design news

Accelerating Engineering Innovation.comAPRIL 2015 $15.00

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Gadget Freak Boat Lift Controller With Remote 56

In the News Fate of Solar Tax Credit Up in the Air 26

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Design News | April 2015 | www.designnews.com

–5–

Accelerating Engineering Innovation www.designnews.comContents April 2015

Vol. 70 no. 4

32

26

38

On the Cover: Design by TM Oovaise.

Images courtesy of arhendrix, sculpies, bgblue, pablographix, ferrantraite, robertsrob/ iSTOCKPHOTO.COM.continued

Cover Story32 Wireless Gaining

Momentum in Remote MonitoringSensor networks can benefit

from wireless communications,

especially in hard-to-reach

applications.

By ChaRles J. MuRRay

Features

34 Design apps for a New WorldFrom advanced touchscreen ap-

plications to new ways for finding

lighter and stronger materials, de-

sign applications are springing up

to improve design productivity.

By RoB spieGel

38 actuators undergo inventive TransformationsActuators are getting a makeover

with new materials, smoother

performance, and greater energy

efficiency.

By RoB spieGel

42 Fasteners Get Tinier, Tougher, and smarter New fastening /joining methods

are making it possible to join

multiple materials and thinner

sheets in consumer and medical

portable electronics, as well as

automotive and aviation systems.

By aNN R. ThRyFT

ColumnsM y O p i n i O n O n …

12 The path to innovation success is Never straightConventional wisdom in product

design, development, and engi-

neering dictates a certain order

of movement, but, in this era,

conventional wisdom often takes

a backseat to the unplanned or

unexpected. So, be on the lookout

for innovation — you never know

when it will come knocking.

By WilliaM NG

M a d e B y M O n k e y s

19 Where Rubber Meets the Bike Rack; Microwave has a Bad ConnectionMade by Monkeys highlights

products that someone slipped

by the QC cops.

C a p ta i n H y B r i d

20 study: Gigafactory Will Create a Giga-GlutTesla Motors’ proposed Gigafac-

tory won’t dramatically transform

the cost of electric cars, and it

might create a glut of lithium-ion

batteries in the marketplace.

By ChaRles J. MuRRay

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Contentscontinued

s H e r l O C k O H M s

24 Flagrant Fan Fuels Diagnostic Failure; Bad Bug spray Baffles engineerSherlock Ohms highlights stories

told by engineers who have used

their deductive reasoning and

technical prowess to troubleshoot

and solve the most perplexing

engineering mysteries.

G a d G e t F r e a k

56 Boat lift Controller Dick Bipes couldnÕt find a boat

lift remote with the specs he

wanted, so he created his own

for automatic operation.

Departments

14 design decisions5 Tips to Meet Control Panel

Space Requirements

22 planet MeMs

MEMS & Sensors Can Bring a

New mHealth World

25 Green sceneEnvironmental News Engineers

Can Use

26 newsTrends, Developments,

Breakthroughs

46 design engineering productsBest of the Engineering

Marketplace

Supplements

automation & Motion Control

These stories, and more, also appear

online at www.designnews.com

DESIGN NEWS® (ISSN 0011-9407) is published monthly by UBM Canon, 2901 28th St., Ste. 100, Santa Monica, CA 90405, 310-445-4200. Periodicals postage paid at Santa Monica and at additional mailing offices. suBsCRipTioNs—Free to qualified subscribers as defined on the subscription card. Rates for non-qualified subscriptions, including all issues: U.S.A, $150.00 one year, $250.00 two years, $300.00 three years; Canada, $184.90 one year, $314.90 two years (includes 7% GST, GST# 123397457); Mexico, $172.90 one year, $295.90 two years; Foreign, $323.90 one year, $579.90 two years. Except for special issues where price changes are indicated, single copies are available for $10 U.S.A and $15 foreign. For telephone inquiries regarding subscriptions 763-746-2792. email: [email protected]. ChaNGe oF aDDRess—Notices should be sent promptly to DESIGN

NEWS® P.O. Box 47461, Plymouth, MN 55447—Please provide old mailing labels as well as new address. Allow two months for change. NoTiCe—Every precaution is taken to ensure accuracy of content; however, the publisher cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein. posTMasTeR—Send address changes to, DESIGN NEWS ® P.O. Box 47461, Plymouth, MN 55447. Printed in U.S.A. Copyright 2015 by UBM Canon. All rights reserved. Reproduction in whole or part without written permission is prohibited.

56


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Design News | APRIL 2015 | www.designnews.com

–9–

NOW ONNOW ON

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CONNECT WITH US

Design News’ System & Product

Design Engineering group:

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Design News’ general Twitter feed:

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Automation & Motion Control

Design News readers spoke loudly and clearly

after our recent news story about a re-

surgence in manufacturing -- and manu-

facturing jobs. Commenters doubted the

manufacturers, describing them as H-1B visa

promoters, corporate crybabies, and clowns.

They argued that US manufacturers aren’t

willing to train workers, preferring instead

to import cheap labor from abroad.

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Design Hardware & Software

Engineers trying to keep track of the

ever-ballooning number of materials and

machines for additive manufacturing (AM)

and 3D printing (3DP) now have some re-

lief. The free, searchable Senvol Database has

data on more than 350 machines and 450

dif erent materials, and has been called the

f rst and only one of its kind for industrial

3DP and AM.

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Electronics & Test

In early March, the US Department of

Energy put new energy ef ciency rules into

ef ect for small, general-purpose electric

motors. The new rules apply to manufac-

turers of open-construction, single-phase,

and polyphase motors built in a two-digit

National Electrical Manufacturers Associa-

tion (NEMA) frame that are rated from 1/4

to 3 horsepower.

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Materials & Assembly

Last year, Dow Automotive Systems intro-

duced commercial availability of its ultra-

fast, under-90-second molding

cycle time VORAFORCE 5300

matrix. This year, the company

announced a new record-breaking,

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for the epoxy resin matrix, with 30-second

times coming later this year.

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Carbon3D Just Solved 3D Printing’s

Painful Speed Problem

3D printing is agonizingly slow, but a new

technology inspired by the movie Terminator

2 is going to get additive manufacturing up

to speed.

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AeroMobil Says it Will Put a Flying

Car on the Market in 2 Years

Speaking at SXSW Interactive 2015,

AeroMobil co-founder and CEO Juraj

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a f ying car to market by 2017 as well as

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Join the fastest growing design engineering

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–10–

EDiTOr-iN-CHiEF

William Ng 718-501-2449

[email protected]

SAlES DirECTOr

Al Schmidt 972-980-8810

[email protected]

EXECUTiVE EDiTOr

Jennifer Campbell 781-778-7787

[email protected]

MANAGiNG EDiTOr

Chris Wiltz 310-445-4282

[email protected]

Charles J. Murray, Senior Technical Editor Ann R. Thryft, Senior Technical Editor Rob Spiegel, Senior Editor

Technical SpecialTieS

CAE Software & Hardware: Rob Spiegel / [email protected]: Charles J. Murray / [email protected] Power/Automation/Control: Rob Spiegel / [email protected] & Assembly: Ann R. Thryft / [email protected]

producTion

Saravanan Selvaraj, Project ManagerMercy Glory Beulah M, Production CoordinatorMarco Aquilera, Creative DirectorQuinn Williams, Art DirectorManikandan Veerakumar, e-Newsletter Specialist

BuSineSS oFFice

Steven Carlisle, Marketing Manager [email protected] / 310-445-8523Stephaney McGinnis, Senior Program & Project Manager [email protected] / 503-643-4262Tanya Von Grumbkow, Webinar Program Manager [email protected] / 310-445-4215 Marissa Decoteau, Sales Operations [email protected] / 310-445-3794

deSign newS adviSory Board

Susan Avery, Executive Director, International Assn. of Plastics DistributionRaj Batra, President, Siemens Industry Inc.Mike Campbell, General Manager, PTCDave Heacock, SVP and Manager, TI Silicon Valley Analog Scott Hibbard, VP of Technology, Bosch Rexroth Ken Karnofsky, Senior Strategist, Signal Processing Applications, The MathWorksChris Loberg Sr., Technical Marketing Manger, TektronixRon Martino, VP of F&D, Automotive and Industrial/Multi-Market Group, FreescaleMark Minnichelli, Director Tech & Development for Engineering Plastics, BASF

u.S. SaleS repreSenTaTiveS

IL/IN/KY/MI/OH/ON/WI Jami Brownlee 310-980-7763 / [email protected]/FL/GA/IA/KY/MD/MN/NC/PA/SC/SD/VA Doug Robertson 781-778-7783 / [email protected]/DE/MA/ME/NH/NJ/NY/RI/VT Julie Simoneau 781-778-7784 / [email protected]/AL/AZ/CA/CO/ID/MO/NV/OK/OR/TX/WA Len Pettek 805-493-8297 / [email protected]

regional/SaleS managerS

CUSTOM PUBLISHING Mike Paul 781-778-7781 / [email protected]

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JAPAN Toshiyuki Uematsu 011 81 3 5775 6056 UK, GERMANY, AUSTRIA, SWITZERLAND Adela Ploner (0)8192-933-78-22

uBm canon execuTive Team

CHiEF EXECUTiVE OFFiCEr Tim Cobbold CHiEF FiNANCiAl OFFiCEr Aharon ShamashCHiEF OpErATiNG OFFiCEr/UBM CONNECT Brian Field CHiEF EXECUTiVE OFFiCEr/UBM CONNECT Sally ShanklandEXECUTiVE Vp/MANAGiNG DirECTOr Josh Dome SENiOr Vp, MEDiCAl pOrTFOliO DirECTOr Stephen CorrickSENiOr Vp, CONTENT & STrATEGy Pam Moore SENiOr Vp, iNTEGrATED MEDiA Amy SklarSENiOr Vp, pEOplE & CUlTUrE Stacey LisowskiVp DESiGN & MFG pOrTFOliO DirECTOr Roger Burg

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–12–

Follow us on:

My Opinion On ....William Ng, Editor-in-Chief

[email protected]

The Path to Innovation Success Is Never StraightConventional wisdom in product design,

development, and engineering dictates a certain or-

der of movement: You listen to customers and look

at their application needs, perform market research,

collaborate with them (I hope) on conceptualiza-

tion and feasibility, and go through the rest of the

engineering design wringer and — voila — you

have a product innovation or, better yet, an innova-

tive product.

Of course, with the pace of innovation and busi-

ness complexities in this era, conventional wisdom

often f lies out the window but sometimes seren-

dipitously lands at the feet of discovery. And, as you

well know, history is littered with famous examples

of unplanned inventions (Velcro and the microwave

oven spring to mind). Luckily, history didn’t stop

from repeating itself at Design News’ Pacific Design

& Manufacturing event in Anaheim in February.

Take igus, for instance. It is known for its “ma-

chinery-motion plastics,” as one company official

described to me at the show, so materials innovation

is obviously integral to its worldwide business oper-

ations. Yet, in the midst of the new bearings, linear

guides, and cable carriers at its stand, was a conspic-

uous roll of blue-colored sheet. The official walked

me over to it and revealed that the company is still

finding applications for Tribo-Tape. It was a strange

remark, since I’m accustomed to hearing an applica-

tions pitch that typically follows new products.

Before igus follows up with me on Tribo-Tape’s

uses, we do know that the low-friction material

can be cut and glued onto surfaces where you want

them to be slippery. The company has posted a hu-

morous video on YouTube that shows it has discov-

ered at least one useful purpose for the blue stuff.

Before you go and search, think Michael Jackson.

Sometimes, you need help coming up with func-

tional uses for a novel development. In these crowd-

sourcing times, Siemens fittingly sent out an open

challenge in January: Find a use for its newly created

piezohydraulic actuator that mimics the function-

ality of human muscle. It can produce low-force,

high-velocity movements or high-force, low-ve-

locity motion, with maximum (blocking) force at

zero velocity — essentially impossible with con-

temporary actuation technologies and potentially

overcoming their associated safety implications.

“We are convinced that applications of this tech-

nology widely surpass our current scope of busi-

ness,” reads Siemens’ pitch literature. “We are

therefore looking for new ideas…‘Exceptional pro-

posals will be rewarded.’” That means access to Sie-

mens’ expertise and resources in refining the actua-

tor prototype to the winning applicant’s functional

needs, as well as help on commercial and licensing

opportunities. The open call for business ideas and

partners ended March 1, and it will be interesting to

see what arises.

At Pacific Design & Manufacturing, while show-

casing new low- and high-durometer grades of

liquid silicone rubber, J. Christopher York, North

America president of Bluestar Silicones, admit-

ted that the pace of innovation in the LSR industry

as a whole is like the material itself: viscous. “The

market hasn’t seen a lot of advancements,” he said.

“LSR is very mature, and the industry is acting that

way.”

The primary takeaways from all this are: always

be on the lookout for innovation; you’re never

above asking for help (even a giant like Siemens

did); and if innovation unexpectedly knocks on

your door, answer it loud and clear, with everything

you’ve got. DN

Read William Ng’s full column at http://ubm.

io/1BMX11G.


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–14–

DesignDecisions

5 Tips to Meet Control Panel Space Requirements

When designing a control panel, you have enough worries and responsibilities

and should not be concerned with additional design challenges. The following

tips can help achieve design flexibility and regulatory compliance while bringing

you peace of mind.

By James Brasch, panduit Corp.

UnUsed space. Energy distribution.

Thermal management. When it comes

to the manufacturing foor, space is

at a premium and the drive to reduce

costs by ftting panels into tight spaces

while complying with safety and regu-

latory requirements can be challeng-

ing. While smaller panels are an option,

they present other challenges such as

noise mitigation, adhering to minimum

separation requirements for electronic

components, and codes and standards

compliance.

What is a Design Engineer to do?

When designing a control panel, you

have enough worries and responsibilities

and should not be concerned with addi-

tional design challenges. The following

tips can help achieve design fexibility

and regulatory compliance while bring-

ing you peace of mind.

Look Closely and You’ll Find

Unused Space

An area that is hardly used in the control

panel is the space between the enclosure

door and the components mounted to

the sub-panel in the rear of the enclo-

sure, sometimes referred to as the three-

dimensional (3D) space. Using products

that tap into this 3D space can save up to

40% of the space on a sub-panel, lead-

ing to a smaller control panel design

or maximizing an existing panel’s ef-

fectiveness. For example, some wiring

duct products allow a DIN rail to be

mounted on the duct itself rather than

on the control panel, allowing the user

to reclaim or repurpose valuable control

panel real estate.

Don’t Cut Corners

Along with the 3D space, corners are

another area inside the control panel

that go unused or underutilized in most

traditional panel layouts. Products that

tap into this unused space, such as wir-

ing duct designed to ft in corners, can

provide an excellent transition from rear

sub-panels to side sub-panels and hold the

potential to save up to 12% of space on

the sub-panels and decrease the enclosure

footprint by 18%.

Noise Mitigation Products

Can Help Space Savings

Noise mitigation products are not typi-

cally space-saving tools. However, there

are products that bring together wiring

normally separated by at least six inches

of air space. This creates an efective EMI

barrier, reclaiming crucial inches of real

estate. Some wiring ducts can incorpo-

rate a metal noise barrier to help achieve

the equivalent of those six inches of air

space, allowing the control panel layout

to become more compact.


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Design Decisions


–16–

Maximize Energy

Distribution

Panel design optimization is important

to minimize equipment size, which af-

fects the protective enclosure contain-

ing the sub-panel, and represents the

outer envelope of the power distribu-

tion and control housing in equipment

design. The approach for introducing

electrical power into and distributed

throughout an enclosure also impacts

its size. Traditional wiring methods use

older components such as power distri-

bution blocks (PDB) where large con-

ductors enter one side of the PDB and

small conductors exit the other side.

PDB requires signifcant labor to install

and anchor a power control component

to a specifc location in the panel de-

sign, leaving little room for variation or

modifcation.

Conversely, modular busbar systems

can distribute power of less than 150A to

well over 1,800A at system voltages of up

to 600V, and are relevant for virtually all

power distribution and control panels in

machine design today. Modular busbar

systems, through their space-saving strat-

egies, can deliver upwards of 25% space

savings in traditional motor control ap-

plications, variable frequency drive appli-

cations, and power distribution panels for

industrial equipment. This space savings

can often allow the designer to select the

next smaller enclosure.

Thermal Demands

Saving space in a control panel often

means mounting active heat-generating

devices in close proximity with one an-

other, and putting them into a smaller,

more compact enclosure. While desirable

for saving space, it creates a problem for

heat dissipation because there are more

heat-generating devices in a smaller en-

closed space.

Understanding the thermal needs of a

control panel is a key component to con-

trol panel design. There are several levels

of thermal management solutions, de-

pending on the amount of heat being gen-

erated inside the panel, the environment

surrounding the control panel, and the

type and size of the enclosure used for the

control panel design. There are also sev-

eral products that can help manage ther-

mal demands, including small footprint

air conditioners, thermoelectric coolers,

and compact cooling fans. These prod-

ucts, when used in the right application

can allow the designer to ft more heat-

generating devices into a smaller space.

It is easy for design engineers to get

overwhelmed by the tremendous demands

encountered when meeting space require-

ments. Follow these tips and you will have

control of your space in no time. DN

James Brasch is associate product manager for

Panduit Corp.

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consumption and significant noise reduction. Up to 5 dB(A) quieter, these compact

40 x 40 x 28 mm fans use 70% less power, achieve an airflow of 22.4 cfm and a

pressure build-up of up to 0.7 w.g. in the saddle area. Even in harsh environments,

the 420J works efficiently! It’s the ideal choice for IT servers, routers, compact

frequency converters and welding inverters as well as general industrial

applications. For more information, visit http://catalog.ebmpapst.us/420J

Quiet but powerful.



–19–

MONKEYSMADE BY

http://bit.ly/MadeByMonkeys

Where Rubber Meets the Bike Rack

When I bought a Prius in 2010, the shape of the rear hatch required me to get a

new bicycle rack. After some research, I bought a Thule Gateway carrier, which

adjusts nicely to clear the rear hatch spoiler.

The rack has two horizontal steel arms with friction fit plastic saddles in which

the bikes sit. I slid the saddles to a good position on the support arms, mounted

two bikes and went for a drive. As soon as I got on the freeway, the wind pressure

pushed the friction fit saddles to the rear of the support arms, maximizing the

cantilever load, jamming the bikes together and threatening to break the end

caps and leave the rack altogether.

When I called Thule tech support about this f law, I was told that perhaps the

powder coat finish on the support arms was too thin, allowing the saddles to slip.

They sent me a replacement rack, which turned out to behave exactly the same

way. As soon as there was wind load on the bikes, the mounting saddles slid to

the most rear position possible.

My solution was to position the saddles where I wanted them, then to drill

through each into the support arm and insert a self-tapping screw. Problem

solved.

Now, four years later, the dense rubber pads which separate the metal rack

from the car body are beginning to tear and fail. I went back to the Thule site

and looked for replacement parts. None were listed, so I sent an email request.

After a short email dialog, I was told that the padding is threaded onto the metal

tubing before the tubing is formed for the rack, and cannot be replaced. They

suggested buying plumbing insulation foam and taping or gluing it in place.

From the email: “Thule’s formal recommendation would be to replace the rack.”

So, this manufacturer has designed a steel rack with rubber parts that will fail

well before the steel, and cannot be replaced. They expect you to replace the

whole rack when that happens.

— CHARLES GLORIOSO

Microwave Has a Bad Connection

About two yeas ago my wife and I sold our longtime home and downgraded to

a manufactured one with little upkeep. We let the appliances go with the house

thinking that new ones would last until we no longer needed them. We were

wrong.

Two years into a one-year warranty, as we were getting ready for dinner one

night, the microwave died. My wife wanted to have service person check it out.

When they opened it up they found a wire end with a blade type connector had

wiggled lose. Can you say “faulty workmanship?” Not to mention the waste of

money on a service call!

— JACK R. JONES

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–20–

Captain Hybriddesignnews.com/blog/captain_hybrid

Captain Hybriddesignnews.com/blog/captain_hybrid

Study: Gigafactory Will Create Giga-Glut

Tesla MoTors’ proposed gigafac-

tory won’t dramatically transform the

cost of electric cars, and it might cre-

ate a glut of lithium-ion batteries in

the marketplace, a recent study says.

The study, “The Tesla-Panasonic

Gigafactory: Analysis of Li-Ion Cost

Trends, EV Price Reduction and

Capacity Utilization,” predicts that

the Gigafactory concept will save

just $2,800 per battery pack and will

fail to produce the huge sales num-

bers that Tesla has projected. “In the

grand scheme of things, the Gigafac-

tory will reduce costs, but it won’t be

enough to signifcantly impact the

market,” said Kevin See, senior ana-

lyst at Lux Research, producer of the

study.

Tesla’s Gigafactory, announced

early last year, is considered one of

the most ambitious manufacturing

eforts in American business history.

It could potentially produce about

seven times more battery capacity,

employ 16 times as many people,

and consume about 15 times as much

land as today’s biggest battery plants.

Proponents of the concept hope that

it will drive down battery costs to a

point that would make electric cars

desirable for mainstream buyers. Tes-

la has said that for the Gigafactory to

reach its production goals, the com-

pany will need to sell 500,000 elec-

tric cars per year by 2020.

Lux Research’s study, however,

predicts that Tesla won’t come close

to that fgure. Using a demand model

based on market size and compe-

tition, Lux projects sales of about

240,000 Tesla cars per year in 2020.

The failure to sell the stated

500,000 cars per year would create

a serious lithium-ion battery over-

capacity, Lux wrote. “We already

have an overcapacity of lithium-ion

batteries right now,” See told us. “So

they are adding capacity into a mar-

ket that already has an overcapacity.”

Tesla has said the Gigafactory

would have a 35-GWh capacity,

which is about seven times more than

Nissan manufactures for its Leaf elec-

tric car and about 35 times more than

LG Chem makes at its Michigan-

based factory.

See told us that if Tesla builds out to

full capacity and fails to sell its stated

number of cars, it probably won’t be

able to unload the entire 57% battery

overcapacity to other automakers, or

into other applications, such as grid

storage.

The larger question, however, is

how the lower sales fgures and over-

capacity would afect Tesla. “It would

certainly be a big blow, especially if

Tesla builds out to full capacity,” See

said. “But even if it happens that way,

it won’t happen overnight, and there

will be some opportunity for dynam-

ic response to customer demand.”

The performance of the Gigafac-

tory will also afect suppliers and in-

vestors, See told us. Panasonic will

contribute about 35% of the initial $4

billion required to build the factory,

and many investors and material sup-

pliers will be afected, as well. DN

Tesla is adding capacity to a market that already has an

overcapacity.

By Charles J. Murray, Senior Technical Editor


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–22–

MEMS & Sensors Can Bring a New mHealth World

LAST YEAR I SPOKE at a conference focused en-

tirely on the topic of mobile health — aptly named

“mHealth Summit” — where I met dozens of com-

panies dedicated to the practice of medicine and

public health through mobile devices. But let’s be

clear: We are not talking about some whiz-bang

new technology that still needs to be invented. We

have the technology now to enable doctors to di-

agnose disease from across the globe, delivering

the results to your smartphone. That technology is

MEMS and sensors, and we are just glimpsing what

it can uncover through the increase in quantified-

self data from wearables and health monitoring

devices.

MEMS/sensors device manufacturers see the

obvious opportunity. According to Marcellino

Gemelli, head of business development Bosch Sen-

sortec (BST), the key is in expanding from the au-

tomotive domain to other markets. BST is eager

to bring MEMS/sensors f irst developed for au-

tomotive safety applications to mobile health, or

mHealth — with product modifications, of course.

As one of the largest providers of MEMS/sensors

to consumer applications such as mobile phones —

which are quickly becoming the conduit between

patients and the healthcare community — BST, it

seems, is on its way to achieving that goal.

CareSpan sees an even larger opportunity: every

patient on the planet. CEO Mark Winter defines

CareSpan as “the first cloud-based platform for real

healthcare (enabling diagnosis and prescription)

that operates entirely inside a Web browser with no

software or special video hardware to install.”

This allows CareSpan to scale up at a tremendous

cost advantage for providers, by using the stan-

dard personal computers, tablets, and smartphones

of patients as medical care terminals, says Winter.

“Doctors and patients can truly be anywhere and

still fulf ill the standards of an in-person exam,” he

said. With billions of people using mobile devices

on a daily basis, and those devices potentially f it-

ted with built-in personal health sensors, imaging

systems, and apps, CareSpan and other technol-

ogy enablers have a built-in audience for mHealth

applications.

CareSpan works off Continua Alliance stan-

dards, Apple HealthKit, and other emerging

mHealth standards, making data “coherent and rel-

evant to individualized patient care,” according to

Winter.

But the biggest challenge is the data. Winter calls

it the “dark side,” asking, “How will physicians and

other healthcare providers manage the avalanche of

personal health data coming at them from their pa-

tients? Even more important, how do these provid-

ers integrate this data in a meaningful way into the

day-to-day care process, whether it is an in-person

visit or a telemedicine exam?”

Nodding his head in virtual agreement, Gemelli

states that BST’s biggest challenge is “the quality of

the collected data.” He points out that consumer

heart-rate monitors cannot easily compensate for

the patient’s motion. Having spoken with numer-

ous companies on the device manufacturer/sen-

sor fusion algorithm side of the house, I know that

companies are working to resolve this issue -- and

believe a solution is not far away. DN

Continue reading at http://ubm.io/1BUOJFc

We now have the technology now to enable doctors to diagnose disease from across

the globe, delivering the results to your smartphone. That technology is MEMS and

sensors, and we are just glimpsing what it can uncover.

By Karen Lightman, MEMS Industry Group


Sherlock ΩhmsFamous investigations into engineering’s most diabolical real-world cases


–24–

http://bit.ly/SherlockOhms

Flagrant Fan Fuels Diagnostic FailureBy rich Wilson, Contributing Writer

Back in the ‘70S, I was working for Dig-

ital Equipment Corporation (DEC). I was

sent to the field to troubleshoot a PDP-8/L

that had intermittent problems. When I ar-

rived, I was told that the local service people

had showed up, found a non-working fan,

which they replaced, and then found that

the computer also failed diagnostics. But

they couldn’t figure out what was wrong.

This was back in the day of loading

a bootstrap program from front-panel

switches, and then reading the final pro-

gram from paper-tape. One of my discov-

eries was that the core memory was getting

corrupted. One of the simple diagnostics

failed regularly at a certain point, and I

could look back and find that corrupted

memory had caused the problem.

I loaded the program again, and memo-

ry was corrupted even before the program

started running. I loaded the program a

second time, but stopped the loading mid-

way. This time the memory was correct.

When I let the load resume, the memory

became corrupted. So the act of reading in

the tail-end of the diagnostic corrupted a

memory location that wasn’t even being

referenced.

I repeated the standard swapping that

had been done by the locals. I swapped

everything -- the power supply, the core

stack, every board in the computer. But the

symptoms stayed the same. What was go-

ing on?

Later that evening, I was looking at a list

of some of the memory locations that were

getting corrupted. There was no pattern

that I could discern: It was various data

bits, and the addresses were all over the

place, not sharing any address lines. But

then I had the ah-ha moment (have you

guessed yet)?

The victim bits were likely physically

near each other. And that immediately led

to the answer: The new fan (which was

very close to the core stack) had a magnetic

field that was large enough to disrupt the

core memory. This field would occasion-

ally combine with the half-select current

in a particular core, and f lip that bit to the

opposite state.

The next day, I unplugged the fan, and

all the problems went away. This same

problem had puzzled engineers during the

development of the computer, and a par-

ticular fan had been specified to solve the

problem. Unfortunately, the locals didn’t

use that fan for the replacement on this

project.

Bad Bug Spray Baffes EngineerBy Josh Boatwright, Contributing Writer

My wife purchaSed a bottle of

bug spray that had an innovative auto-

matic, trigger-controlled sprayer. When

it didn’t work, she assumed the cheap

batteries supplied with the sprayer were

dead. New batteries did not solve the

problem, so she handed it over to me for

a solution. I double-checked the volt-

age on the new AA batteries. They were

both over 1.5V. After disassembling the

handle, I started to check for continuity.

There was continuity across both ends

of the battery terminals, the motor, and

the switch. I even took apart the switch

to verify good contact. Now why wasn’t

this working?

Go to http://ubm.io/1xkh5sw to find

out.

What Made the Mustang Burn Oil?The V-6 powered 2000

Mustang produced a cloud

of oil smoke when it was

started, and about every

200 miles, the check

engine light fashed,

indicating that the en-

gine was misfring.

http://ubm.io/1mHwzkH

Have you applied yourdeductive reasoning and

technical prowess to

troubleshoot and solve an

engineering mystery that

even the fctional Sherlock

would fnd most perplexing?

Tell us about it!

Email Executive Editor

Jennifer Campbell:

[email protected]

DesignNews.com



–25–

Environmental news engineers can use \\\ By Design News Staff

GreenScene

Share your sustainable engineering news with Executive Editor Jennifer Campbell at

[email protected]


–25–

GREEN

UPDATES

Energy researchers are constantly

looking for ways to make cities

and buildings smarter and more

sustainable. With this in mind,

biochemists at Cambridge Uni-

versity have teamed up with archi-

tects and landscapers to design an

eco-friendly bus shelter that uses

energy from the sun and a living

“green wall” to power lighting for

the structure.

Currently on view at the Cam-

bridge University Botanic Garden,

the prototype shelter for people

waiting at bus stops — the vision

of Professor Christopher Howe

and Dr. Paolo Bombelli — fea-

tures eight vertical green wall units

along four semi-transparent solar

panels and two f exible solar panels.

The idea behind the dual sys-

tem of plant and solar energy is for

the solar panels to generate energy

during the day and the plants to

kick in to provide energy after the

sun goes down.

Continue reading at http://ubm.

io/1FDNNGp

Biomimicry Center Emulates Nature to Solve Design ChallengesArizona State University has become

one of a handful of research institu-

tions to open a center devoted entirely

to biomimicry, which some research-

ers believe is the way forward for sus-

tainable design across numerous re-

search disciplines.

The university recently unveiled

The Biomimicry Center, a collabora-

tion between ASU and Biomimicry

3.8, a consulting and training f rm co-

founded by Janine Benyus and Dayna

Baumeister, leaders in the emerging

f eld that looks to nature as inspiration

for design in science, technology, art,

and numerous other f elds. In fact, it

was Benyus’ book Biomimicry: Innova-

tion Inspired by Nature in 1997 that f rst

brought biomimicry to prominence.

The center is aimed at facilitating

education and research to create sus-

tainable solutions by emulating bio-

logical forms and strategies, accord-

ing to ASU. This work will span a

number of professional and research

disciplines, including biology, design,

engineering, business, communica-

tions, material science, and chemistry,

among others.

The ASU center will focus on sus-

tainability and trying to f nd solutions

to solve some of the world’s greatest

challenges with a trans disciplinary

approach using nature as an inspiration

for design, Baumeister -- a biologist

and ecologist who serves as the cen-

ter’s co-director with Professor Prasad

Boradkar of The Design School in

ASU’s Herberger Institute for Design

and the Arts -- told Design News.

Continue reading at http://ubm.

io/1ByUumY

Prototype Bus Shelter is Powered by Energy-Harvesting Plants, Solar Panels

“We know more about the dark side of the

moon than we do about our own oceans,”

biologist Dr. Paul Bunje told an audience

recently at SXSW. And Bunje and the

XPRIZE Foundation think we should do

something about that. Speaking in a session,

“Ocean Exploration: Illuminating the Un-

known,” Bunje outlined his and XPRIZE’s

belief that the oceans, which cover 70% of

our planet, are a key not only to our own

health and wellbeing, but to advances across a

multitude of f elds from engineering to phar-

maceuticals. But our oceans and the many

diverse species within them are also suf er-

ing from crises brought on by pollution and a

lack of understanding.

Continue reading at http://ubm.io/1Lvp2Bb

XPRIZE’s Latest Challenge to Innovators Is to Save the Ocean


NewsTrends \\\ Breakthroughs \\\ Developments

Design News | May 2013 | www.designnews.com

–26–

Sourc

e: F

reesc

ale

Sem

iconducto

r

Not every solar stakeholder is bullish on the ITC and wants to see ielimination would level the playing feld for solar more t

NewsTrends \\\ Breakthroughs \\\ Developments

Design News | april 2015 | www.designnews.com

–26–

Sourc

e: G

oogle

A tAx credit that has inspired

signifcant growth and business gains

in solar energy in the US over the

past decade is set to expire at the end

of next year unless Congress passes

an extension, leaving the fate of the

burgeoning solar industry unknown.

The Energy Policy Act of 2005 pro-

vides a one-time 30% investment

tax credit (ITC) for commercial and

residential solar energy systems once

they’ve been put into service.

The original ITC was supposed to

expire in 2008 but Congress passed

an eight-year extension, which ex-

pires at the end of 2016. At that

time, if no action is taken, the 30%

ITC for businesses will be reduced

to 10%, and the 30% ITC for resi-

dential solar deployments will be

eliminated.

“No one wins if it’s not extended,”

Ken Johnson, vice president of com-

munications for the Solar Energy In-

dustries Association (SEIA), which

unsurprisingly is lobbying Congress

to pass another extension, told Design

News. “The simple fact of the matter

is, the ITC has been hugely success-

ful since it was enacted at the end of

2006.”

Indeed, since it went into efect

the ITC has had an enormous impact

on the use of solar power in the US

and has created a lucrative new busi-

ness for this type of renewable. “It’s

helped to create more than 150, 000

solar jobs in the United States and

nearly $70 billion has been invested

in new solar projects,” Johnson said.

“Since it’s been adopted the so-

lar industry has grown in deploy-

Fate of Expiring Federal Solar Tax Credit Remains Unknown

The fate of the federal subsidy received for large

solar installations like this one by Google hangs

in the balance as the federal solar investment tax

credit is set to expire at the end of next year.


o see it extended, however. Some believe its ore than the subsidy itself does.

ment by a factor of about 20 times

per year,” David Feldman, a fnancial

analyst with the Department of Ener-

gy’s National Renewable Energy Labs

(NREL), which conducts cutting-

edge research in solar and other types

of renewables, told us. “In 2005, there

were 70 megawatts of photovoltaic

units installed in the United States.

In 2014, there were 6,200 megawatts.

That’s quite a big increase.”

SEIA’s Johnson said solar’s estab-

lished competitors in the energy in-

dustry — oil and gas, coal, and nu-

clear energy — have had the beneft

of years of federal subsidies to create

the powerful industries they are today.

Though it’s done remarkably well in

the roughly 10 years since Congress

passed the solar subsidy, the industry

still needs the help of the ITC to get

solidly to its feet in the market.

“We’re close — very close — to

being competitive, but because of

the disadvantages in the tax code and

because of the fact that fuel interests

have had a huge head start, we’re a lit-

tle bit behind the eight ball,” Johnson

said. “We need a little bit more time

in order to bring our industry into the

future.”

Not every solar stakeholder is bull-

ish on the ITC and wants to see it

extended, however. Some believe its

elimination would level the playing

feld for solar more than the subsidy

itself does.

“With the ITC eliminated, we will

have competitive visibility to the so-

lar industry as a whole,” John Berger,

CEO of Sunnova, one of the United

States’ largest residential solar com-

panies, said in an interview. “People

will see this as a real energy business,

eliciting expansion.”

He said costs are low enough that

solar, already in its own right, is a

competitive energy source around the

world. Additionally, doing away with

the ITC also will eliminate the tax

fraud it inevitably causes, he told us.

Nathan Homan, managing part-

ner at Wiser Capital, a fnancial ser-

vices frm that facilitates fnancing

of mid-scale commercial solar proj-

ects through an online platform, said

that while the ITC undoubtedly has

helped the solar industry in the US

grow, its fnancial growth will con-

tinue even without it.

“Investors who take the ITC are

driving many of the third-party f-

nance deals,” he said. “When the ITC

drops, new buyers should enter the

market and even traditional buyers

are going to have to purchase three

times the number of projects to meet

their tax-credit appetite. This should


Ð27Ð


News

increase competition and potentially

drive down the cost of capital.”

Solar transaction costs also will con-

tinue to decrease as the industry moves

toward standardization and efciency,

making solar deals more

viable and leading to

a further uptick in the

market, Homan added.

In the meantime,

stakeholders aren’t wait-

ing to see what Con-

gress decides and are

rushing to implement

major solar installations

before the tax credit ex-

pires. “There is a huge

push to install as much solar as possible

before 2017,” NREL’s Feldman said.

“There has been and continues to be

a huge ramp-up in utilities, and devel-

opers are trying to install through 2016

— a very sharp increase in the amount

of deployment in expectation of the

expiration.”

Among those looking to take advan-

tage of the ITC before its potential re-

duction is Apple, which said in Febru-

ary it would invest $2 billion to turn a

facility that was planned for sapphire-

screen production into a solar-powered

data center near Phoenix.

No matter the fate of the federal so-

lar ITC, it’s not likely that Congress

will make any big decisions this year as

it focuses on debating broad tax reform

instead, according to SEIA’s Johnson.

“We’ve got a window of opportunity

this year to try to come up with a com-

prehensive tax reform

bill,” he said. “We wish

Congress well — these

are not easy mountains

to move.”

Nonetheless, the SEIA

will continue to lobby

and educate lawmak-

ers about the benefts

of the ITC to prepare

for any future decisions

about its lifespan, which

should come next year as Congress be-

gins to look at tax extensions. “That is

when the ITC discussion will rev up,”

Johnson said.

— Elizabeth Montalbano,

Contributing Writer

Since it went into effect the ITC has had an enormous impact on

the use of solar power in the US and has created a

lucrative new business for this type of

renewable.

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–29–

Manufacturers Struggle to Find Trained Tech PeopleAmericA’s Aging manufacturing

base may fnally be on the rebound, but

it still faces an unexpected dilemma —

lack of trained technical people to carry

out the work.

Experts at Manufacturing in Amer-

ica Symposium in Detroit last month

said companies can’t fnd enough peo-

ple for jobs ranging from controls en-

gineers and machine operators to tool

makers and robot programmers. “We

have a 10.7% year-over-year increase

in job openings in the manufacturing

sector,” said Brian Beaulieu, CEO of

ITR Economics during a speech at

the Symposium. “But we can’t fnd

people.”

The problem is so acute that many

OEMs openly recruit trained technical

workers from suppliers, in some cases

paying penalties for doing so. “We’ve

lost two people to Ford in the past six

months,” Kerry Hammer, chief operat-

ing ofcer of The Paslin Co., an inte-

grator of manufacturing assembly and

automation systems, told Design News.

“We had to put a penalty clause in our

contracts that says if you hire one of

our people, it will cost you an exorbi-

tant amount of money. And they’re still

willing to pay.”

The Paslin Co. has dealt with the

problem by paying high hourly wages

to workers who have as little as two

or three years experience. Robot pro-

grammers, for example, can earn $25

to $30 an hour after only three years.

Hammer said the company recently lost

a 21-year-old robot programmer who

was earning more than $100,000 a year

with overtime, after a customer recruit-

ed him. ”It’s one of our biggest prob-

lems,” Hammer told us. “A customer

snapped him up.”

The competition has grown in the

past fve years, as the US auto indus-

try has gone from a 27-year low of 10.4

million vehicles sold in 2009 to 16.4

million in 2014. During that fve-year

period, half of Paslin’s competitors went

out of business and some skilled tech-

nical people retired or left the industry.


News

“Many of the good tool makers out

there are in their mid-to-late 50’s now,”

Hammer said. “So we’re leaving a big

hole.”

Robot programmers are among the

top of the list in terms of demand,

Hammer added. He said he recruits

most from high schools or community

colleges, starts them at $15 an hour,

and pays them large increases in the

frst few years. “They pick it up very

quickly because of their experience

with video games,” he said. “That’s

what a robot is to them.”

On the engineering side, the demand

is even greater, Hammer said. Degreed

controls engineers are stepping into

their frst jobs earning $28 per hour and

rising to $40 per hour within fve years.

With overtime, he said, engineers in

their mid-20’s make well over $100,000

per year and receive ofers from OEMs

and Tier One manufacturers on an al-

most-daily basis.

Economists say that the demand for

such individuals is strangely exceeding

the growth in the economy. In general,

Beaulieu said, US employment was up

only about 2.4% last year, even as the

manufacturing sector saw a 10.7% in-

crease in job openings. The reason for

the diference is that many American

youths no longer have the skill sets

needed to fll such jobs. Moreover,

college graduates often shy away from

manufacturing.

“We haven’t been training people to

work in manufacturing,” Beaulieu said.

“Baby Boomers have spent their lives

teaching their kids that they need to go

to school to get all sorts of degrees, none

of which enable them to use their heads

and their hands at the same time. But

here’s a newsfash: We have enough art

history majors in the United States. We

don’t need any more.” DN

— Charles J. Murray,

Senior Technical Editor21314 Lassen Street, Chatsworth, CA 91311

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–32–

Once was the time the term “wireless” only conjured up images of mo-

bile phones and remote controls.

That’s changed. One of today’s fastest-growing areas of wireless

technology has little to do with cell towers and a lot to do with data. Us-

ing wireless chips and accessories, engineers can now extract data from

the unlikeliest of places — pumps, motors, bridges, conveyors, refineries, cooling tow-

ers, parking garages, down-hole drills, and just about anything else that can benefit from

monitoring. The key is to link a sensor to a wireless card and then broadcast its data via

radio to a receiver, eliminating the need for people to climb and crawl and run wires to

hard-to-reach places.

Because it’s an eminently practical concept, the popularity of wireless monitoring is

growing. “Today, our market space is $16 billion for process control sensor networks,”

Cover Story

Gaining Momentum

Sensor networks can benef t from wireless

communications, especially in hard-to-reach applications.

BY Charles J. Murray, Senior Technical Editor, Electronics & Test

Remote Monitoringin



–33–

said Bob Karschnia, vice president of wireless for Emerson Pro-

cess Management, which makes products to measure and ana-

lyze industrial processes. “But we expect it to go from $16 billion

to $32 billion in the next 10 years.”

Indeed, engineers are finding that wireless can be a powerful

alternative to wired technology in certain applications. Situations

that don’t lend themselves to easy installation of cabling are prime

candidates. “They get to the point where the cost can be so high

that they just don’t do anything,” Karschnia said. “But if they

go wireless, they can reduce that cost.” In many situations, the

wired-or-wireless conundrum is similar to the one faced by con-

sumers deciding whether to use a wireless router or hard wiring

in their homes, he said.

The breadth of today’s wireless applications is stunning. Pro-

cess engineers have employed wireless technology in refin-

ery cooling towers and injection wellheads. Using an IEEE

802.15.4-based sensor networking technology called Wire-

lessHART (Highway Addressable Remote Transducer Proto-

col), Emerson has helped create steam trap monitoring systems

that save refineries $1 million to $3 million a year.

Similarly, National Instruments has used wireless sensor net-

works to monitor stresses on aging bridges. By connecting strain

gauges to data acquisition nodes and then wirelessly sending data

from the nodes to an NI 9792 wireless sensor network gateway,

structural engineers have been able to use wireless to monitor the

impact loads caused by 18-wheelers and garbage trucks rolling

across the bridges. National Instruments says its hardware and

software have also been employed to analyze historic structures,

check energy consumption, monitor machinery and provide

occupancy information in parking garages. “Operators can con-

nect via tablets or smartphones,” Nick Butler, a group manager

of embedded systems at NI, told Design News. “And data can be

viewed, shared, or analyzed across devices, the enterprise, or the

cloud.”

The key to such monitoring lies in the hardware and software.

Numerous suppliers make wireless microcontroller boards. Tex-

as Instruments, for example, recently released its SimpleLink ul-

tra-low power wireless microcontroller platform, aimed at deliv-

ering low-power wireless connectivity to the Internet of Things

(IoT). The first products in the family support Bluetooth Smart,

6LoWPAN, and Zigbee wireless protocols. Similarly, Linear

Technology Corp. offers a WirelessHART chip. Known as the

LTC5800-WHM, the chip features a low-power radio and an

ARM Cortex-M3 32-bit microprocessor. Its processor runs em-

bedded wireless networking software from Dust Networks.

The tricky part, of course, is to make such devices use as little

current as possible. TI’s SimpleLink accomplishes that with a

chip design that can remain in a standby mode, drawing just 1µA,

with memory retention and its real-time clock running. Linear

Technology’s LTC5800-WHM also minimizes current, using

less than 10 mA to send and receive data packets.

“By comparison, WiFi systems will use about 100 times as

much current,” said Karschnia of Emerson. “And a cell phone

uses 1,000 times more power.”

For remote applications, power delivery is another big chal-

lenge. With many wireless applications located in hard-to-reach

locales, physical power cables can be a problem. That’s why

many engineers turn to batteries, with the goal of long life. Most

say they want a minimum of 10 years and possibly as many as 20

from a battery, so that maintenance workers don’t have to make

frequent sojourns to the tops of bridge trusses or cooling towers

to swap out a couple of dry cells.

Makers of lithium thionyl chloride batteries say their technol-

ogy can supply the long life that wireless engineers seek. Tadiran

Batteries, for example, offers lithium thionyl chloride (LiSOCL2)

batteries that it says can deliver up to 40 years in certain applica-

tions. Tadiran also offers a hybrid LiSOCL2 battery called Puls-

esPlus that can deliver higher pulses of up to 15A.

Tadiran also offers TLI Series industrial grade Lithium-ion

(Li-ion) rechargeable batteries that offer up to 20 years of ser-

vice life, 5,000 full recharge cycles, and the ability to deliver up

to 5A pulses. These industrial-grade rechargeable Li-ion batteries

are said to be a good choice for energy harvesting applications,

which continually draw tiny pulses of power from the sun or

some other source.

“If the product doesn’t need long life, then you may not need

an industrial-grade battery,” a Tadiran spokesman told us. “But

in most remote monitoring applications, long life is critical.”

To be sure, not every sensor network needs wireless. Applica-

tions with numerous flow, pressure, level, and temperature sen-

sors, located within close proximity of one another, can often be

better served by wired fieldbuses. But for control and monitoring

of multiple sensors separated by long distances, wireless makes

sense, experts say.

“With wireless, the cost can go down by a factor of 10 — not

only because of labor costs but because of the wiring,” Emerson’s

Karschnia said. “Wireless is changing the cost paradigm in re-

mote monitoring pretty dramatically.” DN

Using wireless Rosemount pressure transmitters (foreground),

engineers from Emerson Process Management have enabled

ref neries and cooling towers to remotely monitor system

pressures.

Sourc

e: E

mers

on P

rocess

Managem

ent




–34–

New Design Apps for A New WorldFrom advanced touchscreen applications to new ways for finding lighter and

stronger materials, design applications are springing up to improve design

productivity.

By rob Spiegel, Senior Editor

New design applications

are popping up ev-

erywhere. Each one is

created to help the de-

sign engineer survive

and thrive in an environment of ever-

increasing speed-to-market. Multi-

touch screens with gesture control

are showing up on large displays, and

touchscreens on phones are becoming

more detailed in that they now respond

to finer touch. The image can be en-

larged for more detailed manipulation

on a mobile device. 2D sketching is

now more sophisticated and easier to

integrate into 3D CAD, and enhanced

PLM systems are helping with materi-

als selection and collaboration.

In some cases such as CAD, the new

applications have familiar but improved

technology; in other cases such as design

collaboration tools, the emerging tech-

nology is pushing the design process

into new directions to meet business

requirements.

Productivity in Design

Here’s a way to trade designs with

team members who are not all using

the same software: Altium Limited has

created 3D PDFs that allow anyone on

the project team to view the printed

circuit board (PCB) in full 3D with-

out the need for specialized software.

In another effort to improve design

productivity, Altium has added design

re-use capabilities, specifically for pads

and vias on PCBs. “Our customers tell

us exactly what you would expect a

customer to tell you: they’re concerned

about time and cost,” David Read,

director of product marketing at

Altium, told Design News. “They need

to complete their projects faster and for

less money.”

Another area where Altium is trying

to improve design productivity is in the

market push to Internet of Things (IoT)

connectivity. “There is a race to be the

first to connect a product. This is true for

every product imaginable,” said Read.

PTC Creo Layout was designed to be an easy-to-use 2D CAD application that lets you

create detailed concepts in 2D, complete with information such as dimensions and

annotations, then produce equally detailed 3D models from the same 2D data.

Sourc

e: P

TC



–35–

“Those who get their products to mar-

ket first are in a great position.” Read

notes that to win the race, the efficiency

of the entire design team is critical. “We

worked on a number of product designs

for IoT. Many of the productivity im-

provements we’ve made in Altium De-

signer 15 stem from that experience.”

Touchscreens Big and Small

Siemens PLM looked at advances in

touch screens as a way to improve the

design engineer’s productivity. It pro-

ceeded along two completely opposite

areas of touch. One approach is to add

f lexibility to the small screen, while

the other is to look at large-area touch,

particularly for presentations. “We

took a step back and looked at multi-

touch and gesture control to drive the

design applications,” Paul Brown,

senior market director at Siemens

PLM, told Design News. “We intro-

duced a new touch application to the

large screen — a touch device that

recognizes gesture.”

The large multi-touch screen allows

multiple users to manipulate an image

simultaneously. “We actually got ev-

eryone on the design team around the

screen, and people were poking on the

image,” said Brown. “The large screen

is not just for display. You can actually

move images over and get real usage in

the design process.”

The importance of touch in design

applications is continuing with mobile

devices, so Siemens has also improved

touch capabilities on these tools. “We

see an increased use in [design with]

touch with smartphones and tab-

lets,” said Brown. “It’s the way people

want to interact. In five-year’s time,

the mouse and keyboard will be gone.

So we’ve introduced improved touch

applications to the 10-inch device and

the 108-inch screen.”

Seamless Move

from 2D to 3D

The design of a product often begins

life as a 2D sketch. As the design de-

velops, it moves into 3D for advanced

work. “Design engineers find that

creating the mechanical design con-

cept is easier in 2D,” Paul Sagar, di-

rector of product management for

MCAD at PTC, told Design News. “If

they want to iterate on an existing de-

sign, it’s often in 2D.” Sagar noted that

PTC’s approach is to create role-based

apps. “We want to develop the right

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app for the right person at the right

time,” he said.

PTC sees a common pattern of

product concepts getting developed

in 2D and then moving to 3D for ad-

vances. “If you’re a company doing

conceptual parts and you want to work

in 2D, we have Creo in a 2D environ-

ment,” said Sagar. “It lets you lay out

your design in 2D.” In moving to the

next stage of design, PTC converts the

2D design concept to 3D. “In most

cases you have to re-do everything

by scratch to get it to 3D,” said Sagar.

“We enable you to take the 2D info

and leverage that to build the rich 3D

engineering data. You can continue to

iterate the design concept while also

seeing it developed in the full 3D rich

data form.”

Quick Search for Lighter,

Stronger Materials

Energy efficiency is critical in most

industries, from automotive, with its

need to prepare for increasingly strin-

gent gas mileage standards, to aero-

space, with its continual need for im-

proved fuel efficiency. A big part of

the drive for efficiency comes down

to finding lighter materials that match

the strength of steel.

Munro and Associates created the

Weight Reduction Material Selec-

tor (WeRMS) to address this need.

“WeRMS can help the design engi-

neer to very, very quickly come up

with lighter weight materials that fit

the parameters that you input based on

the structural properties you require,”

Alistair Munro, director of business de-

velopment, told Design News. “It reduc-

es the time needed for comparisons by

a huge order of magnitude. It essentially

takes an exercise that would take you

several hours — if not days — and re-

duces it to seconds.”

As well as positioning it as a produc-

tivity tool for the design process, Mun-

ro sees value in WeRMS in the board-

room. “If you’re in a design review

or brainstorming session with light-

weighting as the focus, and you quickly

input the parameters into your phone

and then suddenly blurt out ideas and

comparisons, everyone will swivel

around and stare at you like you’re

an alien. No one can spit out answers

that specific and realistic off the top of

their head,” said Munro. “It’s definitely

something you can use to impress your

boss and your peers.”


Design Collaboration

Advances

We’re not working in cubicles any lon-

ger; we’re working in “cable.” So says

Steve Chalgren, vice president of prod-

uct management and strategy at Arena

Solutions. Chalgren sees collabora-

tion tools as the necessary technology

to make a successful move to the digi-

tal design and manufacturing chain.

“We’ve created spaces designed for

specifically for design collaboration,”

Chalgren told Design News. “We creat-

ed Arena Scribe to collaborate, not just

in silos and departments, but straight

through the design stream.”

Part of the growing need for collab-

oration is that more people at different

levels are involved in the design process.

“You no longer throw it over the wall,”

said Chalgren. “People who weren’t in-

cluded before are now included early.”

Chalgren sees the solution in a collabo-

ration platform where someone from

corporate strategy or marketing can

see what’s going on. “The goal is to let

people follow the design like Twitter,”

he said. “They can come in from all over

the world at any time and look at the

history of the design. It breaks down the

silos and lets design teams come up with

ingenious ideas much faster.” DN

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The Weight Reduction Material Selector

(WeRMS) from Munro and Associates is

a tool that can help you make the design

lighter. If your part or assembly is too

heavy, WeRMS can generate a list of

materials that can reduce the weight in

the design.

Sourc

e: M

unro

& A

ssocia

tes




–38–

Actuators Undergo Inventive Transformations

Actuators may look

the same, and they

may do essentially

the same tasks they’ve

done for decades, but

below the surface, these tools are go-

ing through a metamorphosis. For one,

electric actuators are running ahead of

hydraulics and pneumatics in the effi-

ciency race. Hydraulic and pneumatic

actuators are working to keep up by at-

tacking efficiency with reduced leak-

age and friction. Servo technology is

offering greater control, and actuator

manufacturers are competing on over-

all support for their equipment and for

their customers’ wider needs of selec-

tion, maintenance, and repair.

New Materials for the

Old Body

New types of materials are being used

in actuator construction. The goals

are, as always, cost savings, reduced

weight, and increased performance.

Companies are producing improved

bearing materials for reduced fric-

tion and better operating perfor-

mance. “A lot of the new materials

include different types of polymers

for bushes, bearings, and cylinders,”

Mike Guelker, product manager of

actuators, air supply and accessories at

Festo, told Design News. “A lot of our

cylinders are customized with new

materials to meet a particular need.

It’s application-specif ic, or specif ic for

an industry.”

Actuators are getting a makeover with new materials, smoother performance,

and greater energy efficiency.

By rob Spiegel, Senior Editor, Automation & Motion Control

Pneumatic cylinders used in pick-and-place application for filling trays with food items.

Sourc

e: Ave

nti

cs



–39–

SUPPORT

www.exlar.com855-620-6200

LIFE

Compared to Ball Screw Actuators

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ACTUATORS PROVIDE:• 15X Longer Life

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Guelker notes that a lot of Festo’s

application-specific products are made

with new materials or variations of

materials to support high-temperature

environments or for actuators exposed

to chemicals or moisture. “You have

to use corrosion-resistant materials to

reduce or prevent contamination,” said

Guelker. “We also create custom actua-

tors for specific industries such as food

processing, where you have to make

sure the product meets current regu-

lations and is built to perform in that

environment.”

Cost savings can also drive changes

in materials. “Sometimes we introduce

new materials when we can cut costs

without sacrificing the life or perfor-

mance of the actuator,” said Guelker.

“New materials might also improve

performance or provide a lighter

weight.”

Electrification and

Integrated Sensors

Many actuator manufacturers are

switching to electric servo drives and

moving away from hydraulics or pneu-

matics. “You get better control with a

servo, and it’s easier to follow an exact

path, easier than with f luid power,”

Nathan Davis, product manager for

screws and system products at Bosch

Rexroth, told Design News. “With

electric actuators, you can just push a

button to change the profile. That’s a

big reason for electrification.”

Davis notes that electrification also

delivers energy savings. “Customers

want to reduce energy usage, and elec-

trical actuators are more efficient. You

get more control with less energy con-

sumption,” said Davis. Another advan-

tage is the cleanliness. “In the food and

packaging industries, they don’t want

dripping oil,” he said. “Electric ac-

tuators also offer noise reduction, since

pneumatics and hydraulics are noisy.”

Davis sees mechatronics in the future

of cylinders, pointing to integrated sen-

sors and electronics as part of the pack-

age. “Our customers want a way to pre-

dict when a cylinder may fail or when

it may need maintenance,” he said. “You

take a mechatronics approach so you

can see if the actuator slips outside of

a certain envelope. Sensors can detect a

problem or monitor the end-of-life of

an actuator.”

One recent trend that is impacting ac-

tuators is the automation of the manu-

facturing process. “You try to keep costs



–40–


down so you can offer an actuator at

reasonable price. So logically, you look

at the production process to improve

efficiency,” said Guelker from Festo. “In

the past five years, we’ve seen a transition

from manual production processes to

semi-automated production, and on to

fully automated processes where there is

no human hand touching the cylinder.

With automation, you improve the cost,

the quality, and the reliability.”

Performance Issues:

Leakage, Vibration, and

Cycle Speed

Advances in performance have also

changed the functionality of actuators.

Manufacturers are focused on leak-

age, vibration, and cycle speed. “We’re

able to control leakage much more ef-

fectively now,” Phil O’Neil, a product

manager at Aventics, told Design News.

“Conservation is important to air

channels in the cylinder. We can pack-

age one end. That might not sound like

much, but a lot of care goes into it.”

O’Neil points to cushioning technol-

ogy as a way to optimize the throughput

of a cylinder. “Cushioning adjustments

improve the cycle time of the actuator,

and we also get minimum-time to de-

celerate the piston and get optimal time

on the cylinder.” He notes that shav-

ing fractions of time off a cycle may not

seem like a big deal, but with thousands

of fractions over a week, the customer

can manufacture more and with less

vibration and create a more constant

working environment.”

The path to faster cycle time is paved

by less vibration and less leakage. In to-

day’s applications, if you don’t have ad-

equate cushioning, you may have to

enlarge the actuator. “It’s a matter of

right-sizing. If the cushion is right, you

can right-size the actuator,” said O’Neil.

Also, air consumption is an issue, since

each stroke has some air consumption.

“If you reduce the air consumption,

you make the overall machine more ef-

ficient,” he said. “You control the con-

sumption by reducing leakage.”

With more than a thousand different series, models,

sizes, and options there is a Novotechnik non-contact rotary

position sensor to match your application, and there’s one very good

reason to choose Novotechnik: A level of precision that’s unmatched in

the industry. Whether you’re looking for non-contacting, or even touchless,

single-turn, or multi-turn rotary position sensors, Novotechnik has the sensor you

need. They are all detailed in our 96-page rotary position sensor catalog. For your

free copy, contact Novotechnik.

Setting A Higher Standard:

• Operating lives to: unlimited movements

• Independent linearity to ± 0.3º

• Resolution to 0.09º

• Repeatability to <0.03% of signal range

• Maximum rotating speed to: unlimited rpm

• Sealed to protection class IP 69

• Absolute measurements to 360º

• Housing diameters from 13 mm

Novotechnik U.S., Inc.

155 Northboro Road

Southborough, MA 01772

Tel: 508-485-2244 • Fax: 508-485-2430

For complete information, visitwww.novotechnik.com/ncr

Electromechanical cylinders can be used in a variety of applications, including

volumetric filling/fluid dispensing, conveyor line diverters, injection molding,

print roll positioning, component assembly/pressing, and metal forming.

Sourc

e: B

osch R

exro

th



–41–

Tiny, Tiny Actuators

With newer manufacturing capabili-

ties expanding over the years, min-

iaturization has become easier, and

actuators can live in a smaller space.

Miniaturization allows for a higher

number of devices to occupy the same

footprint, thus making the product

highly cost effective. Microelectrome-

chanical system (MEMS) actuators and

sensors are being used as accelerom-

eters and gyroscopes in automobiles,

smartphones, and tablets.

“MEMS by definition is a multi-

physics technology, and the design of

these devices can be quite challenging,”

Yeswanth Rao, applications engineer at

COMSOL, told Design News. “We use

a finite-element multi-physics software

that is designed to handle such design

challenges. It provides the right easy-

to-use platform to enable scientists and

engineers to design MEMS devices

effectively.”

Support for customers who deploy

actuators is getting inventive. Aventics

is providing tools on its website so cus-

tomers can match actuator volume with

working pressure. “You don’t always need

all the pressure. You can return the cylin-

der at a lower pressure. On the return cy-

cle you’re going with gravity, so you don’t

need as much pressure,” said O’Neil. “We

have a tool to calculate the pressure, and

you can tweak the pressures in the simu-

lator to see if you can reduce pressure by

using more pressure on one side and less

pressure on the other side.”

Festo has also ramped up its actua-

tor support. “We help customers engi-

neer the best solution by getting heavily

involved in the plant design,” said

Guelker. “We’ve developed a lot of soft-

ware that helps us recommend the best

product or combination of products.”

The software simulates the application

to determine optimal speed.

Festo also provides self-service tools

on the website so users can search for

products or find information for repair.

“It’s a wiki-based support community,

and it’s not just supported by us,” said

Guelker. “Anyone in the industry can

ask or answer questions. It becomes a

knowledge-based community.” Festo

supports the community by continu-

ally adding information, including

repair manuals, lists of the tools needed

for repairs, and pictures with step-by-

step instructions. The site also provides

detailed operating instructions for indi-

vidual products. DN



–42–


New fastening and joining methods are making it possible to join multiple

materials and thinner sheets in consumer and medical portable electronics,

as well as automotive and aviation systems.

By Ann r. Thryft, Senior Technical Editor, Materials & Assembly

ONSERT combines a fast-curing industrial adhesive from DELO with fastening technology from Bollhoff to join two

pieces of plastics, fiber-reinforced composites, or thin sheet metals such as high-strength steel or aluminum. It was

developed as an alternative for assemblies made of dissimilar, multiple materials like these that can also include glass

and lacquered or polished surfaces, which can be harmed by traditional methods that require heat curing or welding.

Some of the major innovative fastening de-

signs and assembly methods have been

around for decades. Yet lighter, thinner ma-

terials that must withstand higher tempera-

tures are challenging suppliers to devise new

fastening systems that are smaller, stronger, and weigh less.

Shrinking mobile consumer electronics and, more recently,

even tinier wearables are also posing challenges for fastener

makers.

Although there are highly specialized fasteners, like those

Fasteners Get Tinier, Tougher, and Smarter

Sourc

e: D

ELO



–43–

made for aircraft assembly, most of them aren’t aimed at spe-

cific system types or industries, but more at the specific jobs

they have to do. One big exception to that generalization is

the shrinking sizes of consumer electronics — both the system

itself and how everything gets crammed together inside the

machine. Recently there’s been quite a lot of growth in wear-

able devices, including medical wearables, and thus growth in

demand for micro-fasteners used in them. This has required a

re-thinking of what micro-fasteners can and should do on the

part of suppliers like PennEngineering.

“We try to stay ahead of trends, so in the last few years we

started taking apart consumer electronics products, which

now are more likely to be wearables,” said Jay McKenna,

global business manager for the company’s microPEM prod-

uct line. “Sometimes we buy these products at a Best Buy, and

sometimes customers come to us with their own design and

ask if there’s a better way to hold it together.” The result of this

forward-thinking reverse engineering was the development

of the self-clinching microPEM product line, which now in-

cludes three major products: TackPin, TackSert, and now Tack-

Screw.

McKenna’s team noticed that the parts in these machines

are held together mostly with screws. “Generally, screws are

used for removability,” he said. “In compact consumer elec-

tronics, though, you might find a screw threaded into a plastic

part, but then the whole unit is sealed to make it waterproof.

So we found that removability didn’t really exist, and repair-

able fasteners weren’t going to be needed,” he said.

The company’s TackPin and TackSert fasteners can be used

to replace screws, reducing the Z height, as well as reducing

the fastener’s diameter to allow closer spacing of components

near it. The TackPin fasteners for permanently attaching sheets

as thin as 0.2 mm together were developed as an alternative

to micro-screws in metals for compact electronic assemblies.

One European phone company customer that needed to re-

duce product Z height found that by using microPEM fasten-

ers they could use a thinner material, so they moved from steel

to aluminum, which also gave them savings in weight, said

McKenna.

TackSert fasteners are designed for lighter-weight, non-

ductile materials. Besides plastics, these also include magne-

sium and aluminum laptop and tablet casings. Eliminating

threaded hardware in small, compact electronics will become

increasingly important as electronics get smaller, such as cred-

it card readers and SIM card ejectors, and the growing class

of wearables, especially disposables, said McKenna. That’s the

idea behind the TackSert pin. The pins in these fasteners per-

manently attach two panels, or a top panel and a chassis. The

top panels can be made of any material, and the base panels or

chassis are either plastics like ABS or common die-cast mag-

nesium. Installation can be done with a punch and anvil, or

automatically.



–44–


The new TackScrew fasteners integrate Penn’s TackPin

technology with a thread-like feature that lets the fastener

be removed, or even completely reinstalled one time. Dur-

ing product development, after removing them or reinstall-

ing them once from a prototype, they can be replaced with

the TackPin without further

design changes. This can also

be done with a finished prod-

uct such as a wearable. One of

Penn’s next projects is mak-

ing modifications to its Tack-

Pin fastener in order to come

up with new attachment

methods for smart fabrics, said

McKenna.

Some fasteners for light-

weight materials combine

adhesives with fastening tech-

niques. For example, industrial adhesive maker DELO has

partnered with fastening and joining system maker Bollhoff to

develop the ONSERT. Bollhoff is a maker of traditional fas-

teners for attaching typical steel and plastic components. The

company has also developed more advanced joining methods

for composites, high-strength steel, and aluminum.

The ONSERT device joins two pieces of plastics, com-

posites, or thin sheet metals. It was invented especially to cope

with the problems associated with joining composite materi-

als, such as carbon fiber-reinforced composites, which can be

a challenge using traditional

techniques like screws, welds,

or rivets. These materials are

becoming more common

in automotive, aviation, and

consumer applications, and

are increasingly being com-

bined in assemblies made of

dissimilar, multiple materi-

als that may also include thin

sheet metal, glass, and lac-

quered or polished surfaces.

Joining these materials using

traditional methods, especially those that require heat cur-

ing or welding, can stress them and result in a marred surface

appearance.

The ONSERT combines durable, removable screw con-

nections with a rapid, light-curing adhesive. It can be used to

DESIGNED WITH QUICK, EASY

INSTALLATION IN MIND

ARaymond Tinnerman’s two-piece plastic Push-

Rivets ofer a simple alternative to threaded

fasteners, providing quick and easy installation.

• No tools required

• Accommodate multiple materials and

panel ranges

• Used in numerous industries

• Many of these parts are serviceable

• Customized solutions available

1060 W. 130th Street, Brunswick, OH 44212 • www.araymond-industrial.com/north-america • 800.221.2344

“We try to stay ahead of trends, so in the last few years we started taking

apart consumer electronics products, which now are

more likely to be wearables.”



–45–

join cable holders, clips, sensor holders, brake lines, insulation

panels, and claddings. Based on stud welding techniques, the

device’s technology combines bonding and screws with fas-

tening, such as threaded bolts with a plastic base, and bonds

this to fiber-reinforced composites. Its threaded rod can be at-

tached and detached easily and repeatedly.

The device’s pull-off strength is up to 2,000 N when used

with bonded bolts on carbon fiber-reinforced plastic, with

a base diameter of 25 mm. If a greater force is applied, the

base’s predetermined breaking point ensures that the com-

posite stays intact and does not delaminate, and that none of

its fibers get torn out. The device’s adhesive cures within four

seconds using an LED lamp. During production and assem-

bly, this means that bonded bolts can be attached before the

final assembly of polished or lacquered elements. The ON-

SERT withstands testing such as standard automotive cli-

mate change testing, salt spray testing, and storage in aviation

ºhydraulic fluid.

Other fastener designs are aimed at various types of enclo-

sures for telecommunications, computer, power, and energy

applications, as well as industrial machinery, medical equip-

ment, and food packaging equipment. For example, a new

product line from DIRAK includes five versions of latches

that give multiple options for single-point or multiple-point

compression latching in these applications.

The 6-5XX Compression Latch Technology Platform is

aimed at large enclosures with multiple points that require

compression latches. It also targets indoor or outdoor uses

with sheet metal enclosures or panels that need high compres-

sion, concealed latching, low protrusion, noise or vibration

reduction and protection against possible vandalism. Two are

single-point latches, two are multi-point, and one can func-

tion as either. Some of the latches provide up to 20 mm of

compression for securing the door in high-vibration environ-

ments, while some have a locking cover with a magnetic cyl-

inder flap closure that prevents the ingress of water, dust, or

debris from entering the enclosure. All five are IP65 rated.

Some fastener manufacturers are making 2D and 3D draw-

ings of their products available online in multiple file formats.

For example, SPIROL now offers 2D and 3D drawings of

more than 100 different series of its standard and common

special products. Each of these drawings is available in either

metric or imperial dimensions and 40 different file formats,

and the standard part drawings also provide part weight and

the manufacturer’s item number. SPIROL’s products include

coiled spring and hinge pins, inserts, and brass nuts for joining

plastic components. DN

For More Information:

PennEngineering: www.pemnet.com

Bollhoff: www.bollhoff-usa.com/ae/us.php

DIRAK: www.dirak.com

SPIROL: www.spirol.com


Best of the Engineering Marketplace

Design Engineering Products


–46–

Automation & Control

New Sealed linear Actuators For lighter loadsBell-Everman is now offering a new compact model of their SLS sealed linear stage that keeps contamination such as manufacturing debris, particu-late or liquid contaminants outside of the stage housing.

The SLS Light model, which mea-sures 80 x 120-mm, has maximum dy-namic payloads of 15 kg for the direct drive linear motor version and 30 kg for the ball screw version.

Both sizes deliver a proprietary lin-ear lip seal design that integrates with the stage’s anodized aluminum hous-ing. The seal is made from a rugge-dized polyurethane elastomer and re-sists chemicals, temperature extremes and mechanical wear. The seal can be quickly replaced without disassem-bling the stage or removing payload.

Applications for the SLS Light sealed linear stage include any applica-tion where contaminants can threaten the smooth operation of a linear actua-tor including laser machining, weld-ing, semiconductor and machining.Bell-Everman inc.

www.bell-everman.com

AVX introduces New Series of High Temperature, low leakage Automotive VaristorsAVX Corporation, a leading manufac-turer of advanced passive components and interconnect solutions, has intro-

duced a new series of high tempera-ture, low leakage automotive varistors. Qualified to AEC-Q200, the new high temperature, low leakage CANATL Series automotive controlled area net-work varistors exhibit extremely low leakage (≤1µA at 32VDC, 25°C) and are tested, qualified, and specified at 150°C, making them ideal for use in high temperature underhood automo-tive applications, such as transmission control units (TCUs), brake control modules (BCMs), data lines, bus in-terface units, and other capacitance sensitive applications.

Based on AVX’s patented multilayer varistor (MLV) technology, which combines circuit protection and EMI/RFI attenuation functions in a single, high reliability device, CANATL Se-ries automotive varistors are zinc oxide based ceramic semiconductor devices that exhibit non-linear, bi-directional voltage current characteristics similar to back-to-back Zener diodes and an EMC capacitor in parallel. In addi-tion to the space savings provided by enabling EMI/RFI attenuation in the off-state, CANATL Series multilayer varistors provide several valuable per-formance advantages over diodes, in-cluding: high in-rush current capacity (8x20µS), a high 25kV (HBM Level 6) ESD rating, low capacitance (10pF) to minimize signal distortion, no derat-ing over operating temperatures, and very fast response times, which con-servatively clamp the energy before it reaches its maximum. CANATL Series varistors also exhibit multi-strike ca-pability, excellent solderability, and an impressive FIT rate of ≤0.1 per billion hours.AVX Corporation

www.avx.com

New Cable Bushing Maximizes Density, Minimizes installation HeadachesThe Lapp Group’s new SKINTOP CUBE MULTI cable bushing allows combinations of up to 23 electri-cal cables or pneumatic lines to pass directly through the enclosure wall, solving the common problem of try-ing to bring all the necessary power and signal connections into today’s increasingly complex electronics en-closures.

SKINTOP CUBE MULTI system places a rigid, glass-reinforced nylon frame into a standard-sized cutout in the enclosure wall. Inside this rectan-gular frame is a polycarbonate insert with gel-filled hole for the cables or lines to pass through, which is an in-dustry first. The gel allows the cables to be easily inserted through the holes while creating a lasting seal around the cables and provide strain relief.

Available in two versions, CUBE MULTI maximizes wire density for a given size cutout. For example, one version can pack 23 cables, ranging in size from 6 to 9 mm, into 36 x 112 mm cutout, which is the standard size for a 24-pin industrial connector.

The second version squeezes two fewer cables into the same cutout and it supports more varied combinations with room for nine 3 to 6 mm cables, nine 6 to 9 mm cables, two 9 to 13 mm cables and one 13 to 16 mm cable.lApp USA

www.lappusa.com

Murata’s Eighth-Brick DC-DC ModulesMurata Power Solutions’ UWE eighth-brick DC/DC power modules are the industry’s first eighth-brick to


deliver 12Vout at 120W from a nomi-nal 12V, 24V, or 28Vdc source. The UWE-12/10-Q12xx-C series’ 4:1 Vin range of 9-36V, industry standard DOSA compliant form factor, op-tional integrated baseplate, and high efficiency makes it ideal for high reli-ability systems and systems requiring

battery backup. The UWE-12/10-Q12xx-C will operate down to 9Vin, allowing longer battery discharge times in the event of a source failure. The 91+% efficiency rating of these modules also means that they will op-

erate in harsh environments and re-quire less cooling hardware compared to equivalent (larger) power modules. Significant overall system cost reduc-tions can be achieved when employing this eighth-brick solution compared to equivalent quarter- or half-brick solu-tions.

The UWE-12/10-Q12xx-C is an ideal choice for high reliability indus-trial, transportation, and telecom-munications equipment requiring 12Vdc from a source of 12V, 24V, or 28Vdc. Murata developed the UWE-12/10-Q12xx-C to address the need for a 12Vout DC-DC con-verter able to deliver 120W and pro-vide 2250Vdc input to output isola-tion from a 9-36V source. Designed to offer the power systems architect options that include an optional baseplate for conduction cooling ap-

plications, positive or negative logic control and features, 2250Vdc I/O isolation, output overvoltage protec-tion, thermal shutdown, current lim-it/short circuit protection, and Vout adjust (±10%).

The UWE-12/10-Q12-C isolated DC/DC power converter represents the next generation converters in the industry standard eighth-brick pack-age with up to 120W of available out-put power. These DC-DC converters are designed for systems employing distributed power architectures or in-termediate bus architectures in appli-cations that include but are not lim-ited to battery charging/back-up systems, telecommunications, lighting applications, motor control, and any-where that 12V @ 120W is required from a 9-36Vdc source including ap-plications where extreme operating

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Built for Harsh EnvironmentsOrion’s harsh environment AC fans, DC fans and accessories

protect against dust, moisture, salt fog, salt spray, temperature

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temperatures will be required The modules feature an operating tempera-ture range of -40 to 85°C.

Samples are available from stock. Lead-time is 16 to 20 weeks; pricing in OEM quantities is in the mid-$30 range.Murata power Solutions

www.murata.com

CiT relay & Switch illuminated pushbutton SwitchesThe Illuminated Pushbutton Fam-ily of switches offers sealed, thru-hole, right angle and surface mount termi-

nal options with a multitude of choices in cap styles. Our versatile pushbutton switches provide design engineers with several LED color choices. Bi-color

choices make endless the combina-tions and applications for these popu-lar switches.

Specifications and materials are de-pendent upon your choice of switch.

Lead-time averages 4 to 6 weeks. Volume pricing is dependent on op-tion choices. Contact CIT directly for a quote and sample to solve your illu-minated pushbutton needs. CiT relay & Switch

www.citrelay.com

Compact liquid Flow Meter for industrial ApplicationsSensirion AG, the Switzerland-based market and innovation leader for digi-tal microsensor technology, is expand-ing its range of liquid flow sensors for measuring low flow rates. The new SLS-1500 liquid flow meter delivers fast and precise measurements for flow rates of 0 to 40 ml/min. The compact liquid flow meter comes in a robust housing and offers a versatile sensor solution for applications in demand-ing industrial environments and labo-ratory settings. Sensirion’s modular approach of combining the sensor and interface cable ensures an optimum

match with rapid results and makes the integration of a flow sensor very easy.

With a typical response time of 20 ms, the SLS-1500 is able to quickly and reliably monitor highly dynamic dispensing processes. The flow chan-nel inside the sensor is completely

straight and open and has no moving parts. Inert wetted materials provide outstanding chemical resistance and excellent biocompatibility. The SLS-1500 is compatible with SCC1 in-terface cables, thereby offering USB, RS485 and analog voltage output con-nections. The compact, cost-effective and precise SLS-1500 liquid flow me-ter is the perfect choice for optimizing industrial applications.Sensirion AG

www.sensirion.com

When your inventive vision calls for pneumatic control of force, motion and displacement that delivers unparalleled accu-

racy and resolution, it’s Airpot first. Our problem- solving line up of instrument -quality products will keep your project moving. And our Accurate Force Pneumatics is the key. With a precision glass cylinder/seal-free piston technology, coupled with ultra-high quality pneumatics, you’ll find products that give you levels of force and motion control nearly unobtainable by any other pneumatic means. What’s more, many of our products can outlast any machine you put them in. And that’s something we can guarantee! So, when your specifications call for a damping, actuation,

pressure sensing, or displacement device that is optimized for exceedingly accurate and repeatable force control — and at a cost lower than other methods providing comparable function and performance—give one of our application engineers a call. Let’s get started. Whether you’re designing or improving a product line to better serve your customers, or building specialized equipment for research, high-level testing, or precision assembly, get AirpotCorp involved early in your process. Call one of our helpful application engineers at 800-848-7681 or visit us at airpot.com. We will move you in ways you might never have imagined.

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Corp



–49–

Electronics & Test

New 17 to 27 GHz Ultra low Noise MMiC AmplifierCustom MMIC, a developer of per-formance-driven monolithic micro-wave integrated circuits (MMICs), is pleased to announce the release of the CMD163, a 17 to 27 GHz low noise amplifier (LNA) in die form, to their growing line of standard GaAs ampli-fier products.

The CMD163 has a gain of +24 dB, a noise figure of less than 1.3 dB, and an output 1 dB compression

point of +19 dBm across the 17 to 27 GHz bandwidth. Additionally, the CMD163 utilizes an all-positive bias scheme, thereby eliminating the need

for negative voltages and expensive se-quencing circuitry. Bias conditions are Vdd = 4 V @ 120 mA and Vgg = 3.0 V.

The CMD163 is ideally suited for military and space applications, as well as point-to-point and point-to-multipoint communication systems where small die size and high linearity are needed. The LNA is an internally matched 50 ohm design that does not require any external components, aside from bypass capacitors. Addi-tionally, the LNA is available in pack-aged form as the CMD163C4 with similar performance.Custom MMiC

custommmic.com

Siemens Expands its Sinamics V20 Drive Family for Basic ApplicationsSiemens has announced the release of its new single-axis Sinamics V20 AC drive, frame size E, with both Low Overload (LO) and High Overload (HO) ratings. The V20 family features easy setup and operation with excel-lent cost and energy efficiency. With a power rating ranging from 1/6–40hp at 480V AC, Sinamics V20 drives are available in five frame sizes and are

ideal for material handling, conveyor, pump, fan and compressor applica-tions.

This compact drive can be con-nected and installed the conventional wall-mounting method or, option-ally, mounted with heat sinks pushed through the enclosure wall. Since no additional modules or add-on options are required for operation, installation time is minimized.

The integrated Basic Operator Panel (BOP) enables trouble-free commis-sioning and operation on-site. Be-sides the universal serial interfaces that allow for easy connection to Si-

®Airpot is a registered trademark of Airpot Corp, 35 Lois Street, Norwalk CT 06851 USA airpot.com

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With no hydraulic fluid to leak out and no seals to wear out, the super responsive Airpot dashpot can soak up unwanted motion indefinitely.

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–50–


matic programmable logic controllers (PLCs), a Modbus interface is also in-cluded for communication with third-party controls. Pre-built connection and application macros are used for fa-cilitating application-specific settings. For units with power ratings higher than 10hp, a braking resistor can be connected directly to the integrated braking chopper.

Operating the Sinamics V20 drive is just as easy as commissioning. Param-eters that have been optimized for one application can easily be transferred to other drive units using SD cards via the Basic Operator Panel or the bat-tery-operated Parameter Loader. The built-in display has the ability to list only those parameters changed from the factory default values rather than having to scroll through all of them.Siemens industry inc.

www.usa.siemens.com

New long range Wireless Access points for Ethernet and Serial CommunicationsWeidmuller introduces two new li-censed frequency data modems that offer powerful long-range communi-cations (up to 40 miles) to extend Eth-ernet networks into difficult-to-access locations. Unique design features built into the new wireless Ethernet mo-dems provide dynamic network op-timization and intelligent routing for high reliability, lower latency and de-terministic power management. They support 360 to 512 MHz and 928 to 960 MHz configurations; can oper-ate in Access Point/Client configura-tion; function as a network Bridge/Router; or serve as a Serial Server (RS232/485).

The new modems feature node-to-node deterministic mesh network repeatability for extended range, and multiple channel spacing options to increase network scalability. These licensed modems are optimized for throughputs of up to 25.2kbps, pro-viding secure wireless communica-

tions in challenging outdoor envi-ronments and over obstructed paths – typical of remote monitoring and control applications. The integrated Modbus server capability offers seam-less integration with smart sensors, RTUs or I/O expansion through the use of expansion modules.

Ideal for industrial networking ap-plications, these new modems inte-grate with Weidmuller wireless and wired networks to connect remote sen-sors, actuators and instrumentation to mission critical monitoring and con-trol systems for industries that include oil and gas, water and wastewater, mining and power generation.

The modems operate in an extended temperature range of -30°C to 60°C (-20°F to 140°F), provide secure in-dustry standard encryption of 128bit AES, 802.11i with CCMP, WEP, WPA2, and include ATEX/IECEx hazardous area approval. DIN-rail or wall-mount options are available for easy installation.Weidmüller

www.weidmuller.com

Miniature M12 Connector rated to 16 APhoenix Contact has expanded its M12 connector range for power trans-mission in industrial environments with S-coded flush-type connectors and cordsets rated to 16 A and 630

V. (Ratings are per IEC; UL 2237 is pending.) Standard S-coded connec-tors, rated to 12 A, are also available.

They have two positions and protec-tive earth ground (2+PE). The panel-

Complete Mechatronics Motion Solutions

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Toothed belt axis ELGA-RF

Integrated servo motor MTR-ECI

Mini H-Gantry EXCM



–51–

mount connectors are pre-assembled with 0.5 meter long wires with con-ductor cross section of 1.5 mm² (16 AWG). This M12 circular connec-tor system is suitable for use as a main power connector, with IP67 protec-tion and the robust metal M16 X 1.5 panel-mount thread.

The compact panel-mount con-nectors are available in pin and socket versions for front and rear mounting. The unshielded cable cordsets are available in lengths of 1, 2, 5 and 10 meters, with both straight and right angle heads. Both male and female pigtail versions are offered as standard articles. Double-ended cordsets can be manufactured on request through the Phoenix Contact solution center.phoenix Contact

www.phoenixcontact.com

Farsens Unveils the SpiDEr Evaluation Board for the ANDY100 rFiD iCFarsens unveils the SPIDER, an evalu-ation board for the ANDY100 RFID IC for battery-free wireless sensors and actuators.

The Spider evaluation board is thought to test the ANDY100 en-ergy harvesting chip with RFID EPC C1G2 wireless communication and SPI master

The Spider from Farsens S.L., San Sebastián, Spain is an evaluation board for the ANDY100 UHF RFID IC. The chip harvests radio frequency en-ergy from commercial UHF RFID readers and communicates with them using EPC C1G2 standard com-mands. On top of this, it includes an SPI master to drive sensors while keep-ing the tag plus sensor device battery-free.

The Spider includes the ANDY100 chip and a start-up circuit to allow de-velopers to work directly with SPI sen-sors or connect a microcontroller of their choice for further processing.

Spider is thought for testing of the ANDY100 IC but can also be used to test multiple sensor, actuator or other devices. By balancing power consump-tion against read range, developers can easily test/prototype different ideas and create proof of concepts that can later on be implemented into final products.Farsens

www.farsens.com

intersil Unveils Synchronous Buck regulator with Output Tracking and Sequencing for FpGAs and MicroprocessorsIntersil Corporation, a leading pro-vider of innovative power manage-ment and precision analog solutions, has announced the ISL8002B syn-chronous buck (step-down) switching regulator that delivers up to 2A of con-tinuous output current from a 2.7V to 5.5V input supply. The device’s 2MHz switching frequency provides superior transient response, and its key features -- programmable soft-start, and out-put tracking and sequencing of FPGAs and microprocessors -- increase system reliability for point-of load conver-sions in networking, factory automa-tion, instrumentation, and medical equipment.

The ISL8002B enables greater sys-tem reliability through several innova-tive features. For example, the regula-tor’s output tracking and sequencing of FPGAs and MPUs ensures sensitive multi-rails properly start up and shut down. In addition, its output rails are configurable for coincidental, ratio-metric, or sequential settings, ensur-ing the FPGA or MPU’s internal ESD diodes are not biased or overstressed during rising or falling outputs. The ISL8002B’s undervoltage lockout and several other protection/stabil-

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ity features (overvoltage, overcurrent, undercurrent, negative current, over temperature and short-circuit) safe-guard the system from damage when an unwanted electrical fault event oc-curs. And its unique negative current protection prevents switch failure.

The ISL8002B’s superior transient response and high level of integration enable a complete synchronous step-down DC/DC converter solution in less than a 0.10 inch2 footprint. By integrating low RDS(ON) high-side PMOS and low-side NMOS MOS-FETs, the buck regulator eliminates the need for a bootstrap capacitor and diode, and its high efficiency allows the use of small inductors to further re-duce board space.Intersil Corporation

www.intersil.com

Materials & AssemblyStratasys Introduces Versatile 3D Printer for Digital Dentistry Stratasys Ltd. a leading global provider of 3D printing and additive manufac-

turing solutions, introduced the Objet Eden260VS Dental Advantage 3D Printer. The new system delivers ex-panded solutions for digital dentistry.

Engineered to meet the demanding production needs of mid-size dental labs and mid-to-large-sized orthodon-

tic labs, the Objet Eden260VS Dental Advantage supersedes Stratasys’ popu-lar Objet Eden260V Dental Advan-tage platform with new capabilities.

Offering productivity enhance-ments and greater cost-effectiveness for users, the new 3D printer is com-patible with all Stratasys dental mate-rials – VeroDent, VeroDentPlus and VeroGlaze – and it adds a soluble sup-port option, previously unavailable on PolyJet dental systems. Soluble sup-port technology allows the easy clean-ing of dental parts with fine features, such as small removable die inserts in dental models. Additional benefits include automated support removal, which offers further advantages for dental labs by enabling lower labor cost per part.

For complete flexibility, users have the ability to switch between soluble and water jet modes to balance low-cost automation with the occasional need for hands-on support removal.Stratasys Ltd

www.stratasys.com

Struktol Company of America Expands Additive Line for Recycled PlasticsStruktol Company of America, a lead-ing global supplier of polymer addi-tives, has developed unique process additives for reclaimed/recycled plas-tics and for polymer compounds that contain recycled content. The com-pany will highlight the product expan-sion at NPE2015: The International Plastics Showcase (Booth #S27082) March 23-27 in Orlando, Fla.

These products are useful in a va-riety of different resin systems from polyolefins to engineered plastics, of-fering greater processing efficiency and enhanced performance. They are targeted for compounds containing 100% recycled material or materials with varying levels of post-consumer or post-industrial recycled content.

For engineering plastics, Struktol offers two new products that combine

ES591207_DN1504_052.pgs 03.26.2015 22:27 UBM


–53–

a compatibilizer with lubricants to cre-ate a combination product that aids in the incorporation of fillers (mineral or glass) with improved mixing and flow properties as well as mold release. These products result in better pro-cessing, improved surface quality, and in some cases, better physical proper-ties.

Among the new products, STRUK-TOL® TR 229 is for use in both poly-carbonate (PC) and PC/acrylonitrile-butadiene-styrene (ABS) blends as well as nylon 6 and 6,6 compounds. It can be used in FDA-approved ap-plications and is also ideal for use in recycled applications. Struktol also introduced STRUKTOL® TR 219 for use in nylon 6 and 6,6 compounds. It has also been found to be effective in polyester (PET and PBT) compounds, especially recycled or recyclate-con-taining applications or in cases where

the polyester compound is contami-nated with other plastics.Struktol

www.struktol.com

SSAB’s new Hardox Tube 500 range enables extreme wear resistance for lighter products with a long service life“The new Hardox Tube 500 range completes the existing Hardox fam-ily product range. We have a long ex-perience of developing wear-resistant steel tubes. The final properties are set

after tube rolling and welding, which guarantees consistency as well as high hardness and toughness qualities, just like all Hardox products,” says Fredrik Mikaelsson, Manager for Tubes & Sec-tions at SSAB.

Hardox Tube 500 is suitable for transporting all types of abrasive mate-rials such as wet concrete, soil, gravel and ore slurry. Its extreme wear resis-tance allows for a lighter product with a long service life. Using Hardox Tube 500 can increase the competitiveness of certain products by extending their service life by two, five, ten times or more.

Hardox Tube 500 is available from stock in 88.9-133 mm diameters and different material thicknesses. Custom tubes in thinner materials and other diameters are also available.SSAB

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Morgan Thermal Ceramics offers Cerox® fred refractory shapes and engineering expertise for producing clean and contaminant-free metalsMorgan Thermal Ceramics announces the availability of Cerox® fired refrac-tory shapes, offered in a range of ma-terial compositions, including many specifically used for the manufacture of rotating and non-rotating airplane components and automotive turbo-chargers. Dense, hard, and chemically stable, Cerox fired refractory shapes offer resistance to chemical attack from acids, slags, and gasesto produce the cleaner, contaminant-free metal desired by end users in aerospace and automotive steel foundries. They are manufactured at facilities in Cañon City, CO, and Augusta, GA, where product managers and engineers are

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Fired shapes manufactured from Sil-limanite Cerox 200 are composed of 74 percent alumina and fired mullite, which are prized for their chemical at-tack resistance, good thermal shock,

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support customers in the development of crucibles, tundishes, and launder systems. They will provide expert ad-vice on material composition, pre-heat schedules, custom shapes and part in-stallation, throughout the design and development process.Morgan Thermal Ceramics

www.morganthermalceramics.com

Excelitas Technologies® Corp. Unveils New OmniCure® AC2 Series UV lED Curing SolutionsExcelitas Technologies Corp, a global technology leader focused on delivering innovative, customized photonic solutions, has announced the launch of its new OmniCure® AC2 Series UV LED Curing Systems. This compact addition to the AC Series of UV LED Curing solutions supplies outstanding irradiance from an LED system small enough to be included in applications

where space constraints restrict access to the substrate and quality cannot be compromised. This small form factor, air-cooled product provides excellent curing uniformity and allows for the adjoining of multiple systems

to address any length application or working distance. These systems are ideal for applications such as pinning, edge bonding, cable assembly and other small component assembly.

The OmniCure AC275 and Om-niCure AC2110 are high-end, com-pact UV LED systems for customers who are either looking to increase throughput by automating their manufacturing process, or switch-ing to UV LEDs for their particular applications. Available in 75mm and 110mm lengths, the AC2 Series fea-tures custom optics that reduce the output angle of light while providing higher irradiance and greater flex-ibility at various working distances, making the AC2 Series a superior choice versus competitive options. Also, the air-cooled product design allows for seamless integration into new or existing production lines, in-creasing throughput with minimal process interruption and ultimately decreasing costs.Excelitas Technologies Corp.

www.excelitas.com

A.Raymond Tinnerman Industrial, Inc. 44

Airpot Corp. 48, 49

Allied Electronics C3

AutomationDirect 2, iNSErT

Boker’s Inc. 10

Carr Lane Mfg. Co. 6

CIT Relay & Switch 52

Delta Tau 30

Digi-Key Corp. C1, C2

Dymax Corporation 3

EBM Papst 18, 19

Exlar Corp. 39

Fairlane Products 53

Festo 50

Advertisersin this

issue

Advertiser page Advertiser page Advertiser page

Front Panel Express 10

ICOMold 35

igus inc. 4

Job Shop Shows Inc. BEllYBAND

Kepner Prod’s Co. 53

Keystone Electronics 15

Master Bond Inc. 51

Metal Powder Industries Federation 27, 29

Motion Industries 11

National Instruments C4

Neugart 36

Novotechnik U.S. Inc 40

Orion Fans 47

Penn Engineering 37

Proto Labs 8, 16

Pyramid Inc. 54

Quadrant EPP USA INC. 17

Raco International 54

Ringfeder Corporation 28

Rotor Clip Company Inc. 43, 45

Schneider Electric Motion USA 1

Smalley Steel Ring Co. 41

Solenoid Solutions, Inc. 20

Tadiran 31

TDK-Lambda 7

Tolomatic 13

publisher does not assume any liability for

errors or omissions in this index.



–56–

GADGET FREAK The Gadget Freak® Files Case #262

Boat Lift Controller With RemoteAT DICK BIPES’ LAKE HOME, he has a Shore Station boat

lift to lift his boat out of the water when it is not in use. The lift has

a manual crank and wheel, which can be quite tedious to operate.

He added a Lift Mate Universal motor from Shoreline Industries to

crank the wheel for him. This type of lift and lift motor is very com-

mon in the lakes area. The motor works well, but it uses a momen-

tary switch, so you have to stand and hold the switch for the two

to three minutes that it takes to raise and lower the lift. He wanted

automatic operation and remote control. Lift remotes are commer-

cially available, but none that he could find had the specs that he

wanted at a reasonable price.

Here are the features he wanted:

• Long range on the remote — at least 1000 feet, so he can

operate it from the deck of the lake home;

• Automatic operation — stopping by itself when the lift

reaches the fully up or down positions;

• Automatic adjustment for varying lake water levels;

• An auxiliary output for turning on lighting under the lift

canopy. DN

See the full project at http://ubm.io/1LPG2m6.

Are you a Gadget Freak? Design News and Allied Electronics would like to send you a check for

$500 to spend on Allied’s website at www.alliedelec.com/gadgetfreak or anywhere you please. And don’t

forget to supply us with a video file of your gadget in action. Email Design News your proposed project

(must incorporate electronic components and involve sensing, motion, timing and/or networking ele-

ments) to [email protected], along with a description of how it works, a parts list, schematic,

photos, and video. If your project is selected, you’ll receive a $500 check from Design News and will be

featured in an upcoming issue of the magazine or at designnews.com with your invention.

For parts information,

call (800) 433-5700 or go to

www.alliedelec.com/gadgetfreak

Sponsored by »

DesignNews.comCheck out this gadget in action at

http://www.designnews.com/gadget-freak.asp.

Sign up for the Gadget Freak RSS feed and

get the posts delivered directly to your desktop

at http://www.designnews.com/rss_simple.asp.

More of What You Need: Find schematics,

build instructions, and a full parts list at

http://www.designnews.com/gadget-freak.asp.

To get Gadget Freak delivered directly to

your inbox, go to http://www.designnews.com/

register.asp.

Dick Bipes couldn’t fi nd a boat lift

remote with the specs he wanted, so he

created his own for automatic operation.

A D V E R T I S E M E N T

HOMEMADE BOAT LIFT

Amt Part Description Allied Part #

1Momentary toggle switch, SPDT

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2Relay, 120 V, 15A,12V coil, 4PDT

70184913

1Relay, 120 V, 15 A, 12V coil, SPDT

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1 Power supply, 12V 1A 70069560


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

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AUTOMATION & MOTION CONTROL / A SUPPLEMENT TO DESIGN NEWS

April 2015

w w w . d e s i g n n e w s . c o m

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CONTENTS

AuTOmATiON & mOTiON CONTrOl: Oil & GASA S u p p l e m e n t to D e S i g n n e w S

A p r i l 2 0 15

S4 The Smart Oil Field Active data management within the smart oil field is resulting in a push for more open standards, vendor cooperation, and wireless networking solutions. By Al Presher, Contributing Writer

S10 Safety in a Non-Exploding Circuit Allen-Bradley Bulletin 937 intrinsic safety modules were designed to provide a signal interface bridge between hazardous locations and the control system. By Rob Spiegel, Senior Editor, Automation & Motion Control

S12 Wireless Connectivity Offers Distinct Advantages for Industrial Applications While many larger companies are still reluctant to rely on wireless networks to transmit important information in industrial settings, there is an increasing acceptance rate of the newer, more robust wireless options that are now available. By Corey Foster, Valin Corp.

S16 Today’s AC Servo Systems Are Smarter and Faster Technology advances boost positioning accuracy and stability at high speeds, while simplifying setup. By William Nieves, Panasonic

S18 In the Marketplace A look at the best new engineering products.

ES591582_DNS1504_S2.pgs 03.26.2015 23:57 UBM blackyellowmagentacyan

S4 AutomAtion & motion Control: oil & GAs / A DesiGn news supplement April 2015 [ www.designnews.com ]

Automation & Motion Control: Oil & Gas

The Smart Oil Field

Gas networks are continuing to grow in both size and complexity. Cross-continen-tal pipelines are increasing

the global transfer of energy, as well as the complexity of metering, monitoring, and control systems commonplace in the smart oil feld. In parallel with the developed world’s reinvestment in smart oil, growth in modular oil felds has shown no sign of slowing down.

Tese satellite oil and gas networks compliment large-scale upstream and midstream systems by supporting remote extraction operations. By their

very nature, these oil sites were once considered too remote and small to justify intense capital investment. Com-prehensive, robust wireless, and remote

networking product oferings, however, are leading the migration of remote oil and gas networks into greater realms of efciency.

Active data management within the smart oil feld is resulting in a push for more open standards, vendor cooperation, and wireless networking solutions.

By Al PreSher, ContriButing Writer

Smaller, modular wireless systems provide localized networks with optimized latent capacity for more effcient control of remote upstream and midstream applications.

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the future of oil And energy Control iS driving the develoPment of vertiCAl

netWork integrAtion teChnologieS thAt iS Bringing oil And gAS, eleCtriCAl grid SyStemS, And AlternAtive energy

netWorkS together.


[ www.designnews.com ] April 2015 AutomAtion & motion Control: oil & GAs / A DesiGn news supplement S5

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oPen StAndArdS And

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Tree main technology trends are the drivers of the smart oil feld. Te frst is that, especially with the emergence of the Industrial Internet of Tings (IIoT) and Industry 4.0, open standards are becoming the norm, which requires a new level of technological cooperation between process control vendors.

“We are moving toward more open standards, and the basic rules that ap-ply to phones, tablets, and computers, in terms of proprietary versus open systems, are moving down to feld-level devices and implementations in the smart oil feld,” Tomas Nuth, global vertical manager for oil and gas for Moxa Inc., told Design News. “Te Industrial Internet of Tings will require active management of data and new software platforms. On one level, automation vendors are conceding that development is moving that way and their ability to ofer value is through ro-bust DCS (Distributed Control System) oferings.”

Nuth says the value is no longer in the devices themselves, or in the bandwidth of each device, but rather in the opera-tional software that vendors are able to deploy. “Tese can be powerful solutions if a system is controlling lots of network nodes and getting real-time data from each node, all the way down to the sen-sor level including heat, pressure, and fow,” he said.

the SmArt oil field

Te future of oil and energy control is driving the development of vertical network integration technologies that is bringing oil and gas, electrical grid systems, and alternative energy networks together. In oil and gas, “anchoring” implies that greenfeld projects will be physically anchored to existing mid-stream and downstream infrastructure such as a pipeline system and processing facility. Tis allows small-to-midsized upstream sites to more rapidly go opera-tional and supply demand centers with less infrastructure investment.

Tis non-conventional approach is quickly becoming more and more com-mon as oil prices fall, extraction points grow scarce and less concentrated, and Ethernet and wireless systems grow

more capable of connecting the serial world to the IIoT.

Automation vendors, on the other hand, have had proprietary automation protocols and marketed them inde-pendently from one another. But the problem is that these feldbus solutions

basically insulate themselves, and don’t deploy open-standard architecture that can create cross-pollination with other systems. Smart oil feld applications are diferent from enterprise applications, not just because they are mission-critical but also because they must often be



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hot-swappable from one manufacturer to another.

WireleSS teChnology

SolutionS

“A second important trend in the smart oil feld is integration of operations us-

ing wireless technologies,” Nuth added. “Depending on the type of and location of the application, plus factors such as the availability of solar networks, cel-lular, and WiFi, we have been able to coordinate stream and midstream opera-tions together very inexpensively. Tis

trend is accelerating this year simply because OPEC is not cutting produc-tion; the US will not stop ramping up production, and we’re seeing lower oil prices.”

Nuth says that instead of looking for ways to make operations more complex

and sophisticated, acceptance of wire-less will provide additional incentives. A series of fve to 10 wellheads, for example, can be easily tethered together when in the past a robust automated network would have been very expensive and largely impractical to connect using feldbus technology.

“Copper and fber networks are expensive to deploy, so we expect to see wireless coordination between oil felds and pipelines, and also the coordina-tion of power networks with oil and gas networks,” he said. “We expect wireless to be broadly used to coordinate energy applications. Analytics tools and man-agement of data are keys to the success of new applications, along with secu-rity and new capabilities for managing energy resources.”

PumP JACk

monitoring one example of this technology is a leading midstream oil and gas holdings company that has thousands of wells and pump stations placed atop oil well pads throughout the central part of the us. these assets are located in remote locations and are exposed to fluctuating temperatures, extreme pressure conditions, and vibration. every wellhead on every oil well pad must be operational 24 hours a day, seven days a week.

the customer needed a robust wireless solution that could be easily integrated with an existing serial network. the solution provider needed to subscribe to open standards and be able to support assured communication from each and every wellhead to a central control room via a wiFi network and wimAX access.

the AwK-1127 Din-rail wiFi module from moxa allowed the client to deploy an extensive wireless network that provided a serial connection at each wellhead in their field operation. wellheads are managed via a central wiFi access point located at every oil well pad, relaying data back to a central control center several miles away. the module provided an ability to draw the final connection between the sensor network and local access points required to run wellhead operations.


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Wireless technology makes it possible for a series of fve to 10 wellheads to be easily tethered together. in the past, using this approach would have been very expensive and impractical using feldbus technology.


[ www.designnews.com ]


The third key technology trend for the smart oil field is the emergence of better security solutions. Nuth says there are a lot of new firewall and coding solutions and, if we move into proprietary technologies, we can focus on developing a common

platform for implementing security functions.

“When you are developing a solu-tion to penetrate a network, it’s always proprietary,” he said. “From a coding and functionality standpoint, the beneft of a proprietary network is that it can

be used to develop robust, unique, and creative ways to insulate a network from any intrusion or worms. Having an open platform provides an outstanding tool for developers creating applications and security solutions.”

Te problem is that there has been resistance to technological change because many people in industry don’t understand it, and they haven’t wanted to accept it for good reasons. “We know that we need to move forward, and that the Internet of Tings is com-ing,” Nuth added. “It’s already happen-ing [in] other avenues, and we don’t want to be totally left behind. Tere is a need for this technology in oil and gas, and there are a lot of resources behind its development, so it is fnally breaking through.”

A fnal important element is security functions. DCS vendors are power-ful industry leaders, but they don’t necessarily understand wireless security. While they know it’s a concern that needs to be addressed, security technol-ogy is a new area where they are relying on suppliers for help.

“Tere is a need for the indus-trial networking suppliers to provide technology leadership that stands up to the new rigors of the digital age and security. But that’ll only happen if these suppliers have free reign to deploy their products using open standards,” Nuth said. ”Vendors can’t develop a security platform, whether it will be a frewall or rely on intelligent rules, for a proprietary technology that they are selling into a solution that a specifc vendor produces. Te security solu-tion will need to utilize open standard technology.”

“Te goal is to take technology solu-tions developed for the broader market and morph them to provide solutions for the automation industry rather than the other way around,” Nuth contin-ued. “Tis is no longer just a future development, and we have deployed products in remote oil wellheads using wireless technology and open standards. We’re using open WiFi and cellular communications to submit a stream of data into a gateway, for example, that is similar to the way Netfix comes into your personal computer and back to the controller.”


I N D U S T R I A L L I N E A R M O T O R S

l i n m o t u s a . c o m 2 6 2 - 7 4 3 - 2 5 5 5

and are more efficientand are more precise

and make less noiseand last longer...

some things just work better

the future of oil and energy control relies on development of vertical network integration technologies that bring oil and gas, electrical grid systems, and alternative energy networks together, resulting in more intelligent multi-site control rooms.

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Safety in a Non-Exploding Circuit

rockwell Automation has developed safety modules specifcally designed to operate in hazardous environments.

Te Allen-Bradley Bulletin 937 intrinsic safety modules were designed to provide a signal interface bridge between hazard-ous locations and the control system by connecting intrinsically safe-rated equip-ment — such as transmitters, solenoids, and proximity sensors — with controls.

Te modules were developed to help avoid dangerous short circuits in hazard-ous environments. An example of a problem that can occur is a short circuit that can start a fre in the coal mine gas-ses. In one instance, a miner triggered a short circuit (and explosion) when he touched a shovel to a bucket that was connected to a circuit that alerted those at the top of the mine that a bucket was full and needed to be pulled out. Inves-tigators determined the explosion was due to the excess energy in the circuit.

Rockwell’s goal for the modules is to put the safety where the problem originates. If the circuit is designed to operate below the ignition point, it solves the problem of explosion due to circuit ignition. “It’s very common to see diferent safety techniques; one is explosion-proof containers. Yet equip-ment circuits are where safety really shines," Mason Khan, global product manager for signal interface at Rockwell Automation, told Design News. “Te electrical energy is kept at the minimum ignition for each hazardous area. If you know the level that will ignite, and if

you keep the circuits low enough, you know you’re going to be safe.”

Integrated diagnostics in the safety modules help simplify maintenance. Us-ers can switch out modules during on-going operations, and the modules can be installed in systems rated up to SIL 3 for reliable planning and documenta-tion. Users can confgure the modules using DIP switches or Field Device Tool software, and mount them horizontally or vertically with no reduction in opera-tion ratings.

Te modules were designed so plant managers don’t have to turn of the cir-cuit to work on it. “Tat’s an advantage. Tey don’t have to shut down to work on the live circuit and make sure it’s in-

herently safe,” Khan told us. “Te time it takes to repair a circuit is important. In the past it took a while — you had to shut down the circuits to open them.”

Also, if the problem is solved at the level of ignition, standard cable is suf-cient. “You have the containment in the control circuit, so you don’t have to use specialized cable. Tat’s a cost beneft,” he said.

Te Allen-Bradley Bulletin 937 prod-uct family includes zener barriers, gal-vanic isolators, and galvanic converters. Te intrinsic safety modules are available in a range of options that provide a wide range of functionality in hazardous loca-tion applications in industries such as oil and gas, chemical, and petrochemical.

The Allen-Bradley Bulletin 937 intrinsic safety module.

Allen-Bradley Bulletin 937 intrinsic safety modules were designed to provide a signal interface bridge between hazardous locations and the control system.

By RoB Spiegel, SenioR ediToR

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Wireless Connectivity Offers Distinct Advantages for Industrial Applications

Agrowing trend in indus-trial plant design is wire-less connectivity. Recent technological advances have

made wireless protocols signifcantly more robust and reliable than previous versions, enough so to rival traditional hard-wired connections. Te result is an increasingly wide variety of products and solutions for wireless data transfer for upstream communications in indus-trial applications. Plant managers have rejected wireless connectivity in the past for its lack of reliability and security, but newer protocols and infrastructure systems have been developed to ofer greater benefts without the drawbacks of outdated wireless systems.

Modern industrial wireless networks ofer numerous options for the infra-structure of a plant or operation that would otherwise be limited in connec-tivity by hard-wired connections. By eliminating the necessity for each access point to be joined by a physical con-nection, industrial operations gain the access to vastly increased connectivity and more fexible, versatile confgura-tion possibilities.

While many larger companies are still reluctant to rely on wireless networks to transmit important information in industrial settings, there is an increasing acceptance rate of the newer, more robust wireless options that are now available.

By Corey FoSter, Valin Corp.

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Te most common wireless network-ing standards for industrial applications have been 802.11a, b and g. However, there is a newer and better standard, 802.11n, which utilizes multiple anten-nas to increase data rates (a system referred to as MIMO, or multiple-in multiple-out). Tis standard, when paired with the correct equipment, of-fers more transmission paths resulting in data transfer rates in the hundreds of Mb/second. In turn, the increased receiving paths produce greater reliabil-ity in received quality and minimize the impact of RF interference.

While this newer wireless technology is now readily available to industry profes-sionals, even if they are aware of it, many are probably reluctant to adopt it due to their previous experiences or preconceived notions having to do with the security and reliability of these types of networks. As a relatively new technology, wireless connectivity has undergone a growth process including several iterations that were less than satisfactory for industrial applications. As a result, many industry professionals erroneously associate their past experiences involving residential or commercial-grade wireless networks with the more robust, reliable industrial-grade options currently available.

Tis reluctance to adopt wire-less technology can result in industry personnel never experiencing a cor-rectly engineered industrial application of the technology. Just like hard-wired applications, there is a very large quality gap between commercial and industrial performance levels. Due to their techno-logical development and age, hard-wired networks have had more time to develop industrial-grade levels of quality to provide reliable and secure connectivity. Te same is and has been taking place with wireless networks, which have now reached a level of quality capable of de-livering efective solutions for industrial operations.

induStrial network

CategorieS

In industrial automation systems, there are typically two types of networks in operation: the communications or supervisory network (PLCs communi-cating information to computers, HMIs, or other controllers for monitoring and coordination purposes) and the automa-

tion network (PLCs communicating machine control information to and from I/O, motion, vision, and other automation modules). Te information traveling throughout these networks can be categorized into either upstream (information traveling away from the automation system) or downstream

(information being received by the automation system). Upstream network trafc consists of information being sent back to the control center or end user for diagnostics, status, and manage-ment purposes, while downstream trafc consists of information being sent from the PLC to the hardware responsible for

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executing the automation and motion control functions.

Wireless networking can be used in many upstream communications networks for industrial applications due their less critical, lower speed, and less deterministic nature. Tese networks

include standard protocols like TCP/IP and Ethernet/IP, which can be easily adapted to transmit information via wireless instead of hard-wired Ethernet connections. Upstream communications are considered to be less critical to the overall process than downstream com-

munications in a properly engineered distributed-control architecture.

Downstream network trafc is much harder to adapt to include wireless con-nectivity due to the nature of modern automation and motion control systems. Tey typically require extremely high data transfer rates and very high reliabil-ity using protocols that include failure-proof handshaking. EtherCAT is the most recent phenomena to come to the automation world with its blazing fast speed and jitter of less than 1 us. Very little efort relatively has been expended into wireless architectures for these types of applications. ZigBee is one low-power and short-range protocol that has been developed and is being used in the commercial markets. While it has been looked at in the industrial markets, there is very little of it available still at this point.

induStrial wireleSS

appliCationS

Due to its unmatched versatility, wire-less networking can make some indus-trial applications much simpler and, in some cases, provide options that would have previously been impossible using traditional hard-wired connections. Tese benefts are proving efective for a wide variety of industries, from refning and manufacturing to remote drilling and mining applications.

In one case, an industrial plant had a rail-mounted crane that needed to transmit information back to the con-trol center wirelessly. Te only option when the plant was built was to not transmit the data back at all. How does one efectively run a communications cable from a building out to a rail car on a track that is half a mile long extend-ing through and under the building itself? As wireless technology emerged, they implemented a wireless platform that regularly dropped connectivity and lost data as a result. After replacing the transmitters with a newer, more robust platform and better system architecture, the plant can now transmit important data wirelessly without the fear of losing the connection. Tis is a prime example of the reliability ofered by modern wire-less networks that are often overlooked by industry professionals.

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With traditional hard-wired connec-tions, thousands of feet of wire would need to be routed from place to place in a time-consuming and expensive instal-lation process. By implementing a wire-less network with minimal installation requirements, factory managers can save time and money while putting a system in place that can be easily updated and maintained. Te critical processes taking place in a factory can then be consis-tently relayed to a central control room thanks to the high throughput of mod-ern wireless transmitters. With a robust wireless network implemented through-out a factory facility, there is always the option to add new connection points or transmitters with minimal changes to the system infrastructure.

In yet another example, a coal mining operation in China utilized wireless net-working to relay information from un-derground tunnels to control rooms on the surface level. Integrating a wireless network both above and below ground ofered the operation an unprecedented amount of fexibility in transmitting information.

An additional application of wireless technology is in oil feld applications. With a sizeable network of well sites and controllers spread out over a large geographical area, running wired con-nections to each remote site would be a considerable undertaking. Traditionally, cellular signals have been used requir-ing cellular cards and service contracts. However, implementing an 802.11 wireless network is as simple as equip-ping each well site with a wireless router capable of relaying information back to the control center. Tese routers are also capable of being bridged to receive and transmit information from sites that are farther away. Putting many of these units together is referred to as a mesh network, in which all stations in the network cooperate in distributing data. Additionally, mesh networks can utilize self-healing algorithms to continue their operation even when a particular node stops working or when a connection loses strength, providing outstanding reliability for the entire network. In one particular application the nodes were located as far as 20 KM away from each other and could still successfully transmit information with a throughput of more than 100 Mb/s.

ConCluSion

While many larger companies are still reluctant to rely on wireless networks to transmit important information in industrial settings, there is an increas-ing acceptance rate of the newer, more robust wireless options that are now available. Tese wireless platforms

ofer a greater combination of speed, functionality, and fexibility than any previous types of wireless networks as well as the majority of hard-wired con-nections.

Corey Foster serves as Northern Califor-nia automation sales manager for Valin Corp.

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Today's AC Servo Systems Are Smarter and Faster

Aservo systems have long been the workhorses of industrial automation, but it’s time to start thinking of them

as thoroughbreds. Tanks to ongoing advances in control algorithms and processing power, the best AC servo drives can now exert degrees of control that would not have been possible even a year ago.

Not every AC servo drive, however, has what it takes to qualify as the best, making it difcult to bring about signif-cant improvements in line speeds, posi-tioning accuracy, vibration control, and other important automation objectives.

Which features should you look for in advanced AC servo drives and which applications do these features target?

BooSt Frequency reSponSeTe top speed of a motion system and its ability to respond quickly to posi-tioning commands obviously depend, at least in part, on the servo drive’s frequency response. AC servos can vary widely in their frequency responses. Te fastest systems today can achieve a fre-quency response of 2.3 kHz, while more typical response value would be on the order of 1.0 kHz (See Figure 1).

Tis extra speed can come in handy in any application that benefts from enhanced positioning accuracy and repeatability, such as semiconductor processing equipment. Speedy motion systems can also improve the productiv-

ity of fast-moving processes. Packaging lines are a prime example.

Beyond speed and positioning ad-vantages, a fast frequency response also tends to reduce vibration, which can be important in just about any moving machine application.

MaxiMize reSolutionTanks to breakthroughs in signal processing, the resolution available from incremental encoders has recently improved exponentially.

Panasonic's new MINAS A5 AC digital servo drives, to take a leading ex-ample, use proprietary signal processing methods and a dedicated serial commu-nications bus to get 1.04 million pulses per revolution from a 20-bit encoder. Compare that ultra-high resolution to the 2,500 pulses per revolution that a conventional AC servo drive would get from the same encoder.

Tis support for high encoder resolu-tions translates directly to smooth, vibration-free motion and ultimately

Technology advances boost positioning accuracy and stability at high speeds, while simplifying setup.

By WilliaM nieveS, panaSonic

Figure 1. ac servos can vary widely in their frequency responses from 2.3 kHz at the top level down to a more typical response value of 1.0 kHz.



helps increase positioning accuracy. Machine tools, textile machines, and semiconductor equipment can all get a signifcant performance boost from the additional resolution.

SiMpliFy Setup WitH advanced auto-tuningOne often overlooked, but increasingly important, diferentiator among AC servo drives is ease of use. While some controls engineers have the knowledge and time to tune PID loops manually for each and every application, more advanced drives have supplemented manual tuning with automated tuning capabilities that make servo drives easier and less costly to set up. Equally impor-tant, auto-tuning can also improve servo performance by eliminating tuning er-rors and achieving a level of control not easily reached by manual tuning.

Consider the auto-gain tuning in Panasonic's MINAS A5 servo systems, for instance. Based on changes in stif-ness alone, it can calculate the relevant inertia ratios, resonance frequency, oscil-lation, and gains. To set up and operate the system, users simply single tuning parameter that corresponds to a specifc operating goal — including positioning, vertical axes, high-friction axes.

Variants of auto-tuning have become commonly available from many automa-tion vendors, though you will notice diferences in how well and how quickly diferent auto-tuning algorithms will work.

reduce cogging torqueEven the most advanced control algo-rithms do not adequately compensate for cogging torque, which leads to uncontrolled vibration and positioning errors. Te right type of motor, however, can go a long way in reducing cogging torque.

increaSe HigH-perForMance FilterSMost moving machines will beneft from a reduction in noise and vibration, both for the longevity of the machine components and also for the machine to operate at its top speed. Notch and damping flters are two of the key con-trol strategies for reducing vibration.

Notch flters reduce the noise and

vibration caused by resonant frequen-cies. MINAS A5, for the frst time, has four adaptive notch flters covering a frequency range from 50 to 5,000 Hz. Available in both auto- and manual-tuning modes, the flters can reduce noise and vibration due to resonance in applications such as semiconductor or packaging machines.

Advanced servo systems should also include damping flters, which remove

the natural vibration frequency from the command signal. Te result is drastically reduced vibration, particularly when a motion axis comes to a stop or settles on a position (See Figure 3).

Not all AC servo drives are created equal. But if you select one with the right combination of combination of speed and smarts, you can make all kinds of industrial machines run faster, smoother, and better.

Figure 2. the Minas a5 algorithms combine both feed forward and feed back terms.

Figure 3b. advanced servo systems should include damping flters, which remove the natural vibration frequency from the command signal.

Figure 3a. notch flters reduce the noise and vibration caused by resonant frequencies.

Notch Filter Characteristics

Frequency scan

Completion of adaptive

filter setup

Vibration

generatedVibration

reduced

Without Damping Filter With Damping Filter



IN THE MARKETPLACE


CompaCt 1” x 1” 25W DC/DC

ConverterS

The MI2500RU series, a family of minia-ture 25W DC/DC converters, is available immediately from MicroPower Direct. These high performance power convert-ers are designed to provide the high power density, long field reliability and

high perfor-mance features required for space critical applications.

Twelve models operate from 4:1 input

ranges of 9 to 36 VDC, or 18 to 75 VDC, providing tightly regulated single and dual outputs of 3.3, 5, 12, 15, ±12 or ±15 VDC. Standard features include an input/output isolation of 1,500 VDC, low output noise, tight line/load regulation and efficiency as high as 90%. All models have output power protection, continu-ous short circuit protection and a remote control input. The MTBF (per MIL HDBK 217F) of the MI2500RU series is 315 khours.

The MI2500RU family is packaged in an ultra-miniature, 1.0 x 1.0 x 0.40 inch metal case. The pin-out is industry standard. Each model is specified for op-eration over the wide operating industrial temperature range of -40°C to +65°C. An optional heatsink is available to ex-tend the operating temperature range.

The MI2500RU series is an ideal choice for a wide variety of board level power applications where board space is limited but high output power, robust perfor-mance and miniature packaging are essential.

Micropower Direct

www.micropowerdirect.com

poWer entry moDule DC12 for

proteCtion ClaSS ii meDiCal

equipment uSeD at Home

CHURTER expands its wide range of power entry modules to include versions, without ground pin, for use in Protection Class II double-insulated applications. The DC12 power entry module is already popular for use in Protection Class I equipment, due to its high performance switch and EMC filter functions integrat-ed into one compact package.

The new DC12 Class II version is ac-cording to IEC 60320-1, style C18. It is particularly well suited for use in medical equipment according to the IEC standard 60601-11, which outlines additional safety measures specific to medical equipment intended for use in the home. There is increasing demand for such equipment as populations around the world age and healthcare costs continue to rise.

Protection Class II equipment, in contrast to Protection Class I equip-ment, generally has no metal case. This category of equipment is called double insulated, and requires higher safety levels for energized components relative to exposed surfaces. The DC12 Class II

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power entry module provides double insulation between energized compo-nents and exposed parts. This reinforced insulation is tested with a voltage of 4000 VDC between the energized conductor (L) and the neutral conductor (N) relative to the filter case.

The DC12 line switch is available in 1- or 2-pole and touts high surge withstand capability. The EMC filter is available in medical and low leakage, M5, versions. This integrated filter at the power input provides highly effective interference suppression, which results in optimized electromagnetic compatibility. Current ratings range from 1-10 A at 250 VAC. Versions with quick-connect or solder terminals are available. The DC12 is available in black or white. Mating V-Lock cord sets are available to safeguard against unintentional disconnection of the power.

The DC12 Class I and Class II are ENEC and cURus approved. They are suited for use in equipment according to IEC 60950, IEC 60601-1, in addition to IEC 60601-1-11.

Schurter inc.

www.schurterinc.com

ultimaker launCHeS ultimaker²

go anD ultimaker² extenDeD

Ultimaker, a leading 3D printer manu-facturer, announces the launch of the Ultimaker² Go and Ultimaker² Extended, two cutting-edge desktop 3D printers, pre-order from March 2015 and available from April 2015. Built with premium parts and materials, these 3D printers bring imagination to life with high definition printing technology. The new Ultimaker² Go and Ultimaker² Extended follow the success of the top-rated Ultimaker², which was awarded best in shootout 2015 from Make Magazine and best consumer product at the 3D Printshow global awards 2014.

“After receiving recognition and awards from the leaders in the industry, we were inspired to make these new versions of the ground breaking Ulti-maker², supporting our vision to aim for the ultimate 3D printing experience,” says Siert Wijnia, CEO of Ultimaker, “The Ultimaker² Go is a compact printer that is easy to use as a starting printer while the Ultimaker² Extended has added a

ten centimeter larger build volume for users who want to create larger and more complex projects.”

The two newest desktop 3D printers in Ultimaker’s collection include the fol-lowing: Ultimaker² Go (€1195,- / $1450,-)* The mighty mini 3D printer: This compact 3D printer is the perfect solution for mak-ers who want to start with 3D printing on a premium level. This lightweight Ulti-maker² Go offers a high-quality product with a friendly interface which makes it an ideal starter machine for new users. Through its slimmed design, together with its dedicated portable packaging, it is the perfect 3D printer for the maker on-the-go and allows people to use it easily in different contexts. Because of its compact design and allowing a quick start the Ultimaker² Go is not equipped with a heated bed. You can now start your print even faster.

Ultimaker² Extended (€2495,- / $3030,-)* Think large, Print Big: For those who just want a little bit more than the best. The Ultimaker² Extended boasts some of the highest speed and accuracy found on any desktop 3D printer, with speeds of up to 300mm/s, 0.02mm layer resolution and a 10 cm (4 inches) larger build vol-ume. This larger desktop printer makes a statement at any workspace with its sleek design.

The launch of these two new products is accompanied by an addition to the Ul-timaker website that provides a stage for community members to share their proj-ects and get inspiration from others. This addition gives 3D printing enthusiasts the unique opportunity to get insight on upcoming Ultimaker projects, interact with Ultimaker experts and influence decisions on new experimental products, contributing to the whole Ultimaker 3D printing experience.

Ultimaker

ultimaker.com

Systems and Service | Industrial Networking and Connectivity |

Industrial Identifi cation | Object Detection |

Linear Position Sensing and Measurement | Fluid Sensors | Accessories



meggitt pioneerS multiple-

frequenCy HanDHelD SHaker

Meggitt, a leading supplier of vibration sensing products, introduces Reference-Mate, an advanced portable vibration reference source (aka handheld shaker) with multiple frequency outputs—an industry first that eliminates manual conversions between imperial, metric or calibration sheet values. With a number self-diagnostic features to ensure data integrity, Meggitt believes this to be one of the most trustworthy handheld shak-ers on the market.

ReferenceMate delivers a known vibra-tion level that enables users in the field to easily verify sensor performance and the integrity of the cabling and connec-tors between the sensor and the data acquisition system. According to Stuart Parker, Senior Vice President of Sales & Marketing, “ReferenceMate allows you to have confidence in your entire measure-ment chain before beginning expensive tests or taking critical data.”

Trust in the reference source is fundamental to verifying the acceler-ometer setup. Refer-enceMate is designed with a multitude of fea-tures to assure the user that the reference vibra-tion is accurate and the unit is functioning properly. LED indicators illuminate if battery lev-els are low or if the unit is overloaded. Internal test points, accessed via the battery cavity, verify the calibration of the internal reference accelerometer, which

maintains a 1 g test level for sensors weighing up to 250 grams.

Frequency and measurement type (peak or RMS) can be selected in accor-dance with the user’s requirements.

• 61.4 Hz for imperial measurements: 1 g (acceleration) equivalent to 1 in/sec (velocity)

• 100 Hz to simulate standard calibration conditions

• 159.2 Hz for metric measurements: 9.81 m/sec2 (acceleration) equivalent to 9.81 mm/sec (velocity)

Affordable ReferenceMate kitted systems include common mounting accessories for a variety of applications. The REF2510 kit includes the commonly used 1/4-28 to 1/4-28 mounting stud for monitoring industrial manufacturing equipment and rotating machinery. The REF2520 kit includes additional mount-ing adaptors for test and measurement users involved with applications such as general laboratory vibration, automo-tive, research, component reliability, and consumer electronics. Both kits include a carrying case with shoulder strap to organize accessories for easy transport. Battery life of up to 40 continuous hours allows extensive tests. The shaker can also be DC powered to eliminate down-time.

Meggitt plC

www.meggitt.com

ClipparD all StainleSS Steel

pneumatiC CylinDerS

Designed for use in a broad range of ap-plications including those in washdown and caustic environments, these quality cylinders are constructed of durable

303 and 304 stainless steel. They include a Nitrile rod wiper to keep potential

contaminants from penetrating inside the cylinder, and are available with bore sizes from 3/4” to 2”. Standard stroke lengths are from 1” up to 32” on some models. Features include precision rolled con-struction for a solid, leakproof cylinder and an interchangeable design.

Clippard instrument laboratory

www.clippard.com

integrateD motorS WitH

inDuStrial ConneCtorS over

etHernettCp/ip

Networking over EthernetTCP/IP via industrial M12 circular connectors is now available in Lexium MDrive® integrated motor systems, NEMA motor sizes 23


MICRO-EPSILON

Raleigh, NC 27617 / USA

Phone +1/919 787 9707

[email protected]

www.micro-epsilon.com

Extreme precision

Modular – up to 4 synchronized

channels

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via WEB interface

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& 34. EtherNet/IP, ModbusTCP and Profinet are all software selectable from one product, delivering system flexibility to a wide range of automation machine builders.

M12 Lexium MDrive products inte-grate stepper motor, controller, I/O and drive electronics with closed loop per-formance in a compact package ideal for many motion applications. High torque step motors are integrated with drives from 12 up to 70 VDC, controller, I/O, and internal encoder. In certain applica-tions, LMD closed loop performance can replace servomotors, lowering cost and reducing complexity.

Schneider Electric Motion USA

motion.schneider-electric.com

JoHnSon eleCtriC launCHeS

DoSing Solution for DieSel

exHauSt fluiD

Johnson Electric announced a new Brushless motor dosing module for Die-sel Exhaust Fluid (DEF) used in the Selec-tive Catalytic Reduction (SCR) process in heavy-duty diesel engines. The new dosing modules are custom designed for both air-assisted and airless DEF systems used in trucks, bus, and off road vehicles. Johnson Electric’s brushless motor and control technology provides the industry’s widest speed range to cover variable urea dosing requirements. Integrated motion control enables exact amounts of urea to be delivered to the selective catalytic reduction system for maximum NOx reduction.

Johnson Electric Group

www.johnsonelectric.com

iCp DaS uSa introDuCeS neW

intelligent Serial-to-etHernet

DeviCe Server

ICP DAS USA, Inc. releases iDS-718iM-D, a new generation Device Server with a

powerful 32-bit, 720 Mhz CPU, and vari-ous connectivity (Ethernet, micro SD and serial port) options and communication interfaces. As one of the most powerful systems in the market, this new device server features a high-performance 720 Mhz ARM-based processor with UDP support, 256 MB flash, 256 MB DDR3 memory, unique 64-bit hardware serial number, and real-time clock, etc. provid-ing excellent performance at low power consumption.

iDS-718iM-D is designed to allow Ethernet and Internet connectivity to any RS-232 and RS-422/485 device, and to eliminate the cable length limitation of legacy serial communication. The iDS de-vice server, coupled with a large built-in RAM buffer, allows fast transmission and prevents congestion of serial data on the

network. The preloaded high-performance operating system is open, flexible, scal-able and allows user to easily add or remove application/service from configuration mechanism.

iDS-718iM-D is ideal for factory auto-mation, industrial automation, process control applications in various industries.

ICP DAS USA is a cost-effective leader in the U.S. industrial market; offering a stunningly competitive price/perfor-mance ratio, while catering to the latest solutions for current industrial trends. We seek to provide our customers with cost-effective, flexible, and easy-to-use solu-tions for their Data Acquisition and Em-bedded Control Applications. ICP DAS USA provides a great variety of products with modular and universal solutions for any scale application or projects.

iCp DAS USA

www.icpdas-usa.com

gen. 3 inDuCtive enCoDerS WitH

funCtional Safety

Heidehain’s new generations of absolute inductive rotary encoders with functional safety are now available. The Genera-tion 3 ExI 1100 and 1300 series encoders provide a single encoder safety solution

Features:32 axis of synchronous motion controlt

250 micro-sec position updatest

512 points of I/O controlt

Hi-speed input interruptst

Multiple connectivity optionst

Fieldbus networkt

SERCOS III or II network interfacet

Motor/drive systems up to 55K wattst

Electronic cam and ratio functionst

Easy programmingt

Free servo system sizing supportt

Call us for a quote today!t

Emerald

Automation

Controller

The EMC-2100

brings a new

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Industrial Indexing Systems, Inc.

+1 (585) 924-9181

Web: http://www.iis-servo.com

Email: [email protected]

Emerald Motion

Technology




for many industries such as packaging, automation and robotics. These new products are especially suitable for safety-related applications up to SIL 3, PLe, and Category 4 or any application involving high risks for the operator, such as when they are required to interact with a robot directly.

The ExI 1100 encoders are 35 mm sized encoders while the ExI 1300 series feature a larger 56 mm hub size. Both these series encoders are implemented with a HYDRA III scanning ASIC and also offer a host of different safety-related functions that can be upgraded even further with the implementation of safe control that supports the EnDat Safety Master. These additional measures can be implemented independently of the control loop parameter. This allows the safety measures available to work directly with a controls safety module, without being affected by changes in control-loop parameters

The ECI 1x19 and EQI 1x31 each fea-ture an increased single turn resolution of 19 bits while the EQI 1x31 can track 4096 (12 bits) revolutions. These next gen. encoders showcase improved vibration specifications (400 m/s2 stator and 600 m/s2 rotor), as well as a more durable multi-turn gearbox, and an increased permissible axial motion of the shaft up to ± 0.4 mm. They also have the advan-tages of previous bearingless, inductive encoders which include the non-contact design, resistance to contamination, no mechanical self-heating, and reduced sensitivity to radial runout.

Heidenhain Corporation

www.heidenhain.us

graCo afD announCeS tHe

tHerm-o-floW Bulk Hot melt

SyStem for tHe CaBle inDuStry

Graco Advanced Fluid Dispense (AFD), a world leader in fluid handling products

and systems, announces the Therm-O-Flow Bulk Hot Melt System, an ideal fit for moisture block coating applications in the cable industry. With material throughput capability 200 percent great-er than the leading competitor, Therm-O-Flow systems have been designed to improve process efficiency and produc-tion capacity while reducing energy costs and supporting environmental initiatives.

The Therm-O-Flow 200 is available in configurations specially tailored for dis-pensing a moisture block primary cable coating, applied to facilitate adhesion of a moisture block powder deposited onto the cable downstream in the process. The Therm-O-Flow 200 dispenses a hot-applied, butyl-based, inert compound into a heated coating head. Bare cable strands are pulled through the coating head after a braiding process.

Dispense tem-peratures range from 300 to 350°F (149 to 177°C). Higher melt and flow rates directly improve productiv-ity in this appli-cation – the Therm-O-Flow 200 can dispense up to 11 pounds (5 kilograms) per minute through a 15 foot (4.6 meter) heated hose. Precision temperature control ensures consistent processes, with accurate temperature control of up to 10 customer-defined heat zones in a single system.

Adjustable low/empty level sensors are standard on every Therm-O-Flow, so you never run out of material unexpectedly. Other features include an integrated drum air blow-off that reduces downtime by facilitating quick, easy drum changes. Easy-to-use, graphic-based control screens reduce training time, and USB data downloads allow for better process monitoring and control.

Graco inc.

www.graco.com

Zero BaCklaSH inDexing Drive

nut iS alSo Jam proof

The Amacoil-Uhing Model RS drive nut provides smooth backlash-free linear mo-



tion in machine design. Unlike a screw, the RS drive nut runs on a smooth shaft without threads. This eliminates the po-tential for clogged threads and jamming. If debris does become lodged in the drive nut’s travel path, the drive simply

slips until the operator can remove the obstruction. Slipping, as opposed to the churning and grinding associated with screw-based systems, prevents damage to the nut and other components in the linear motion system. Additionally, with less downtime required to clean out threads and make repairs, more consis-tent production rates are achievable with the RS drive.

The RS linear drive operates on the rolling ring linear motion principle. The inner race of each rolling ring bearing inside the nut is specially machined. Each bearing is installed under pressure and contacts the shaft at a single point only. When the shaft is rotated, the rotary mo-tion input is immediately converted into linear output as a result of the friction created. The point contact between the rolling ring bearing and the shaft assures there is no play or backlash during move-ment of the drive nut. This is true even during reversal.

As components in a variety of indexing and reciprocating linear motion systems, Amacoil-Uhing RS drive nuts have a wide range of application in material handling machines, winding equipment, test and measurement devices, parts transfer systems, packaging machines and other production, converting and finishing equipment.

Available in 10 sizes to meet varying payload and linear speed requirements,

the RS drive nut is suitable for vertical or horizontal travel. Each of the ten sizes is available in five different linear pitch settings. Shaft rotational speeds may be up to 10,000 rpm depending on the size of the drive. Linear travel speed ranges from 0.5 ft/sec up to 4.0 ft/sec, again depending on the size of the drive and also on the weight of the payload. RS drive nuts offer axial thrust from 22 to 449 pounds and the only maintenance required is periodic lubrication of the shaft with grease.

Amacoil inc.

www.amacoil.com

H2W teCHnologieS

manufaCturerS BruSHleSS

linear motorS

Ironless brushless linear motors are ideal for long stroke, high speed, closed-loop applications. With a lower moving mass, they operate at speeds up to 240 ips [6 m/s], and can be precisely controlled when coupled with a linear encoder. Zero

From the world’s largest

manufacturer of world-class

electromagnetic clutches

and brakes,SLJ[YVTHNUL[PJJS\[JOLZ IYHRLZ

MVY]PY[\HSS`L]LY`HWWSPJH[PVU

For holding and stopping

applications

A wide array of standard torque

ranges (1.75in/lbs - 880 in/lbs)

Custom designed and manufactured

for your application

Manual release, zero backlash, and

adjustable torque also available

Inch and metric bores available

ENN#0&1.2*1#&1/'45'6XNLLKG*10'UKGFgFKEgKGJE#:UKGFgFKEgKILN'$5+6'Uhttp:ogura-clutch.com/spring

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SpringApplied

Brakes

Spring Applied

Brakes

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




cogging in brushless linear motors, make them ideal for appli-cations requiring smooth motion at both low and high speeds. H2W can provide motors with precision linear encoders or with hall effect sensors for trapezoidal commutation.

Typical applications for the ironless brushless motors include: Inspection, pick-and-place, clean room, robotics, machine tools, coordinate measurement, patient handling, scanning, semiconductor handling, and laser and water-jet cutting.

The complete line of linear electric motors includes: Single and dual axis linear steppers, DC brush and brushless linear

motors, voice coil actuators, and AC in-duction motors. Also offered is a complete line of ball screw, lead screw and belt driven positioning stages.

Other motion con-trol products include: Limited angle torque

motors for compact, limited angular excursion rotary servo ap-plications, 3 phase brushless rotary servo motors with matching digital servo amplifiers and permanent magnet linear brakes for fail-safe, zero power braking for baggage handling and people moving applications as well as amusement park rides.

H2W Technologies inc.www.h2wtech.com

For technical assistance,[email protected]

Brushless DC Motors

t High performance housed and frameless brushless motors and drives for demanding applications.

t Sensorless or hall motors and drives for aerospace, military, medical, industrial, canned pumps, vacuum, extreme temperature applications. Custom drive programing and designs available.

t Standard or custom designs up to 98% efficient, up to 200,000 rpm.

t )JHIFTUQPXFSEFOTJUZJOUIFJOEVTUSZ

t 4MPUMFTTBOETMPUUFEEFTJHOT"WBJMBCMFXJUIFODPEFST and gearheads and separate or integral electronics.

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Data sheets at www.koford.com

A D V E R T I S E R S I N T H I S I S S U E


Allied Electronics SC1, SC2

Aurora Bearing S23

B&R SC4

Balluff S19

C-flex S24

Digi-Key Corp. S3

Harmonic Drive SC3

Helukabel USA Inc. S22

IDEC S11

Industrial Indexing S21

Koford S24

Lin Mot S9

Maple Systems S6

Mayr S5

Micro-Epsilon S20

Ogura S23

Parker Hannifin S1

Peninsular S7

PHD S13

Posital Fraba S18

Pro-Dex S8

R&W S14

Renishaw S2

US Tsubaki S15

Publisher does not assume any liability for errors or omissions in this index.


• Complete line of gearheads now available

• Harmonic Drive® or Harmonic Planetary® gearheads

• Zero backlash and low backlash versions

• Ratios: 3:1 - 160:1

• Peak Torque: 3. N•m - 3 40 N•m

• Sizes: 40mm - 230mm

• Output ConÄgurations: Hollow Shaft, Flange, Keyed Shaft

Simply couple any servomotor to one of our precision Quick Connect™ gearheads!

Building a high-precision actuator is easy!

Harmonic Drive LLC • 800. 21.3332 • www.HarmonicDrive.net

Harmonic Drive and Harmonic Planetary are registered trademarks of Harmonic Drive LLC.


ALL SHAPES. ALL SIZES.

ALL COLORS.

< PLC + HMI = Power Panel C-Series

< Pure HMI = Power Panel T-Series

< For I/O, drives and safety

< POWERLINK | Ethernet | USB | CAN | RS232 | RS485

< 4.3" | 5.7" | 7" | 10.1"

www.br-automation.com/PowerPanel


design news - april 2015

Documents

uniform curing

control system

dymax edge

ubm blackyellowmagentacyanthe

ubm blackyellowmagentacyannow

ubm blackyellowmagentacyancall

active curing area thats