor before the brake engages; they’re also suitable as holding mechanisms.

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

Industrial designs that operate in hot environments may benefit from friction brakes with specialty frictionsurface geometries and materials (such as phenolic resin or ceramic).

Motion applications that don’t get a lot of maintenance also benefit from the longer life these friction materials get.

Brakes that use permanent magnets for operation automatically adjust for wear.

brakes & clutches – Motion Control HB 08.18 V4 FINAL.indd 21

years machine designers have relied on us for made-to-order products that meet their exact requirements.

• Pneumatic & mechanical models • Torque capacities to 60,000 lb.in.

• Experienced application help • Quick and reliable lead times

One call or email connects you with an engineer: 859-291-0849 engineering@machiii.com

BRAKES FOR HIGH-CYCLE APPLICATIONS Where applications run at 50 to 300 cycles per minute (as in indexing with a clutch brake) each clutch engagement transfers a torque spike to the connection between the motor shaft and input shaft of the clutch brake. High-cycle applications can cause severe hammering on the shaft connection of the motor to the clutch brake. For convenience and ease of assembly, standard C-Face connections are most common — but the loose fit can cause torque to transfer through the key and keyway, which hastens failure. Here, clutches and brakes that connect with shrink-fit or clamping couplings for a 360° connection perform better.

In applications that must rapidly stop, start, reverse, and change speed, clutch brakes that use oil shear technology are also suitable. Here, a boundary layer of transmission fluid shears between friction discs and drive plates. As the parts come together, the fluid in shear transmits torque. This eliminates direct friction-disc contact during high-speed slip.

Heat from the friction surface is dissipated as the fluid circulates to the housing. That’s useful on axes with startstop cycles or cycle rates to 300 cycles per minute. Here, oil-shear brakes last five to ten times longer than dry clutchbrake offerings.

Materials in the Carlyle Johnson Machine Co. MAXITORQ EMA500 electromagnetic clutch let it run in both wet and dry applications. This self-contained unit is sized for dynamic engagement requirements; for static-engagement applications, clutches can be smaller.

11 • 2018

Searching for components eats up valuable time. For more than 45

DESIGN WORLD — MOTION

BRAKES • CLUTCHES TORQUE LIMITERS

21

11/19/18 11:58 AM

M O T I O N S Y S T E M A P P L I C AT I O N S

Electroflight is using the E3.series software from Zuken to design wiring harnesses for an all-electric aircraft for the ACCEL All-Electric Flight Research Initiative.

Software tools streamline

cablemanagement design, A CRITICAL but sometimes overlooked component, cables come in a variety of customized versions to meet specific application requirements. Cable properties such as the number of solid conductors or wire strands for transmitting power to motors as well as feedback to and from controllers and sensors are an example of what designers must consider when selecting a cable for an application.

In motion control applications, cables typically have to handle tight bending radii, abrasion, flexing, and possibly even torsional motion. On the other hand, cables for VFDs must minimize EMI effects and other sources of electromagnetic noise. Another consideration is the cable jacket material that protects conductors and insulation from harsh environments where exposure to chemicals and oil can damage the cable and interfere with signal transmission. Special varieties are available for use with mobile machinery or machine tools or even welding applications, which may require a flameretardant material.

Often enough, cables used in the flexing and rotating applications in motion control require high tensile strength and resistance to abrasion and flammability. They’re most often manufactured using polyvinyl chloride (PVC), chlorinated polyethylene (CPE), polyurethane (PUR) and thermoplastic elastomer (TPE).

22

DESIGN WORLD — MOTION

cables – Motion Control HB 08.18 V2 FINAL.indd 22

From this wide array of choices, cable manufacturers can aide designers in selecting the right cable for their applications in several ways, through handson design assistance but also increasingly via online tools that offer engineering assistance such as product selectors and other design tools. Case in point; Zuken’s E3.series software is being used by UK-based Electroflight to design an all-electric aircraft for the ACCEL All-Electric Flight Research Initiative.

Electroflight is using E3.series to design, build, test and commercialize an all-electric aircraft – all within a 24-month timeframe – as part of the Accelerating the Electrification of Flight (ACCEL) research initiative. ACCEL involves a consortium of partners which aims to address the technical challenges associated with all-electric flight, to develop a more robust supply chain and ultimately contribute to cleaner, greener flight.

“With such a compressed timeframe for the ACCEL aerospace initiative, speed is everything,” says Stjohn Youngman, Electroflight’s Programme Manager. “E3.series was selected because of its ease-of-use, flexibility, and output capability for all data needed to manufacture wiring harnesses, including bills of materials.”

E3.series is already a common design tool in the aerospace industry, but also in the motorsport industry, where it helps meet racing deadlines.

Electroflight plans to take advantage of E3.series’ aerospace/motorsport synergies as it will use System 25 mil-spec motorsport connectors and harness construction techniques on the ACCEL aircraft.

Youngman adds: “We’re at the start of an extremely ambitious R&D project. To get from concept to commercial offering in just two years is unheard of in the aerospace industry. Our learning curve has to be incredibly fast.”

Optimization will be key for many aspects of the design of the ACCEL aircraft. This is because for all-electric flight, it’s necessary to tackle the twin challenges of energy storage capacity and powertrain performance. To keep the weight of the aircraft down, Electroflight will be trying to keep cable runs as short as possible – through the smart placement of sources, switches and loads. In this respect, E3.series’ ability to integrate well with leading MCAD tools is an added benefit.

11 • 2018

motioncontroltips.com | designworldonline.com

11/20/18 2:47 PM

Messy Wires?

GO FLAT! Flat cable brings simplicity and order compared to the messy spaghetti of round cables. Simplify design, simplify assembly, and simplify maintenance by specifying Cicoil Flat Cables.

u One Cable For Everything: Combine Power, Signal, and Tubing into a single flat cable for the smallest packaging density. u Standard or Custom: A wide variety of standard cables are available, and our engineers can design custom cables for any requirement or industry. u Design Your Own: Our Online Configurator lets you design virtually any flat cable in minutes! You get an immediate drawing, and your custom cable is delivered in less than 2 weeks.

Learn How To GO FLAT at

cicoil.com

PHONE: 661.295.1295 Cicoil 12-17.indd 23 Cicoil_Simplify-FullPg_ad_DW.indd 1

11/16/18 10:13 3:37 PM 12/22/15 AM

M O T I O N S Y S T E M A P P L I C AT I O N S

Rigid-chain actuation

actuates breathtaking new hall

NOW a new SERAPID QSX Seating System based on SERAPID rigid-chain actuators and other technologies operates at the Philharmonic Concert Hall at Zaryadye Park in Moscow. The QSX installation is the first to combine raked curved-row seating with a reconfigurable venue system. In fact, the entire hall can transform from a flat floor to raked seating in less than 15 minutes. For the latter, twenty curved rows range from 23 to 30 meters for 677 seats total.

Zaryadye Park includes three performance venues, with the concert hall considered its most complex element. The integrator Doka selected SERAPID motion systems for the hall automation. The concert hall opened in September 2018.

The QSX Seating System is a smooth-operating installation that’s fully automated. It works for straight, curved, or faceted tiers — regardless of rows, seats, or configurations.

SOLUTIONS FOR PRECISION MOVEMENT OF VERY HEAVY LOADS

QUICK DIE CHANGEപͳപSTAGE AND ORCHESTRA LIFTSപͳപCUSTOM ENGINEERED SYSTEMSപͳപINDUSTRIAL LIFTS LinkLiŌ liŌ columns

RollBeam Telescopic push-pull

LinearBeam guided push-pull Press-mounted dual push-pulls

SERAPID Inc. | 34100 Mound Rd. | Sterling Heights, MI | Tel +1 586-274-0774 | info-us@serapid.com | www.serapid.com

chain – Motion Control HB 08.18 V3 FINAL.indd 24 DW half page rv.indd 1

11/19/18 2:31 PM 4/12/2016 2:17:33 PM

CONTROLLERS

Motion-controller applications Sheet-metal workcells (such as the deep-drawing presses shown here) get higher throughput with centralized PC-based control and EtherCAT connectivity. Modular hardware and software from Beckhoff also help minimize tolerances. Press-specific software tools include a Beckhoff TwinCAT PLC Hydraulic Positioning library for implementing efficient servo hydraulics. TwinCAT Analytics leverages comprehensive data acquisition for condition monitoring and minimal downtime.

Motion controllers range from single-axis smarts to programmable automation controllers (PACs) that synchronize hundreds of axes and data communications.

Consider the following examples that illustrate migration to industry-specific components and software. motioncontroltips.com | designworldonline.com

controllers – Motion Control HB 08.18 V5 FINAL.indd 25

PC-BASED CONTROL ON INDUSTRIAL SHEET-METAL PRESSES Sheet-metal workcells can deliver higher-quality parts in greater quantities than traditional builds when designed with centralized PC-based control and EtherCAT connectivity. That’s especially true of deep-drawing press applications as shown here, where modular hardware and software from Beckhoff maximize throughput and minimize tolerances.

To review, deep drawing is the process by which sheet metal is placed between two halves of a forming die and mechanically pressed via punch into a shape. Such drawing is deep drawing where the new shape’s depth is more than its diameter.

Press-specific software tools include a Beckhoff TwinCAT PLC Hydraulic Positioning library for implementing efficient servo hydraulics. In addition, TwinCAT Analytics leverages comprehensive data acquisition to support condition monitoring for minimal machine downtime. The software supports OPC UA, MQTT, and AMQP standards for IIoT scalability and secure Cloud communication. Avoidance of data incompatibility and latencies (as those in communications between different systems) allows synchronization of press

11 • 2018

DESIGN WORLD — MOTION

25

11/20/18 3:48 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

APPLICATION-SPECIFIC

axes and processes — and trims the costs associated with extraneous hardware and engineering.

On the hardware side, Beckhoff Compact C6015 and C6017 Industrial PCs serve as universal control and visualization platforms or (in some setups) as IoT edge devices. (Precision synchronization makes for better workpiece quality with fewer reject parts.) Within the press itself, actuation with servo-electric hybrid axes leverages the fast motion cycles and simple mounting requirements of hydraulics while improving on their baseline efficiencies and need for maintenance. Beckhoff’s dynamic servodrive solution consists of the AX5000 servo drive and AM8000 servomotor with One Cable Technology — controlled via the aforementioned TwinCAT PLC Hydraulic Positioning software.

For material handling into the press and machine tending, AMP8000 distributed servo drives integrate amplifier DESIGNS: electronics directly into servomotors, allowing engineers to build modular workcells.

Putting power electronics in the machine makes control cabinets smaller — to a single coupling module for supplying the workcell’s servo drives with one cable via a distribution module.

Drives for AGVs and electric vehicles

Now a new integrated traction drive from Applied Motion Products includes onboard motion control as well as a brushless servo motor, planetary gearbox, and flange output ready to mount a drive wheel.

I/O and communications network to vehicle computers and sensors without necessitating an external drive (amplifier) electronics.

The design’s high torque density (and the low inertia of its servomotors) make powerful yet efficient drives for AGVs as well as autonomous mobile robots (AMRs), electric bicycles, and electric wheelchairs.

Setup of motion controls is through Q Programmer software that allows setup, configuration, and tuning of systems based on programmable stepper and servo drives from Applied Motion Products. Commands available via Q programming consist of those for controlling motion, I/O, drive configuration and status, register manipulation, and math operations.

DIGITAL PRINTING PAIRS WITH A MACHINE CAPABLE OF HANDLING ITS VARIED OUTPUT VITS International makes sheeting and finishing machines for packaging, printing, and converting. The OEM saw the digitalprinting market needed finishing capable of commercial production speeds. So VITS designed and built

26

controllers – Motion Control HB 08.18 V5 FINAL.indd 26

the SPRINT Variable Data Finisher with a Bosch Rexroth drive and control platform to meet the demand.

Digital inkjet printers can execute output comparable to that of traditional web-offset printing — at near-commercial rates to 1,000 feet per minute. Digital printing also allows variable data printing to dynamically vary the number of pages and content on the pages — even handling significantly varied page dimensions. Such capabilities enable incredible customization but complicates the finishing of printed web. So finishing systems on digital printing lines must be able to quickly cut, collate, and assemble disparate pages.

“We decided to develop such a machine to support both offline and inline finishing,” said VITS International president and CEO Deirdre Ryder. The result is VITS’ SPRINT Variable Data Finishing System that turns print material into finished product at up to 1,500 fpm. The SPRINT machine works for inline systems (which get and finish a single web directly from the digital printer) and offline multi-web finishing (for processing multiple webs into a single finished signature or book).

“Our printing customers want to output larger products at faster rates,” said VITS director of product applications Kim Markovich. “Particularly for direct mail, being able to finish multiple webs and ribbons with suitable register control means printers can assume more work.”

SPRINT finishing machines include independently driven axes controlled by a Rexroth IndraMotion MLC motion control system. A Bosch Rexroth L45 controller employs SERCOS III for deterministic synchronization of drives and fieldbus communication for I/O. The inline machine version usually has 10 to 12 driven axes; multi-web offline versions can have up to 30. A Rexroth cross-communication card with SERCOSIII-based communication helps synchronize VITS finishers with inline-mounted printing presses (also sporting Rexroth controls).

Machine modules trigger functions to convert printed web into books or mailers with Rexroth IndraDrive servo drives and servomotors for actuating the functions.

Offline multi-web machines interface with paper rolls on register splicers.

DESIGN WORLD — MOTION

11 • 2018

11/20/18 3:48 PM

maxon control electronics for strong DC brushed and brushless motors.

maxon motor control

Power under control.

When good control properties and fast startups are needed, maxon motor’s servo controllers are the ideal choice. The 4-Q PWM servo controllers have fast digital current and speed controllers with a large range. They offer highly efficient control of permanent magnet-activated DC motors.

Maxon Motor 2-18_Robot 228.6x276.225.indd 13 Report.indd 27

maxon precision motors 101 Waldron Road, Fall River, MA 02720, USA Phone 508-677-0520 info@maxonmotorusa.com, www.maxonmotorusa.com

11/16/18 13:40:12 3:37 PM 04.08.2016

M O T I O N S Y S T E M A P P L I C AT I O N S Shown here is a train of 20-kg RC20 AGVs from Vecna Robotics. RC20s carry individual totes or containers and gang to form virtual conveyors. Some such vehicles include pre-engineered traction drives.

These continuously feed web at a constant-tension infeed with precise gain and control to prevent issues.

1. The paper goes through a station that slits it in half and stacks the halves.

2. The paper halves travel to a ribbon-gathering station and onward to a station that folds the ribbons in half.

3. The paper web goes through a shear-slitting station for edge trimming.

4. Web goes through a variabledata rotary cutter that slices each page to size and collates finished product for final binding or saddle stitching.

SPRINT Finishing machines use the Rexroth IndraMotion for Printing automation platform with independently driven axes under a central IndraMotion MLC motion controller (similar to the one here).

28

DESIGN WORLD — MOTION

controllers – Motion Control HB 08.18 V5 FINAL.indd 28

Maintaining registration for these steps ensures all pages in all signatures are cut to the same dimension. Nothing prints perfectly, so the length of any print usually varies ±0.001 in. from page to page … error that can accumulate quickly

11 • 2018

over hundreds of fast-moving pages.

“We use the built-in intelligence of Rexroth drives to dynamically maintain web registration — and keep the central controller’s processing power free,” said integrator Bruce Parks of Parks Consulting, who helped on the machine design. A virtual master holds all drives in synchronization.

Tension zones between drives maintain tension during web splitting, merging, and cutting.

Controls can also command groups of drives to adjust tension … and bring the web into register with the virtual master.

SPRINT engineers used the IndraMotion for Printing version of Rexroth’s MLC system to automate tasks via IEC 61131-compliant motion logic and PLCopen function blocks — and software libraries specific to printing and converting.

“IndraMotion for Printing includes tools for most web-handling

motioncontroltips.com | designworldonline.com

11/20/18 3:48 PM

CONTROLLERS

These and Rexroth’s PLCopen function blocks helped us build functions and camming profiles for our proprietary Clear Channel registration,” said Parks. Clear Channel registration control allows the cutting thousands of pages per hour while maintaining precise page registration impossible with legacy finishing systems. It enables faster size changes as well as cut tolerances impossible with standard finishing systems.

Another strength of the SPRINT machine is its rotary cutter … capable of handling images of 5 to 25 in. and configurable to cut different width chips — blank spaces between pages on the paper.

Machine operators trigger the change with a push of a button. At the cutter station, twin knives slice the chip out; the knives are spaced by the width of the chip … and cutting must be synchronized with the speed of the web through the station. “Our camming lets users cut output of variable size with multiple knives and still maintain chip size — because the camming always synchronizes with the web speed through the cutting zone,” said VITS director of new product development John Salamone.

This is the first machine series VITS built on a Bosch Rexroth control and drive platform. “We had a great relationship with the previous supplier. Bosch Rexroth gave us similar commitment … and Rexroth technology let us quickly develop equipment with accuracy no competitors have. So now Rexroth-equipped machines of ours work flawlessly all over the world.

controllers – Motion Control HB 08.18 V5 FINAL.indd 29

This VITS Variable Data machine executes saddle stitching for book finishing.

11/20/18 4:13 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

ETM’s direct-drive motor imparts advanced functions to simplify automated tasks.

Conveyors with backlighting

get more electical outlets out

MICHIGAN-BASED Byrne Electrical Specialists designs and manufactures power and data technologies for office, teaching, and hospitality environments.

Recently, the company began using industrial conveyors from QC Conveyors to increase their throughput of electrical outlets.

A trio of robotic assembly cells — each with its own threesome of busbar conveyors and solo output conveyor — build electrical outlets for modular office furniture. Then one packaging cell at the end of the line collects the output from these assembly-cell feeds for final testing and shipping.

30

DESIGN WORLD — MOTION

conveyors – Motion Control HB 08.18 V3 FINAL.indd 30

1.

2.

3.

Operators set the parameters for the current job via a human machine interface (HMI) based on the specifics of the current order being processed — including parameters such as color, size, needed outlet count per case, and so on.

Operators then load the outlets’ front shells and back plates by hand on one side of a machine … and put metal bus bars into hoppers on the other. “Each electric outlet has five parts — including three busbars for line, neutral, and ground. Each busbar has its own hopper and conveyor-based sorting line to let us take these raw components and basically dump them into hoppers.

Then each hopper drops busbars onto a cascading three-layer conveyor system,” explained Byrne engineer Dan Wierenga.

The first of the three conveyors moves very slowly and drops busbars onto a faster middle conveyor (in a way that spaces them evenly). In the middle of this conveyor is an underlit section — provided by Spectrum Illumination.

The underlit conveyor region is monitored by a Datalogic vision system. As busbars travel over the underlighting, the vision system confirms they’re right-side up and clear of other parts — and then commands the conveyor to stop to allow pickup by a robot. Any busbars that are bad, misoriented, or clumped together continue onward until they fall onto a third (fastest-

11 • 2018

motioncontroltips.com | designworldonline.com

11/20/18 3:37 PM

Power Transmission, Motion Control and Engine Braking Solutions

Creating A Premier Industrial Company Ameridrives

Deltran

Kilian

Portescap

Twiflex

Bauer Gear Motor

Formsprag Clutch

Kollmorgen

Stieber

Warner Electric

Bibby Turboflex

Guardian Couplings

Lamiflex Couplings

Stromag

Warner Linear

Boston Gear

Huco

Marland Clutch

Svendborg Brakes

Wichita Clutch

Delevan

Jacobs Vehicle Systems

Matrix

TB Wood’s

Nuttall Gear

Thomson

Delroyd Worm Gear

altra – motion systems applications 11.18.indd 31

www.AltraMotion.com 11/16/18 3:38 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

4.

5.

moving) conveyor that (via an elevator) returns them to the original hopper. Next a Nachi six-axis robot gets the X, Y, and angle of the busbar, grips and reorients it, and puts it in a holding station.

Another robot takes the first of two plastic halves — the outlet’s front shell— and puts it into a nest. Then it picks three busbars (readied by the previous robot) and inserts them into the front shell. Then the robot puts the outlet’s back shell half on the front and presses them together.

From there, the robot places the completed assembly on another conveyor (from QC Conveyors) to inspection and packout.

Finished electrical outlets are lifted off the conveyor and inspected visually on both sides. They then pass an inkjet printer that prints a symbol specific to the current order on the front of the outlet.

The printer applies logos in three different colors depending on the outlet’s body color. After printing, all the electrical outlets get a label on the back and then go into the proper case for that order.

The system was designed for Byrne Electrical Specialists by Criterion Manufacturing Solutions, where Wierenga worked during the installation design before joining Byrne to keep the line optimized. A local QC Conveyors distributor, Industrial Control based in Zeeland, Mich., worked very closely with engineers at Byrne on the design specifications for the automated installation.

“We used QC Conveyors because Byrne has partnered with Industrial Controls on an array of projects before.

Plus the conveyors have a convenient form factor and come in custom sizes and lengths — and with an array of belt types,” explained Wierenga. “The latter let us use low-friction belts, transparent belts, and high-durability belts to maximize functionality and lifespan. On QC Conveyors, the belts are also easy to install and replace.”

32

DESIGN WORLD — MOTION

conveyors – Motion Control HB 08.18 V3 FINAL.indd 32

11 • 2018

motioncontroltips.com | designworldonline.com

11/19/18 3:19 PM

CONVEYORS

A major challenge was integrating the moving belt and stopping the belts and then coordinating the vision system's vision space to real-world robot coordinates. Complicating matters is that the lines must do that for several dozen part variations.

“That means we had to design a system that lets us program and calibrate the different parts very easily — which took a fair amount of development,” added Wierenga.

Before this automated machinery, parts were assembled by hand. Each assembler had a manual station where he or she would put the outlet parts together and then weld the part closed. Then the outlets went to another station to get printed and UL testing.

All secondary audits, labeling, and packaging after that was manual. In contrast, now Byrne takes raw components and does 100% of its testing, 100% of its parts inspection, and 100% of its boxing for shipment with automation.

LOCKED INTO OLD TECHNOLOGY?

Integrated STM/SWM stepper motors from Applied Motion Products help save space, wiring, and cost on advanced conveyors. For one conveyor to handle packages of various configurations, the integrated steppers help position as rapidly as the analog control updates target position — every 4 msec. Here, the motors also address changing requirements for sorting, alignment, and singulation. Combining a motor, control, and drive, STM/SWM motors are capable of automatic stall detection and prevention … and include an encoder for feedback on motor position. Q Programmer motion control software on the integrated stepper-motor controls simplifies configuration to specific conveyor requirements. In addition, EtherNet/IP communications replace noisy analog signals … and eliminate the need to run long signal wires from as many as 100 motors to a central PLC. That lets even the most advanced conveyors coordinate high-speed maneuvers with precision.

11 • 2018

DESIGN WORLD — MOTION

conveyors – Motion Control HB 08.18 V3 FINAL.indd 33

WE HAVE AN ANSWER FOR THAT. CONTI® SYNCHROCHAIN CARBON never needs oiling or retensioning and greatly increases performance for applications with extremely high torque. Let’s talk soon if you need a better drive combination.

WeHaveAnAnswerForThat.com

33 COTPOT_18000_RustAd_Design_World_vFA.indd 1

10/11/18 4:35 PM 11/19/18 3:19 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

better products. better solutions.

Regardless of what makes your material handling application unique mk can provide a standard or custom solution — that meets your needs and keeps your business moving. h Aluminum framed conveyors h Featuring plastic modular belt, roller, chain and belt conveyors h Pallet-handling conveyor systems h Stainless steel conveyors h Extruded aluminum t-slot framing

www.mknorthamerica.com

conveyors – Motion Control HB 08.18 V3 FINAL.indd 34

“We went from four or five different part handoffs to zero handling of the completed part … and much higher end-product quality,” said Wierenga.

CONVEYORS WITH DIRECT-DRIVE MOTORS OFFER KEY ADVANTAGES American Axle Manufacturing (AAM) is increasing the functionality of its St. Mary’s, Pa. manufacturing operations with conveyors sporting advanced drive technology. Small yet powerful direct-drive motors from Electric Torque Machines actuate Dorner conveyors that move small parts around the AAM facility.

AAM designs, engineers, validates, and manufactures an array of driveline, metal-forming, powertrain, and casting technologies — and is known for manufacturing large components such as axles and differentials. However, the AAM St. Mary’s facility manufactures many of the small and lightweight parts that go into AAM drivetrains. Transporting these parts from station to station and within workcells requires small and precise conveyors.

The challenge is that the compactness of such conveyors is degraded by the bulk of traditional gearmotors. That’s what prompted AAM to specify conveyors driven by Dorner’s Universal Drive offerings — with direct-drive motors from Electric Torque Machines at their core.

The direct-drive motors have high continuous torque density (particularly at lower operating speeds) to eliminate the need for a bulky gearbox. Integrated into Dorner’s 2200 Universal Drive — which includes the motor, configurable motor mount, and controller — they reduce the conveyor-drive size by nearly 70% while boosting functionality and maintaining required output torque.

“We chose Dorner’s Universal Drive for its unique motor,” said AAM facilities engineer Michael Vandervort.

“The motor is smaller and lighter than traditional ac motors … and can run in

34

DESIGN WORLD — MOTION

11/20/18 3:38 PM

CONVEYORS

For the Byrne Electrical Specialists application, assembly cell #1 might be making white outlets while assembly cell #2 is making black ones.

These must be matched to the proper order at the packaging cell. So once the electrical outlets are assembled, a robot places them on a single takeaway conveyor with a dedicated lane for each assembly cell. The conveyor delivers the outlets to a packaging cell with controls that know the order to which each outlet belongs based on the lane it exited.

designated working areas unguarded, because the motor runs cool. In contrast, traditional ac motors are too hot to touch.”

Vandervort also cited the wide speed and torque ranges of the Dorner Universal Drive as key benefits.

“The drive lets us use the conveyors for applications such as slow pass-under vision tasks; heavy accumulation tasks; and high-speed part transfers.”

The on-conveyor inspection function is especially challenging. “At our facility, we use a lot of small conveyors to move light loads. Electric Torque Machines developed motor tuning functions to help stabilize our vision imaging on pass-under applications with very low torque requirements. We really appreciate ETM working with us and developing solutions for our specific needs,” Vandervort added.

“It was energizing to work with industry leader AAM — and encouraging to see the industry ready to adopt new technologies. AAM’s application illustrates the advantages of direct-drive motors,” added ETM V.P. of engineering Scott Reynolds.

motioncontroltips.com | designworldonline.com

conveyors – Motion Control HB 08.18 V3 FINAL.indd 35

Electric Torque Machines helped improve the material handling setup inside the Pennsylvania facility of American Axle Manufacturing.

11 • 2018

DESIGN WORLD — MOTION

35

11/19/18 3:19 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Couplings, shaft locks, and flexible shafts

for automated applications MECHANICAL CONNECTIONS for machine designs include couplings, shafts, and keyless locking devices. Consider the latter, which go beyond keyed bushings to fix gears, pulleys, and other mechanical components onto drive shafts for motor-output transmission sans eccentricity, wear, or backlash. In fact, the most common keyless shaft locks employ mating rings with internal tapered wedges to apply radial pressure and lock mechanical components into place. But taper-locking devices are any components that use a wedge action from tightening a screw or screws to induce radial locking pressure at a hub and shaft bore.

Quick detachable or QD bushings are split rings with a screw that bridges a flange and taper opening. Often just a few inches in diameter, screw tensioning clamps the bushing to the shaft for an interference fit.

Recall that traditional shrink fits are when a mounted component’s ID comes to an interference fit with the shaft onto which it’s mounting. A technician heats the component to make Shown here is it expand; upon cooling the an ETP Express shaftlocking bushing. It locks gears, ID contracts and fixes the pulleys, sprockets, and other component to the shaft. components in automated machinery Still another into place with torque from 34 to 12,538 keyless shaft lock ft-lb. Tightening the pressure screw to employs viscous fluid recommended torque advances an internal that expands to lock piston to the bore bottom for uniform surface pressure on hub and shaft. The components onto bushings make for quick phasing (of shafts; certain variations cam-driven axes, for example) and include a double-walled mounting and repositioning of hardened steel sleeve components to shafts. Image and filled flange. The latter courtesy Zero-Max Inc. has a screw that depresses a

36

DESIGN WORLD — MOTION

couplings – Motion Control HB 08.18 V3 FINAL.indd 36

11 • 2018

motioncontroltips.com | designworldonline.com

11/19/18 4:06 PM

Single Source

Over

2,500

shaft collars for your

DESIGN.

Widest range of shaft collars including over 2,500 standard parts to simplify the design process and ensure the collar you need is available from stock.

carefully Made Shaft collars are manufactured from select north american bar stock in our Marlborough, Ma factory using proprietary processes developed over 75 years.

SHafT collar Hub ruland.com is your source for product specifications, cad models, technical articles, installation videos, live inventory, and application support.

Find CAD models for your next design at www.ruland.com

3.21.16_R1_RU_Design Ad_9x10.875.indd 1 ruland – motion systems World applications 11.18.indd 37

3/21/16 11/16/18 12:16 3:39 PM PM

M O T I O N S Y S T E M A P P L I C AT I O N S

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

WWW.RW-AMERICA.COM

sealed piston down a channel to pressurize the sleeve. Then this sleeve uniformly expands between shaft and hub to make a rigid joint.

No matter the iteration, most keyless shaft locks are designed to have low inertia, deliver high torque, and allow for easy adjustments of mounted components — say on cam-driven axes or those sporting pulleys for tandem belt drives requiring synchronization.

Manufacturers who sell keyless locking devices suitable for certain uses on axes driven by high-performance stepper motors and relatively large servomotors (Tsubaki and its POWER-LOCK device, for example) recommend a safety factor greater than one for all maximum or peak torques to which the axis will be subject.

Calculations for an acceptable factor account for the effects of inertia, shock, thrust, total load, and rated transmissible torque.

ZERO-BACKLASH COUPLING USES Couplings for servo applications usually connect precision drives to sensitive loads, so they cannot induce any error.

That’s why servo couplings should be zero backlash — to prevent issues with timing and predictability (not to mention failures due to hammering on reversing axes). Couplings for servo applications must also have high torsional stiffness while imparting slight forgiveness of misalignment of rotating shafts … even while holding transmitted rpm steady to motor output rpm.

But these are just a couple servo coupling considerations. Consider a typical application — to connect a servomotor to a ballscrew. Here, couplings with low inertia let the axis deliver faster acceleration and deceleration without unnecessarily degrading overall system efficiency.

In fact, couplings for servo designs must often compensate for subtle power-transmission issues to minimize errors down to 1 arc-min. or lower. That’s especially true where servo systems take the form of exacting positioning axes.

Here’s a more complete list of parameters to consider for proper coupling operation in such designs:

38

couplings – Motion Control HB 08.18 V3 FINAL.indd 38

DESIGN WORLD — MOTION

11/19/18 4:06 PM

COUPLINGS, LOCKING DEVICES & FLEXIBLE SHAFTS

Coupling type: Torsionally rigid options (ideal for motion designs) include specialty bellows couplings, rubber-jaw couplings, and disc couplings.

Curved-jaw couplings have good damping characteristics to optimize performance of axes with quick acceleration and deceleration. Elsewhere, both disc-type couplings and certain bellows couplings excel on high-speed axes. Other offerings abound to serve other design objectives.

One caveat on coupling type though: Never use rigid couplings to replace flexible servo couplings on axes where the latter seem to fail frequently. Here, this issue is most likely insufficient alignment between the motoroutput shaft and next component in the powertrain.

Sizing for torque (and speed): After specifying the coupling type, the design engineer must select a coupling size. This is heavily dependent on axis speed (rpm), the levels of torque the axis must transmit, and the service factor the application requires.

Axes that transmit steady torque are simpler to specify; in contrast, axes that transmit variable torque need additional consideration. Here, define the application’s average operating torque and the peak torque.

Stiffness: Along with exacting control of position, force, or output velocity, it’s often essential to maintain high efficiency. Couplings that exhibit windup or backlash degrade this efficiency because they must overcome load

Shown here is a fighter jet afterburner nozzle that uses flexible shaft. Image courtesy S.S. White Technologies

inertia every move cycle. This can be a significant drawback in some setups ... which is why (especially on axes employing rigid couplings) couplings should be prevented from inadvertently functioning as flywheels.

Inertia: As mentioned, this is an important parameter for a few reasons. Applications with particularly aggressive motion profiles rely on low servo coupling inertia most of all.

Damping capabilities: Disc couplings, certain bellows couplings, and high-gain rubber-type couplings are all options for coupling-based damping in servo applications. In fact, the most demanding servo applications have in recent years spurred improved response frequencies ... but vibration (and hunting) arise with high gain settings on assemblies using torsionally stiff couplings.

FLEXIBLE SHAFTS IN AEROSPACE APPLICATIONS

By Steve Grimes • S.S. White Technologies

While not all aerospace-related innovations are as well-known as propellers or jet engines, many have come to greatly benefit aircraft design … and the designs of other industries. That’s certainly true of flexible shafts. In fact, flexible-shaft assemblies work in in everything from 787s to children’s toys. Long life even under continuous operation at speeds to 50,000 rpm is typical; many can withstand temperatures from -300° to 1,000° F. How do they work? Flexible shaft consists of nested springs that are tightly wound for torsional (rotational) strength — and not the tensile strength of wire rope or cable that flexible shafts resemble. So flexible shafts can bend around obstacles even while transmitting rotary motion like solid shafts. Flexible-shaft assemblies consist of rotating shaft (sometimes called a core) with metal end fittings for

motioncontroltips.com | designworldonline.com

couplings – Motion Control HB 08.18 V3 FINAL.indd 39

attachment to mating parts. Some include a protective outer casing with fittings or ferrules that keep that flexible shaft fixed and protected from the environment.

In aerospace applications, flexible shafts are common in flap actuation, valve overrides, pedal adjustments, rescue hoists, afterburner nozzle and canopy actuation, refueling tubes, and thrust-reverser actuation systems or TRASs. The latter are engine brakes — located at the back of the engine on the turbo fan or jet engine to close bypasses and divert thrust forward to slow the plane. During forward motion, thrust comes in the intake and out the exhaust and bypass. During stops, the thrust comes in the intake and (with the bypass closed) TRASs divert bypass flow through forward-facing matrices to make the plane stop. Here, four flexible shafts synchronize and connect the actuators that open both of the thrust reverser’s halves. Two more flexible shafts in a trans cowl lock keep the TRAS from deploying during flight.

11 • 2018

DESIGN WORLD — MOTION

39

11/19/18 4:06 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Shown here is an aerospace application example — that of a thrust-reverser actuation system or TRAS — which uses flexible shaft. Image courtesy S.S. White Technologies

Shaft connections: Most servo couplings connect shafts with clamping or locking mechanisms (and not keyways).

Though keyways are often offered as an option to prevent shaft slippage, the truth is that they can be a liability — adding concentrations of stresses in shaft connections, unnecessary cost, risk of imbalance, and other drawbacks.

Ability to handle reversals: Servo applications that must make quick directional changes require special consideration.

Here, consider torque associated with system inertia starting and stopping. Service factors can often quantify the effect this value will have on assembly dynamics. Another aspect of reversing loads to consider is coupling-material fatigue. Keep in mind that some servo couplings that perform for years in regular applications with fail within weeks or sooner when forced to transmit power under reversing conditions.

Function to protect more expensive subcomponents: Though system failures are best avoided, couplings can be designed to protect the axis actuator or motor and gearbox by breaking if there is a machine crash or catastrophic overload.

That’s especially useful in high-speed servo applications where drive-based current limits aren’t fast enough to address kinetic energy associated with the drivetrain and load upon a jam or impact.

Realistic understanding of allowable misalignment: Flexible couplings for servo applications do accommodate misalignment. However, OEMs must be realistic about the level of permissible misalignment for a given axis — and specify assembly techniques and mounting that ensure levels that ever exceed the rating of the coupling. Otherwise, coupling or another component failure may occur.

40

couplings – Motion Control HB 08.18 V3 FINAL.indd 40

DESIGN WORLD — MOTION

11 • 2018

11/20/18 3:42 PM

DA M P I N G S P R I N G S

Addressing lost motion and vibration with

springs

DESIGN ENGINEERS typically work with manufacturers to customize wave springs to operating conditions by material, thickness, number of turns, and other geometric features. All wave springs apply load in an axial direction ... and consistent loads within a small tolerance range at different work heights.

That lets engineers adjust their design to set requirements.

AVOIDING SPRING SURGE Spring surge is a potential concern in assemblies with a compression spring having one free end. Depending on the motion input, such springs can exhibit resonance that’s large enough to cause temporary loss of contact with the assembly housing — and damage surrounding machine elements. That’s an issue of highest concern if the spring material provides little damping and the spring operates on an axis that must make fast reciprocating strokes.

Well-chosen wave-spring geometry and material can help avoid issues of spring surge and resonance excitation.

ADDRESSING LOST MOTION AND VIBRATION Wave springs also help address vibration in other two ways — by preventing lost motion (backlash or endplay) and damping.

Consider the first, where wave springs takeup looseness from the stackup of tolerances or changes in subcomponent dimensions due to thermal expansion or contraction. One common place is on motor-shaft bearing assemblies subject to high rpm. Here, wave springs can prevent vibration and noise that might Shown here are wave-spring otherwise result from system play. application examples. From Now consider the latter, where top to bottom, these include springs help improve designs as clutches, automotive vehicle vibration dampers. Here, the design mirrors, rolling doors, airbag inflators, water sprinklers, general relies on material deformation as well airbag assemblies, nightas mechanical contact for friction (with vision lenses, and bayonet the assembly housing or another spring connectors. Image courtesy section) to diminish system kinetic energy.

Rotor Clip Company Inc. Nested wave springs made of flat wire exhibit the most surface contact between turns, so allow for loss factors that are high enough to constitute useful energy dissipation.

Nested wave springs also suit applications requiring higher forces to meet safety regulations, such as those in government or military applications. Plus nested wave springs provide more load than a single-turn wave spring (or stamped wave washers) while using the same radial space as a single-turn design.

motioncontroltips.com | designworldonline.com

damping springs – Motion Control HB 08.18 V3 FINAL.indd 41

11 • 2018

DESIGN WORLD — MOTION

41

11/20/18 12:09 PM

Rotor Clip — MC Handbook 8-18.indd 42

11/21/18 8:03 AM

DRIVES

Drives system upgrade

aid in baggage handling

IN TODAY’S EVOLVING AUTOMATION ENVIRONMENT, the move is towards using data supplied by IoT sensors to streamline operations and improve productivity and efficiency. This push extends across components including controllers and drives that are designed to operate in a range of environments and interface with different networks across platforms.

Examples can be found from manufacturing and warehousing and distribution to material handling. Case in point; a drive that helped an airport baggage handling system improve efficiency and operation.

Though passenger numbers and luggage volume at Victoria Airport in British Columbia, Canada, are nowhere near the numbers at large international hubs, it was exactly for this reason that the baggage handling system (BHS) posed major challenges to the handling system OEM. The airport did not have a lot of room to accommodate all the usual modules – from check-in through

motioncontroltips.com | designworldonline.com

drives MB – Motion Control HB 08.18 V1 MB.indd 43

security screening to sorting. The airport company commissioned Glidepath, a manufacturer specializing in baggage conveying, parcel sorting, and freight logistics technology, to design a new system.

The new handling system has a capacity of 750 pieces of luggage per hour. “The baggage handling system is made up of 85 conveyors with a total length of some 250 m,” says Jason Williams, project engineer at Glidepath. “It comprises two in-line screening CT machines. It has two decision points for sortation and two separate infeed lines. It has four-way sorters, spiral power curves, bag alignment devices, a luffing conveyor, and Glidepath’s proprietary ploughs and power curves.”

All drive tasks are carried out by IE4 ac vector drives from NORD DRIVESYSTEMS. Each drive unit consists of an IE4 permanent-magnet synchronous motor, a motor-mounted NORDAC FLEX frequency inverter, and a two-stage gearbox. The hollow shaft gearboxes are secured on the drive axis with a Gripmaxx bushing, ensuring safe, easy-maintenance

11 • 2018

Left: The designated installation space for safety and sorting systems for baggage logistics at Victoria Airport was limited, which meant optimizing the design with components that could satisfy space constraints.

Right: NORD AC vector drives consisting of an energy-efficient geared motor and a distributed frequency inverter power the conveyor modules.

DESIGN WORLD — MOTION

43

11/20/18 2:51 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

fitting without keys. The drive systems are highly efficient even in the partial load range and at low speeds, paying for their initial cost within a few years or even only months, and significantly reducing total expenses over the product lifespan. The frequency inverters are configured exactly to Glidepath’s specifications – with plug-in connectors for power, communications, encoders, and sensors. They feature an internal EtherNet/IP interface and are designed for easy feed-through installation.

The pluggable drives saved Glidepath a lot of time during installation and commissioning, with the coded connectors ensuring speedy, error-free networking.

“Thanks to the field I/O capability of the

NORD drives, we were able to connect the majority of our field devices directly to the frequency inverters,” adds Williams. Featuring industrial Ethernet communications, the drives enable not only remote monitoring and control of all drive axes, but also seamless monitoring of connected sensors and actuators. For Williams, this was a crucial factor: “The real advantage here is the drives support high-speed Ethernet, which allows for reliable bag tracking on our system.”

The drive systems take on various tasks at the conveyor modules. They move luggage at different speeds from one belt to the next. They ensure accurate height adjustment when conveying diagonally.

Glidepath only came to realize the full

potential of the integrated positioning function of NORDAC FLEX inverters once the drives were commissioned. As they gathered parameters for various applications, NORD engineers soon found that the positioning function was the optimal solution for the luggage sorters.

A NORD specialist for their industrial sector provided significant support to Glidepath through efficient standardization. “On this project, we have just five different gear ratios for a job that has 90-odd motors in total and three different motor sizes”, Williams says. “That is a huge advantage. As a consequence, we need only one spare drive per gear type and engine size.”

#electricRULES Motion control that’s stronger, faster and smarter than pneumatics Make your next machine everything you imagine it can be.

Optimize cost, performance and flexibility with our electric linear motion actuators.

Speeds to

• Configurable strokes to fit your design • Clean, leak-free performance • Fast delivery

6 m/sec Forces to 58 kN (13,039 lbf)

To learn more, visit www.tolomatic.com/electricRULES 800-328-2174

www.tolomatic.com

drives MB – Motion Control HB 08.18 V1 MB.indd 44

11/20/18 2:52 PM

DC DRIVES

Drives for quick settling ... for faster wafer testing

WHEN semiconductor test-equipment manufacturer Proaut Technology GmbH began upgrading its PMA wafer-testing series, the goal was to reach a throughput of 40,000 components per hour. The company met its goal using high-efficiency servo drives from Elmo Motion Control.

Recall that semiconductor fabrication relies on sophisticated and expensive equipment to move through complex sequences of time-consuming steps.

Quick positioning can cause overshoot and oscillation about commanded positions — and error or low throughput. Some drives solve the problem with quick settling via gain-scheduling technology.

The microelectronics industry can deliver massive computing power at reasonable pricing because of batch processing — the simultaneous fabrication of hundreds of identical chips on dinnerplate-sized wafers. But the economics of batch processing only hold if the final chips are operational. That means component testing is core to process control, quality assurance, and standards compliance.

Testing of these semiconductor wafers begins with the patterned wafer to identify any bad chips before expensive packaging. With individual devices measuring just millimeters across, test equipment must be precise, repeatable, and accurate. Test systems must also have the smallest possible footprint — because space in any semiconductor fab is at a premium. What’s more, the testing process must be fast enough to keep pace with the output of microlithography machines.

motioncontroltips.com | designworldonline.com

Drives DC – Motion Control HB 08.18 V3 FINAL.indd 45

Now, gain scheduling by profile lets one controller on a semiconductortesting machine rapidly and automatically adjust parameters for high-speed positioning with minimal settling time.

11 • 2018

DESIGN WORLD — MOTION

45

11/20/18 8:23 AM

M O T I O N S Y S T E M A P P L I C AT I O N S

FASTER SETTLING FOR HIGHER SEMICONDUCTOR THROUGHPUT Before measurement can begin with the Proaut Technology PMA machine, the wafer or panel must be installed in the est chamber. Here, a PMA handling system uses a vacuum chuck to remove the component carrier from a magazine located next to the unit … and then place the carrier on a rotary positioning stage. The actual measurement system consists of the stage, a vision system for wafer-position feedback, and optical and electronic measurement tips to collect actual test data.

The stage can execute moves with nanoscale positioning in X, Y, and Z … and positioning in ф to a fraction of a degree. The camera can be positioned along the Z axis for autofocus. During measurements, the system tests

sections of the patterned wafer sequentially — taking measurements and then advancing and aligning the wafer to place the next area beneath the measurement tips.

The challenge with quick moveand-settle positioning is that inertia can cause load-move overshoot and oscillation about the commanded position (given the high accelerations and small increments). This can introduce measurement error or slow the measuring process.

Legacy PMA designs were capable of throughput to 30,000 components per hour. But to reach their target throughput of 40,000 components per hour, Proaut engineers needed a way to get higher performance out of existing mechanics. That led them to employ Elmo Gold Whistle servo drives.

These drives feature a function called Gain Scheduling by Profile Status.

In gain scheduling, an algorithm lets the system define separate sets of controller parameters — proportional gain (KP), integral gain (KI), higherorder filter links, and so on — to optimize system performance for several distinct application conditions.

During operation, the drive can automatically change from one set of controller parameters to another based on the current working point. Filtering helps smooth the effect of changing controller parameters — to ultimately make for faster settling.

EFFICIENT SERVO DRIVES FOR COMPACTNESS AND RELIABILITY The servo drives impart other advantages.

The wafer-test application involves highly coordinated motion: The wafer

This Proaut Technology wafer-testing machine uses compact Gold Whistle servo drives from Elmo Motion Control.

46

DESIGN WORLD — MOTION

Drives DC – Motion Control HB 08.18 V3 FINAL.indd 46

11 • 2018

handling axis must coordinate with the positioning stage … and the ф axis of the positioning stage must be tightly coupled with positioning in X, Y, and Z. This type of motion control requires high-speed fieldbus connectivity. Gold Whistle drives are available with either EtherCAT or CANopen. These protocols have ultrafast cycle times and minimal jitter to support best-in-class realtime performance.

Getting this level of coordination also necessitates a centralized control architecture on a master controller to manage the individual axes’ drives.

Controller and drives install in a centralized cabinet for simplified wiring and integration. One caveat: Packing six drives into a small enclosed space traps heat that could potentially build enough to degrade performance and cause early electronics failure. Because downtime in the semiconductor industry can cost hundreds of thousands of dollars per hour, Proaut Technology needed to avoid this problem.

Gold Whistle drives operate with a wall-plug efficiency of better than 99% for a minimal heat needing dissipation.

Besides top efficiency, the drives also fit well into the small cabinet space — for a smaller overall machine footprint.

“The PMA machines are very compact with a small internal switch cabinet,” says Thiol Wicht, Managing Director of Proaut Technology GmbH. “The miniature size of the servo drive … is a benefit.”

The drives include onboard intelligence with built-in safety functionality — including safe torque off (STO, SIL-3, IEC 61800-5-2). STO lets the drive stay energized while removing torque from the axis. That makes for quick restarts while ensuring the safety of operators, equipment, and product.

In addition, Elmo Application Studio (EAS) software provides a unified environment for servo drive and motor setup and product or process changes.

With ultra-fast settling times via gain-scheduling technology, the drives let Proaut increase its semiconductor testmachine throughput by 30%. The 99% efficient drives also impart reliability in a compact form factor.

motioncontroltips.com | designworldonline.com

11/20/18 3:42 PM

Discover the Matrix

Using complicated systems for low harmonics or power regeneration?

Try the efficient way with the U1000 Industrial Matrix Drive.

Our greenest drive ever, the U1000 goes beyond the performance of conventional drives. Enjoy extremely low harmonic distortion and regeneration in a space-saving design, completely without the need for additional components.

ACTIVE COMPONENT SYSTEM

Input Fuses

12/18-PULSE SYSTEM

12/18-Pulse Transformer

U1000 INDUSTRIAL MATRIX DRIVE SYSTEM

LC Filter

Input Fuses

3 Wires In

Active Rectifier

Standard Drive

U1000

Yaskawa America, Inc. Drives & Motion Division 1-800-YASKAWA

yaskawa – motion systems applications 11.18.indd 47

Standard Drive

3 Wires Out

yaskawa.com

For more info: http://go.yaskawa-america.com/yai1215

11/21/18 8:04 AM

M O T I O N S Y S T E M A P P L I C AT I O N S

9 factors in selecting a

servo drive

SIZING A MOTOR for a servo application requires evaluating the move profile and torque requirements to determine the mechanical demands of the system, such as maximum velocity and acceleration, RMS and peak torque values, and load-to-motor inertia match. Once the motor is chosen, the next step is to select a drive.

Selecting a servo drive (also referred to as a servo amplifier) may seem to be a matter of simply matching the drive’s voltage and current output to the motor’s requirements. But there are many factors that need to be considered to ensure the drive operates satisfactorily. While some applications may require other more specialized functions from the drive, here are key factors that guide the selection of a servo drive for most applications.  Motor type: A servo drive can be used with any motor that operates in a closed-loop system — including stepper, induction, and asynchronous — but the two most common types of motors that are paired with servo drives are brushless DC motors and synchronous AC motors. Of these, synchronous AC motors are more common in motion control applications.  Commutation: The type of commutation required by the drive depends on the type of motor being driven and the application’s sensitivity to torque ripple. Brushless DC motors can operate with either trapezoidal or sinusoidal commutation, while AC synchronous motors use sinusoidal commutation. Trapezoidal (also referred to as six-step) commutation is the simpler method, using three Hall sensors to determine the commutation sequence. But it produces high torque ripple. Sinusoidal commutation virtually eliminates torque ripple and provides more precise control by continuously varying the current supplied to the motor windings. But it requires a high-resolution feedback device to determine the rotor position.  Feedback: Servo systems require feedback to provide closedloop operation and detect and correct any errors in the motor’s actual position, torque, or velocity. This feedback can be provided

by Hall sensors, resolvers, or encoders, although most high-end systems use a resolver or an encoder. Regardless of the feedback mechanism, the drive must be compatible with its signal to process it and communicate it to the controller.  Voltage and current: The most basic requirement of the motordrive relationship is that the power from the drive — maximum voltage, continuous current, and peak current — must be sufficient to produce the mechanical output required by the motor — torque, speed, and position. Because the operation of the motor and the drive are co-dependent, manufacturers provide torque-speed curves that define the performance of specific motor-drive combinations.  Operating mode: Servo control loops within the drive are used for controlling torque, velocity, or position (or a combination of the three). While all servo drives incorporate a torque control loop and a velocity control loop, only digital drives can provide position control.

48

DESIGN WORLD — MOTION

drives SERVO – Motion Control HB 08.18 V4 FINAL.indd 48

11 • 2018

This is a Nidec Control Techniques Digitax HD M753 servo drive with an integrated two-port EtherCAT switch for easy integration into centralized motion-control applications.

motioncontroltips.com | designworldonline.com

11/20/18 8:43 AM

beckhoff – motion systems applications 11.18.indd 49

11/21/18 8:05 AM

M O T I O N S Y S T E M A P P L I C AT I O N S

 Analog or digital: Traditional servo drives were analog and converted ±10-V signals from the controller to current commands for the motor to control torque or velocity. In order to tune an analog drive, gain values and other parameters are set via potentiometers. With newer digital drives, the command can be executed by either digital or analog inputs, and tuning is done via software. Along with torque, velocity, and position loops, digital drives can also manage higher-level functionality, such as path generation. Digital drives are also capable of monitoring internal functions of the drive (such as following error) and providing more detailed fault diagnostics.  Communication: In order for the drive and controller to talk to each other, they must have a common language. So servo drives are offered with myriad communication protocols — from basic serial links such as RS485 to more advanced protocols, such as traditional fieldbus networks (DeviceNet, for example) or Ethernet protocols. The choice of communication protocol will largely depend on the required communication speed, whether there is a master-slave arrangement between multiple drives, and in some cases, the type of controller being used.  Integrated safety: Functional safety is now mandated on many machines and is governed

by EN/IEC 62061 and EN/ISO 13849-1 safety standards. To comply, safety functions such as Safe Torque Off (STO) and Safe Stop 1 (SS1) integrate into many high-level drives.  Mounting: For industrial applications, most servo drives are either panel-mounted or PCBmounted. Panel-mounted drives often install in a control cabinet where they are protected and can be externally cooled. PCB-mounted drives (also called plug-in drives) provide a compact solution for direct integration onto a PCB and are commonly used in high-volume OEM applications.

APPLICATION EXAMPLE: FORM-FILL-SEAL MACHINE Form-fill-seal machines are used to package edible powders, dry food, and liquids into bags and pouches. It’s a common machine design that comes in versions for both continuous and intermittent operation. No matter the design, top design objectives for form-fill-seal machines are high throughput with minimal downtime and the ability to reconfigure the machine to satisfy changing production requirements.

Mitsubishi Electric Automation Inc. offers an array of solutions in its Pak/iQ suite to improve the builds of such packaging equipment with reliable machine performance and communication of system analytics for IIoT functionality.

50

DESIGN WORLD — MOTION

drives SERVO – Motion Control HB 08.18 V4 FINAL.indd 50

Example courtesy Mitsubishi Electric Automation

Consider the build shown in the illustration. Bulk food product enters from the top as servo-driven axes pull bag material off roll stock (spools). The funnel hood shapes the plastic sheet into a cylinder. Then a thermal heat sealer melts together bag edges; bags are filled from above as the web travels downward.

Vertical film index drives time this function to match the machine’s operation cycles. From there, the bags get their final cutting and sealing — and then go onward to conveyors that carry them away. On this machine, a PLC (in the form of an iQ-F compact controller) provides necessary functions while helping OEMs keep cost down.

Programming of the PLC is through simple parameter setting: iQ-Monozukuri Packaging software gives engineers sample programs, sample GOT HMI screens, and auto-generated Shown here is a Mitsubishi function blocks — including those for rotaryMR-JE-10BF servo amplifier. cutter, camming, long-dwell, flying-shear, boxmotion, and mark-detection tasks.

To command and drive the motion tasks, the machine build uses an FX5 Simple Motion controller, MR-JE Series servo amplifiers, and (on the conveyor) an FR-E700 Series VFD. Two of the MR-JE Series servos are for web-index control; one is for the sealer axis. The three servo-driven motor axes are networked through fiber-optic-based SSCNETIII/H. Servo-network refresh rates to 0.222 msec allow accurate control.

Capabilities of Mitsubishi-outfitted form-fill-seal machines include autogenerated function blocks for camming as well as advanced synchronization that’s easy to configure … for fully synchronous multi-axis performance. The hardware also allows for direct control of the VFD from the Mitsubishi GT25 Series HMI via networking via the SSCNETIII/H open field network.

11 • 2018

motioncontroltips.com | designworldonline.com

11/20/18 8:44 AM

MEET DIGITAX HD

Introducing our next generation servo family. Perfect for dynamic applications where high peak torque is required. It packs a real punch from a tiny package; just over 1.5” wide.

Eddie Hall

The World’s Strongest Man

Minimum size, maximum performance. Helping you reduce your costs and maximize your space. A specialist drive, from Control Techniques the drive specialists.

DRIVE SPECIALISTS SINCE 1973

Control Techniques | 7078 Shady Oak Road | Eden Prairie | MN | 55344 | USA Tel : +1 800 893-2321 | Email: info.cta@mail.nidec.com

www.ctdrives.com/HD 100818DW meet Digitaxapplications HD.indd 1 11.18.indd 51 nidec – motion systems

10/5/2018 3:58:01 11/21/18 8:05 PM AM

M O T I O N S Y S T E M A P P L I C AT I O N S

Medical applications benefit from

precision encoders

ENCODERS ARE ESSENTIAL to accurate positioning in most motion systems, particularly where high precision is most needed. For instance, applications like semiconductor manufacturing with nanometer precision, or medical applications where there is virtually no room for error, because that could mean the difference between life and death.

Designers of medical equipment are able to use a plethora of new technologies. Motion control is an area where designers need to keep up to date with as technology increases in complexity. Medical applications such as robotic surgery, radiation treatment, and laboratory analysis such as DNA sequencing are all benefiting from advances in encoder technology.

RADIATION TREATMENT Machines that treat patients for tumors with radiation inherently have complicated coordinated motion control. Guiding the radiation beams when the patient is on the table is critical, and any errors in positioning may damage healthy cells.

Because of the radiation environment on the machine, communication between encoders and the control is of utmost importance and requires redundancy.

What caught the attention of medical machine designers is a little known ENDAT function called CRC. ENDAT is the highspeed serial interface from HEIDENHAIN that is RS-485 based and offers a fast bi-directional communication protocol.

CRC is Cyclic Redundancy Check and is transmitted along with the position words from the encoder to the control.

Basically, the CRC reports the number of bits transmitted to the control, and the control can then evaluate the number of bits and make a checksum. If the number of bits match, then everything is operating normally. However, if the checksum does not match, then the ENDAT interface

52

DESIGN WORLD — MOTION

Encoders (MB) – Motion Control HB 08.18 V2.indd 52

reports an error which the control can then handle and take the proper steps needed for reliable motion control.

has interpolation error at +/- 1 nanometer.

This kind of encoder helps to ensure the stability of the image required to evaluate the colors of the wells on the flowcell.

LABORATORY ANALYSIS ROBOTIC SURGERY Machines that are performing large Surgery robots that are surgeon-assist amounts of chemical analysis like drug based are becoming more accepted in the testing machines or those that sequence medical world. In fact, over 80% of prostate DNA are also reliant upon high quality surgeries done in the U.S. today are done encoder feedback. For drug testing with robotic assist surgery robots. Some machines, they typically use pipettes surgery robots need to have redundancy and a high number of wells per tray. for the motion control components, while Smooth reliable motion is critical here as others can drill and measure distances at the machines are usually left to operate the same time, making accuracy especially overnight and sometimes 24 hours a day. important. Here again, a reliable highWhen moving the pipette array or trays, a speed serial interface such as ENDAT motion that is jerky or somehow unsmooth as well as a full line of rotary and linear can destroy data, as liquids can spill from encoders that are Functionally Safe with the pipettes into unwanted wells. various mechanical options can fulfill the Repeatability is also critical. As the need for these applications. machine operates and heats up, the shape of the machine may change. Linear encoders that report the real position versus a rotary encoder/ ball screw Encoders from set up are more accurate, the latter HEIDENHAIN are possibly causing repeatability issues used to provide exceptional that can even lead to the pipette repeatability and array missing its targeted wells or reliability required causing a crash. for computer DNA sequencing machines are tomography. those that use flowcells, which are a “Lab on Chip” and may contain several billion micro wells. Colors need to be detected from these tiny wells and the motion system with cameras is designed for sub-micron repeatability. In these fine resolution applications, the interpolation error of the encoder (or sub-divisional error) is critically important. When the encoder signal periods are electronically subdivided to gain more resolution, errors can happen within that signal period and then eventually lead to errors in data collection from the camera. One encoder, the HEIDENHAIN LIP 200,

11 • 2018

motioncontroltips.com | designworldonline.com

11/20/18 1:39 PM

Reliability Quantified

Accurate Precision

Compact Versatility

Most complete line of rotary and drive encoders on the market Enabling automation technology in your most challenging motion control applications.

Encoder solutions providing absolute speed and position accuracy along with condition monitoring, functional safety and lightning fast cycle times.

HEIDENHAIN CORPORATION, 333 East State Parkway, Schaumburg IL, 60173

847-490-1191

www.heidenhain.us

HEIDENHAIN | LEINE & LINDE | RENCO

Heidenhain — Motion Control Trends 03-18.indd 53

11/16/18 3:46 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Two conveyors run while a Soft Robotics gripper on a FlexPicker quickly executes pickand-place tasks from above.

One gearmotor (driving the demo’s front conveyor) had a snapped encoder shaft — necessitating same-day encoder replacement.

Programmable

encoder

JUST BEFORE the recent Pack Expo 2018 in Chicago, Soft Robotics Inc., manufacturer of soft robotic gripping and automation solutions, had a brand-new show-demonstration workcell go down.

That prompted one of the company’s engineers to reach out to Encoder Products Co. exhibiting in another McCormick Place hall to get the demo working again.

“We had a last-minute issue with an encoder on a system we’d built specifically for Pack Expo,” said Soft Robotics application engineer Craig DeMello. “The day before the show, we had to replace that encoder. We needed a specific count — a very specific encoder — and Encoder Products Co. provided one that was programmable … and set it up for

54

DESIGN WORLD — MOTION

Encoders (LE) – Motion Control HB 08.18 V3 FINAL.indd 54

saves a tradeshow

us to get the demo back to working in just a few hours.”

Within the demonstration cell, side-byside conveyors run while a Soft Robotics gripper on an ABB FlexPicker quickly executes pick-and-place tasks from above.

The gearmotor driving the demo’s front conveyor was the one needing a new encoder to work.

“The demo uses the FlexPicker and ABB’s picking software,” explained DeMello. “The encoder in question is on the belt from which the robot picks items … and the robot must keep track of each object — from the time the camera sees the object to the time it’s picked. That means it's imperative that the robot knows where that product is when it goes to pick it — and the systems has to be very accurate.”

11 • 2018

DeMello found Encoder Products Co. by going down the exhibitor list — and looking for one that might be able to help his team — with something he could buy that day.

“I contacted Tracey Howard with EPC, and it was really nice of him to help us out. His team was able to setup the counts and wiring on the new encoder for us very easily. In fact, all we had to do was change the mounting bore — that was it.”

The specific encoder supplied by Encoder Products Co. is a Model 25SP Accu-CoderPro programmable encoder.

“The programmable feature is why we were able to help Craig and the crew at Soft Robotics. With the millions of possible encoder configurations, it

motioncontroltips.com | designworldonline.com

11/20/18 4:26 PM

ENCODERS

Accu-CoderPro encoders are setup through a simple GUI. Within their rugged housing are advanced electronics that allow programming of the encoders to application needs — to six different output types, 32 different waveforms, and resolutions from 1 to 65,536 CPR — 262,144 counts using 4x quadrature counting.

would’ve been unlikely we would have had an encoder to meet their needs without the ability to program the resolution, output type, and waveform,” said Howard.

Soft Robotics enables robotic automation for large markets and labor-starved industries such as food and beverage, advanced manufacturing, and e-commerce and retail. Leveraging patented material science and AI algorithms, Soft Robotics designs and builds automation solutions and soft robotic gripping systems that can grasp and manipulate items with the same dexterity of the human hand.

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

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

Call EPC today to learn how an EtherCAT

absolute encoder can fit your application.

1-800-366-5412 • www.encoder.com

Encoders (LE) – Motion Control HB 08.18 V3 FINAL.indd 55

11/20/18 8:58 AM

M O T I O N S Y S T E M A P P L I C AT I O N S

The German Bionic Systems Cray X exoskeleton uses strain-wave gearing.

Applications for GEARS operate in an array of motion applications. They are the natural complement to electric motors in industrial and consumer designs.

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

Helical gear reducers are costlier than spur sets but work in designs needing high horsepower and efficiency.

Textile machinery, conveyor drives, rolling mills, and elevators all use helical gearing to engage gradually over tooth faces for smooth operation and high load capacity.

The only caveat is that the machine setup must include 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-

56

DESIGN WORLD — MOTION

gearing – Motion Control HB 08.18 V4 FINAL.indd 56

gears 2018

processing machinery. Input and output shafts protrude in different directions; gear teeth are worm, hypoid, bevel (straight, spiral or zerol), skew or crossedaxis helical. Common bevel gearsets often go into material-handling and packaging equipment.

Hypoid gears (useful for hightoque applications) are like spiral-bevel gearsets, but output and input shaft axes don’t intersect — and that simplifies integration of supports. Common in aerospace, zerol gearsets have curved teeth that align with the shaft to minimize thrust.

Speed reducers work with an array of motors. These gearsets alter the torque of a motor—usually as an increase proportional to rpm reduction. Common in material-handling setups, shaftmounted gear reducers come in designs that use special couplings to address reactionary torque. Other shaft-mounted reducers actually mount to the machine housing (especially in machine setups with surrounding enclosures) so the input shaft doesn’t support the reducer.

11 • 2018

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

Consider worm-gear reducers.

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

Metal cutting and forming machinery, construction equipment, and packaging machinery all benefit from the low backlash of this gearing type. To illustrate, printingpress rolls hold tight print registration at high speeds thanks to the ability of doubleenveloping worm gearing to withstand shock and extreme acceleration. The gearing’s low inertia also lets presses start and stop more quickly than those with multi-stage gearing.

motioncontroltips.com | designworldonline.com

11/20/18 3:55 PM

247 Lynnfield Street, Peabody, MA 01960 • 978.532.1800 • www.HarmonicDrive.net Harmonic Drive is a registered trademark of Harmonic Drive LLC. Valkyrie image courtesy of NASA.

DW Robotics Ad2.indd 1 harmonic drive – motion systems applications 11.18.indd 57

10/11/18 3:18 PM 11/16/18 3:47 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

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

The latter (also called strain-wave gearing) is for special speed-reduction applications in robot-arm articulation, medical equipment, and offshore drilling. (Strain-wave gearing is also manufactured under a registered trademark of Harmonic Drive Systems.)

Such gearing helps designs with zero backlash and high torque density.

Allied Motion Technologies now sells an integrated electric power steering (EPS) motor for autonomous AGVs, steer-by-wire warehouse vehicles, and other material transport vehicles. This integrated motor includes a controller, gearbox, and optional output pinion. It comes in three frame sizes and 16 models to meet the electricsteering requirements of small pallet lifters, AGVs, and even reach trucks.

An optional feature (Turning Wheel Absolute Position Control) lets the controller track absolute wheel position of without external sensors.

58

gearing – Motion Control HB 08.18 V4 FINAL.indd 58

DESIGN WORLD — MOTION

Consider a specific example — in the German Bionic Systems Cray X exoskeleton. This 7.9-kg design assists plant personnel with manual handling of tools and heavy goods while reducing lower-back compression pressure. The exoskeleton joints use strain-wave gearing to reduce their brushless motors’ high rpm for an output of low rotational speed with high torque.

On a related note, at 2018 Consumer Electronics Show harmonic-gearing manufacturer Harmonic Drive exhibited with a team from suitX, designer of the Phoenix walking-assist exoskeleton … which also uses strain-wave gearing.

Exoskeletons are most useful where human work cannot be fully replaced by robotics — in industrial production for automotive, logistics, or and healthcare industries. BIS Research predicts that the market for wearable robotics could grow to U.S. $4.65 billion by 2026.

The Cray X has a battery life of about eight hours give its wearer 15 kg

11 • 2018

11/20/18 3:55 PM

A custom gearbox from CGI Inc. is used to drive the spindle onboard JPL’s latest coring drill test unit for the Mars 2020 mission. The gearbox’s dual-output interface provides the ability to switch between a high speed (for drilling) and a secondary hightorque mode (for isolating and extracting samples). JPL leveraged CGI engineering support to design and fabricate this customized dual-output gearbox to meet performance and interface requirements.

GEARS

of assist. Worn like a backpack, the Cray X extends down the legs and straps to the user’s thighs. Battery-driven electric motors at the joints then help the user with lifting or (in another mode) stand up straight with a constant vertical force (for core support) after bending down for a task. The Cray X begins actuation when an armband tracking forearmmuscle tension sends feedback to a processor indicating that on object is being lifted. Then the exoskeleton’s strain-wave-gearing-fitted motors go into action.

Production Cray X models are now available for order. “After testing with several industrial companies, we made the first models available.

Now, scaling production and further technological development are top priorities for us,” said German Bionic Systems CEO Peter Heiligensetzer.

dual output servo gearheads



Did you mean: DieQua Corporation?

Heiligensetzer predicts his company’s technology will help trim healthcare costs and (in manufacturing and logistics settings) raise productivity levels. “This technology could solve pressing societal issues now — a time of broad demographic shifts and reported shortages of skilled workers … and exoskeletons may also help workplaces avoid age discrimination.”

DYNAMIC WALL USES STEPPERS AND GEARTRAINS TO ACTUATE NETWORKED MOTION A new architectural wall called the Breakfast Brixel is making some installations more dynamic. The system is built from dozens of digitally controlled rotating bricks that act as pixels to create waves, stripes, and undulating shapes on the moving walls. Brixel

Applied Motion Products uses planetary gearboxes from Neugart USA in their AGV traction drives. The gearboxes are lightweight and efficient with high torque density. A flanged output allows direct coupling to drive wheels for further weight reduction.

Read more about the traction drives on page 26.

The search is over!

The Tandler high precision right angle servo gearheads provide unmatched performance, durability, and design flexibility. Look no further than DieQua. • Backlash to ≤ 4 arcmin • Torque capacities up to 1000 Nm • Single or DUAL output options include solid shaft, hollow bore, or shrink disk • Peak torque up to 2050 Nm To find what you’re looking for, check us out on the web, or give us a call.

diequa.com/dw 800-430-1439

half page ad 2018.indd 1

gearing – Motion Control HB 08.18 V4 FINAL.indd 59

4/24/18 3:03 PM

11/20/18 4:29 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Brixel walls can display an array of digitally programmed visuals and movements.

The bricks come in various sizes, shapes, materials, and colors. Within each brick, a stepper motor actuates the commanded rotations through a geartrain.

installations even run customizable artwork and facades to evolve in response to real-time data and software commands.

Breakfast engineers designed everything from scratch — PCBs included — and employ geared stepper motors to rotate the bricks. The center support shaft of each Brixel column allows each brick to spin endlessly in either direction without tangled wires or the use of sliprings.

“A computer runs a fully featured application in the background. It sends data to the Brixels with movement commands that include speed and direction. We can also set custom acceleration and deceleration curves at any time on the fly when the Brixels are moving. This lets us create beautiful and organic displays — such as wind animations,” explained Breakfast CTO and cofounder Mattias Gunneras.

For high-level programming of animations and interactive movements, controls were dynamically scripted was Python, OpenCV-Python, and Numpy. In addition, for Brixel Silhouette — a Brixels mode that causes the wall to rotate bricks to mirror the shapes and movements of people in front of the installation — Breakfast engineers used 3D simulation for testing through a VR headset. That let the team get a feel for the displays before a prototype physical installation was ready.

“We’re using stitched-together 3D depth cameras to create a point cloud of the scene in front of the installation,” said Gunneras. With this technique, we can create the mirroring effect to map a person … regardless of how close they stand to the installation.”

60

DESIGN WORLD — MOTION

gearing – Motion Control HB 08.18 V4 FINAL.indd 60

11 • 2018

When there’s nobody standing in front of the installation, kinetic animations and relevant information can play across the installation in the form of letters created by positive and negative colors and space.

A Linux controller sits at the heart of each installation to execute programs that process visual data and pass highlevel data to the bricks. Data goes via RS-485 connections to controller PCBs at the bottom of each column. Each controller PCB then sends the data over serial lines up the columns to each individual brick. Brixel installations are controllable and updated via a web-based app running off the Linux controller — for access from any mobile device. Users can upload content, create playlists, and set schedules.

motioncontroltips.com | designworldonline.com

11/20/18 4:29 PM

YOUR YOUR CUSTOM CUSTOM SOLUTIONS SOLUTIONS ARE ARE CGI CGI STANDARD STANDARD PRODUCTS PRODUCTS

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

800.568.GEAR (4327) • www.cgimotion.com 800.568.GEAR (4327) • www.cgimotion.com

copyright©2018 cgi inc. all rights reserved. 0516spd copyright©2018 cgi inc. all rights reserved. 0516spd

CGI — MC Handbook 8-18.indd 61

11/16/18 3:48 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Hygienic, stainless

gearmotors improve fish-processing plant

PROCESSING FRESH FISH necessitates a hygienic environment with regular washdowns, followed by frigid temperatures for freezing final products.

That’s why machinery in such settings must be extremely rugged — and why one fish supplier used motors from Bauer Gear Motor for the last few years.

Van Der Lee Seafish processes approximately 200 tons of fresh fish every week. Fish is subject to conveyordriven sorting, filleting, breading, freezing, and packaging processes. Drives for these conveyors must meet strict foodindustry hygiene requirements.

“Product quality is paramount, so fish must be processed quickly and efficiently,” said technical director Willem Van der Lee. “We can have seven processing and five packaging lines operating at any given time, and each one employs many motors and drives.

62

DESIGN WORLD — MOTION

gearmotors – Motion Control HB 08.18 V2 FINAL.indd 62

That necessitates spare parts be kept to minimize downtime should a breakdown occur.”

That’s why Van Der Lee Seafish standardized on Bauer's gearmotors throughout its food-processing facility a few years ago. The AsepticDrive from Bauer Gear Motor (of Altra Industrial Motion Corp.) has a hygienic gearmotor design with smooth surfaces and no cooling fins that can promote bacteria accumulation. Standardizing on the gearmotor minimized spare-parts inventory. What’s more, the permanent magnet synchronous motors (PMSMs) have high energy efficiency, especially under partial load. Plus the synchronous nature of the PMSM motor maintains constant speed independent of load. That means as long as the mains frequency is held constant the motor speed doesn’t vary, even under overloading or voltage drops.

11 • 2018

The gearmotors delivered the promised level of performance on almost all counts. One exception was on some motors subject to mechanical damage from other equipment. On these units, degradation of the hygienic coating threatened to compromise the hygienic design. So for certain locations in the plant, Bauer engineers supplied a newer gearmotor — a stainless-steel HiflexDrive variation with maximum mechanical resilience and the ability to withstand harsh washdowns.

“The AsepticDrive has let us trim spare-parts inventory, and the HiflexDrive in stainless steel is a direct replacement for running in frozen storage areas,” added Van der Lee. Bauer's HiflexDrive comes in a modular design allowing gearbox, electric motor, and external finish selection. Motors rated up to IE5,

motioncontroltips.com | designworldonline.com

11/20/18 2:53 PM

Control Freak?

If you like being in control, then SEW-EURODRIVE is your perfect partner! We put you in charge of every move with our gearmotors and electronics. No headaches, no whining, and virtually no maintenance.

You build it and we move it…simple!

Don’t you wish all partners were this easy…?

seweurodrive.com | 864-439-7537

sew eurodrive – motion systems applications 11.18.indd 63

11/16/18 3:49 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Top: Standardizing on the AsepticDrive units improved overall foodprocessing facility energy efficiency.

Top right: A new stainless-steel gearmotor variant is now employed where the fish processor needed maximum machinery ruggedness.

Bottom right: VFDs run the gearmotors to allow precise control of conveyor speeds.

64

DESIGN WORLD — MOTION

gearmotors – Motion Control HB 08.18 V2 FINAL.indd 64

11 • 2018

according to IEC TS 60034-30-2, offer top energy efficiency, while pairing with variable speed drives allows exact conveyor-speed setting. Including a PMSM in the drives reduces heat losses from the rotor by 100% and total losses by approximately 25% — plus boosts total efficiency by 10% or more. Such savings are significant especially for stainlesssteel motor variations that dissipate heat less efficiently than those built with aluminum or cast-iron housings.

HiflexDrive system flexibility lends itself to the food and beverage industry. The stainless-steel construction eliminates hygiene risks posed by mechanical impacts or extended operation subject to rigorous cleaning. Ingress protection is to IP69K — a washdown designation for applications subject to high temperature and high-pressure water.

Flexible designs also mean Van der Lee Seafish can move its conveyors around to various areas and not worry about drive reliability. Stainless-steel HiflexDrive units ensure maximum productivity.

motioncontroltips.com | designworldonline.com

11/20/18 2:54 PM

QUALITY YOU CAN TOUCH

IDEC touchscreens are redefining Human Machine Interaction.

Featuring up to 800-nit brightness and over 100,000 hours of backlight life, they’re the brightest, longest-lasting displays on the market. And with functionalities and connectivity options, IDEC’s touchscreens are the perfect fi t for your toughest industrial application—from semi-conductor and advanced manufacturing to packaging and wastewater treatment.

KEY FEATURES:

• • • • • •

Display sizes: 4.3, 5.7, 8.4, 10.4 and 12.1 inches Backlight life up to 100,000 hours with 800 nit Remote access, monitor and control functions FTP, Email, multi protocols and Multimedia Functions Up to -20 to 60°C operating temperature 3 year warranty

For more information, visit HMI.IDEC.COM

(800) 262-IDEC | HMI.IDEC.COM

idec – motion systems applications 11.18.indd 65

11/16/18 3:50 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

HEINEKEN Vietnam partnered with Gebo Cermex to boost its beer production in Vietnam. Sidel filler and EvoFILL Can machine installations include intuitive HMIs to allow personnel to access and adjust blow molding, filling, capping, and other functions.

HMI applications on automated machines HMIS include software and hardware to give machine operators a way to interact with and manage machine functions through a graphical user interface (GUI).

Communication is to supervisory and machine-level functions. Development of this software can be expensive upfront but ultimately lower long-term costs and redundancies.

Applications for HMIs dictate which software features are relevant. Some machines demand data collection and logging; others require that the HMI software is programmed to show operators various system parameters.

Other pieces of HMI software to go on equipment with lots of changeovers are setup to let programmers or even

66

DESIGN WORLD — MOTION

HMIs – Motion Control HB 08.18 V3 FINAL.indd 66

plant personnel switch run modes on the fly. Choosing the right HMI software for an application starts with analysis of machine specifications — including system architecture, performance requirements, integration and cost of procurement and operations.

Other HMIs works with portable platforms such as the Microsoft Windows CE, a scalable version of the Windows operating system for handheld devices.

This trims cost, as the operating systems are distributed on machinelevel embedded HMIs, solid-state open HMI machines, distributed HMI servers, and portable HMI devices. Also, some applications in pharmaceutical and medical machinery use advanced HMI

11 • 2018

features to differentiate themselves from competitive offerings.

HMI SIMPLIFIES AUTOMATION TASKS Integrator Inovatech Automation recently decided they were spending too much time programming expensive HMI and PLC platforms, so contacted Pro-Face America for help. The integrator needed an HMI capable of universal robot and I/O-Link integration, legal for Inovatech Automation branding, and easy to program.

“I was apprehensive at first because we have a lot of projects going … so timing is short,” said Inovatech director of operations Travis Buset. “More specifically, I had concerns about

motioncontroltips.com | designworldonline.com

11/20/18 9:20 AM

HMI

something on the fly — and feared the onboarding experience and programming were going double our time investment.”

Pro-Face America supplied its LT4000M HMI plus Control unit. This hardware reduces costs by eliminating the need for an external PLC. In addition, for Inovatech Automation the LT4000M halved engineering time for configuration; offered easy integration to a Universal robot and IO-Link network; and was delivered with a custom overlay for branding purposes. Trimming the time for

For motion control innovation, Solution City never sleeps.

setup was the most important benefit, though. “Another platform needed two different pieces of software. In contrast, Pro-Face uses one software with drag-and-drop functionality.

What once took me 32 to 40 hours to program now takes eight hours on the Pro-Face.” In fact, Buset had one programmed in eight hours his first time trying.

“This a powerful unit and well worth its cost for the level of configuration it allows.” Inovatech estimates it’s now operating 75% more efficiently than before.

Whatever keeps you up at night, we’ve got a solution—the largest selection of motors, pumps and air-moving devices available.

Plus, one-of-a-kind solutions ready to be custom-engineered for your precision industrial, commercial, combustion or transportation application.

If you can dream it, you’ll find it at Solution City. ametekdfs.com

Inovatech uses Pro-Face America’s LT4000M HMI plus Control unit on its modular automated station.

100 East Erie Street • Kent, OH 44240 © 2017 by AMETEK Inc. All rights reserved.

11 • 2018

HMIs – Motion Control HB 08.18 V3 FINAL.indd 67

DESIGN WORLD — MOTION

67

AMETEKPMC 15818_City Never Sleeps Ad_3x10.875.indd 1

11/20/18 9:21 AM 7/14/17 3:00 PM

maple systems – motion systems applications 11.18.indd 68

11/16/18 3:50 PM

LINEAR SLIDES, GUIDES & RAILS

This SIMO XYZ assembly includes ML linear actuators and self-lubricating linear guides, RST round shaft technology, and CFT (constant force technology) integrated stepper motors and leadscrews with a constant-force anti-backlash mechanism. Image courtesy PBC Linear

Application dictates

linear guides which lubrication is best for

LACK OF LUBRICATION is generally regarded as the number one cause of bearing failure. For recirculating linear bearings, such as profiled rail guides and ball screws, lubrication separates the bearings (ball or roller) from the raceways, minimizes friction and wear, dissipates heat, and prevents corrosion. It also promotes smooth running of the seals and reduces seal wear, ensuring their effectiveness in keeping the lubrication in and keeping contamination out.

The theory of elasto-hydrodynamic lubrication defines the conditions for development of a lubricating film in recirculating linear bearings. Simply stated, the formation of the lubricating film is dependent on the viscosity of the

linearmotiontips.com | designworldonline.com

linear guides slides – Motion Control HB 08.18 V2.OK.LE.indd 69

lubricant, the speed of the bearing, and the pressure between the bearing and the raceway. For profiled rail guides and ball screws, lubrication can be achieved with either grease or oil. The choice depends on the application parameters, including: temperature, load, vibration, speed, environment, contamination, and stroke length.

Benefits of grease abound. For most linear guide and drive applications, grease is the better lubrication option. It adheres to bearing surfaces better than oil, lasts longer, and is less likely to run off or be ejected from rotating parts.

Grease lubricants are made of three primary components — a base oil, a thickener, and additives (typically rust

11 • 2018

inhibitors). When selecting a grease lubricant, the viscosity of the base oil determines how the lubricating film, which separates the rolling elements from the raceways, develops. The consistency class of the grease, which is defined by the National Lubricating Grease Institute (NLGI), indicates how the grease will flow and disperse within the bearing.

Linear systems typically use lithium-based greases, with no solid additives such as MoS2 (molybdenum disulfide) or PTFE (Teflon), in consistency class between 0 and 3.

These greases perform well in highload applications and have good stability against oxidation.

DESIGN WORLD — MOTION

69

11/20/18 11:05 AM

M O T I O N S Y S T E M A P P L I C AT I O N S

There are applications that perform better with oil lubrication as well. Oil lubrication is recommended for high-speed applications, since it dissipates heat more readily than grease. It also flows and disperses better than grease. But when oil lubrication is used, the orientation of the bearing and the location of the lubrication ports must be taken into account. When components are mounted on their sides or vertically, oil lubrication will not flow to bearings and raceways that are above the lube ports.

Some machine builders employ a misting system for oil lubrication. Although these systems can be more complex and

costlier than manual or even automated systems for grease lubrication, an oil mist system provides the additional benefit of creating positive pressure inside the bearing.

This helps prevent contamination from entering the bearing and further assists in cooling.

Note that incompatibility between lubricants can cause separation of the lubrication components and render it ineffective. Some manufacturers provide linear guides and ball screws that are prelubricated, ready to install and use, while others simply apply a preservative grease or oil. To ensure compatibility between the initial lubrication and the in-service lubricant,

RESIN UNIT ON LINEAR GUIDE

Some lubricant technologies for linear guides are also applicable to ball screws. Case in point: K1 Lubrication Units from NSK Precision America allows maintenance-free operation of linear guide, ball screw, Monocarrier linear actuator, and Robot Module components for more than five years or 10,000 km. NSK K1 subcomponents consist of a porous synthetic resin containing significant lubricant to constantly supply fresh oil to working component surfaces they contact. The units excel where grease is unacceptable or washed away by the application.

RESIN UNIT ON BALL SCREW

Ball slide Clamping ring NSK K1

Garter spring

End seal

End cap

NSK K1 Ball nut

Protective cover

K1 cap

Rail

Labyrinth seal Screw shaft

STANDARD SEAL VERSUS SEAL MADE OF LUBRICANT-SATURATED POROUS SYNTHETIC RESIN ON LINEAR GUIDE With NSK K1

ON BALL SCREW With NSK K1 No lubricant

50,000 km and still able to run

No lubricant

Damaged at 79 km

0

10,000 20,000 30,000 40,000 50,000 Running distance (km)

70

DESIGN WORLD — MOTION

linear guides slides – Motion Control HB 08.18 V2.OK.LE.indd 70

11 • 2018

0

23,600 km and still able to run Damaged at 8 km 5,000 10,000 15,000 20,000 25,000 Running distance (km)

linearmotiontips.com | designworldonline.com

11/20/18 11:05 AM

ISO 9001:2015/AS9100D CERTIFIED

NEED A

CUSTOM ENGINEERED LINEAR SLIDE ASSEMBLY?

When a Medical Equipment Manufacturer needed a custom linear slide assembly, they came to Del-tron.

Other

Precision Linear Motion

Products

Many linear motion applications require CUSTOM DESIGN. Del-Tron Linear Engineering has the products, knowledge and expertise to help you design and achieve the perfect linear motion solution for your specific needs.

Based in the United States and more than 40 years of experience, we have been providing our customers with design assistance, product prototyping and full service manufacturing for custom linear ball slides, crossed roller slides, positioning stages and complete linear positioning systems. Ranging anywhere from a standard ball or crossed roller slide requiring custom holes or special materials to a complex positioning system, Del-Tron Linear Engineering can help.

Utilizing our customized or standard slides, let one of our knowledgeable engineers provide you with immediate technical assistance, enabling you to find work-arounds to design and develop unique out-ofthe-box solutions. Call us today. You’ll find we’re always ready to help and offer personalized attention that’s unparalleled in the industry. We expect you’ll experience a level of responsiveness you just won’t see anywhere else. Help us to help you use our products!

Non-Magnetic Ball Slides

Linear Slides Ball & Crossed Roller

Micrometer Positioning Stages Micrometer Driven Ball & Crossed Roller Stages

Call Today! 800.245.5013 Solid Models Available for all Del-Tron Model Numbers

del-tron – motion systems applications 11.18.indd 71

Designed & built in the U.S.A

www.b uydeltron.com

11/16/18 3:53 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

lubricant, check the manufacturers’ lubrication specifications. If the two are not compatible, components should be wiped down and purged before any additional lubrication is applied.

Regardless of the lubrication type— grease or oil—maintaining the proper amount of lubrication is critical to achieving optimum bearing life. Manufacturers of linear guides and ball screws publish recommended lubrication quantities and intervals, which are primarily based on the type of lubrication being used, along with the speed and temperature of the application.

Other factors, such as shock loads, vibration, and contamination can also affect the life and performance of the lubricant.

For applications with these conditions, lubricant manufacturers can analyze the operating parameters and recommend a lubricant that will ensure optimum bearing life.

BACK TO BASICS — LINEAR COMPONENTS IN OTHER DESIGNS Linear guide systems include guide rails, slides and ways. Industry categorizes them into a few basic types — including profile rails, drawer slides, linear bearings, guide wheels and plain bearings. A typical arrangement includes a rail or shaft and carriages and runner blocks.

Linear guide systems are also distinguished by method of contact — either sliding or rolling.

Linear guide systems include guide rails, slides and ways. Industry categorizes them into a few basic types — including profile rails, drawer slides, linear bearings, guide wheels and plain bearings.

A typical arrangement includes a rail or shaft and carriages and runner blocks. Linear guide systems are also distinguished by method of contact — either sliding or rolling.

Some PBC Linear products include polymer lubricators made of porous oil-filled polymer to outperform wipers made of filled felt. In some cases, the lubricators last the life of the application without relubrication. Lubricant within the polymer is NSF registered for H1 and H2 applications for direct and indirect contact with food. It also works in washdown applications. The lubrication within the polymer contains corrosion inhibitors, antioxidants, and extremepressure additives.

Motion Control Solutions from

LSM Series bit.ly/Config-LeadScrew

Compact Series bit.ly/Config-Compact

ML Series bit.ly/Config-ML

SIMO Series

P

bit.ly/Config-SIMO

b

Try Our New Configurators Today at pbclinear.com linear guides slides – Motion Control HB 08.18 V2.OK.LE.indd 72

11/20/18 4:34 PM

LINEAR SLIDES, GUIDES & RAILS

A major function of rolling guides is to reduce friction in machines. They’re used in 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 more than 150 μm/m.

For cleanroom and food-processing applications that can’t tolerate contamination, certain linear guides that use

Shown here is an automated transfer-system example from PHD Inc. Linear slides and actuators (and fluid-power rotary actuators) from the manufacturer execute vertical (and rotary) motion.

A part from the conveyor approaches the first linear actuator. Then this mechanism’s rotary section turns 90˚ to align vacuum cups for pickup.

Other mechanisms in the workcell extend to dip parts they’re holding into treating bins. Once complete, the mechanisms put finished parts into a bin.

Extra Small to Extra Large

PLA Series bit.ly/Config-PL

MTB Series bit.ly/Config-MT

MUK Series bit.ly/Config-MUK

and Make Your Tailored Solution! linear guides slides – Motion Control HB 08.18 V2.OK.LE.indd 73

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

11/20/18 4:34 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

rolling elements (as well as plain bearing systems) are unsuitable because of their need for lubrication. In contrast, applications demanding extremely high precision and accuracy use fluid-floated bearings. 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.

Considerations for choosing a linear-motion rolling guide include the loading (both static as well as applied), 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.

CASE-SEALER MAST USES VEE RAILS 28

4

15

Shown here is the vertical section of the Loveshaw Little David LDX RTB cardboardbox sealing machine.

The machine is an operator fed semiautomatic random case sealer — meaning it automatically adjusts for box height and width. The machine then applies tape to top and bottom to seal.

The LDX RTB machine assembly includes vee-guide rails on the vertical masts.

38

40 12

33 3

33

24 9

33

13

16

ITEM

30

32

34 23 13

3

2

22

14

6

5

1

26

20

9

6

31 5

5

8 32

26

25

9

5

9

17

8

35 27

14 15 16 17 18 19 20 21 22 23 24

2 2 4 4 2 4 2 2 2 1 12

25 26

GUARD, MAST CAP, MAST GUARD SUPPORT NUT PLATE, V TRACK MAST WELDMENT SPACER, CYL. PIN, MAST CYL NECK SUPPORT NECK PLATE, REAR HEAD LOCK PLATE BUMPER CRUSH SLEEVE 2 BRKT. BUMPER 12 NYLOCK NUT M6

29 30 31 32 33 34 35

4 2 2 12 6 2 4

36 7 9

36 37 38 39 40 41 42

29

8

DESCRIPTION STUDDED VEE 8 WHEEL, ECCENTRIC 2 CYLINDER 24" stroke 26 NYLOCK NUT M8

QTY

7

7

32

2 3

1

41

42

39 13

VEE TRACK BUMPER, HEAD BUMPER STOP SHCS M6x16 LG. HEX HD 8-32 x 3/8 BREATHER SHCS M6 X 1.0 X 12 LG. 16 LOCK WASHER M8 4 SHCS M8 X 20 2 MAST CRUSH BLOCK 4 SOC. HD. CAP SCREW M8 X 65L 1 CLAMP SW. SCREW 2 BUMPER, PLATE 4 HHCS M6 X 30

26

37 36

3

9

3 18

8

37

36

9 8

13

36

39 3

ASSEMBLED VIEW

10 32

13

11 16

8

74

DESIGN WORLD — MOTION

linear guides slides – Motion Control HB 08.18 V2.OK.LE.indd 74

11 • 2018

9

12

19

linearmotiontips.com | designworldonline.com

11/20/18 4:34 PM

HIGH PERFORMANCE. STANDARD.

NSKHPS Spherical Roller Bearings deliver dramatically increased load ratings, limiting speeds and operating life across an expansive range of series and sizes. With an optimized internal design that’s built to yield, NSKHPS Spherical Roller Bearings increase output and improve costefficiency across a vast array of industrial applications - outperforming, outlasting and keeping machinery and equipment reliably in motion.

NSKHPS SPHERICAL ROLLER BEARINGS

www.nskamericas.com

NSK — PT Guide 5-18.indd 75

11/16/18 3:55 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Frameless dc motor example USE OF LIGHT DETECTION and ranging (LiDAR) in the automotive industry is growing exponentially. Two common variations are solid-state LiDAR and hybrid spinning LiDAR. Solid-state LiDAR are non-spinning systems. Some employ a phased array to steer the laser beam sans moving parts; others include a tiny mirror to steer the laser beam. Still another solid-state design called flash LiDAR illuminates entire scenes in a single flash to allow detection of returned light via a two-dimensional array of sensors — similar to the operation of a digital camera. These methods provide cost-effective LiDAR functionality.

Sometimes manufacturers put all the LiDAR electronics on a single chip, including the laser, any beam-steering circuitry, detectors for the return signal, and supporting computer power. But singlechip solutions for solid-state LiDAR are vulnerable to environmental challenges such as heat, cold, humidity, rain, and corrosive substances. End users needing to repair systems often find replacement ICs costly.

The latter is significant because a typical solid-state LiDAR setup provides a single fixed-in-place field of view of 120° or less. That means it takes at least four units to cover a full 360° safety zone. That contrasts with spinning LiDAR systems, which cover 360° operation with no blind spots due to gaps or overlapping … problems inherent to solid-state systems.

In addition, safety rules dictate that LiDAR must not generate output capable of damaging eyesight — even if a person were to look directly at the LiDAR unit for a number of seconds.

Leveraging the advantages of both solid-state and spinning LiDAR is hybrid LiDAR. These designs have a field of view that’s seamless and repeatable. Plus safety regulations permit moving laser sources to emit higher-power beams than stationary ones. So more powerful lasers let hybrid spinning LiDAR units map wide ranges and (when incorporated into systems for autonomous operation) help vehicles avoid the need to make short stops (which can pose hazards to passengers). As we’ll see, trimming the cost of these designs is possible with frameless motors.

MOTOR PARTS THAT LIDAR SYSTEMS DON’T NEED Recall that brushless dc motors are more powerful than brushed motors — and avoid the friction and voltage drop associated with brushes for commutation. That’s why brushless dc motors are used in LiDAR systems.

Spinning LiDAR designs usually turn at 200 to 500 Frameless motors as these from Lin rpm. The mirror assembly Engineering integrate into designs to reduce waste and redundant mounting the motor turns is very light, supports, plates, and brackets. They also so torque isn’t typically an omit endcaps that can easily account for issue. But many of today’s up to 50% of overall motor length.

76

DESIGN WORLD — MOTION

DC Motors STORY 2 – Motion Control HB 08.18 V2.LE.OK.CUT.indd 76

11 • 2018

LiDAR systems use off-the-shelf (OtS) NEMA 17 and NEMA 23 motors — which can make for unnecessarily bulky builds.

That’s because most OtS brushless dc motors are structurally and mechanically self-supporting. Endcaps suspend rotor in stator; the LiDAR’s moving assembly couples to an output shaft. In fact, motor ends can easily account for half a motor’s length.

In contrast, frameless motors omit additional mounting supports, plates, brackets, and couplings to let design engineers directly integrate loads into the rotor design; in addition, the stator can be seamlessly incorporated into the system for a smaller design that doesn’t sacrifice performance.

Frameless motors also help improve vehicle aerodynamics and styling. It’s easier for engineers to incorporate wider flatter shapes to car exteriors than tall narrow shapes. Frameless motors can deliver this kind of geometry — with large diameters and less height than comparable OtS brushless dc motors. In addition, a portion of the LiDAR mirror load can sink down into the frameless design’s stator. Both of these options help reduce the overall LiDAR height for a streamlined shape.

Frameless motors aren’t constrained to standard sized motors, so give design engineers more freedom to tailor motor shape and size to the application. This makes for LiDAR systems with the smallest footprint possible. When paired with the lightweight sensors of solidstate technologies, the motors have less mass to move and lower torque requirements to satisfy — allowing for a much smaller motor to do the job.

motioncontroltips.com | designworldonline.com

11/20/18 11:30 AM

Stepper Motors

Piezo Motors

Brushless DC Motors

Linear Actuators

FAULHABER coreless (brush) DC motors feature compact dimensions, low power consumption, high efficiency, and low noise, making them ideal for challenging medical equipment applications requiring high precision and smooth motion.

As the exclusive provider of FAULHABER products for North America, MICROMO creates value through advanced design and engineering services.

Precision Actuation Systems Design & Integration of Components Drive & Control Integration Performance & Cost Optimization

micromo – motion systems applications 11.18.indd 77

Clearwater, FL USA www.micromo.com 800-807-9166 ISO 9001, ISO 13485 certified

11/16/18 3:57 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

Which

linear motors are suitable where LINEAR MOTOR SPEEDS range from a few inches to thousands of inches per second. The designs can deliver unlimited strokes and (with an encoder) accuracy to ±1 μm/100 mm. For this reason, a variety of medical, inspection and material-handling applications use linear motors to boost throughput.

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

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

78

DESIGN WORLD — MOTION

Linear Motors – Motion Control HB 08.18 V3 FINAL.indd 78

11 • 2018

Linear stepper motors deliver speeds to 70 in./sec, suitable for relatively quick-acting pick-and-place and inspection machines. Other applications include part-transfer stations.

Cost-sensitive applications benefit from hybrid linear motors, as they have inexpensive ferromagnetic platens. They vary magnetic saturation from the platen to shape opposition to magnetic flow. Feedback plus a PID loop with positioning control helps the motor output servo-grade performance. The only catch is that ANCA hybrid motors have limited output Motion LinX and exhibit cogging from coupling M-series linear motors are efficient and delivers precision required

by CNC processes and high-speed automation.

linearmotiontips.com | designworldonline.com

11/20/18 11:56 AM

L I N E A R M O TO R S

This is a highprecision miniature linear stage from the Electromechanical & Drives Division of Parker Hannifin Corp. It includes an iron-core linear motor, integrated high resolution feedback, and precision square-rail guidance.

between forcer and platen. Two solutions are phase-teeth offset and driving for partial saturation of platen teeth and forcer teeth sections. Some hybrid motors also use external cooling.

Linear ac synchronous motors can output 7,000 N or more. Such designs find use in baggage-handling systems and amusement rides. Linear ac induction motors that run to 2,000 in./sec work for people movers, roller coasters and large aerospace applications. General-purpose types can move a few inches to 150 ft/sec or faster.

Cylindrical linear motors have steel rods and a moving coil or rods filled with stacked magnets, so work in myriad machines that need quick and accurate strokes. Ironless-core (or air-core) linear motors output up to 3,000 N and speeds exceeding 230 in./sec … useful in longstroke pick-and-place applications, flyingshear setups, and laser and waterjet cutting. In contrast, many iron-core motors excel in machine tool and robotics applications.

11 • 2018

Linear Motors – Motion Control HB 08.18 V3 FINAL.indd 79

Multi-axis stages that use linear motors on each axis are more compact than traditional setups.

DESIGN WORLD — MOTION

79

11/20/18 11:38 AM

M O T I O N S Y S T E M A P P L I C AT I O N S

Germany startup SUPERWURM uses copious igus components in automated machines for breeding and growing of giant red worms. Assisted by automated guided vehicles (AGVs), two robots, and a conveyor belt, the machines fully automate feeding and watering processes. Monotonous 24/7 feeding and watering steps are no longer done manually — so without error. The Langhoffs plan to market their automated setups through spinoff RobCoTec.

Worm farm uses array of

motion components ONE AUTOMATED WORM FARM in Germany to breed and grow worms includes machines to continuously lift, transport, release, stack, drill, and spray giant red worms called dendrobena. Durenbased SUPERWURM uses robots and automated guided vehicles (AGVs) until the worms are ready for sale to fishermen, as food for animals, and as natural fertilizer for gardens and greenhouses.

Now, SUPERWURM founder Martin Langhoff has a new business called RobCoTec aimed at marketing the automation products he originally developed for SUPERWURM. “Small businesses need to affordable production and warehousing automation to keep pace with big businesses. Their machines must operate reliably and for a long time,” said Langhoff.

Wear-resistant and maintenance-free igus parts are core to the new RobCoTec offerings.

80

DESIGN WORLD — MOTION

Stepper Motors – Motion Control HB 08.18 V3 FINAL.indd 80

11 • 2018

Langhoff was originally inspired to start his giant-redworm business based on his son’s curiosity about worms in general — and discovered igus products while seeking components for his first self-built machine.

Feeding and watering processes had to be automated, and parts needed to work even when subject to dirt, soil, and moisture. Plus they had to work without lubrication, to prevent worms and soil contamination.

First Langhoff purchased drylin quad-block carriages (with solid plastic bearings) to ride twin parallel shafts on one machine. Then he purchased igus E4 e-chains to keep its water and power cables organized.

AGVs take earth and worm-filled containers in batches from the warehouse to a feeding and watering installation. Twin synchronously driven drylin ZLW toothed-belt axes (including gantry center drive) pull container stacks onto the AGV. The belt drives include stepper motors that move containers to 265 lb. E6 e-chain guides the cables to prevent cables from being crushed. The lightweight system requires little power to operate and is resistant to shock and dirt.

Once the AGV has loaded its containers, an igus NEMA-23 stepper motor closes a gate for safety during transport. Then the AGV takes the

motioncontroltips.com | designworldonline.com

11/20/18 12:16 PM

Schneider — Motion Control Trends 03-18.indd 81

11/16/18 3:57 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

C

A

B

D

A: E4-Series energy chain (e-chain) keeps cables organized and safe during fast robot moves … and protect cables on long axis strokes. igus NEMA-23 stepper motors fitted with gearboxes power robot grippers to place containers on assembly lines.

B: At the watering and feeding station, soil and moisture fall on the bearings … but the sliding elements of the linear guides are plastic with embedded solid lubricant, so no oil contaminates the factory floor or worms. Plus there’s no grease or oil to which dirt can adhere. In fact, drylin linear bearings work like snow plows to force foreign bodies out of the way via contact surface between the plastic sliding element and shaft.

C: SUPERWURM also has a setup to automate the drilling of ventilation holes into worm habitats in batches. The gantry includes drylin components and shafts that ride twin igubal KS pillow-block bearings. Drilling ventilation holes produces fine plastic particles; motion components from igus that require no lubrication are suitable for use around such swarf.

D: The SUPERWURM warehouse is stacked with containers of soil and worms. A machine uses pneumatic grippers to advance containers in twos to a station for a light water spray and food sprinkling. Drylin carriages serve as bearings for the movable gripper elements.

82

DESIGN WORLD — MOTION

Stepper Motors – Motion Control HB 08.18 V3 FINAL.indd 82

containers to a feeding and watering cell. A robot takes the containers one by one off the AGV and places them onto an assembly line. Then the robot works with an intelligent gripper to detect container position and grip and reposition them as needed. Shafts on igus igubal ES pillow blocks let the gripper open and close even while withstanding high radial loads. Plus the lightweight pillow blocks impart vibration damping.

On the assembly line, the containers are automatically watered and food is scattered on the soil. Then a second robot lifts the watered and fed containers off the line and onto a trolley for the AGV to collect and return to the warehouse.

When its battery needs it, the AGV automatically drives to a charging station for quick 30-minute charge.

SUPERWURM worm buckets were originally drilled with large air

11 • 2018

holes (and then glued with custom plastic sieves) by hand. But that was inefficient and costly … and self-adhesive sieves cost more than $2,800 a year. Now, the company uses an automated process to clamp 40 buckets at once.

"Now it only takes 10 minutes … with a power tool moved by a drylin gantry to automatically drill the ventilation holes. The shafts of the gantry ride twin igubal KS pillow-block bearings,” said Langhoff.

Plus the new design omits sieves because the power tool drills the company logo into the buckets with tiny holes.

One prototype of the drill gantry included toothed-belt axes with stepper motors … but the motor for the vertical axis was too weak and could not move the power tool as needed.

Now, a larger motor and e-chain on the axis delivers long strokes.

motioncontroltips.com | designworldonline.com

11/20/18 12:19 PM

The Step Motor Specialists BACKED BY

GET THE EXACT

STEP MOTOR POWERED

LINEAR ACTUATOR

YOU NEED IN YOUR DESIGN EASY AS 1

2

3

√ Select Your Motor √ Select Your Screw √ Select Your Nut

Optimized for Your Application

Quick Prototype Turnaround

Configure Online Now

www.LinEngineering.com/Actuators

DW_LE_Linear_Actuator_Ad_2018.indd 1 Lin Engineering 1-18.indd 83

Small Batch to OEM Volume Production

US Based Support & Manufacturing

Or Call 408.919.0200

And Speak With One Of Our Application Specialists

1/9/2018 11:53:33 AM 11/16/18 3:59 PM

A Quantum Leap in Piezo Nanopositioning Aerotech’s Q-series piezo nanopositioners and controls deliver industry-leading performance in a compact, affordable package.

Microscopy • Interferometry • Dynamic Focusing • Precision Alignment Features and Benefits: • Linear, XY, and vertical travels up to 600 µm provide sub-nanometer performance with minimal footprint • Superior linearity, repeatability, and resonant frequency allow for ultra-precise positioning and measurement • One control platform for all axes in your system – piezo, servo, stepper, and galvo – simplifies integration and startup, and helps to achieve the lowest total cost of ownership • Quickly and easily generate motion profiles graphically with our Motion Designer software – no need to write code!

MOTIONDESIGNER

www.aerotech.com • 412-963-7470 AF0918A-TMG

AF0918A-TMG-Piezos-9x10_875.indd 1 aerotech – motion systems applications 11.18.indd 84

9/24/2018 1:41:29 11/16/18 4:00 PM PM

S TA G E S • TA B L E S • G A N T R I E S

Ballscrews & Rollerscrews

Industrial Robots

SIMATIC S71516F controllers help improve gantry performance with better connectivity and faster servo-driven axis coordination.

Linear Motors

Where

goniometer stages excel

A GONIOMETER is a device that measures angles or one that rotates objects to a precise angular position. The former is widely used in physical therapy (to measure the range of motion of joints) and in laboratory science (for measuring the angles between crystal faces or X-ray diffraction, for example).

Goniometers for rotating objects around a fixed axis are much like linear stages ... but instead of providing motion on X, Y, or Z axes, goniometer stages produce partial rotation around a fixed point or axis above the stage. Rotation angles are 90° to a few arc-seconds.

Common industrial uses for goniometer stages include micromachining and the alignment of mirrors for inspection. In laboratory applications, they’re often used for directing lasers and aligning mirrors or lenses in microscopy equipment, such as transmission electron and scanning electron microscopes.

Linear Actuators

Like linear stages, goniometer stages come in myriad designs, but every design incorporates a low-friction guide and a high-precision drive mechanism. The guide mechanism can be a curved dovetail bearing, a curved crossed roller guide, or even an air bearing. In some designs, bearing races are machined directly into the stage to form the equivalent of a partial, single-row rotary bearing that supports and guides the load.

The drive mechanism can be a highratio worm gear, a ball screw or lead screw (typically with an anti-backlash nut) or a direct-drive motor. Because goniometers are often used for very fine positioning, worm gear versions use very high ratios — in the range of 300:1 — and can be driven by hand with a micrometer or with a stepper or servo motor. Similarly, ball and lead screw versions use very small leads, and these are often driven by servo or stepper motors. Goniometer stages with crossed roller guides and

Linear Guideways

Linear Encoders / Positioning Measurement Systems

AC Servo Motors

Hiwin D1 and D2 Servo Drives

For more information visit

motioncontroltips.com | designworldonline.com

tables & stages & gantries – Motion Control HB 08.18 V2.LE OK.indd 85

11 • 2018

DESIGN WORLD — MOTION

85

www.hiwin.com

11/20/18 1:47 PM

READY TO ROLL Compact, rigid and easy to install, IKO’s crossed roller bearings can handle complex loads in any axis—making them a great fit for motion systems with high load capacities, including robot, machine tool and other industrial applications.

To learn more, visit ikont.com/rollerbearings iko international – motion systems applications 11.18.indd 86

11/16/18 4:01 PM

S TA G E S • TA B L E S • G A N T R I E S

Güdel linearrobot arrangements include gantries that can accurately and quickly handle loads to several tons.

The Cartesian setups come in versions to five axes of motion, and all integrate well with other automatic welding, machining, and assembly equipment.

piezo motors can provide ultra-high resolution for small ranges of motion to meet the needs of micro- or nanopositioning applications.

With so many variations, goniometer stages work in an array of applications, including cleanrooms and vacuum environments. Most goniometer stages allow stacking of multiple stages, providing orthogonal rotation around a common point. What’s more, manufacturers of goniometer stages

WE Series Linear Guideway Wide Series Ball Type.

often manufacture linear stages and make it easy to integrate the two types from a mounting and control standpoint ... for engineered solutions that deliver both linear and rotational movement.

PG Series Linear Guideway Integrated Magnetic Encoder.

GANTRIES GET NEW (PLC) SMARTS Linear gantry systems help industrial manufacturers in material handling, assembly, sorting, inspection, packaging, and palletizing. Many

I N S P E C T I O N ( U S I N G S TA G E S ) G O E S I N - L I N E W I T H M A N U F A C T U R I N G TA S K S

“Quality control is a longtime focus of industrial manufacturing — but now, design verification is moving from lab-based tests and measurements to inline inspection equipment. Such operations execute in the same space and time as manufacturing tools. No wonder we’ve seen increased demand for automation stages and motion controllers to automate high-throughput inspection processes. The focus now is on stages and controllers rugged enough for manufacturing environments — but nimble enough to let design engineers test and measure more parts in less time ... and with the same tolerances possible in quality-control lab environments.”

MGN / MGW Series Linear Guideway Stainless Steel Miniature Linear Guideway Size 5 Now Available.

HG / EG / RG Series Linear Guideways Ball and Roller Type.

- WILL LAND • BUSINESS DEVELOPMENT MANAGER AT AEROTECH motioncontroltips.com | designworldonline.com

tables & stages & gantries – Motion Control HB 08.18 V2.LE OK.indd 87

11 • 2018

DESIGN WORLD — MOTION

87

11/20/18 1:47 PM

of better products. better solutions. mk North America is a member of the mk Technology Group, a leading worldwide conveyor manufacturer, and supplier of aluminum conveyors, workpiece pallet conveyors, stainless steel conveyors, and extruded aluminum framing.

Since 1988 mk has been delivering conveyors and extruded aluminum framing through industry know-how, ISO-certified quality, fast shipping, and competitive pricing. mk North America's products are unsurpassed in variety and flexibility.

8 6 0 .7 6 9 . 5 5 0 0 | M K N O R T H A M E R I C A . C O M | S A L E S @ M K N O R T H A M E R I C A . C O M

mk North America | 09.18 V1.indd 88

11/16/18 4:01 PM

S TA G E S • TA B L E S • G A N T R I E S Dynamic metrology is the collection of data on objects traveling on moving machine axes. It’s increasingly common with laser-based inspections and spectrometry ... primarily for semiconductor and electronics manufacturing that uses line scanning of discrete product during processing.

Life-science applications such as cell analysis or DNA and gene sequencing — which necessitate high data-collection throughput — also employ dynamic metrology. Yet another application is in precision laser cutting.

Because the stages carrying the product are in motion during measurements, they must exhibit minimal error.

LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

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

One solution is to specify stages based on linear motors — as the one shown here from the Electromechanical & Drives Division of Parker Hannifin Corp.

gantry systems employ CNC-based motion control functions. While they’re precise and allow manipulation of all motion functions, such gantries can also be expensive and necessitate high-level support for engineering and maintenance. So one maker of gantry systems — Harry Major Machine — recently began offering a PLC-run gantry to boost performance for end users. The new gantry from Harry Major Machine is an XYZtype machine to execute flexible materialhandling tasks — and incorporates Siemens components.

Siemens engineers reviewed the existing gantry-machine mechanical designs, developed a bill of materials (BOM) with recommended additions, and then helped in their integration. Now, five new gantry

models (the MGL-30, MGL-50, MGL150, MGL-250, and MGL-500) support various end-user functions with SIMATIC S7-1516F PLC control. The controllers are easily configurable with quick software deployment and a smart library to simplify use of universal functions.

Another benefit is that the PLC allows use of servo drives — a setup once too slow for industrial applications.

New servo-drive components plus advanced PLC and automation control make for flexible and user-friendly gantries that outperform CNC-controlled motion systems. With its new controller, new Harry Major Machine gantries also accept cabled and wireless connectivity with integrated safety.

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

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

AC Servo Motors.

IAI Inc. CT4 Cartesian robots have quick cycle times — to 32% faster than comparable builds — for small-parts assembly and inspection that’s more efficient.

motioncontroltips.com | designworldonline.com

tables & stages & gantries – Motion Control HB 08.18 V2.LE OK.indd 89

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

11 • 2018

DESIGN WORLD — MOTION

89

11/20/18 1:47 PM

SEAL and

DELIVER

M O T I O N S Y S T E M A P P L I C AT I O N S

Shaft seals ensure reliability in wind turbine bearings

Don’t Get Caught In a Labyrinth of Bad Seals Our Patented Centrifugal Pressure Seals: ✓ Keep lubricants in and contaminants out ✓ Reduce down time ✓ Support horizontal and vertical applications ✓ Prevent friction and overheating with a non-contact design ✓ Create a dynamic pressurized barrier

A COMPONENT’S RELIABILITY and service life are top priorities for wind turbine manufacturers. This is especially true for main shaft seals, which are exposed to powerful forces.

The main bearing seal protects the bearing against harsh environments by keeping lubricants in place. But with larger shaft diameters, these seals are faced with more stringent operating requirements. To this end, Freudenberg Sealing Technologies developed the Seventomatic seal to prevent leaks from the grease-lubricated main bearings used in conjunction with these shafts.

Manufacturers continue to increase wind turbine size to generate clean energy. Rotors with a diameter of 180 m are now common. But systems of this size produce powerful forces during operation that impact main shaft roller bearings and seals. Freudenberg’s new seal can be used for radial internal and external sealing and can even tolerate strong shaft runout.

Traditional shaft seals produce pre-stressing forces on the seal lip by using a worm spring. These easily reach the limits of capabilities when faced with large diameters. Additionally, solutions providing radial external sealing are difficult or even impossible to execute with this design. The Seventomatic is

intended for shaft diameters starting at 1.5 m. It uses a meander spring to build up the needed pre-stressing forces. The product gets its name from the figure “7” — a long sealing leg is linked with the stationary portion of the seal using a flexible joint.

The Seventomatic seal produces consistent linear forces and is less susceptible to shaft runout than other shaft solutions. In its standard size, the shaft seal tolerates a deflection of ±4 mm without a decline in its performance.

As a result, it handles the shaft’s manufacturing tolerances extremely well. It is made from hydrogenated nitrile butadiene rubber.

The basic form of the Seventomatic is based on Freudenberg Sealing Technologies’ tried-and-tested seals for tunnel boring machines. The goal was to combine the special design of a seal for tunnel boring machines with the advantages of a classic radial shaft seal ring for the rotor’s main shaft.

Freudenberg Sealing Technologies’ Seventomatic shaft seal prevents leaks from grease-lubricated main bearings in massive wind turbines.

✓ Support extremely low-viscosity fluids

A Carlyle Johnson Company

centritecseals.com 860-643-1531

seals – Motion Control HB 08.18 V5 FINAL.indd 90

90

DESIGN WORLD — MOTION

11 • 2018

11/20/18 11:51 AM

S H O C K A N D V I B R AT I O N DA M P I N G

Shock & vibration damping ensure smooth, safe designs FOR MISSION-CRITICAL MOTION SYSTEMS, any oscillation can cause damage to the machines themselves, the product they’re used to manufacture and the people operating them. From shock damping materials to more advanced dampers, wire rope attenuators and shock absorbers, these components can be engineered and designed to meet specific needs, ensuring machines can run faster and more accurately while offering more throughput.

ENSURING GENTLE MOTION WITH HYDRAULIC DAMPERS Textile machines require precise unreeling and gentle motions. In one application, dampers from ACE Controls bring the sled movement of this textile machine (right) to a gentle stop. At the turning point of the 287-lb reeling spools, a sled should move up and down smoothly without causing a collision at the end of stroke position. The solution was ACE’s DVC-32-100 hydraulic damper.

These self-contained sealed units come ready to install. Featuring a maintenance-free design, they are ideal for precise control of speeds in both directions of travel. Travel speed is maintained throughout the entire stroke

motioncontroltips.com | designworldonline.com

shocks & damping & vibration – Motion Control HB 08.18 V3 FINAL.indd 91

11 • 2018

DESIGN WORLD — MOTION

91

11/20/18 2:55 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

and can be independently adjusted in each direction of travel. These dampers provide precise, independent, external adjustment of in-and-out speeds.

In another application, ACE dampers helped to minimize the dangers of crashes on LISCO linear axes. These small, yet durable components were installed on rails as end-position dampers, protecting both the components and larger system in the event of a crash.

LISCO manufactures various motion control products, from individual axes to entire linear axis systems. For use in material handling and delivery systems, LISCO needed a way to control the impact in the end position should a software error or power failure occur. The resulting damage could lead to very costly repairs or even downtime for the entire system.

Since LISCO’s linear axes include profile rails and guides, it made sense to find a

compact, easy-to-install solution that engineers could simply attach to the left and right of each rail. TUBUS profile dampers (type TA17-7) from ACE Controls fulfilled these requirements.

TUBUS profile dampers feature a copolyester elastomer—a material that only heats up slightly and ensures consistent damping during operation. These components are also a cost-effective alternative to hydraulic dampers, saving money on the overall construction of the linear system without compromising safety. Additionally, they feature a space-saving size of 12 to 116 mm and can be installed quickly and easily using a special screw.

ELASTOMERIC MATERIALS ACT AS BUMPERS ON PACKAGING MACHINES To protect products as they arrive at the endof-line for packaging and shipment, Hamrick Manufacturing & Service Inc. turned to Sorbothane.

Here, the engineering and production team devised a Sorbothane “bumper” system to protect the product as it arrives, and is prepared and packaged at the end-of-line station. The Sorbothane bumpers needed to accept systematic, repeated compressions and perform without failing. Sorbothane can attenuate up to 94.7% of impact shock and recover fully for the next blow.

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

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

MADE IN THE U.S.A.

800.838.3906

sorbothane.com

ISOLATORS, SHOCK ABSORBERS SURVIVE ROUGH TERRAIN Military ground vehicles require rigorous components that withstand severe shock and vibration, as well as heat, moisture and dirt exposure. ITT Enidine’s energy absorption and vibration isolation components are used heavily in military ground vehicles. For example, its SIDAS blast seat mitigation shock is designed to protect soldiers during transport.

The Shock Isolator Double Acting Spring (SIDAS) combines a preloaded mechanical spring to provide static preload forces with a low-pressure hydraulic damper to provide dynamic damping forces.

During a shock event, the SIDAS experiences a pressurized condition (1,500 psi) for less than 1 sec. This low-pressure situation ensures positive fluid sealing, thus providing long life shock attenuation over the range of all four-deck frequencies.

Additionally, Enidine’s rate control products also meet the heavy demands for reliable, consistent and smooth operation of armored vehicle doors, while several custom energy absorption and vibration isolation products are featured on several armored vehicle platforms.

92 Sorbothane_DesignWorldAd_6-17_r3.indd 1 shocks & damping & vibration – Motion Control HB 08.18 V3 FINAL.indd 92

DESIGN WORLD — MOTION

6/12/17 11:21 AM 11/20/18 2:56 PM

Slow down to speed up

...with ACE industrial shock absorbers. · Decelerate moving loads · Protect against wear and tear on machines · Increase throughput & reduce downtime 800-521-3320 | www.acecontrols.com 23435 Industrial Park Drive, Farmington Hills, MI 43885

WTWH_ACE_fullpg_shocks_073118.indd 1 ace controls — MC Handbook 8-18.indd 93

7/31/2018 2:15:03 PM 11/16/18 4:02 PM

M O T I O N S Y S T E M A P P L I C AT I O N S

The FinWave navigates pipes and tight underwater spaces.

(Image courtesy Phillipp Freudigmann)

Sensors ROBOTICS is undoubtedly one of the most exciting and fastest growing areas of technology. Each year more and varied robots are being used in applications from industrial to consumer uses and beyond.

In addition to controllers and motion components such as motors and actuators, sensors play a vital role in robotic operation by providing data about the robot’s environment.

The latest bionic robots from Festo demonstrate the role sensors play. The company’s Bionic Learning Network earlier this year released new biomimicry innovations to support ongoing research in engineering, manufacturing, and materials science drawn from natural systems. The new bionic robots include a transforming spider, a robotic fish and a semiautonomous flying bat.

SPIDER-LIKE ROBOT ROLLS UPHILL The biological model for the BionicWheelBot is the flic-flac spider, a species that lives in the Erg Chebbi desert on the edge of the Sahara. Just like living flic-flac spiders, the Festo BionicWheelBot propels itself with a tripod gait using six of its eight legs to walk. To start rolling, the BionicWheelBot bends three legs on each side of its body to form a wheel. Two

94

DESIGN WORLD — MOTION

sensors & transducers– Motion Control HB 08.18 V2 FINAL.indd 94

at heart of bionic robots

lower-middle legs are folded up during walking then extend and push the rolled-up spider off the ground to propel it forward.

An inertial sensor lets the robot track its current pose so it accurately times its next push-off sequence. The robot rolls faster than it walks and can roll up a 5% incline.

DEFT UNDERWATER NAVIGATION BY SOFT-FINNED ROBOT For the 15-oz BionicFinWave, the Festo bionics team found inspiration in the undulating fin movements of marine animals such as the polyclad and cuttlefish.

Its propulsion mode lets the underwater robot autonomously maneuver through waterfilled acrylic tubing. Swimming autonomous robots such as the BionicFinWave could eventually find practical application in inspection, measurement, and data acquisition in water, wastewater, and other process industries. Knowledge gained in this project could also find use in the manufacture of soft-robotics components.

Undulation forces from longitudinal fins also let the BionicFinWave maneuver itself

11 • 2018

forward or backward. The fin drive unit is particularly suitable for slow and precise motion and causes less turbulence in the water than conventional screw-propulsion drives. While it moves through tube systems, the robot also communicates via radio to share temperature and pressure sensor readings to nearby I/O. The BionicFinWave’s two lateral fins are molded from Just like silicone and the flic-flac spider it’s modeled on, the can move Festo BionicWheelBot independently propels itself with a tripod gait using six of its eight legs to walk.

w

motioncontroltips.com | designworldonline.com

11/20/18 2:34 PM

TRANSDUCERS & SENSORS

to generate different wave patterns (or swim in a curve). The BionicFinWave moves upwards or downwards by bending its body in the target direction. Integrated crankshafts, joints, and piston rod are 3D printed from plastic. Other geometrically complex components are also 3D printed, which helps keep weight down. Pressure and ultrasound sensors constantly register the BionicFinWave’s distance to the walls and its depth in the water, which prevents collisions with the tube system. This autonomous and safe navigation needed the development of compact, efficient, and waterproof or water-resistant components that can be coordinated and regulated using appropriate software.

FLYING ROBOT USES MACHINE LEARNING TO CHOOSE FLIGHT PATH To emulate the flying fox, among the world’s largest bats, the wing kinematics of the BionicFlyingFox are divided into primaries and secondaries with all the joints in the same plane. To let the BionicFlyingFox move semi-autonomously within a defined space, the robot communicates with a motion-tracking system, which in turn plans the flight paths and issues commands.

Starting and landing are performed by a human operator, then an autopilot takes over during flight. Pre-programmed flight routes stored on a computer specify the path taken by the 20.5-oz (580-g) BionicFlyingFox as it performs its maneuvers. The wing movements needed to effectively implement the intended movement sequences are calculated by its on-board electronics. The BionicFlyingFox optimizes its behavior during flight and follows the specified courses more precisely with each circuit.

A membrane covering the skeleton was specially developed by the bionics team.

It consists of two airtight foils and a woven elastane fabric, which are welded together at approximately 45,000 points. The fabric’s honeycomb structure prevents small cracks in the flying membrane from increasing in size. The BionicFlyingFox can thus continue flying even if the fabric sustains minor damage. Due to its elasticity, the flying membrane stays almost crease free even when the wings are retracted.

Leading the way.

Reinventing positioning.

Revolutionizing safety.

SIL 3/PL e with One Sensor safePXV and safePGV

Safe

absolute positioning or AGV navigation with just one sensor connection to safety PLC Unique combination of 2D camera and multi-color Data Matrix code tape Direct

www.pepperl-fuchs.com/safe-positioning

sensors & transducers– Motion Control HB 08.18 V2 FINAL.indd 95

11/20/18 2:54 PM

Ad Index M O T I O N S Y S T E M A P P L I C AT I O N S

ABB Motors & Mechanical ................................................... 9 ACE Controls Inc. .................................................................93 Aerotech ................................................................................84 AllMotion . . ................................................................................ 4 Altra Industrial Motion Corp. . . ............................................31 AMETEK - Haydon Kerk Pittman . . .....................................13 AMETEK DFS ........................................................................67 Applied Motion Products . . ................................................... 5 AutomationDirect .............................................................. IFC Beckhoff Automation .........................................................49 Bison Gear and Engineering ........................................... IBC Bosch Rexroth ..................................................................... BC C-Flex Bearing . . ................................................................... 40 Carlyle Johnson Machine Company . . ............................. 20 Centritec Seals .................................................................... 90 CGI Motion . . ............................................................................61 Chieftek Precision .. ..............................................................79 Cicoil ....................................................................................... 23 ContiTech .............................................................................. 33 Del-tron Precision, Inc. ........................................................71 DIEQUA Corporation ....................................................12, 59 Encoder Products Company . . ...........................................55 Festo. . ........................................................................................ 7 Fluid Lines Products .. ..........................................................29 Harmonic Drive . . ...................................................................57 Heidenhain Corporation . . ................................................... 53 HIWIN . . ...................................................................... 85, 87, 89 IDEC Corporation . . ...............................................................65 igus . . .........................................................................................15

IKO International ..................................................................86 Intech . . ....................................................................................58 ITT Enidine . . ............................................................................91 Lapp Group USA ..................................................................... 1 Lin Engineering .. ................................................................... 83 Mach III Clutch Inc. ................................................................21 Maple Systems .....................................................................68 maxon precision motor ......................................................27 MICROMO ................................................................. cover, 77 Mitsubishi Electric Automation .. ........................................ 3 mk North America ........................................................ 34, 88 Nidec .. ......................................................................................51 NSK Precision .......................................................................75 PBC Linear . . .................................................................... 72, 73 Pepperl+Fuchs .....................................................................95 PHD Inc. .. ..................................................................................11 Pyramid Incorporated .........................................................18 R+W America . . ...................................................................... 38 Rotor Clip Company, Inc. .. ..................................................42 Ruland Manufacturing . . ....................................................... 37 Schneider Electric Motion USA .........................................81 Serapid Inc. ...........................................................................24 SEW Eurodrive .....................................................................63 Sorbothane ...........................................................................92 THK TOS .. ................................................................................19 Tolomatic, Inc........................................................................44 Yaskawa Electric America .................................................47 Zero-Max, Inc. . . ......................................................................17

Sales

Leadership Team

Jami Brownlee

Bill Crowley

David Geltman

Jim Powers

Publisher

EVP

jbrownlee@wtwhmedia.com

bcrowley@wtwhmedia.com

dgeltman@wtwhmedia.com

jpowers@wtwhmedia.com

Mike Emich

Marshall Matheson

310.980.7763

610.420.2433

516.510.6514

312.925.7793

memich@wtwhmedia.com

mmatheson@wtwhmedia.com

@wtwh_david

@jpowers_media

508.446.1823

805.895.3609

Mike Caruso

Michael Ference

@wtwh_memich

mference@wtwhmedia.com

Neel Gleason

Courtney Seel

@mmatheson

408.769.1188

ngleason@wtwhmedia.com

cseel@wtwhmedia.com

Managing Director

@mrference

312.882.9867

440.523.1685

Scott McCafferty

@wtwh_ngleason

@wtwh_CSeel

smccafferty@wtwhmedia.com

mcaruso@wtwhmedia.com 469.855.7344

Garrett Cona gcona@wtwhmedia.com 213.219.5663

Mike Francesconi

310.279.3844

mfrancesconi@wtwhmedia.com

@SMMcCafferty

630.488.9029

WTWH Media, LLC 6555 Carnegie Ave., Suite 300 Cleveland, OH 44103 Ph: 888.543.2447 FAX: 888.543.2447

DESIGN WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. DESIGN WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care.

DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2018 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

Subscription Rates: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only.

Subscriber Services: To order a subscription or change your address, please email: designworld@halldata.com, or visit our web site at www.designworldonline.com POSTMASTER: Send address changes to: Design World, 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

96

DESIGN WORLD — MOTION

ad index – motion CASEBOOK 11.18.indd 96

11 • 2018

motioncontroltips.com | designworldonline.com

11/21/18 9:18 AM

November Design World Print Ad bleeds.pdf 1 10/16/2018 12:09:56 PM

®

A Complete Washdown Rated Gearmotor in A Compact Package • Complete gearmotor encased in 304 stainless steel.

Speed Range 7 - 345 RPM

• Special two-part stainless steel output shaft seal system.

Torque Range 7 - 500 In-lbs.

• Laser marked permanent nameplate meets extreme washdown rating.

Input Horsepower 1/20 - 1/8

C

M

Y

• Food-grade H1 grease lubricated for maintenance-free lifetime lubrication.

Frame Sizes 34 & 49

CM

MY

CY

• 2 power cord connector options, straight and right-angle, available in lengths of 2m, 5m, and 10m*.

CMY

K

• Made in the USA *power cord sold separately

IP69 Rated 15 in-stock standard ratios available. Contact us to discuss customization options.

1-800-282-4766

3850 Ohio Ave. • St. Charles, IL 60174 • 1-800- AT BISON • info@bisongear.com • www.bisongear.com

bison gear – motion systems applications 11.18.indd 130

11/16/18 4:03 PM

We Move.

You Win.

Electromechanical Cylinders for Clean, Efficient Motion.

For applications requiring high precision and heavy load capacity, Bosch Rexroth has the electromechanical cylinders to help you win. With Rexroth’s EMC and EMC HD, you get a clean, energy-efficient, self-contained precision actuator with either a ball screw or planetary roller screw design. High-thrust, high-speed operation is no problem, and the EMC’s multi-position electromechanical actuation lets you execute production changeovers faster than ever. Heavy load? Tough environment?

Experience the flexibility and control that comes from the leader in drive & control. Whatever your application requires, Rexroth has the right solution.

Make your move to Rexroth EMC and EMC-HD.

Order the free Linear Motion & Mechatronics@Work Resource Kit: www.movewithrexroth.com For expert advice call 1-800-REXROTH (739-7684) or email us at info@boschrexroth-us.com

432319D-DCUS media creative_Design World Full Page Ad-EMC-F.indd 1 bosh rexroth – motion systems applications 11.18.indd 1

10/22/18 1:41 PM 11/16/18 4:04 PM