Design World September 2015

Think

Allie

d for

Autom

ation

& Co

ntrol

APR15-A&C Snipe_Snipe 3/13/15 2:39 PM Page 1

September 2015www.designworldonline.com

INSIDE:

84

FASTENING & JOINING: Enable efficient structures with friction stir welding. PAGE 106

SENSORS: Current industry requirements provide new direction. PAGE 114

busbars and IEC

standards

reigns supreme with

LINEAR MOTION: Components for linear motion systems change with the times. PAGE 74 Modular

Cover_DW_September 2015_FINAL.indd 1 9/8/15 9:49 AM

We go out of our way to ensure complete customer satisfaction. We reach out and listen to customers around the globe and deliver the world-class products you've come to expect fromTHK. Our range of solutions are a part of the latest technological advances in the medical, automotive, aerospace, semiconductor, seismic and many other industries.

LM GU IDES | BALL SCREWS | BALL SPL INES | ACTUATORS | CROSS ROLLER R INGS

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

840-15203 THK Value Ad_R1_pick_Layout 1 6/18/15 6:34 PM Page 1

THK 7-15.indd 1 9/2/15 3:32 PM

EZ Automation 9-15.indd 1 9/2/15 3:33 PM

PNEUMATICS 2.0 HAS ARRIVEDIntroducing IntelliSense, a one-of-a-kind technology platform that delivers real-timeperformance data on standard Bimba pneumatic devices for maximum uptime. Never before has such a wide range of industries been able to move from emergency repair to proactive maintenance, thus optimizing plant effi ciency and production as a whole. Visit us at Pack Expo booth S-6133.

bimba.com/smarter Copyright 2015 Bimba Manufacturing Company. All Rights Reserved.

THE EXPERTS AGREE

WINS FOUR PRESTIGIOUS AWARDS FROM LEADING INDUSTRY ANALYSTS AND TRADE PUBLICATIONS

INTELLISENSE

UPTIME TIME

BIM-2488 Bimba Resizes_2015_Design_World_IntelliSense 4 Awards_SNIPE_090115.indd 1 8/24/15 4:40 PMBimba 9-15.indd 2 9/2/15 3:36 PM

Reliable Detection For Your Application

You cant afford not to know. See it all at thinkallied.com/sensors

Allied Electronics, Inc 2015. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.

1.800.433.5700

SEPT15 Sensors NC Ad (DW)_Design World 8/11/15 2:05 PM Page 1

Allied Electric #1 ad_9-15.indd 3 9/2/15 3:35 PM

I n s i g h t s

4 DESIGN WORLD September 2015

Earlier this year, I was part of a journalist delegation to Thailand, the Southeast Asian country thats probably known more for tourism than industrial engineering prowess. But after a week of touring manufacturing facilities that included such international heavyweights as Caterpillar and Nissan, I left with a new mindset for how industry needs to succeed in todays global economy. And here are three key areas where I found that Thailand seems to be getting it right:

1. Get government buy-in. Thailands government has been active in promoting investment in the private sector for decades. The Board of Investment, founded in 1966, actively works with manufacturers to encourage them to build factories in the country. Theres a liberal investment policy, with 100% foreign ownership allowed, no export requirements and no restrictions on foreign currency. Corporate tax exemptions are granted for up to eight years.

2. Education has to focus on emerging technology. Automation is here on the factory floor, so its best to embrace it. I toured the Institute of FIeld roBOtics (FIBO) at King Mongkuts University of Technology, and it was refreshing to see such a variety of developments happening. Researchers and students were looking at the entire spectrum of robotics, from industrial to medical to entertainment. Thai universities know that there is a huge need for qualified engineers in this growing industrial space in their country, and theyre actively answering the call.

3. The right kind of training for blue collar workers is critical. We hear so much about the skills gap in the U.S., so I was really impressed upon visiting the Thai-German Institute, a joint initiative of those two countries. Founded two decades ago to be a conduit for transferring high-tech industrial knowledge into the country, its blossomed into a training center for advanced manufacturing technology. They conduct short, medium and long term training in a realistic actual factory setting. More than 300 courses are offered on subjects including fluid power, predictive maintenance, PLCs, motors and drives, mechatronics, robotics, testing, welding and CAD. Theres a fantastic 12:1 student to teacher ratio, and youll generally find one student per machine, so this is truly hands-on learning.

Thailands industrial sector still has challenges, for sure. Leaders clearly want more R&D type investment, and that may be a difficult road. Its one thing for foreign companies like Caterpillar or Nissan to build plants there, but the tougher push is trying to break past the assembly side of manufacturing. Higher incentives are in place for R&D type ventures, and it will be interesting to see if that gamble pays off.

What manufacturing can learn from Thailand

Pa u l J. H e n e y - Ed i to r i a l D i re c to rp h e n e y@w tw h m e d i a .co m

What do you think manufacturers need to do now to improve their bottom lines?

Comment on Pauls blog on Pneumatic Tips, www.pneumatictips.com/blog On Twitter @ DWEditor

Insights 9-15_Vs3.LL.MD.indd 4 9/2/15 3:31 PM

The Low Cost Way To Convey!

EXAIRs most powerful conveyor has been engineered to convey more material over longer vertical and horizontal distances. The hardened alloy construction is ideal for abrasive materials and is available from stock in many sizes.

Heavy DutyLine Vac

EXAIRs Light Duty Line Vac is the ideal way to convey small volumes of materials over short distances. Eight sizes for diameters from 3/4" to 6" (19 to 152mm) are available. Construction is aluminum.

Light DutyLine Vac

The compact design features large throat diameters for maximum throughput capability. Available from stock in many sizes. Construction is your choice of aluminum, Type 303 or Type 316 stainless steel.

Line Vac ThreadedLine Vac

@EXAIR

Fits standard hose or tube Quiet High temperature models available

www.exair.com/58/464.htm

Highest throughput capability Quiet Fits standard hose, tube and pipe


Moderate throughput capability Quiet Fits standard hose or tube


Models from 3/8 NPT to 2 NPT Quiet High temperature models available


Attaches easily to plumbing pipe couplers, making it easy to build a complete system using ordinary pipeand ttings from any home center or plumbers supply. Construction is your choice of aluminum, Type 303 or Type 316 stainless steel.

Easily conveys bulk materials from point A to point B

EXAIRs compressed air operated Line Vac connects to standard hose, tube or pipe tocreate a powerful in-line conveyor. Line Vacconveyors are ideal for moving large volumesof material over long distances. No moving parts or electricity assures maintenancefree operation.

Plastic pellets Scrap trim Textiles Bulk solids Food products Chips

Paper Pills/tablets Small parts Shavings Sawdust Granules

A fast, low cost way to convey:

A B

Manufacturing Intelligent Compressed Air Products Since 1983

11510 Goldcoast Drive Cincinnati, Ohio 45249-1621(800) 903-9247 fax: (513) 671-3363 E-mail: [email protected] www.exair.com

Exair 9-15.indd 5 9/2/15 3:34 PM

Te s c h l e r o n To p i c

Big data, of course, refers to the use

of predictive analytics to extract value

from data, usually lots of data. Big data

is thought to hold a lot of promise for

improving industrial operations and

making them more productive. In a

perfect world, big data techniques

will help predict when complicated

production equipment will breakdown

well before there are obvious signs of

trouble. They will also eliminate minute

variations in manufacturing processes

that degrade product quality.

L e l a n d Te s c h le r - Exe c u t i ve Ed i to rlte s c h le r @w tw h m e d i a .co m

My big data nightmare

On Twitter @ DWLeeTeschler


In reality, most manufacturers could experience big data as an expensive exercise in chasing your own tail. To understand the reason why, consider what goes on at a National Science Foundation facility in Cincinnati called the IMS Center for Intelligent Maintenance Systems. The IMS Center directs a lot of high-powered research at eliminating fix and fail maintenance, replacing it with predict and prevent efforts where production machines will never go down and the products coming off manufacturing lines never have variations. Big data is the heart and soul of the Centers efforts. Its not unusual for production machines the Center studies to each generate a terabyte of data every day. The IMS Center had a meeting a while back that makes clear the kind of intellectual horsepower it takes to profit from big data coming out of factories. The meeting was basically a room full of super-sharp Ph.D. candidates. One applied something called Mahalanobis-Taguchi methods to predict the health of rolling element bearings on a CNC machine spindle. The math got pretty deep pretty fast. He looked at a virtual sea of sensor readings while using a Mahalanobis distance to gauge the abnormality of patterns within them, then applied Taguchi methods to evaluate the accuracy of machine health predictions. Another researcher predicted defect levels in semiconductor wafers using sensor data massaged with autoregressive moving averages and ensemble methods. Ensemble methods are basically machine learning techniques

using arcane numerical methods such as Bayes optimal classifiers, bootstrap aggregation and Bayesian parameter averaging. If you get the idea these big-data projects involved a lot of rocket-science calculations, youd be right. Trouble is, most industrial concerns are likely to apply big data without having the insights of the IMS Center. Heres the scene that could unfold: The people who will try to make sense of data coming from production-line machines will be engineers, not data scientists. These engineers all have had a basic statistics class in school. They have never heard of Mahalanobis-Taguchi or Bayesian parameter averaging. So they may just assume all the sensor readings they see follow bell curve distributions. Real data scientists, like those at the IMS Center, would look at the bell curves and basic statistics going to these efforts and realize they are just too simplistic to ever work. But the people on the shop floor are unlikely to see the problem. The sinister thing about this scenario is that the underlying behavior models will be wrong but will occasionally lead to random correct predictions about machine behavior. The engineers involved will believe that they are just a few tweaks away from a system that works wonderfully. In reality, they will be spinning their wheels guided by a model filled with unknown unknowns. Until expectations catch up with the reality of the resources it takes to mount a successful effort in factories, big data will be a big disappointment and possibly an expensive nightmare. DW

I have had a vision of what big data will look like on the factory floor. And it is scary. Really scary.

Lee Teschler Column 9-15_Vs4.LL.MD.indd 6 9/2/15 3:26 PM

Helical 9-15.indd 7 9/2/15 3:37 PM

Follow the whole team on twitter @DesignWorld

WTWH Media, LLC6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

Ph: 888.543.2447 FAX: 888.543.2447

NEW MEDIA/WEB/

BUSINESS DEVELOPMENT

Web Development ManagerB. David [email protected]@wtwh_webdave

Web Development SpecialistPatrick [email protected]@amigo_patrick

Video ManagerJohn [email protected]@wtwh_jhansel

Video CoordinatorJoshua [email protected]@wtwh_josh

Video InternNeil [email protected]

EDITORIAL

Editorial DirectorPaul J. [email protected]@dw_editor

Managing Editor Leslie Langnau [email protected]@dw_3DPrinting

Executive EditorLeland [email protected]@dw_LeeTeschler

Senior EditorMiles [email protected]@dw_Motion

Senior EditorMary [email protected]@dw_marygannon

Senior EditorLisa [email protected]@dw_LisaEitel

Associate Editor Mike [email protected]@wtwh_Michael

Assistant Editor Michelle [email protected]@wtwh_Michelle

Director, Audience DevelopmentBruce [email protected]

WORLDA DESIGN WORLD RESOURCE

Business Development ManagerPatrick [email protected]@wtwhseopatrick

Online CoordinatorJennifer [email protected]@wtwh_jennifer

MARKETING

Marketing Team LeaderStacy [email protected]@wtwh_Stacy

Marketing CoordinatorCarli [email protected]@wtwh_Carli

Marketing and Events CoordinatorNicole [email protected]@wtwh_Nicole

Marketing and Events CoordinatorJen [email protected]@wtwh_jen

Content AssociateLexi [email protected]@medtech_lexi

Traffic ManagerMary [email protected]

GRAPHICS

Director, Creative ServicesMark [email protected]@wtwh_graphics

Visual Design Manager Matthew [email protected]@wtwh_designer

Graphic Designer/Production Coordinator Margaret [email protected]@wtwh_Meg

2014 Winner

Crains Cleveland Business Fast 50 2014


Graphic Design Intern Erin [email protected]

2011, 2012, 2013, 2014

Cut to Width Roll Slitting

Custom Lamination

Custom Sheeting

Custom Belting

Custom Shape Die Cutting

We dont just sell the high endmaterials your company needs,

we cut to order, so you are neverstuck with wasted material again

With a comprehensive selection of specialized materials such as Teflon, Kapton, Silicone, PEEK, Kevlar, FEP, and PTFE coated fabrics, if your appli-cation demands performance, we can

provide a solution.

800 461 4161

Staff page 9-15_Vs1.indd 8 9/2/15 4:33 PM

www.moog.com/components

Ethernet Slip Ring Features:Continuous360rotationMaintenance-freeoperationRobustperformanceHighperformancecontact technologyPlug-and-playEthernet connections

Slip Rings

+1-540-552-3011800-336-2112(USA)[email protected]

Looking for more? Scan to view slip ring specifications.

Packagingequipmentrequireshighperformancesolutionsfortransferringpoweranddataacrossrotatinginterfaces.MoogoffersslipringsthathavebeendevelopedforEthernetdatacommunicationnetworks.Modelsareavailable incapsuleandthrough-boreconfigurationsandmultipleEthernet,powerandsignalcombinations.

LearnmoreaboutMoogssolutionsforautomation.Standardslipringdesignsarereadyforquickdeliveryorcanbetailoredforuniqueprojects.Contactustodiscussyourapplications.

Moog 4-15.indd 9 9/2/15 3:38 PM

IS EDGEWINDING THE NEXT BIG THING?

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

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

The edgewinding process coils pre-tempered at wire on edge to give Smalley products strength and stability far superior to stamped retaining rings.

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

section rings a real performance edge. Its a combination of manufacturing innovation and technical expertise that only Smalley delivers.

THE ENGINEERS CHOICE

SmalleyEdgewinding Process

Traditional Stamping Process

IS EDGEWINDING THE NEXT BIG THING?

Ask Smalley. Edgewinding is our precision forming operation that offers unique advantages. Unlike the conventional stamping process, Smalley edgewinding delivers maximum strength, effectively eliminates material waste, and offers No Tooling Chargesto make prototyping or custom designs easier and affordable.

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

The edgewinding process coils pre-tempered at wire on edge to give Smalley products strength and stability far superior to stamped retaining rings.

Visit smalley.com no-charge test samples.

section rings a real performance edge. Its a combination of manufacturing innovation and technical expertise that only Smalley delivers.

THE ENGINEERS CHOICE

SmalleySmalleyEdgewinding ProcessEdgewinding Process

38139_Smalley_BrandAd_Edgewinding_DesignWorld.indd 1 8/5/15 4:04 PMSmalley 9-15_NEW AD.indd 10 9/2/15 3:39 PM

July 2015 DESIGN WORLD 1 1

l C o n t r i b u t o r s S p o t l i g h t

84Work with stronger joints and lighter materials

MARY C. GANNONSenior EditorDesign World

NATHAN XAVIER

Consulting EngineerRittal Corp.

IEC devices and busbars take down control-panel costs 106

How IIoT is being used now

LESLIE LANGNAUManaging EditorDesign World

September 2015 DESIGN WORLD 1 1

74

Leslie has been an editor for more than 28 years. She has been covering the 3D printing/additive manufacturing industry, among other subjects, since joining with Design World more than 8 years ago. She has a B.S. degree in Mechanical Engineering from Michigan State University.

1. What trend or new technology would you like to see emerge over the next five years? I would like to see better ways to ensure/encrypt your data for security. I know a big part of the problem is users just dont change factory settings. Thats an easy fixprevent the device from working until they change the setting. But I for one will not buy IoT devices for the home. I simply dont trust that any of these devices will have strong enough security levels. 2. What do you think is the biggest issue editors face today? Getting noticed in the right way. You want people to read your work and value the information and explanations you deliver. But its unfortunate that we have to play the click-bait game to get attention. My colleagues know I dont like headlines such as 3D print an organ! Its technically not possible yet, and may never be. Accuracy is compromised in favor of popularity.

Nathan Xavier has been with Rittal since 2007. He holds a B.S. in Mechanical Engineering and provides customer-specific applications support relating to Rittal industrial enclosure and power distribution solutions.Mary primarily covers fluid

power and interconnect technologies. She has been working as a technical editor for 10 years. She earned her B.S. in Journalism at Boston University in 1998, and has worked as a business reporter, public relations associate and now technical editor.

1. How do you think the world will change in the next 20 years?I think well be more connected, with continually faster and faster technologies changing how we live and do business daily. I think our society will be more reliant on technology.

2. What technology do you find the most frustrating? Wearable tech. Not only are most of these devices not that accurate or where they will probably be in the next five years, I do find them to be almost confining as we are constantly needing to check our smart watches and Fitbits. [Even though] we clearly know were walking ourselves, if were not tracking it, it somehow doesnt count. And thats absurd when you think about it.

96

Miles has been in the publishing world for 15 years, more than six of which have been spent with WTWH Media. He holds a BSEE and M.A. in Philosophy. He previously worked as an engineer for a small controls company. Miles has also taught electronics courses at local tech colleges and has been teaching philosophy part time (adjunct) for about 10 years.

1. What part of society do you see being most affected by advances in engineering over the next decade? Computing and internet technology have changed practically every aspect of society and continue to do so every day. But also, it looks like robotics and AI, as well as medicine, will also experience revolutionary changes.

2. What first attracted you to the world of media/publishing? Maybe it was my love of the printed word. As far back as I can remember, Ive always been surrounded by printed matter, and my parents were big readers as well, so it probably rubbed off on me in some mysterious way.

Linear Evolution

MILES BUDIMIRSenior EditorDesign World

Contributor Page 9-15_Vs3 MG.MD.indd 11 9/3/15 4:37 PM

Te c h n o l o g y F o r w a r d

Change is a constant with additive

manufacturing (AM), also known

as 3D printing. The next trend

youll find is the growth of additive

services. Part of this growth is

driven by customer need, part by

the frequent acquisitions made by

the larger vendors.

L e s l i e L a n g n a u - M a n a g i n g Ed i to rl la n g n a u r @w tw h m e d i a .co m

Additive manufacturing moves beyond the cool phase

On Twitter @ DW3Dprinting

1 2 DESIGN WORLD September 2015

Customer need turns out to be an interesting driver. SMS Research Advisors conducted a survey on AM. The majority of the 700 respondents are familiar with additive and its benefits: 79% know AM gives users access to more complex design capabilities, 79% know it reduces lead time for product development and 42% see AM improving manufacturing efficiency. But only 20% see AM improving product quality and enabling more integrated products. Still, knowledge and understanding about AM is fairly strong. The respondent makeup was 47% engineer, 15% designer, 14% executive, 13% other and 9% project manager. What was more interesting from this survey was the view about the choice between in-house versus outsourcing additive projects. About 73% of the respondents see service bureaus as giving them access to advanced equipment. 60% see less of an investment risk by using service bureaus (versus

purchasing a machine). 53% said service bureaus are a way to produce parts that cannot be internally manufactured. And 47% said service bureaus offer access to additive expertise. Selling AM machines to end users may no longer be the main goal of vendors in this industry. Instead, a trend may be developing where vendors offer AM production services for users. Survey respondents noted several challenges with AM machines: 63% said current costs were an issue, while 58% felt that future costs wont be as much of an issue. Post-processing and material availability were seen as challenges now and in the future, with the future coming in at 34% and 46% respectively.

Noted Joe Allison, CEO of Stratasys Direct Manufacturing, such challenges indicate that the industry should change the conversation from one of emphasizing AMs technical benefits to that of AMs overall business value. I recently had the opportunity to visit the fairly new Stratasys Direct Manufacturing company at its Austin plant. This company emerged from the acquisitions of Solid Concept, RedEye and Harvest Technologies. It is one of the largest service bureaus in the U.S. In the past 12 to 18 months, it has tripled its capacity to prototype and build customer parts, with much of that growth coming in metals. Imagine a company with the following machines: 13 Polyjet, 42 stereolithography, 43 laser sintering, 97 extrusion, 14 direct metal laser sintering, 23 CNCs and 13 injection molding systems. Yeah, impressive. In addition to these technologies, the company also offers urethane casting, tooling and finishing services. Several of the laser-sintering machines are DTM versions before that company was bought by 3D Systems. Stratasys Direct Manufacturing is additive technology agnostic. Most of the direct metal laser-sintering machines come from EOS. Metal additive projects are more likely to be outsourced to a service bureau than done in house. Many of the reasons have already been mentionedaccess to advanced equipment, less risk and the ability to manufacture parts not possible internally. The survey indicates that AM is moving to the next phase. First, it changed how prototypes were made. Now its changing how production parts are made. The survey also indicates that many engineers and designers are optimistic about using AM. They generally believe it will play an important role in manufacturing in the future. DW

Leslie's Column 9-15_Vs3.LL.MD.indd 12 9/2/15 3:30 PM

Applied Motion Products 9-15.indd 13 9/2/15 3:40 PM

2015

3

Co n te n t s | S e p t e m b e r 2 0 1 5 v o l 1 0 n o 9 | d e s i g n w o r l d o n l i n e . c o m

1 4 DESIGN WORLD

LINEAR MOTION

Linear EvolutionFrom nanometer resolution to high-force actuation, components for linear motion systems are changing with the times.

74

F E A T U R E S

96 INDUSTRIAL ETHERNETHow IIot is being used nowThe latest development of industrial Ethernet is how it will be a part of the Industrial Internet of Things (IIoT).

2015

revenue over $3 million

ELECTRONICS

Busbars and IEC devices take down control-panel costsMore North American engineers than ever use IEC devices instead of NEMA componentsespecially with modular busbars to replace

traditional wiring for controls.

84

ON THE COVERBusbars and standardized IEC devices let integrators build systems less expensively than ever.

Image courtesy of Rittal

106 FASTENING & JOININGWork with stronger joints and lighter materialsEnable consistent, strong and more efficient structures with friction stir welding. 2015

ONLINE

114 SENSORSIndustrial sensing evolves to address the IoTCurrent industry requirements are providing new direction for industrial sensors

126 MACHINE VISIONImage dimension measurement system makes tolerance checks fasterWhen a French manufacturer required precise measurement of medical parts, a new imaging system brought the flexibility to accurately measure 99 points in mere seconds.

CONTENTS SEPTEMBER 2015_first page_Vs3.LL.indd 14 9/2/15 4:18 PM

Altech 9-15.indd 15 9/2/15 3:41 PM

Co n te n t s

D E P A R T M E N T S

4 Insights

6 Teschler on Topic 11 Contributors

12 Technology Forward 18 Green Engineering

22 Engineering Exchange

24 Design For Industry

40 Design Notes

50 Coupling Notes

54 CAE Solutions

62 Internet of Things

131 Product World

140 Ad Index

9. 2 0 1 5


40

62

50

24

Rod Ends and SphericalBearings designed andmanufactured to Aurora'sexacting standards for qualityand durability.

Registered and Certified toISO-9001 and AS9100.

From economy commercial toaerospace approved, we've got it all !

Aurora Bearing Company901 Aucutt RoadMontgomery IL. 60538

Complete library of CAD drawings and 3D models available at:w w w . a u r o r a b e a r i n g . c o m

Aurora-Where_the_Action_Is:Aurora 11/5/10 1:10 PM Page 1

2815 S. Calhoun RoadNew Berlin, WI 53151Phone: 800-877-8351Fax: [email protected]

Stainless Steel Machine Components

J.W. Winco, Inc. offers stainless steel parts for industry with very high corrosion resistance, hygienic properties, and the ultimate in material quality. Pictured is just a sampling of our products.

Explore our full line at www.jwwinco.com or contact us with your application requirements.

SEE US AT PACK ExPo BooTH 6411

Contents SEPTEMBER_second page_Vs1.indd 16 9/2/15 4:24 PM

Whatever keeps you up at night, weve got a solutionthe 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, youll nd it at Solution City.

FOR MOTION CONTROL INNOVATION, SOLUTION CITY NEVER SLEEPS.

2015 by AMETEK Inc. All rights reserved.

100 East Erie StreetKent, OH 44240ametekdfs.com

AMETEKPMC 18611_City Never Sleeps Ad_9x10.875.indd 1 7/29/15 9:14 AMAMETEK PMC (Solutions City) 8-15 (NEW).indd 17 9/2/15 3:45 PM

Energy storage solutions forsolar-powered devicesn By: Sol Jacobs VP and General Manager Tadiran Batteries

G r e e n E n g i n e e r i n g


Energy harvesting is seeing dramatic growth, especially for wireless devices that use small photovoltaic systems to draw energy from sunlight. The energy storage solutions being used in

photovoltaic systems are also applicable to similar devices that harvest energy from vibration/

motion, heat differential and RF/EM signals.

There are five basic components to an energy harvesting device: sensors, transducer,

energy processor, microcontroller and optional radio link. The sensors detect and measure

environmental parameters such as motion, proximity, temperature, humidity, pressure, light,

strain vibration and pH. The transducer and energy processor work in tandem to convert, collect

and store the electrical energy in either a rechargeable lithium battery or a supercapacitor.

The microcontroller collects and processes the data. The radio link communicates with a host

receiver or data collection point using RF or cell phone technology, typically in conjunction with

low-power communications protocols such as ZigBee, Green Power, Bluetooth LE and

6LowPan, which all operate within a peak power range of 10 W to 100 mW.

The power available through energy harvesting is sometimes limited and

variable, so design engineers need to find ways to conserve energy wherever

possible. This is possible through power-efficient microprocessor and component

design, as well as by programming the device to remain in a dormant state that

draws little or no energy, then to periodically query the data, awakening only if

certain thresholds have been exceeded.

To determine if a remote wireless application is well suited for energy

harvesting, several factors need to be considered, including the reliability of

the device and its energy source, the expected operating life of the device,

environmental requirements, size and weight considerations, and total cost

of ownership. Remote wireless applications characterized by a processor

that awakens periodically often draw a big, brief pulse of current at periodic

intervals. The current pulse arises when the processor awakens and transmits

its data. The current levels can be on the order of hundreds of milliamps or

more for time periods ranging from fractions of a second to several seconds.

These sorts of power levels necessitate some form of energy storage capability

using either a rechargeable Lithium-ion (Li-ion) battery or a supercapacitor.

Supercapacitors, also known as ultracapacitors or Electric Double Layer Capacitors

(EDLCs), are often used to backup memory in mobile phones, laptops, digital cameras and other

consumer devices. Supercapacitors work by storing energy in an electrostatic field rather than

in a chemical state.

Green Engineering_9-15_Vs4.LL.MD.indd 18 9/2/15 4:11 PM

Dunkermotor is a leading manufacturer of customized rotary and linear motion solutions providing low-risk product development, lower total system cost and faster time to market for original equipment manufacturers in the automation, medical, solar, packaging, semiconductor and transportation industry segments. 1500 Bishop Ct - Mt Prospect, IL 60056

Call: [email protected]

WHEN SPEED MATTERS THE MOST. And

More than 1,000 motion solutions to choose from, most with same-day shipping option. Design your own, today!

Brushed and Brushless DC motors Planetary and Worm gearboxes options Integral All-in-One BLDC Diameter from 30 to 75mm

Power from 10 to 450 Watts

Motor stall torque up to 400Ncm (580 oz.in)

Gearbox output torque up to 160Nm (120 ft.lb)

dunkermotor.com/express

Dunkermotor 9-15 new logo.indd 19 9/2/15 3:46 PM

G r e e n E n g i n e e r i n g


Additionally, their energy density is low and they

have a high self-discharge (up to 60% per year).

Supercapacitors linked in series also require

balancing circuits. As a result, supercapitors are

much bulkier than comparable industrial grade Li-

ion batteries.

Certain energy harvesting applications may

be well suited for standard consumer-grade Li-ion

cells that are relatively inexpensive and widely

available. However, consumer grade LI-ion batteries

have notable limitations. These limitations include

a life expectancy of less than five years and 500

recharge cycles, and a temperature range of only 0

to 60 C.

Industrial-grade Li-ion batteries are probably a

better bet if the wireless device is intended for use

in remote, inaccessible locations where battery

replacement is difficult or impossible, or in extreme

environmental conditions. These ruggedized

batteries can deliver up to 20 years of operating

life with 5,000 full recharge cycles, along with an

expanded temperature range of -40 to 85 C. They

can also provide high-current pulses (5A for a

AA-size cell) common in remote energy harvesting

uses. Industrial grade Li-ion cells also feature

glass-to-metal hermetic seals, whereas consumer

rechargeable Li-ion batteries use crimped seals that

may leak.

Industrial grade Li-ion batteries are generally

recommended for applications that involve extreme

temperatures and remote, inaccessible locations,

where the labor to replace a battery can often far

exceed the cost of the battery itself. Industrial

grade Li-ion batteries also make sense for use in

large-scale projects, where their 20-year operating

life can eliminate multiple rounds of scheduled

battery change-outs, while also reducing the

potential risk of compromised data and lost revenue

due to battery failure. All these factors should

be considered when estimating the total cost of

ownership, an important yardstick when choosing

between consumer grade and industrial grade Li-

ion batteries. DW

Tadiran Batteries tadiranbat.com

Generally speaking, supercapacitors are

not well suited for long-term deployment

in industrial wireless devices. They excel

at providing short bursts of energy. But

their discharge qualities are such that

applications cant use all their available energy.

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

U S T S U B A K I . C O MTotal Package

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

INTRODUCING THE CUSTOMERS CHAMP... TSUBAKI BACKSTOPS.

Just like the full range of Tsubaki products, Tsubaki backstops provide the winning combination; unmatched quality, durability, reliability and service & support. Prove youre a winner too by protecting your application against costly downtime with Tsubaki brand backstops and clutches.

WITH OVER 50 YEARS OF GLOBAL EXPERIENCE, YOULL WANT TSUBAKI BACKSTOPS IN YOUR CORNER

Green Engineering_9-15_Vs4.LL.MD.indd 20 9/2/15 4:12 PM

www.catalystmotiongroup.com

A single resource for integrated mechanical, electronics, drives and software, with experienced customer support for the development

of simple-to-sophisticated automation systems.

At Catalyst Motion Group

We are able to accomplish this through coordinated utilization of our extensive engineering resources and vertically integrated manufacturing resources.We put it all together customized motion systems that include stepper motors, brush and brushless DC motors, linear mechanics, drives, electronics and an extensive array of peripheral system components. Our considerable and wide-ranging in-house manufacturing capabilities allow us full control of the entire process, from development of prototypes to delivery of fully tested production units. And, with our engineering capability, if we don't have it ...we can develop it! We have successfully developed and taken to production fully customized motion solutions for a wide variety of advanced technologies including: Medical devices for diagnostics, surgical procedures, therapeutics and pharmaceuticals Laboratory and analytical instrumentation and equipment Industrial automation including robotics and production line processing operations

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

Your Catalyst to InnovativeMotion Control Solutions

1500 Meriden Road Waterbury, CT 06705 U.S.A. Call 1 203 725 3852

CATALYSTM O T I O N G R O U P

C

M

Y

CM

MY

CY

CMY

K










C

M

Y

CM

MY

CY

CMY

K

AMETEK Catalyst 8-15 (New).indd 21 9/2/15 3:44 PM

CONNECT with Design World

DIGITAL ISSUE

Visit designworld-digital.com for our latest issue!

FOLLOW US

Connect with 339,805 engineers at

facebook.com/DesignWorldNetwork.

Grow your network. Join the Design World

group on LinkedIn.

Hot products and topics are streaming at

youtube.com/Design-WorldVideo.

Hang out and track what's new at

plus.google.com/+DesignWorldOnline.

See shared slides atslideshare.net/

DesignWorldOnline.

Over 13,000 members - global educational engineering community - join today.

engineeringexchange.com.

Find meaningful links and tweet along with us

@DesignWorld.

Check the boards and see whats being pinned up at

pinterest.com/engineeringex.

Think

Allie

d for

Autom

ation

& Co

ntrol

APR15-A&C Snipe_Snipe 3/13/15 2:39 PM Page 1

September 2015www.designworldonline.com

INSIDE:

84

FASTENING & JOINING: Enable efficient structures with friction stir welding. PAGE 106

SENSORS: Current industry requirements provide new direction. PAGE 114

busbars and IEC

standards

reigns supreme with

LINEAR MOTION: Components for linear motion systems change with the times. PAGE 74 Modular

How additive technology will affect manufacturingFor 16 years, ExOne has focused its efforts on developing

additive machines for use in manufacturing. ExOne President

Dave Burns explores this shift of 3D printing into additive

manufacturing and how it will affect design engineers.

Wow...This is a great video - A heart pump that keeps kids alive

FACEBOOK

ENGINEERING EXCHANGE

GOOGLE+

2 2 DESIGN WORLD

YOUTUBE

TWITTER

http://dwo.me/1PCbySJ

http://dwo.me/1PCeSgw

Editorial Director Paul Heney chats about some

engineering topics with his 8-year-old son, Matthew, in

the Design World offices. They discuss everything from

types of engineers to what engineers doand also look

at some high-tech components.

http://dwo.me/1PCcsys

What is an indirect drive?

http://dwo.me/1PCczKr

What is hydraulic fluid conditioning part 1

Leslie Langnau, Managing Editor

http://dwo.me/1PCeFtL

When choosing a coupling,

the type of drive system were

dealing with is an important

consideration.

Engineering Exchange 9-15_Vs1.indd 22 9/2/15 4:10 PM

2015 by AMETEK Inc. All rights reserved.

Nothing moves air with more rock-solid reliability than AMETEK Rotron regenerative blowers. Fifteen years service life is not unusual. These low-pressure, high-volume blowers feature rugged, compact construction and quiet operation. Their proven design makes them ideal in applications from chemicals, wastewater and furnaces to vapor recovery and more. Plus, theyre backed by the industrys most knowledgeable engineering experts. AMETEK can customize your blower for harsh environments, high voltage and specialized applications, too. So make your next air-moving challenge a breeze. Call us at +1 330-673-3452 or visit our website to get started.

Whats 15 years to one of our blowers?A warm-up.

100 East Erie StreetKent, OH 44240ametekdfs.com

AMETEKDFS Regen Blower Ad_9x10.875.indd 1 6/1/15 5:03 PMAMETEK 6-15 (NEW AD).indd 23 9/2/15 3:43 PM

01

m i l i t a r y / a e r o s p a c e

D e s i g n f o r I n d u s t r y

2 4 DESIGN WORLD September 2015 www.designworldonline.com

Encoder for machines with loose mechanical motion

Some machines have a significant amount of flexure near the area requiring motion feedback. The MSA 37x series linear motion feedback encoder system was designed for machines with loose mechanical motion during operation. These encoders suit motion applications such as press brake and metal forming/bending machines. The encoders include a bearing set internally for guiding the scanning optics, and a bearing set externally for the attachment of a coupling rod that affixes to the machine, thereby allowing for measurement of the moving elements of the machine. Digital TTL resolutions of 5 and 1 are possible, with accuracies up to 10 . The encoders also have magnetic limit switches that can be used to send end of travel signals to the control. Reference marks can be in the center, on either end of travel, or every 50 mm. The encoders are designed to handle large shock and vibrations, and the series is ROHS compliant. DW

RSF Elektronik rsf.at/en

m a c h i n e t o o l

WHAT DO YOU THINK?

Connect and discuss this and other design engineering issues with

thousands of professionals online

DFI 9-15_Vs6.LL.MD.indd 24 9/2/15 1:13 PM

Haydon Products Division1500 Meriden RoadWaterbury, CT 06705 U.S.A. Telephone: 203.756.7441Fax: 203.756.8724

Kerk Products Division1 Kerk DriveHollis, NH 03049 U.S.A. Telephone: 603.465.7227Fax: 603.465.3598

Call 1.8OO.243.2715

www.HaydonKerk.com

Haydon Kerk Motion Solutions Micro Series lead screw products enable a whole new range of micro-solutions that facilitate big advances in medical technology. The Micro Series provides precise control, reduced power consumption, and weight reduction without sacricing performance or reliability. Prototype kits are now available in our online store and shipments can be made in 24 hours.For custom, application-specic needs, Haydon Kerk oers in-house engineering and manufacturing including machining, mold making, and injection molding capabilities, strategically integrated to satisfy your needs for a hundred, a thousand, or a million assemblies. For more information: www.HaydonKerk.com > Lead Screws & Nuts > 2 mm Lead Screw

SURGICAL PRECISION RE-DEFINED

For extreme control in medical applications including infusion pumps, intravenous therapies, surgical robotics, radiology, opthalmic instruments, microscopes, and other instruments that require ultra-precise motion control in confined spaces.

Haydon Kerk Motion Solutions Micro Series Lead Screw Technology

Micro Series BFWR Rectangular Nut Assemblies

Micro Series BFWB Barrel NutAssemblies

24 -HR SHIPPING / E-COMMERCE

2 mm (5/64-in) diameter Micro Series Standard Lead Screw Assembly










C

M

Y

CM

MY

CY

CMY

K

Haydon Kerk 9-15_updated.indd 25 9/2/15 3:47 PM

the #1 value in automationOrder Today, Ships Today!

* See our Web site for details and restrictions. Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405

Research, price, buy at: www.automationdirect.com/circuit-protection

Protect your gear at AutomationDirect prices!U

L 98

UL

508

SUPPLY

MOTOR

CCM

OL

Main Circuit

Motor Circuit

Control Circuit

Motor feeder shortcircuit and groundfault protection

Motordisconnectingmeans(NEC 430.101-430.113)

Motor branch-circuitshort circuitprotection(NEC 430.51-430.58)

Motor controller(NEC 430.81-430.91)

Motor overloadprotection(NEC 430.21-430.44)

OSHA Lockout/tagoutdisconnect(NEC 430.81-430.91)

ControlTransformer

PLC I/O ContactCoils

Relays

Ensure that your equipment is safeguarded at every point in the power distribution network with high-quality, cost-effective circuit protection and disconnection devices that meet UL standards.

Theyll pay for themselves in no time!

UL 248General Fusesstarting at $2.00 (5-pack)

Class CC, general purpose class M (Midget) and small dimension glass and ceramic fuses Ideal supplementary protection up to 30 amps for branch circuits and 50 amps for end of line equipment

UL 1077Supplementary Protectorsstarting at $9.00

DIN rail mountable Optional busbar system and a full line of

auxiliary switches, alarm switches and padlock lockout accessories

B trip curve 1 to 63 amps C trip curve 0.5 to 63 amps D trip curve 0.5 to 40 amps

Bryant ManualMotor Controllersstarting at $23.50

Lockout / Tagout capability 30, 40 and 60A up to 600 VAC 2-pole and 3-pole switches Quick make, slow break design UL Listed as Suitable as Motor Disconnect under UL 508

UL 508Load Switchesstarting at $26

35mm DIN rail mountable or direct mountable Loads from 16 to 125 amps IP20 degree of protection

UL 98 and UL 508Compact FusibleDisconnect Switchesstarting at $19.50

Up to 30A, utilizing Class CC or Midget fuses 1, 2 and 3-pole models Open fuse indication Lockout/Tagout capability

UL 489MCCBsstarting at $182

Rated current up to 800A, max 600V Standard and high-interrupting capacity types

UL 489 MiniatureCircuit Breakers,up to 40Astarting at $18.00

DIN-rail mounted Up to 40 amps 1, 2, or 3-pole available 10kAIC @ 277/480VAC

UL 98DisconnectSwitchesstarting at $88

Non-fusible and fusible rotary disconnect switches Make/break loads up to 800 amps

UL 248 Current Limiting Fusesstarting at $7.75(Class T 1-pack)

Class T, RK5, RK1 and Class J current limiting short circuit protection up to 600A Sold in packs of 1, 5 or

10 fuses

NEW!

NEW!

1509-DesignWorld-LoadProtection-MAG.indd 1 8/4/2015 7:27:27 AM

AutomationDirect 9-15.indd 26 9/2/15 4:00 PM


WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly.

Visit our websitewhittet-higgins.comto peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local or a good distributor.

33 Higginson Avenue, Central Falls, Rhode Island 02863Telephone: (401) 728-0700 FAX: (401) 728-0703 E-mail: [email protected] Web: www.whittet-higgins.com

POWER TRANSMISSIONRETAINING DEVICES &maintenance & assembly tools

WHITTET-HIGGINS

USA

BEARLOK SHOELOK BEARLOK Shrink Disc

BEARHUG CLAMPNUT TANGENTLOK

PRECISION NUTS & WASHERS ADAPTER SLEEVE ASSEMBLIES

NUTS & WASHERS HARDENED TONGUE WASHERS SPLIT COLLAR

RETHREADING DIES ADJUSTABLE SPANNER WRENCH BEARING ASSEMBLY SOCKET

INCH and METRIC THREADSLEFT HANDED as well as

RIGHT -HANDED

Materials of:CARBON, ALLOY and HARDENED ALLOY

STEELS

Materials of:ALLUMINUM and

CORROSION RESISTANT STEEL

m i l i t a r y / a e r o s p a c e

High power RD devices solve TWT radar issuesTwo gallium nitride (GaN) high electron mobility transistors (HEMT) promise to solve several long-standing issues for radar systems using traditional travelling wave tube (TWT) amplifiers. GaN-based solid-state amplifiers operating at 50 V are not prone to the failures seen with high voltage (kV) TWT power supplies, and thus have longer lifetimes. Also, these transisters have near instant on capabilitywith no warm upand have longer detection ranges and improved target discrimination. Conceived to enable these benefits, these two GaN RF transistors were engineered to deliver high power and efficiency in a small package size. The first device, a 350-W/50- fully matched GaN HEMT is the highest power C-Band transistor available on the market. The second, a 500-W/50- GaN HEMT, is the highest power S-Band transistor fully matched to 50 in a single-ended package of its size. According to the manufacturer, the C- and S-Band products break power records for GaN power and efficiency performance housed in a small 50- package. This efficient power enables the economical combination of transistors to achieve multi-kilowatt power amplifiers required for defense, weather and air traffic control radar. Offering pulsed saturated power performance typically greater than 400 W, the CGHV59350 is most often used in ground-based defense and Doppler weather radar systems. The 50-, fully matched GaN HEMT operates over a 5.2 to 5.9 GHz bandwidth, exhibits 60% typical drain efficiency, and is packaged in an industry standard 0.7 x 0.9 in. ceramic/metal flange package. Delivering 700 W of typical saturated RF pulsed power, the CGHV31500F is offered for air traffic control radar systems. The 50-, fully matched GaN HEMT operates over a 2.7 to 3.1 GHz bandwidth, exhibits 12 dB power gain, and is packaged in an industry standard 0.7 x 0.9 in. ceramic/metal flange package. DW

Creecree.com

02


The engineers at Technowrapp had an idea that, if successfully executed, would result in the worlds fastest arm pallet wrapper. But they also wanted to ensure their Runner Arm would be simple to operate and easy to maintain. In the Runner Arm automatic rotary arm pallet wrapper, the engineers created a device that can wrap 136 pallets/hour with 10 turns per pallet, stabilizing a pallet with just 76 g of stretch wrap film (value achieved with 15 m film). The rotary arm with centripetal contrast ring contains and guides the arm as it moves and makes it possible to reach 45 rpm, combining this with low structural stress. The cutting and welding pliers operate on the moving load, contributing to the increase in speed and efficiency of the work cycle.


03 D e s i g n f o r I n d u s t r y p a c k a g i n gMotors key to fast arm pallet wrapper

Your perfect cylinder starts at nasoncylinders.com.Your perfect cylinder starts at

The perfect cylinder doesnt come from a shelf.It comes from your head.After all, you know your application better than anyone.

Thats why Nason starts by doing something revolutionary.

WE LISTEN. Then we build it just for you.

NAS_0366 Trade Ad-Half Pg-DW.indd 1 3/6/14 4:12 PM


BOSTON GEAR Original Domed Crown Stainless Steel 700 Series Reducer

Altra Industrial Motion

Vol. 4 | No. 3 | 2015

The Power Brands in Power TransmissionPower Review

Altra Industrial Motion The Power Of Experience

Ameridrives Couplings

Ameridrives Power Transmission

Bauer Gear Motor

Bibby Turboflex

Boston Gear

Delroyd Worm Gear

Formsprag Clutch

Guardian Couplings

Huco Dynatork

Industrial Clutch

Inertia Dynamics

Kilian Manufacturing

Lamiflex Couplings

Marland Clutch

Matrix International

Nuttall Gear

Stieber Clutch

Svendborg Brakes

TB Woods

Twiflex Limited

Warner Electric

Warner Linear

Wichita Clutch

For more information contact us at: [email protected] or visit www.altramotion.com

Featured in this Edition...

Find Altra Industrial Motion on:

Scan to downloadthe interactive version of the Power Review

Boston Gear Original Domed Crown Stainless Steel Reducer

Formsprag Rebuild and Overhaul Service

Twiflex USA Brake Calipers

TB Woods Sure-Flex Plus

Huco Oldham Couplings

Warner Linear Programmable S-Track Linear Actuator

Certied

Altra Industrial_#1_9-15.indd 29 9/2/15 3:50 PM

Boston Gear Original Domed Crown Stainless Steel 700 Series

The Boston Gear 700 Series Worm Gear Speed Reducer has been a foundation in food and beverage applications for decades. As a leader in worm gear technology, Boston Gear continues to improve product performance by developing innovative designs to meet more stringent demands and anticipated tightening of federal regulations in the food and beverage industry.

Utilizing the often imitated but never equaled 700 series worm gearing combined with new exterior designs, the new stainless steel 700 series performance has been optimized to withstand the harshest washdown conditions! The new line incorporates features that were designed with the input of some of the food processing industries leading players to maintain optimal performance in the toughest caustic environments.

The Stainless Speed Reducer is NSF International certified and the Stainless Gearmotor is UL / ULc Certified.

For more information download P-1998-BG & P-7756-BG from www.AltraLiterature.com or visit www.BostonGear.com

Laser marked nameplate provides worry-free part identification while maintaining a smooth, unetched surface. Rounded housing prevents foreign matter adherence and fluid accumulation.

Boston Gear Stainless Gear Drives Enhance Food SafetyThe Clean Product Advantage

NSF Certified Sealed motor flange Electropolished exterior finish Covered hardware Maintenance friendly features

Process improvements have yielded the BEST standard leadtime for stainless worm gear reducers.

The Boston Gear Service Advantage

Standard 2 day delivery on any cataloged SS700 Series product Same day break down service After hours/holiday hotline Stocked at local and regional distribution centers

Certied

P-7756-BG

Send Formsprag your old clutches to make them like new again. The difference is not just cosmetic.

All internal components sprags, energized springs, retainer, bearings, seal and hardware are refurbished or replaced to new performance standards. The inner and outer races are ground to specifications noted below so that no wear patterns remain.

Sprag Surface is hardened to 58-62 Rc Sprag Surface finish is 15-25 microinches Sprag Surface taper limit is 0.0002 inch per inch

Consider these advantages:

- Price A guaranteed savings of at least 30% or more versus new product- Speed Clutches are received, inspected and rebuilt in the shortest possible time

frame- Warranty 1 year on labor and materials, same as new clutches- Emergency Breakdown Program All products that are air freighted into the

Warren plant are processed immediately and, in most cases, are able to be rebuilt within a 24-hour period.

For more information download Application Guide P-1465-FC from www.AltraLiterature.com

Formsprag Rebuild and Overhaul Service


Proven Oldham Couplings 25% Higher Torque

Warner Linear has expanded the S-Track linear actuator product line with the addition of a new programmable model.

An easy-to-use integrated keypad allows operators to set and reset end of travel positions as well as two intermediate stops.

New S-Track electric actuators are designed for better control and quieter operation in general duty applications including medical, industrial, turf & garden and recreational vehicles.

For more information download catalog P-1581-WL from www.AltraLiterature.com or visit www.WarnerLinear.com

Programmable S-Track Linear ActuatorJust introduced, the Oldham lateral offset couplings are designed to handle 25% higher torque than their forerunners.

Previously, a peak torque rating of 44Nm was the highest available. Now, 55.36Nm is possible using a specially designed larger diameter disc.

The Oldham is precision engineered throughout and comprises two hubs with inward facing tenons. These engage with matching slots spaced at 90 in a central lightweight torque disc. A hard, low friction facing on the working surface guarantees long, trouble-free operation.

Typical applications range from the incremental control of fluid valves to positional systems in machinery, robots and slide tables. They can also be applied to microstepper and closed loop servo systems and, to a lesser extent, half and full step motor drives.

Twiflex USA Brake Calipers

Sure-Flex Plus: A New Standard for Performance

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

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

Hydraulically Applied Brakes address higher torque requirements, while spring applied calipers are essential where braking must be maintained in the event of supply system failure

Mechanically Applied Units are suitable for light tensioning duties or where no external power is available; they may also be specified when designers wish to use their own means of actuation.

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

For over 50 years, TB Woods has led the coupling industry with the original TB Woods Sure-Flex design. And we havent stopped innovating: this industry favorite just got even better.

Our new Sure-Flex Plus EPDM and Neoprene sleeves are best-in-class for coupling performance and value. Heres why:

High Torque Rating30% Increased Torque RatingProvides longer service life in demanding applications, reducing required maintenance and associated replacement cost.

Longer LifeSure-Flex Plus Lasts Over 3X Longer than the CompetitionExtensive testing shows our sleeves outlast the imitators. More uptime means less costly downtime.

Better ValueSave Money Using a Smaller CouplingThe increased rating of the Sure-Flex Plus sleeves lets the user choose a one-size-smaller coupling for over 50% of common applications. This lowers the cost of both initial purchase and future sleeve replacement.

InterchangeableRetrofits to Existing FlangesNo need to replace the full coupling The Sure-Flex Plus sleeve design is 100% compatible with the current industry standard that TB Woods created over 50 years ago.

Call Twiflex Toll-Free: 844.723.3483

For more information download P-7819-TBW from www.AltraLiterature.comor visit www.TBWoods.com

TB Woods Incorporated


Altra Electric Clutch Brake brands offer the largest selection of clutches, brakes and linear actuators available from a single source...worldwide.

Warner Electric, Matrix International, Warner Linear and Inertia Dynamics have over 60 years combined experience designing and manufacturing technically-advanced, cost-effective braking and positioning systems. State-of-the-art Altra clutch and brake solutions are utilized on drivetrains in an array of global markets including material handling, packaging machinery, food & beverage, elevator & escalator, turf & garden, agriculture and off-highway, forklift and medical.

www.AltraMotion.com

Warner Electric www.warnerelectric.com

Matrix International www.matrix-international.com

Inertia Dynamics www.idicb.com

Warner Linear www.warnerlinear.com



To achieve these speeds, the engineers used Bonfigliolis C, W, and BE/BN motor series for the pallet and vertical carriage movement as well as the ring rotation and the servo-assisted tensioning systems. The motors were used for the tensioning, feeder, and plier carriages, as well as for the presser and linear roller. The carriage system is equipped with Bonfigliolis W63 and BN_FD Motors with a motor power of 0.75 kW. In addition, the tensioning and plier carriage are also equipped with W63 and BN_FD Motors, with motor powers of 0.55 kW for the tensioning carriage and 0.37 kW for the plier carriage; the tensioning carriage also uses a W86/BE motor with a motor power of 1.1 kW.

WHAT DO YOU THINK?



p a c k a g i n g

The arm rotation uses Bonfigliolis W110/BN_FD motor series with 4 kW of motor while the presser uses a W63 BN_FD motor with 0.55 kW of motor power. The linear roller uses the C22 BE series with 0.75 kW of power. These various motor solutions have helped the Runner Arm achieve high speeds while maintaining low structural stress. DW

Bonfigliolibonfiglioli.com

Bring Your Machine To Life With Custom DrivesAerotech can partner with you to design a custom automation solution for your specifi c application at a minimum price.

In our concept machine at right, Aerotechs drive packaging can be customized to fi t into the wasp body with special algorithms developed at the fi rmware layer for fl ight control.

Aerotech can accommodate your custom automation controller needs by using our plug-in architecture for specifi c algorithms such as 2D bar code, interfaces to non-standard sensors, signal outputs synchronized to servo sample time, and more. If you have a need for custom hardware or fi rmware in your drive package, contact Aerotech today.

Contact our Control Systems Group at 412-967-6839 or [email protected] to discuss your application today, or see go.aerotech.com/csg46

Dedicated to the Science of Motion

Hardware Software HMI Firmware Packaging I/O Motors Electronics

We customize Aerotech automation for you

The Americas Europe Asia-Pacifi cGlobal sales, service, and support

AH0315C-CSG

Bring Your Machine To Life Bring Your Machine To Life Bring Your Machine To Life Bring Your Machine To Life Bring Your Machine To Life Bring Your Machine To Life Bring Your Machine To Life Bring Your Machine To Life Bring Your Machine To Life Bring Your Machine To Life Bring Your Machine To Life Bring Your Machine To Life Bring Your Machine To Life Custom DrivesCustom DrivesCustom DrivesCustom DrivesCustom DrivesCustom DrivesCustom Drives

Aerotech can partner with you to design a custom Aerotech can partner with you to design a custom Aerotech can partner with you to design a custom Aerotech can partner with you to design a custom Aerotech can partner with you to design a custom automation solution for your specifi c application at a automation solution for your specifi c application at a automation solution for your specifi c application at a automation solution for your specifi c application at a automation solution for your specifi c application at a automation solution for your specifi c application at a

In our concept machine at right, Aerotechs drive In our concept machine at right, Aerotechs drive In our concept machine at right, Aerotechs drive In our concept machine at right, Aerotechs drive In our concept machine at right, Aerotechs drive packaging can be customized to fi t into the wasp body packaging can be customized to fi t into the wasp body packaging can be customized to fi t into the wasp body packaging can be customized to fi t into the wasp body packaging can be customized to fi t into the wasp body packaging can be customized to fi t into the wasp body with special algorithms developed at the fi rmware with special algorithms developed at the fi rmware with special algorithms developed at the fi rmware with special algorithms developed at the fi rmware with special algorithms developed at the fi rmware

Aerotech can accommodate your custom automation Aerotech can accommodate your custom automation Aerotech can accommodate your custom automation Aerotech can accommodate your custom automation Aerotech can accommodate your custom automation Aerotech can accommodate your custom automation controller needs by using our plug-in architecture for controller needs by using our plug-in architecture for controller needs by using our plug-in architecture for controller needs by using our plug-in architecture for controller needs by using our plug-in architecture for controller needs by using our plug-in architecture for specifi c algorithms such as 2D bar code, interfaces to specifi c algorithms such as 2D bar code, interfaces to specifi c algorithms such as 2D bar code, interfaces to specifi c algorithms such as 2D bar code, interfaces to specifi c algorithms such as 2D bar code, interfaces to specifi c algorithms such as 2D bar code, interfaces to non-standard sensors, signal outputs synchronized to non-standard sensors, signal outputs synchronized to non-standard sensors, signal outputs synchronized to non-standard sensors, signal outputs synchronized to non-standard sensors, signal outputs synchronized to non-standard sensors, signal outputs synchronized to non-standard sensors, signal outputs synchronized to servo sample time, and more. If you have a need for servo sample time, and more. If you have a need for servo sample time, and more. If you have a need for servo sample time, and more. If you have a need for servo sample time, and more. If you have a need for servo sample time, and more. If you have a need for custom hardware or fi rmware in your drive package, custom hardware or fi rmware in your drive package, custom hardware or fi rmware in your drive package, custom hardware or fi rmware in your drive package, custom hardware or fi rmware in your drive package,

Hardware Software HMI Firmware Packaging I/O Motors Electronics

We customize Aerotech automation for you

Global sales, service, and supportGlobal sales, service, and support

Ethernet Connectivity

Vision

Automation Controller

Custom Motor Design

Custom Software

Advanced Control Algorithm

s

Custom Drives

Dedicated to the Science of Motion

VisionVisionVisionVisionCustom Custom Custom Custom

SoftwareSoftwareSoftwareSoftwareSoftware

AH0315C-CSG-WASP-Custom Drives-8_5x4_75.indd 1 8/5/2015 9:13:38 AM


WHAT DO YOU THINK?



Gearmotors deliver efficiency in packaging applications


In packaging, the demand for smaller, lighter, reliable and energy-efficient power transmission components is constant. A new entrant into the efficient power transmission market is the ie3 premium efficiency gearmotors, which offer increased efficiency over standard IE1 models throughout the speed range and initiate less mechanical stress, which directly translates into long-term energy savings. The ie3 gearmotors run cooler and with less noise and, as they are sealed for life and require practically no maintenance, significantly reduce costly downtime. Two key factors enhance the durability of these gearmotors: ultra-long-lasting e-coat paint and lubrication through premium H1 food-grade grease.

Key attributes of these gearmotors include: light, reliable and compact in size high torque at low speed sealed for life for maximum efficiency and reduced labor standard high-grade grease for lifetime lubrication and reduced maintenance/downtime high-quality, durable, e-coat paint to withstand the toughest environments hypoid gearing for efficiency DW

Brother Gearmotorsbrother-usa.com/gearmotors

04 p a c k a g i n g D e s i g n f o r I n d u s t r y


Graybar 7-15.indd 35 9/2/15 3:59 PM

D e s i g n f o r I n d u s t r y 04

www.designworldonline.com September 2015 DESIGN

e n e r g y

Military and commercial markets continue to demand capacitors capable of high-reliability, long lifetime performance at operating temperatures in excess of the current 125 C. The AT Series MLCCs offer two new case sizes (0603 and 0805), two new voltage ratings (16 V VHT 250 C and 25 V VHT 200 C), and new C0G and VHT temperature coefficients that differentiate the 200 C parts from the industry-leading 250 C parts. These high temperature MLCC capacitors reliably test data at 250 C, and are rated at both 250 C and 200 C for de-rating schemes. The series

Capacitors for high temperature applications

2015-DesignWorld_halfhoriz_precision_OTLNS_FINAL.indd 1 3/6/2015 11:34:56 AM

DFI 9-15_Vs6.LL.MD.indd 36 9/4/15 9:12 AM

Together a winning combination for todaysservomotor applications.

Our ServoClass couplings have been recently redesigned to enable your actuator to go even faster and achievethe positional accuracy that will take your designs to the next level. Our couplings will do all this with low bearing loads.

3 New sizes now available.

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

Check our FAST deliveries.

www.zero-max.com 800.533.1731

2010 ZERO-MAX

Your ball screw Your servomotor

Our coupling

# Zero-Max_full_pgs_r10_Design World 2/12/10 4:02 PM Page 1

Zero Max ad 8-15.indd 37 9/2/15 4:35 PM


D e s i g n f o r I n d u s t r y 04 e n e r g y

exhibits high current-handling capabilities, high volumetric efficiency, high insulation resistance, and extremely low ESR and ESL, in addition to high frequency performance and capacity retention with frequency, and low parasitics and dc leakage for circuit stability and efficiency.

Now available in an extended range of sizes (0603 to 2225), values (100 pF to 1 F), voltages (16 to 50 V), and dielectrics (C0G and VHT), AT capacitors perform in demanding automotive, avionics, aerospace and energy applications. They are suitable for: automotive applications, including under hood power, engine control units, and hybrid electric and plug-in electric vehicles (HEVs and PEVs); avionics and aerospace applications, including transducers, engine controls, spacecraft, and flap and brake controls; and energy applications, including down-hole oil exploration, logging while drilling, geophysical and geothermal probes, seismic sensors, and solar and wind energy conversion. The series can also be used as decoupling and bypass capacitors and for dc filtering in motor drives and high frequency ripple currents, and is also well suited for use in sensors and timing circuits, high-pulsed current circuitry, dc/dc power conditioning converters, dc current sensing and subsystems, ac/dc converters, and dc/ac inverters.

AVX Corp. avx.com

WHAT DO YOU THINK?



Personal CNC

Prototyping - Product Design - R&D - Engineering

PCNC mills shown here with optional

stand and accessories.

Eisertech, a medical device company in San Diego, CA, designs and manufactures spinal implants and surgical instruments with the help of their Tormach PCNC 1100. What started out as garage shop prototypes has grown into a successful medical device product line.

To read more about this story, and to see what others are doing with their PCNC mills, visit www.tormach.com/design.

www.tormach.com/design

PCNC 1100 Series 3

PCNC 770 Series 3

Titanium bone screws and surgical spinal implants manufactured by Eisertech LLC.


Q4X Laser Distance Sensor

Reliable sensing across a variety of diffi cult targets, materials and surfaces

Real-time distance measurement for faster setup and troubleshooting

Reduce downtime due to broken sensors with an IP69K-rated, FDA-grade stainless steel housing

STAINLESS STEEL LASER DISTANCE SENSOR.

bannerengineering.com

With superior performance and rugged durability, the Q4X provides reliable detection when other sensors cant. AnFDA-grade stainless steel housing means the Q4X stands up in the most aggressive washdown procedures. The Q4X is the right choice for your most challenging applications.

2015 Banner Engineering Corp., Mpls, MN USA

BA-2336A 02.0915.06 QX4 Candybar Ad_DW.indd 1 7/29/15 4:17 PMBanner 9-15.indd 39 9/2/15 4:36 PM

By using various machines and a PCNC 1100 mill from Tormach, the NASA team can quickly prototype and develop different versions of unique components. Were making parts for flight projects, high-altitude balloons, and prototyping things for an eventual satellite mission, said Alan Kogut.


Mike Santora Associate Editor D e s i g n N o te s

Both the costs and risks of spaceflight are always high. So what do you do when you dont have the time, budget and room

for error to outsource the machining of ever-evolving prototypes?

NASA Goddard Spaceflight Center uses an array of manufacturing

and engineering tools to develop their one-off, highly customized

technologies. In fact, they use a shop that is connected to their

labs, which houses an array of manual milling, CNC and production

machines.

According to Alan Kogut, an astrophysicist at the center, without

their attached shop they would be relegated to outsourcing the

creation of various components and instruments. By using various

manual machines and a PCNC 1100 mill from Tormach, the team

can quickly prototype and develop different iterations of unique

components. Were making parts for flight projects, high-altitude

balloons, and prototyping things for an eventual satellite mission,

he said.

Personal CNC mill helps NASA boldly go...

The Goddard Spaceflight Center is producing projects like PIPER

(the Primordial Inflation Polarization Explorer) to measure the linear

polarization of the cosmic microwave background. The satellite

instrument looks for the signal from primordial gravity waves excited

during an inflationary epoch shortly after the Big Bang.

They fly these telescopes in containers of liquid helium, which

keeps the temperatures near absolute zero (about 1.5 K). The cold

temperatures keep the telescopes heat radiation from interfering

with the radiation the researchers are trying to see, which is limited

to a few parts per billion.

For PIPERs precision sensors and instrumentation to operate

correctly at such low temperatures, the team needs to compensate

for differential contraction of components in their designs. Brackets

and fixtures holding sensitive instruments for getting data back

to Earth are housed in these icy temperatures. If the differential

contraction is not compensated for in the design, signals and

Design Notes 9-15_Vs6.LL.MD.indd 40 9/2/15 1:32 PM

September 2015 DESIGN WORLD 41

measurements could be lost in the vastness of outer space. This is

where its advantageous to have a machine shop so closefaster,

less expensive prototypes and flight-ready final components.

The teams at Goddard have also customized their Tormach mill

with a unique fixture for wire-winding. According to Kogut, they have

to wrap a couple miles of thin wireabout 13 as thick as a human

hairin an extremely uniform manner for the satellites. You take

a couple miles of this wire and you wrap it around to make a whole

bunch of parallel strands over large distances, he said. This creates a

grid that is about 2 ft across.

The strands have to be held to a plane so they form a flat surface

(to a few millionths of a meter) and the wires have to be spaced

accurately to about 4 or 5 m, which is where the need for CNC comes

into play. We are able to use the mill to both cut the fixture that the

wires get wound onto, and then use it to put the wires in place, said

Kogut.

Using a high-accuracy CNC machine is vital to the proper operation

of a component like this. As the maker movement has emerged,

both manual and automated machines have become more

The teams at Goddard hav

e

customized their Tormach m

ill with

a unique fixture for wire-wind

ing.

The PIPER (the Primordial Inflation

Polarization

Explorer), measures the linear polariz

ation of the

cosmic microwave background. The s

atellite instru-

ment looks for the signal from primo

rdial gravity

waves excited shortly after the Big B

ang.

They fly these telescopes in contain

ers of liquid

helium, keeping the temperatures ne

ar absolute

zero (about 1.5 K). The cold keeps th

e telescopes

heat radiation from interfering with th

e radiation

the researchers are trying to see, whic

h is limited to

a few parts per billion.


D e s i g n N o te s


readily available and less expensive. It has also

ushered in prosumer-style machines, which

are capable of production-quality work, but

available on a budget and in a footprint that

small businesses and consumers can handle.

NASA has been able to circumvent traditional

manufacturing within this facility, allowing

them to prototype, produce and innovate faster

and on a tighter budget.

These projects are not high-budget

projects, but they still involve a lot of parts that

are sort of custom-made to fit, Kogut said.

Rather than going to all the trouble of figuring

out exactly what we want, making up shop

drawings, sending it out to a shop, getting a

quote, and then getting the part produced, we

decided to just get our own machine that we

could make our own brackets and fixtures with

a much faster turnaround.

Though they dont use many exotic

materialsmostly aluminum, stainless steel,

copper and the occasional block of titanium

NASA has to keep their tolerances tight and

their budgets even tighter. DW

Tormachtormach.com

WHAT DO YOU THINK?



Low Outgassing

Tg

Hardness >80 Shore D

Meets low outgassingspecifications

Serviceable to +650F

Tensile strength 10,000 psi

www.masterbond.com

One part adhesive compound EP17HT-LO

Glass transition temperature 225C

Hackensack, NJ 07601 USA Tel: +1.201.343.8983 [email protected]

Request the new 56-page catalog featuring hundreds of rotating unions, along with complete specifi cation and application information.

Phone: 1-847-689-8600Email: [email protected]: www.deublin.com

NOW OFFERING ELECTRICAL SLIP RINGS

ONLINE ORDERING AVAILABLE

Need Rotating Unions

15_DBL_204_DesignWorld_Need.indd 1 8/19/15 5:52 PM


The Minus K BM-8 negati

ve-

stiffness vibration isolator

provides

0.5 Hz isolation performance

vertical,

and 0.5 Hz horizontal, using

a totally

passive mechanical system

no air or

electricity required.

September 2015 DESIGN WORLD 43

Negative-stiffness isolators a plus for CMM system

Manufacturers need to control processes to produce a consistent, reliable product. Where precision surface engineering is

required, surface measurement is a key part of maintaining control

of the process.

Laser interferometers are widely used in industry for the

measurement of small displacements, refractive index changes

and surface irregularities. When built into inspection equipment,

like a coordinate measuring machine (CMM), a laser interferometer

system reports the surface condition of a product with more

accuracy than any other method. These CMM laser interferometry

surface measurement systems, however, can be negatively

affected by plant low-frequency vibrations, which can distort the

interferometry measurements and deliver inaccurate readings.

One specific CMM system, designed and manufactured by

Arnold Gauge Company, has directly addressed the vibration

issue. The companys CMM system maintains its throughput

by integrating a compact negative-stiffness vibration isolation

platform.

Every second, the laser in the CMM is generating about 2,000

readings, said Michael Bruins, president of Arnold Gauge Company.

These readings, taken at the micron level, are displayed on a chart

and plotted against the pre-engineered ideal surface. Due to these

Edited by: Mike Santora Associate Editor

Top Plate

Transmissibility for negative-stiffness isolator versus an air table

Upper Column PlateVertical

Negative-StiffnessFlexures

Rigid Support

Beam-Column

Support Tube (Threaded)

BaseLeveling Screw


Schematic of negative-stiffness isolator



micro-tolerances, any vibrations on the plant

floor, such as from forklifts, are g

Documents

Design World September 2015