Download - Design World December 2015
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December 2015www.designworldonline.com
MOTION CONTROL: Protecting against mechanical overload damage PAGE 66
LINEAR MOTION: Linear encoders improve accuracy PAGE 72
TEST & MEASUREMENT: Space vectors aide drive for optimal efficie y PAGE 80 IoT Enabled
Mechatronics 86
INSIDE:
Integrating Internet Connected Smart Robot Modules
2015Leadership Winners 3 - 15
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2 0 1 5Here in our ninth
annual issue on
Leadership in
Engineering, we
announce the
winners in the Leadership
Awards Program that we
have been
promoting throughout
the year.
The Design World User
Community has cast votes
and we are pleased to
celebrate the
winners in this
special section of
Leadership in Engineering.
Networks
Mechanical
Test & Measurement
Fastening & Joining
Motion
Electrical
Fluid Power
Advanced Materials
Software
Digital Manufacturing
Mechatronics
www.designworldonline.com December 2015 DESIGN WORLD 3
L e a d e r s h i p i n E n g i n e e r i n g
L e a d e r s h i p W i n n e r s
Switches
Leadership Winner_Intro 2015_Vs2.indd 3 12/3/15 3:13 PM
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4 DESIGN WORLD December 2015 www.designworldonline.com
Herrmann UltrasonicsWhen it comes to welding thermoplastic materials with ultrasonic vibrations, Herrmann Ultrasonics has you covered.
The HiQ VARIO is a flexible machine that can be configured
to fully satisfy the needs of the user. Experienced project
management supports machine automation concept
designs, proposes machine work area layout, and performs
extensive collision analysis. Founded in 1961, the company
now has three headquarters spread around the world and
multiple tech centers across the U.S. Local support teams
allow customers global access to Herrmann personnel for
sales, service and training.
LE
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eadership Winners
ADVANCEDMATERIALS
L e a d e r s h i p i n E n g i n e e r i n g
Advanced Materials
Congratulations
LEADERSHIP 2015 WINNERS PAGES_Vs2.MD.indd 4 12/7/15 1:37 PM
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AccumoldAccumolds primary focus is on
manufacturing micro-sized plastic parts
and components for industries that
require fast turn around and complex
parts, such as micro-electronics,
micro-optical and medical. The original
Micro-Molder was designed to help
manufacture parts with minimal waste
and short cycle times for electronic
component manufacturing. These minute
parts are often measured in microns,
are no bigger than 0.5 in.3 and typically
weigh less than 1 g. In addition to their
size, these parts have tight tolerances and
must be molded efficiently and precisely.
Incorporating small features on a normal-
sized part (up to about 3 in. in diameter) is
another of the companys capabilities.
www.designworldonline.com December 2015 DESIGN WORLD 5
L e a d e r s h i p i n E n g i n e e r i n g
Digital Manufacturing
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eadership Winners
DIGITAL MANUFACTURING
Congratulations
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eadership Winners
ELECTRICAL & ELECTRONICS
6 DESIGN WORLD December 2015 www.designworldonline.com
L e a d e r s h i p i n E n g i n e e r i n g
CicoilCicoil was founded in 1956 with an innovative new product for the early
mainframe computersthe
flat ribbon cable. The cable
allowed companies like IBM to replace bulky, stiff, round
cables with sleek, flexible, ribbon cables. Called ribbon cables,
variations of these flat cables are still used today in most
computers, printers and many electronic devices. In addition
to the strong, flexible cable jacketing, every Cicoil cable
incorporates finely stranded, ultra-flexible wire conductors.
Conductors and shields are specially heat-treated and plated
to maximize their flexibility, while providing an extremely long
flex life in the most demanding applications.
Electrical/Electronics
Congratulations
LEADERSHIP 2015 WINNERS PAGES_Vs2.MD.indd 6 12/2/15 11:24 AM
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Master BondMaster Bonds expansive line of epoxies, silicones, UV curable and LED curable compounds can be
customized to meet a myriad of property requirements,
including high/low temperature resistance; electrical
conductivity/insulation; thermal conductivity; high/low
viscosity; and chemical resistance. Developed to withstand
harsh environmental conditions, products feature long-
term durability and are certified for the following: NASA
low outgassing; USP Class VI; UL 94V-0 and UL 94V-1; and
ISO 10993-5. To keep customers informed of the latest
developments in adhesive technology, Master Bond offers a
collection of white papers, catalogs, case studies and videos
on its website.
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eadership Winners
FASTENING & JOINING
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L e a d e r s h i p i n E n g i n e e r i n g
Fastening & Joining
Congratulations
LEADERSHIP 2015 WINNERS PAGES_Vs2.MD.indd 7 12/2/15 11:23 AM
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Fluid Power
8 DESIGN WORLD December 2015 www.designworldonline.com
L e a d e r s h i p i n E n g i n e e r i n g
Humphrey ProductsMichigan-based Humphrey Products has been in the manufacturing industry for more than 100 years as a leading
producer of fluid control products, serving organizations
worldwide. The family-owned company designs and
manufactures pneumatic fluid control componentsvalves
and cylindersfor a variety of applications, including medical
devices, analytical instrumentation, factory automation and
package conveyor systems. Humphrey, who said 96% of its
suppliers are from the U.S., has a subsidiary company, South
Haven Coil, also based in Michigan. LE
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eadership Winners
FLUIDPOWER
Congratulations
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Smalley Steel Ring Co.Smalley Steel Ring Company offers a variety of rings and springs for myriad applications. Product offerings include:
wave and compression springs, constant section rings, Spirolox
retaining rings, laminar sealing rings and hoopster rings. Spirolox
Rings, also known as Spiral Rings, offer a 360 retaining surface
and are interchangeable with standard stamped ring grooves.
The company offers an exclusive Circular-Grain process, which
is not a stamping, but rather a continuous coil that is made
from edge-wound, pre-hardened, spring-tempered flat wire.
Smalleys unique manufacturing process reduces scrap, allowing
for the economical production of exotic alloy, carbon and
stainless-steel products.
www.designworldonline.com December 2015 DESIGN WORLD 9
L e a d e r s h i p i n E n g i n e e r i n g
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eadership Winners
MECHANICAL
Mechanical
Congratulations
LEADERSHIP 2015 WINNERS PAGES_Vs2.MD.indd 9 12/2/15 11:19 AM
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YaskawaYaskawas broad product range of rotary, linear and direct-drive motors, accompanied with digital SERVOPACKS
(3 W to 55 kW), can be matched with single- or multi-
axis machine controllers. The company adds value to
its offerings by consistently delivering reliable
service for more than a century, working in
tandem with customers to provide them the
resources, time and confidence needed to
develop reliable automation solutions. With
nearly 300,000 robot arms installed worldwide,
the Yaskawa Robotic product portfolio ranges
from 4- to 15-axis industrial robots with load
capacities of 2 to 800 kg, to special machines,
devices and turnkey systems.
Mechatronics
1 0 DESIGN WORLD December 2015 www.designworldonline.com
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MECHATRONICS
L e a d e r s h i p i n E n g i n e e r i n g
Congratulations
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Haydon KerkHeadquartered in Connecticut, Haydon Kerks linear motion products are used in much of todays
medical equipment, laboratory instrumentation,
machinery automation, aerospace, analytical
equipment, computer peripherals and
semiconductor manufacturing equipment that
requires precision motion. Established in 1976,
the companys Products Division has been
building electric motors and stepper motor-based
linear actuators for almost half a century. It has
grown to be one of the worlds largest exclusive
manufacturers of non-ball leadscrews, linear rails
and actuator systems.
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MOTIONCONTROL
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L e a d e r s h i p i n E n g i n e e r i n g
Motion Control
Congratulations
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Networks
1 2 DESIGN WORLD December 2015 www.designworldonline.com
L e a d e r s h i p i n E n g i n e e r i n g
PC-based control technology from Beckhoff Automation
provides the ideal toolbox to implement leading automation
concepts, including the Internet of Things, cloud computing,
centralized PC-based control systems and ever-more connected
devices through industrial Ethernet and OPC UA. Users are
integrating Beckhoff controllers into their production networks,
enabling them to communicate with databases, performing remote
maintenance over the Internet or requesting cloud-based services.
With the Power of One controls philosophy from Beckhoff (one
PC-based controller, one software platform and one network),
manufacturers and machine builders can make great strides toward
establishing meaningful Industry 4.0 practices while ensuring lean
automation designs and streamlined system architectures.
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NETWORKS
Congratulations
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www.designworldonline.com December 2015 DESIGN WORLD 1 3
Software
L e a d e r s h i p i n E n g i n e e r i n g
PTCPTC enables manufacturers to achieve
sustained product and service advantage.
The companys technology solutions help
customers transform the way they create,
operate and service their products across the
entire product lifecyclefrom conception
and design to sourcing and service. The
companys solutions for Product Lifecycle
Management (PLM), Computer Aided Design
(CAD), Application Lifecycle Management
(ALM), Supply Chain Management (SCM)
and Service Lifecycle Management (SLM) let
users aggregate, analyze and deploy product
information to drive the strategy and dynamic
decision-making processes on which their
success depends. PTC employs more than
6,000 professionals to help customers
optimize activities within individual functions
of their organizations, from engineering to
supply chain and manufacturing, and from
sales to service.
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eadership Winners
SOFTWARE
Congratulations
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Switches & Sensors
L e a d e r s h i p i n E n g i n e e r i n g
BEI SensorsBEI Sensors manufactures reliable position sensors for harsh environments, including
encoders, potentiometers and Hall-effect sensors.
The companys goal is to produce the finest
products that not only perform in the harshest environments,
but change with the advance of technology. BEI Sensors
understands the need to have high-performing encoders
and sensors no matter how severe the environment, and
offers a wide array of products to meet these challenges.
Its linear position sensors are designed to take the heat
relying on strong, proprietary, conductive-plastic resistive
inks that are tough enough to withstand operating
temperatures from -40 to 200 C, high linear velocities
exceeding 2,000 mm/sec and aggregate mechanical
travel exceeding one million meters. The company also
understands the need for functional safety, which is why it has
developed a range of functionally safe incremental encoders
for use in systems up to SIL3 and PLe.
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SWITCHES & SENSORS
Congratulations
1 4 DESIGN WORLD December 2015 www.designworldonline.com
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National Instruments
L e a d e r s h i p i n E n g i n e e r i n g
National Instruments (NI) provides tools for engineers and
scientists developing next-generation control and monitoring
systems in the energy, industrial control, life sciences and
transportation industries. NIs embedded systems combine
LabVIEW software with off-the-shelf hardware to simplify
development and shorten time to market. All hardware
enabled by the LabVIEW RIO architecture features floating
point processors, reconfigurable FPGAs and modular I/O. With
LabVIEW, engineers can customize hardware and integrate
custom timing, signal processing and high-speed control
without requiring expertise in low-level hardware description
languages or board-level design. The company offers a variety
of hardware platforms based on the LabVIEW RIO architecture,
including CompactRIO, Single-Board RIO, R Series devices
and PXI-based FlexRIO modules. With varying degrees of
performance, cost, I/O rates, form factor and ruggedness, NI
RIO hardware devices can meet the unique needs of most
embedded control and monitoring applications.
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eadership Winners
TEST & MEASUREMENT
Test & Measurement
Congratulations
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I n s i g h t s
1 6 DESIGN WORLD December 2015
College has changed a lot since I was a student. Shortly after I graduated from Georgia Tech, the campus underwent quite the building boom, thanks to its upcoming status as the Olympic Village for the 1996 Summer Olympic Games. Touring the school in the subsequent years always left me amazed at the new amenities. And I can recall looking at the University of Arizona when I was considering graduate school, my jaw dropped at the prospect of high-rise dorms with huge swimming pools right beside them. It was like spring break compared to what Id known. But changes in the college experience today go far beyond mere physical structures. While touring the new Sears Think[box] innovation hub on the campus of Case Western Reserve University, I was blown away ... what these engineering students have at their disposal today is incredible. Think[box] functions as a comprehensive fabrication laboratory, a place where the University hopes members of the engineering, design, arts, humanities, science, medical and business communities will interact. The goal is to help both students and faculty become the entrepreneurs and technology leaders of the future. Think[box] is also open (and free!) to the public, which I think will add a great mix to this campus hub. Think[box] has been around since 2012, but its just moved into a new $35M home, a seven-story, 50,000 sq-ft building. The layout of the project is quite impressive: The fir t floor includes interactive presentation and workshop areas, an inventors hall of fame and social meeting spaces focused on users from outside the university, including K-12 students, industry groups and community groups. The second floor has open space to support generation and development of ideas. There is a range of informal, re-configurable spaces for users to meet, think and develop their ideas. It will include multi-media equipment to support group collaboration and expression. The third floor focuses on prototyping, with a wide range of state-of-the-art digital manufacturing equipment for users to quickly turn their ideas into some form of physical object. The fourth floor houses traditional fabrication/manufacturing workshops. The next phase of the project, to happen over the next year, will add a garage-style project floor; a floor devoted to startup assistance (including business planning, intellectual property and legal advice), and a floor for incubating startup companies that develop both within and outside the university. Ive been told that top-notch universities have been visiting Think[box], to see how to create similar spaces on their campuses. My thought was: What a great recruiting tool for CWRU. I tried to imagine prospective engineering and design students getting a campus tour and then seeing this lineup of toys: 3D printers, circuit-board routers, laser cutters, a computer-controlled ShopBot router, a Lynx 3D Microscope, a 3D scanner, a mixed signal oscilloscope and a vacuum chamber. What aspiring engineer wouldnt want to playand learnhere? DW
Thinking outside the [box]
Pa u l J. H e n e y - Ed i to r i a l D i re c to rp h e n e y@w tw h m e d i a .co m
How much will Maker spaces play a role on campuses in the future?
Comment on Pauls blog on Pneumatic Tips, www.pneumatictips.com/blog On Twitter @ DWEditor
Insights 12-15_Vs2.MD.indd 16 12/2/15 12:09 PM
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Encoder solutions for a world in motionAdvanced Opto-ASIC circuitry and intelligently designed, robust mechanical packaging combine to deliver reliable, high-performance rotary motion feedback. Made in the USA, and backed by an industry-best three year warranty, fast delivery and global support, Encoder Products Company rotary encoders work when it counts which is all the time.
1-800-366-5412 www.encoder.com
Encoder Products 12-15_New full.indd 17 12/2/15 11:48 AM
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Te s c h l e r o n To p i c
Theres a lot of public lamentations that too few youngsters see engineering as a
profession worth pursuing. Ive
come to think part of the problem
is with experts trying to describe
what engineers really do, giving
explanations that are murky and
unsatisfying. So kids have trouble
distinguishing the activities of
engineers from those of car mechanics
or maintenance personnel.
One who has taken a stab at explaining what engineers do is Guru Madhavan, a biomedical engineer. He wrote a book called Applied MindsHow engineers think, in which he claims engineers visualize the structure of a problem by breaking it down into elements linked by logic, time, sequence and function. Madhavan also says engineers work under constraints, make tradeoffs o get reasonable solutions and divide complicated problems into manageable pieces.
L e l a n d Te s c h le r - Exe c u t i ve Ed i to rlte s c h le r @w tw h m e d i a .co m
What do engineers really do? And do computer programmers really do it?
On Twitter @ DWLeeTeschler
1 8 DESIGN WORLD December 2015
This description sounds reasonableuntil you consider that real estate developers, scrap yard managers and movie producers might all claim to go through similar sorts of processes to get a job done. Alternatively, some might say Albert Rothenberg gets closer to the essence of engineering in another book called Flight from Wonder: An Investigation of Scientific Creativity. Rothenberg is a psychiatrist who does research on creative thinking processes. He said the creative thinking techniques he describes in his book come from Nobel laureate scientists, not engineers. Nevertheless, engineers reading the book are likely to recognize cognitive tricks they use themselves. For example, a visual imagery exercise called homospatial reasoning involves overlaying and combining ideas in different ways. With another technique called the sep-con method, you conjoin functionally separate ideas or objects in odd ways to see what happens. Rothenberg also takes a crack at describing broader qualities that Nobel laureates possess. They include passion, self-confidence, openness, courage and domain expertise. Many of us would probably say weve often seen colleagues display those qualities and thinking processes. Trouble is, passion, self-confidence and an ability to combine ideas in novel ways arent exclusively found in either engineers or Nobel laureates. Its not out of line to say farmers, fire ghters and construction workers can display the same qualities. The inability to defi e what engineers really do has lead to a disagreement about who an engineer really is. That brings us to video game
designer Ian Bogost. Writing in The Atlantic, he recently suggested that software experts are programmers, not engineers. The title engineer is cheapened by the tech industry, he writes. Bogost asserts that an engineer is someone who is regulated, certified and subject to continuing education requirements. He or she has to jump through these hoops because something could go terribly, horribly wrong with unqualified actors at the helm When it comes to skyscrapers and bridges and power plants and elevators and the like, engineering has been, and will continue to be, managed partly by professional standards, and partly by regulation around the expertise and duties of engineers. But 50 years worth of attempts to turn software development into a legitimate engineering practice have failed, he said. Bogost argues that, in contrast to maintaining professional standards, there is an informality to software work that is being made worse by movements such as agile development, which focuses on rapid iterations rather than long-term planning. This sort of slap-dash fi -it-later thinking is the antithesis of engineering. Bogost didnt set out to explain what engineers do, but he helps show what separates engineering from areas where a cobbled-together solution is acceptable. Simply put, engineers are people who have a responsibility to produce a product that is safe and reliable. Their expertise as builders and designers originates from that responsibility. DW
Lee Teschler Column 12-15_Vs3.MD.indd 18 12/2/15 12:05 PM
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@ MachinedSprings.com
For more information on Machined Springs, including custom applications, go to MachinedSprings.com or call (877) 435-4225
2015 Helical Products Company | www.heli-cal.com
SOLUTIONS FOR SURGICAL TOOLS, MEDICAL DEVICES AND IMPLANTS
Helical 12-15.indd 19 12/2/15 11:49 AM
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Te c h n o l o g y F o r w a r d
3D printing stocks have been tanking
for several months. 3D Systems CEO Avi
Reichental stepped down. Everyone is
waiting for HP to introduce its super-fast
new 3D printer next yearand blow
established 3D printing vendors out of the
water. According to stock analysts, this
is practically a fait accompli because HP
has more money than the other players,
and obviously money trumps all other
capabilities. If HP doesnt introduce a new
3D printer, it can just buy Stratasys or
3D Systems, say the stock analysts, and
achieve market dominance that way.
L e s l i e L a n g n a u - M a n a g i n g Ed i to rl la n g n a u r @w tw h m e d i a .co m
Riding the Tigers tail
On Twitter @ DW3Dprinting
2 0 DESIGN WORLD December 2015
Then we have the news that traditional printer companies Canon and Ricoh have decided to enter the 3D printing market. Investors are showing a disappointing lack of knowledge about 3D printing/additive manufacturing (3DP/AM). And this ignorance is harming those involved in this industry. Investors should have done due diligence; their actions (selling off tocks, short selling the market, fili g lawsuits) indicate they did not. A 3D printer in every home? Eventually. Just not this year. Probably not next year either. Will 3DP/AM revolutionize manufacturing? Not likely. Ever. 3DP/AM is not a replacement for traditional manufacturing. Its simply another tool for traditional manufacturing to usewhen it
makes sense. When you can stamp out thousands of parts for fractions of
a penny, why would you install a slower, more expensive process to
accomplish that? Could 3DP/AM get as fast or faster than traditional manufacturing? Maybe. But it will take years. Meanwhile, traditional manufacturing technology is not standing
still. 3DP/AM is a long-term
buyprobably 10 years. Why? Education. Whats needed now is
the ability to design to 3DPs advantages. Just wait until todays students, who are exploring 3DP now, graduate. Stock investors will see a different market then. And they may wish they had stayed in this market early. Several companies in this industry have the potential to be the next Apple. This industry is just beginning to fi d its legs. Developers have known what problems it solves for some time. But the message is still getting out. As of today, and tomorrow, the best problems that 3DP solves are those that involve creating custom, one-offproducts and developing parts impossible to make other ways. Just consider the weight reduced Airbus bracketsthere is no way to machine these parts. The industries that can best take advantage of these capabilities are where 3DP is working best today, like medical, including dental and prosthetics, and aerospace. Rather than short sell companies in this market, smart investors will see that they can get in on the ground floor of this industry now. DW
Leslie's Column 12-15 Vs3 LL.MD.indd 20 12/2/15 12:08 PM
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Proto Labs 11-15.indd 21 12/2/15 11:55 AM
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2014 Winner
Crains Cleveland Business Fast 50 2014
2 2 DESIGN WORLD December 2015
2011 - 2015
ControllerBrian [email protected]
Cut to Width Roll Slitting
Custom Lamination
Custom Sheeting
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We dont just sell the high endmaterials your company needs,
we cut to order, so you are neverstuck with wasted material again
With a comprehensive selection of specialized materials such as Teflon, Kapton, Silicone, PEEK, Kevlar, FEP, and PTFE coated fabrics, if your appli-cation demands performance, we can
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Staff page 12-15_Vs1.indd 22 12/2/15 12:15 PM
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SV200 Digital Servo Drives offer a wide range of
control options including pulse & direction, analog
torque or velocity, streaming commands, stored program
execution and fieldbus.
www.Applied-Motion.com
Cost effective, high performance servo drives and motorsIn stock for immediate deliveryFree samples to qualified OEMs
Compact, efficient servo drives for every application
Auto-tuning and anti-vibration for easy setup and smooth motion with any load
Performance-matched J Series Servo Motors up to 750 Watt continuous and 62 in-lbs peak torque
Built-in Safe Torque Off (STO) circuit for safety-rated applications
Servo DrivesSV200
Applied Motion 12-15_New.indd 23 12/2/15 11:56 AM
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HOW DO I KNOW IF IM TALKING TO AN ENGINEER OR A SALESMAN?
THE ENGINEERS CHOICE
Ask Smalley. We have nothing against sales people. But when it comes to differentiating Inconel from Elgiloy or overcoming dimensional variations within a complex assembly, wouldnt you rather work with an engineer?
Our customers would. Thats why they collaborate directly with our world-class team of Smalley engineersexperienced professionals whose only focus is helping you specify or design the ideal wave spring, Spirolox retaining ring or constant section ring for your precision application.
Smalley wave springs reduce spring operating height by 50%, saving space and weight, tting tight radial and axial spaces. We offer more than 4,000 stock sizes in carbon and stainless steel.
Visit smalley.com for your no-charge test samples.
HOW DO I KNOWIF IM TALKING TO AN ENGINEER OR A SALESMAN?
THE ENGINEERS CHOICE
Ask Smalley. We have nothing against sales people. But when it comes to differentiating Inconel from Elgiloy or overcoming dimensional variations within a complex assembly, wouldnt you rather work with an engineer?
Our customers would. Thats why they collaborate directly with our world-class team of Smalley engineersexperienced professionals whose only focus is helping you specify or design the ideal wave spring, Spirolox retaining ring or constant section ring for your precision application.
Smalley wave springs reduce spring operating height by 50%, saving space and weight, tting tight radial and axial spaces. We offer more than 4,000 stock sizes in carbon and stainless steel.
Visit smalley.com for your no-charge test samples.
Smalley wave springs reduce spring operating height by 50%, saving
tting tight radial and axial spaces. We offer more than 4,000 stock sizes in carbon and
smalley.com for your no-charge
reduce spring operating
Coil SpringSmalley Wave Spring
38139_Smalley_BrandAd_DesignWorld_r3.indd 1 9/1/15 3:43 PMSmalley 10-15.indd 24 12/2/15 11:57 AM
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July 2015 DESIGN WORLD 2 5
l C o n t r i b u t o r s S p o t l i g h t
Protecting against mechanical overload damage
EDD BROOKSTechnical RepresentativeNexen Group
MATT RECK
Product Line Manager Air Bearing SystemsPhysik Instrumente
December 2015 DESIGN WORLD 2 5
Space vectors aide drive for optimal efficiency
JOHANNES TEIGELKTTERHBM
Why you should consider air bearings
Johannes has worked in the industry for 14 years, from 1986 until 2000. He worked in fields ranging from power electronics and instrumentation to drive technology for locomotives. But recently, he has been teaching and researching as a professor in the fields of electrical machines, power electronics and drives at the University of Applied Sciences in Ascheffenburg. Sometimes young engineers only rely on outputs of a computer calculation without verifying, he said. I think its very important to learn how to check these results on the basis of physical phenomenon. The best thing about his job, he said, is working with students to find a creative solution for technical problems. A few years ago, I developed an electric powered kart with my students. We carried out several test runs to optimize the system, he said. During one test run, the right rear wheel broke and the kart was overtaken by the wheel. Luckily, the kart was able to run on three wheels and could be brought to a halt without any accidents. And while he works with the future of engineering, he still doesnt see a predictable future. To quote Niels Bohr, Prediction is very difficult, especially if its about the future he said. The world is changing very fast so its impossible to predict whats going to happen in 20 years.
fun factJohannes enjoys both the Harry Potter novels and movies. He especially likes watching the movies and reading the novels with his children.
66
80
Matt earned his bachelors degree in Mechanical Engineering from the University of Pittsburgh. While in school, he participated in a co-op program where he spent 16 months working as a junior engineer for a Fortune100 company full time. (Students should) take every chance to engage in internships and co-op programs, he said. After his time in the co-op program, Matt said knew so much more about how things get done in the industry than he would have without that experience. The work experience also helped guide my class selection in my last year of school, as I became more interested in certain topics. But, he also wishes he had learned more about the manufacturing processes during his time as a student. I think schools should do a much better job teaching students how metal parts are machined, PCBs and ICs are made, plastics are molded, optics are ground and so on, he said. When you understand how the things we use every day are actually made, I think you become a more creati e engineer.
fun fact
Matt doesnt think a robot take over will happen anytime soon. Personally, I think we have bigger problems to worry about, such as global climate change, long before AI becomes a threat, he said.
100
Throughout Edds 47-year career, he has developed, designed and marketed power transmission devices. He also provided selection and performance data to help customers with their machines. A lot of people think engineers have answers to any technical question, whether the subject is in the area of expertis of the individual or not, Edd said. Often times, the answer is available with a little research. Edd used to work with Horton Industrial Products, where he was responsible for the design and patent of clutches, breaks and torque limiters from conception to market ready. As a custom business unit manager, he was responsible for the design of special products for specific applications. He now has three patents for fluid-powered products and has written white papers on rotary and linear motion. During his time developing and designing, Edd found that a en ve engineers are the key to success. Engineers must pay attention to the markets they serve and design products that have appeal as usable items that are cost effective, he said.
fun factEdd loves to spend time with his sons and their families. He can be seen at a variety of sporting evens or at car shows that range in subjects from the latest technologies to collectables.
Top 10 benefits of IoT enabled mechatronics
MARK HUEBNERMarketing & Market DevelopmentPBC Linear
Mark Huebner is a graduate of Hyles-Anderson College and has been with PBC Linear since 2010. He is an experienced field sales and account manager for linear motion and bearing manufacturers. In addition, he has experience managing projects in a variety of capacities, helping to streamline processes, develop new products and deliver them to the market place.
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Contributor Page 12-15_Vs2.MD.indd 25 12/3/15 2:55 PM
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2015
3
Co n te n t s | D e c e m b e r 2 0 1 5 v o l 1 0 n o 1 2 | d e s i g n w o r l d o n l i n e . c o m
MOTION CONTROL
Protecting against mechanical overload damageMechanical torque limiters help remove energy from drivetrains, reducing machine faults and downtime.
66
F E A T U R E S
80
2015
revenue over $3 million
LINEAR MOTION
Linear encoders improve accuracyLinear encoders boost accuracy by correcting errors downstream of mechanical linkages.
72
ON THE COVEROperators no longer sit in a control room waiting for something to happen on the factory floor. Thanks to networking technology and data analysis, better information is leading to greater efficiencie Photo courtesy of PBC Linear
TEST & MEASUREMENT
Space vectors aide drive for optimal efficiencyUsing space vectors in test equipment helps engineers get a clearer, more precise picture of three-phase motor electromagnetics.
2015ONLINE
86 INTERNET OF THINGSTop 10 benefits of IoT enabled mechatronicsThe latest trend in machinery design is to take advantage of the Internet of Things benefits, which are seen throughout a machines life cycle.
92 3D CADHow simulation helps accelerate the design processThe capability to design, test and validate in the digital world helps get products to market faster for less money.
100 MECHANICALWhy you should consider air bearingsIts easy to overlook air bearings. Most of the time, mechanical bearings work well enough for a motion application. Most, but not all. Here are tips that will smooth out the specification process.
MAKE PARTS FAST
107 - 127
A supplement of Design World December 2015
Inside:
110
How do you really use 3D
printing systems?
114
3D printing aids in design
of patient simulator
Material advances in metal printing3D 120
COVER_MPF 12-15_FINAL Vs2.MD.indd 107 12/2/15 12:47 PM
2 6 DESIGN WORLD
INTERCONNECT
129 - 158
InterA supplement of Design World December 2015
I N S I D E : Selecting VFD Cables Board Connector Challenges Trends
2015 Cable & Connector
Handbook
Cover photo courtesy of Fischer Connectors
COVER_Interconnect_2015_Vs1.indd 129 12/2/15 1:02 PM
CONTENTS DECEMBER 2015_first page_Vs3.LL.MD.indd 26 12/3/15 9:42 AM
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Whatever keeps you up at night, weve got a solutionthe largest selection of motors, pumps and air-moving devices available. Plus, one-of-a-kind solutions ready to be
custom-engineered for your precision industrial, commercial, combustion or transportation application. If you can dream it, youll nd it at Solution City.
FOR MOTION CONTROL INNOVATION, SOLUTION CITY NEVER SLEEPS.
2015 by AMETEK Inc. All rights reserved.
100 East Erie StreetKent, OH 44240ametekdfs.com
AMETEKPMC 18611_City Never Sleeps Ad_9x10.875.indd 1 7/29/15 9:14 AMAMETEK PMC (Solutions City) 8-15 (NEW).indd 27 12/2/15 12:02 PM
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Co n te n t s
D E P A R T M E N T S
16 Insights
18 Teschler on Topic
20 Technology Forward 25 Contributors 30 Green Engineering
32 Engineering Exchange
34 Design For Industry
46 Design Notes
54 CAE Solutions
60 Internet of Things
159 Product World
164 Ad Index
12 . 2 0 1 5
2 8 DESIGN WORLD December 2015
46
60
Rod Ends and SphericalBearings designed andmanufactured to Aurora'sexacting standards for qualityand durability.
Registered and Certified toISO-9001 and AS9100.
From economy commercial toaerospace approved, we've got it all !
Aurora Bearing Company901 Aucutt RoadMontgomery IL. 60538
Complete library of CAD drawings and 3D models available at:w w w . a u r o r a b e a r i n g . c o m
Aurora-Where_the_Action_Is:Aurora 11/5/10 1:10 PM Page 1
34
Contents DECEMBER_second page_Vs1.indd 28 12/2/15 12:40 PM
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Call on the global quality and value leader.Now part of AMETEK Precision Motion Control, and recognized since 1950 as the world market leader in customized
fractional horsepower motion control solutions for the medical, packaging, automation, semiconductor and renewable
energy industries.
1500 Bishop Ct - Mt Prospect, IL 60056
Call: 773-289-5555
www.dunkermotoren.com
Call on the global quality and value leader.Now part of AMETEK Precision Motion Control, and recognized since 1950 as the world ma
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Dunkermotor 11-15 (new).indd 29 12/2/15 12:03 PM
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Danfoss cutting energy consumption by half
n Paul J. Heney Editorial Director
G r e e n E n g i n e e r i n g
3 0 DESIGN WORLD December 2015
The International Energy Agency has stated that energy efficiency can deliver 38%
of the greenhouse gas reduction required
to avert climate change. Danfoss is now
accelerating its own eff rts by introducing
new ambitious climate targets.
Most of the worlds energy consumption
comes from industry and buildings, and
the potential for cutting it is huge. Danfoss,
wanting to be a role model, has set new
ambitious targets for itself ahead of the
COP21 climate summit in Paris. By 2030, the
company plans to use half as much energy to
run its business, and emit half as much CO2
from the energy it uses.
Worldwide, we deliver some of the most
innovative and efficient technologies for
saving energy, helping cities and companies
to reach their targets, said President and
CEO Niels B. Christiansen. Now, we are
intensifying our own eff rts in the form of
a new, ambitious climate strategy, which
builds on what we have already done and
achieved. We see this as a natural part of
leading the way within the climate sector.
The company is already making progress
in living up to these targets. Between 2007
and 2014, its net sales increased by 55%,
whereas energy consumption dropped by
29%. Danfoss has been running energy-
saving projects, among other things, at the
largest factories worldwide. Typically, this
reduces energy consumption for operating
the buildings by 25 to 30%. The savings are
primarily obtained through the optimization
of the systems controlling the ventilation,
heating and cooling using their own
products.
Based on the positive experiences, the
company is now intensifying its eff rts
to energy-optimize the companys buildings
all over the world. In addition, production line
processes will be systematically examined for
further energy cuts.
Green energy sources are another focus
area. In 2013, for example, the manufacturer
set up a solar cell parklikely the biggest of its
kind in Scandinavianext to its headquarters
in Nordborg, Denmark. The park produces
electricity corresponding to the annual
consumption of 400 single-family houses, and
has a total capacity of 2 MW. A 1-MW solar-cell
system was also opened at the companys new
campus in India last year. Moreover, the new
campus has received the international LEED
Platinum rating, whereby it is certified as a
green and sustainable building complex. DW
Danfossdanfoss.us
Green Engineering_12-15_Vs3.MD.indd 30 12/2/15 12:20 PM
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2015 by AMETEK Inc. All rights reserved.
Nothing moves air with more rock-solid reliability than AMETEK Rotron regenerative blowers. Fifteen years service life is not unusual. These low-pressure, high-volume blowers feature rugged, compact construction and quiet operation. Their proven design makes them ideal in applications from chemicals, wastewater and furnaces to vapor recovery and more. Plus, theyre backed by the industrys most knowledgeable engineering experts. AMETEK can customize your blower for harsh environments, high voltage and specialized applications, too. So make your next air-moving challenge a breeze. Call us at +1 330-673-3452 or visit our website to get started.
Whats 15 years to one of our blowers?A warm-up.
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with Design WorldDIGITAL ISSUE
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December 2015www.designworldonline.com
MOTION CONTROL: Protecting against mechanical overload damage PAGE 66
LINEAR MOTION: Linear encoders improve accuracy PAGE 72
TEST & MEASUREMENT: Space vectors aide drive for optimal efficie y PAGE 80
Top 10 benefits f
IoT Enabled Mechatronics
86
INSIDE:
Integrating Internet Connected Smart Robot Modules
2015Leadership Winners 3 - 15
Cover_DW_December 2015_FINALFINAL.indd 1 12/3/15 3:05 PM
NASA helps puch additive manufacturing boundaries
How do dynamic bearing loads affect bearing life
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Legacy CAD and Engineering Data: Keep it Updated
What are Ball Screws?
Bearings are subjected to certain levels of repeated stress or dynamic loading on their raceways and rolling elements
during operation under proper loading, appropriate mounting
and sufficient lubrication.
connect
A team at Marshall Space Flight Center is exploring additive manufacturing (3D printing) for NASAs Space Launch System
(SLS) rocket. The team is looking into the capabilities, costs
and benefits of using additive manufacturing on their latest
liquid rocket injector.
Posted by David Herres
http://dwo.me/1QPWy6e
Ball screws are mechanical devices that convert rotational motion to linear motion with a minimal amount of friction.
Ball screws are used in an array of applications ranging
from low accuracy transport guides to high accuracy
precision grade screws. They are also used in robots,
machine tools and precision assembly devices.
http://dwo.me/1QPXvLJ
Legacy information and original drawings are being lost as enterprise software is updated beyond the package used to create the original drawings and as the engineers who made the original drawings retire or move to another position or company. The issue,should be of concern to everyone, including designers.
Quantum tunneling and tunnel diodes
3 2 DESIGN WORLD December 2015
Engineering Exchange 12-15_Vs1.indd 32 12/3/15 3:06 PM
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BGS Linear Rail Systems...
BGS04 Size 11, Standard Assembly, 1.1-in. 2 (28 mm)2, (22 lbs. [100 N] max. horizontal load)
BGS08 Size 23, Standard Assembly, 2.3-in. 2 (57 mm)2, (225 lbs. [1,000 N] max. horizontal load)
BGS06 with optional programmable IDEA stepper motor drive
Haydon Products Division1500 Meriden RoadWaterbury, CT 06705 U.S.A. Telephone: 203.756.7441
Kerk Products Division1 Kerk DriveHollis, NH 03049 U.S.A. Telephone: 603.465.7227
Call 1.8OO.243.2715 www.HaydonKerk.com
ACCURACY REDEFINED
BGS (Ball Guide Screw) linear rail systems from Haydon Kerk Motion Solutions
raises accuracy to a new level
Haydon Kerk Motion Solutions BGS products are designed to position heavy loads and maintain repeatability and accuracy while withstanding signicant cantilevered loading. A Black Ice TFE coated lead-screw drives a precision nut embedded in a machined aluminum carriage mounted to a stainless-steel ball rail. The result is a smooth operating, yet rigid linear motion system. Maximum stroke lengths: BGS04 18 in. (460 mm); BGS06 24 in. (610 mm); BGS08 30 in. (760 mm).
All motorized BGS rail systems utilize Size 11, Size 17 or Size 23 hybrid linear actuator stepper motors. A programmable IDEA Drive is available for Size 17 or Size 23 frame sizes. By combining technologies into a single pre-assembled motion system, Haydon Kerk is able to improve system integration for the OEM or end user.
Haydon Kerk Motion Solutions also oers BGS Linear Rail design and manufacturing exibility. A system can be customized to accommodate a customers unique application. The BGS product line is supported by an experienced technical team recognized for innovation, customization, and dedicated customer service.
For more information: www.HaydonKerk.com > Linear Rails, Guides & Splines > BGS Linear Rail Systems
BGS06 Size 17, Standard Assembly, 1.7-in. 2 (43 mm)2, (135 lbs. [600 N] max. horizontal load)
NOW... 24 HOUR SHIPPING of standard assembly BGSlinear rails, ordered online at www.HaydonKerkExpress.com
24 -HR SHIPPING / E-COMMERCE
Haydon Kerk 12-15 (Accuracy Redefined).indd 33 12/2/15 11:59 AM
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01
m i l i t a r y / a e r o s p a c e
D e s i g n f o r I n d u s t r y
3 4 DESIGN WORLD December 2015 www.designworldonline.com
Modular conveyor system for quick assembly
f o o d / b e v e r a g e
Attaching and uncoupling the finis ed
roof linings are the only manual procedures
required in this fully automated system.
This system helps increase productivity as
factory personnel may use the time savings
to complete other tasks. Currently, this
automotive manufacturer operates four
complete manufacturing lines using the
same application of VarioFlow plus.
In combination with MTpro planning
software, the modular chain conveyor
system saves time during project planning.
The complete conveyor system can be
designed in just a few stepsall the
way from drag and drop selection of
Noise reduction is an increasingly attractive way to improve factory work
environments. VarioFlow plus is one of
Bosch Rexroths major contributions to
noise reduction, with particularly low-noise
operation thanks to sliding bars with lateral
fi ation, low-friction materials and patented
hinge bolts. At the same time, modular chain
conveyor system provides optimum sliding
properties for reduced wear, even with chain
tensile forces up to 1,250 N.
An example of its flexible application can be found in the automotive industry.
To improve handling and save space during
transport, an innovative manufacturing cell
based on VarioFlow plus can convey roof
linings, at a height of about 3 m, directly to a
robotic unit at a processing station.
components to order placement, including
verification of workpiece carriers and complete system configuration. The VarioFlow plus chain conveyor
system is available in six conveyor widths
between 65 and 320 mm; seven chain types
and two models in aluminum and stainless
steel with FDA-compliant materials opens up
a wide spectrum of applications. DW
Bosch Rexrothboschrexroth-us.com
The VarioFlow plus modular chain conveyor system offers universal and quick application, easy planning and
assembly. The system also boasts
extremely quiet and low-wear operation.
DFI 12-15_Vs4.LL.MD.indd 34 12/3/15 8:49 AM
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Altra Industrial Motion
Vol. 4 | No. 4 | 2015
The Power Brands in Power TransmissionPower Review
Altra Industrial Motion The Power Of Experience
Ameridrives Couplings
Ameridrives Power Transmission
Bauer Gear Motor
Bibby Turboflex
Boston Gear
Delroyd Worm Gear
Formsprag Clutch
Guardian Couplings
Huco Dynatork
Industrial Clutch
Inertia Dynamics
Kilian Manufacturing
Lamiflex Couplings
Marland Clutch
Matrix International
Nuttall Gear
Stieber Clutch
Svendborg Brakes
TB Woods
Twiflex Limited
Warner Electric
Warner Linear
Wichita Clutch
For more information contact us at: [email protected] or visit www.altramotion.com
Featured in this Edition...
Find Altra Industrial Motion on:
Scan to downloadthe interactive version of the Power Review
Svendborg Brakes SOBO iQ and Industrial Product Line
Warner X-Small Brakes
Bauer Stainless Steel Products
Kilian Application Profiles for the Medical Industry
TB Woods Sure-Flex Plus
Ameridrives Repair Program
Boston Gear Expanded Stainless Steel Line
Altras YouTube How-To Video Series
Twiflex Brake Calipers
SVENDBORG BRAKES Industrial Product Line
SOBO iQ Controller
Altra Industrial_#1_12-15.indd 35 12/2/15 11:41 AM
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Svendborg Brakes: SOBO iQ and Industrial Product Line
Kilian Provides Solutions for the Medical Industry
Warners Custom Designed X-Small Brakes
TB Woods Sure-Flex Plus
Bauer Gear Motor Stainless Steel Products
Svendborg Brakes introduces SOBO iQ controlled braking for general and conveyor systems for any application with hydraulic failsafe brakes where consistent stopping times or distances are desired and less wear and tear on equipment. The SOBO iQ provides a soft and predictable braking sequence and is typically utilized in applications such as conveyors, cranes, hoists, water gates, bridges, barge unloaders, plus many others.
As a standalone unit, the SOBO iQ is capable of controlling up to four different hydraulic power units up to 100km away. The SOBO iQ is meant to be a single control unit for all of the brakes in a single mechanical chain.
Svendborg Brakes comprehensive product range also includes: custom, active and failsafe hydraulic brakes, hydraulic power units, brake discs, etc. Complete braking solutions include extensive design services, market-leading products, a quality-focused supply chain and unmatched after sales services.
For more information download P-7916-SV, P-7923-SV & P-1723-18-SV from www.AltraLiterature.com or visit www.Svendborg-Brakes.com
X-Small Brakes are electrically released spring-set holding brakes for applications where weight or space are major constraints.XS Brakes have been designed with two key constraints in mind: optimize the torque level in the smallest space design and at the lightest weight. XS Brakes are highly reliable, fail safe devices designed as statically engaged/disengaged holding brakes. These brakes provide low cycle rate stopping action in emergency situations.
XS Brakes are particularly suited for applications where verysmall space envelopes and extra low weights are critical: aerospace, medical machinery, machine tools, etc.
For more information download P-7778-WE & P-7899-WE from www.AltraLiterature.com
Bauer Gear Motor provides a full complement of worm and helical gear drives with varying degrees of sanitary protection to meet the needs of the diverse requirements within a production facility. From standard cast iron and aluminum housings with white or stainless epoxy paint, to fully aseptic or complete stainless steel units, Bauer Gear Motor can provide a drive solution to meet the application requirements.
For more information download P-7665-BBG from www.AltraLiterature.com
Kilian Manufacturing provides unique solutions for several facets of the medical field. Precision and custom bearing assemblies are provided for hospital overbed tables, mobile medical workstations, x-ray tables, ambulance stretchers, and blood centrifuges.
Kilian engineers can develop custom solutions to meet OEM requirements. Kilian works to design cost-effective, easy-to-install assemblies to satisfy custom application requirements.
For more information download Application Profiles P-7846-KM, P-7847-KM, P-7848-KM, P-7850-KM & P-7851-KM from www.AltraLiterature.com
For over 50 years, TB Woods has led the coupling industry with the original TB Woods Sure-Flex design. And we havent stopped innovating: this industry favorite just got even better.
Our new Sure-Flex Plus EPDM and Neoprene sleeves are best-in-class for coupling performance and value. Heres why:
High Torque Rating - 30% Increased Torque Rating Longer Life - Lasts Over 3X Longer than the Competition Better Value - Save Money Using a Smaller Coupling Interchangeable - Retrofits to Existing Flanges
For more information download P-7819-TBW from www.AltraLiterature.comor visit www.TBWoods.com
TB Woods Incorporated
Altra Industrial_#2_12-15.indd 36 12/2/15 11:44 AM
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Ameridrives Repair Program
Altras How-To Video Series on YouTube
Boston Gear Expanded Stainless Steel Line
Twiflex Brake Calipers
Call Twiflex Toll-Free: 844.723.3483
For more information download P-7949-C from www.AltraLiterature.com
Ameridrives remanufactured couplings look like new, perform like new and are warrantied like new.
Ameridrives Rebuild Service can refurbish your old, worn couplings for substantially less than the cost of a new replacement coupling. The economical rebuild service applies to all Ameridrives couplings including Ameridisc, Ameriflex and Amerigear high performance, high speed couplings used primarily on turbomachinery, compressor and pump applications in the power generation, oil & gas and marine industries. Other coupling brands are accepted on a case-by-case basis.
As a leading global coupling manufacturer, Ameridrives has the team, facilities, and nearly 100 years of inspection and repair experience to rebuild and replace all coupling components as required. Repairs are completed to meet the exacting standards of the original coupling.
For more information download P-7948-AC from www.AltraLiterature.com.
For details on the rebuild program, call 814.480.5095 or visit www.Ameridrives.com
Twiflex offers the largest range of industrial disc brake calipers in the world. Spring applied units may be retracted pneumatically, hydraulically or electrically (depending on caliper design) while most direct acting brakes have some form of positive retraction device.
Pneumatically Applied Brakes are best suited for light to medium stopping duties and for tensioning applications where a high degree of control is required.
Hydraulically Applied Brakes address higher torque requirements, while spring applied calipers are essential where braking must be maintained in the event of supply system failure
Mechanically Applied Units are suitable for light tensioning duties or where no external power is available. They may also be specified when designers wish to use their own means of actuation.
For more information download P-1648-TF from www.AltraLiterature.com
Boston Gear has recently expanded the Stainless Steel product line to include:
3 New Sizes of SS700 Series - Worm Gear 713, 715 and 724 center distances now available SSHF713 redesigned to include hollow bores up to 1.00
All SS700 Series Now Available With QC Option QC Quick-Connect motor mount option Compact coupling for quick and easy motor disassembly
3 New Sizes of SS2000 Series - Helical Inline 2030, 2050 and 2070 frame sizes with full compliment of mounting
options Output torque to 7500 lbf-in
Larger AC Motors Now Available 5, 7.5 and 10 HP TEFC motor sizes 208-230/460 -3-60 VAC, 1800 RPM nominal
2 New Styles of SS Mounted Bearings Offering now includes 3-bolt drop bearing and wide slot take-up styles Expanded range of bore sizes
New Coupling Bore Sizes, Universal Joints and Shaft Accessories More complete offering of shaft accessories
Visit Altra Industrial Motion on YouTube to see our newest videos, including our recently added instructional How-To Video Series.
The How-to Video Series offers helpful how-to videos on a variety of industrial applications. We upload new videos routinely, so check back often.
Warner Electric, TB Woods, and Boston Gear currently have videos featured in the How-To Series that include installation instructions and troubleshooting.
Scan to visit the How-To Video Series
www.YouTube.com /user/AltraIndMotion
Ameridrives Rebuild Service can refurbish your old, worn couplings for substantially less than the cost of a new replacement coupling. The economical rebuild service applies to all Ameridrives couplings including Ameridisc, Ameriflex and Amerigear high performance, high speed couplings used primarily on turbomachinery, compressor and pump applications in the power generation, oil & gas and marine industries. Other coupling brands are accepted on a case-by-case basis.
As a leading global coupling manufacturer, Ameridrives has the team, facilities, and nearly 100 years of inspection and repair experience to rebuild and replace all coupling components as required. Repairs are completed to meet the exacting standards of the original coupling.
Couplings are received, inspected and rebuilt in the shortest possible time frame. We will work to accommodate your shut down schedule.For details on our cost-saving program call (814) 480-5095 or visit www.Ameridrives.com.
A l t r a I n d u s t r i a l M o t i o n
The Ameridrives Rebuild Service Team will conduct a comprehensive inspection of your coupling and perform the following to restore your coupling to its original specifications with a new coupling warranty: All potential wear components metallic and gear flex elements, shims, and fasteners are
refurbished or replaced to new performance standards. Magnetic Particle Inspection
(MPI) on all torque transmitting components. Removal and repair of surface defects on a lathe and glass bead blasting as appropriate while
maintaining original coupling integrity.
Precision dimensional and Total Indicator Run-out (TIR) measurement
Rebalancing to original API 671 certification if applicable. This re-certification requires the return of the entire coupling structure.
I N T R O D U C I N G
Ameridrives Rebuild Service
Ameridrives remanufactured couplings look like new, perform like new and are warrantied like new
For more information call (814) 480-5095 or visit www.Ameridrives.com.
P-7948-AC 10/15 Printed in USA
www.ameridrives.com1802 Pittsburgh AvenueErie, PA 16502 - USA814-480-5000Fax: 814-453-5891
For more information download P-7631-BG & P-1998-BG from www.AltraLiterature.com
Altra Industrial_#3_12-15.indd 37 12/2/15 11:45 AM
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Power Transmission and Motion Control Solutions for Industrial Applications
The Power Brands in Power Transmission
Ameridrives Couplings
Ameridrives Power Tranmission
Bauer Gear Motor
Bibby Turboflex
Boston Gear
Delroyd Worm Gear
Formsprag Clutch
Guardian Couplings
Huco Dynatork
Industrial Clutch
Inertia Dynamics
Kilian Manufacturing
Lamiflex Couplings
Marland Clutch
Matrix International
Nuttall Gear
Stieber Clutch
Svendborg Brakes
TB Woods
Twiflex Limited
Warner Electric
Warner Linear
Wichita Clutch
www.AltraMotion.com
Altra Industrial_#4_12-15.indd 38 12/2/15 11:47 AM
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Brakes ensure precise control
As products move along automated packaging systems, accurate positioning is key to operation. PBZ variable torque
brakes handle needs for variable torque tensioning control in
automated packaging systems and similar applications.
Unlike conventional mechanical brakes, the variable torque
brakes are magnetic particle brakes. They use self-contained
magnetic particles that slow, stop, hold and restart a system with
repeatable accuracy. The torque is independent of slip speed and
is variable from zero to the rated torque.
The brakes precise, fast engagement ensures accurate
positioning without jolts or jerking motion. This feature enables
repeatable positioning of plastic film in luding labels, bar codes
and other packaging elements with accuracy. A gradual or fast
engagement setting is adjustable for different application requirements. The adjustment range is variable up to the brakes
control circuit capacity.
Another feature: These brakes do not have components
that can wear. They are unaffected by atmospheric conditions, so are suited for temperature extremes in a range of operating
environments.
Available in three 24/80 V models with rated torque of 3, 6
and 12 Nm, all three sizes have a 400-rpm allowable rotation. DW
Miki Pulley Industrial Brakesmikipulley-us.com
www.designworldonline.com December 2015 DESIGN WORLD 3 9
D e s i g n f o r I n d u s t r y 02f o o d / b e v e r a g e
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4 0 DESIGN WORLD December 2015 www.designworldonline.com
m e d i c a l
December 2015 DESIGN WORLD 4 1
03 D e s i g n f o r I n d u s t r y 3D printers prototype winding body for MRI scanner
3D printing is becoming a common tool for the design of prototypes for medical equipment.
This includes, for example, the development of
components of a patient table for use in MRI
scanners. The specific project for Popp Group involved the development of a winding body for
a rotating device, which later had to be fitted directly on the patient table.
DFI 12-15_Vs4.LL.MD.indd 40 12/3/15 2:57 PM
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December 2015 DESIGN WORLD 4 1
WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly.
Visit our websitewhittet-higgins.comto peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local or a good distributor.
33 Higginson Avenue, Central Falls, Rhode Island 02863Telephone: (401) 728-0700 FAX: (401) 728-0703 E-mail: [email protected] Web: www.whittet-higgins.com
POWER TRANSMISSIONRETAINING DEVICES &maintenance & assembly tools
WHITTET-HIGGINS
USA
BEARLOK SHOELOK BEARLOK Shrink Disc
BEARHUG CLAMPNUT TANGENTLOK
PRECISION NUTS & WASHERS ADAPTER SLEEVE ASSEMBLIES
NUTS & WASHERS HARDENED TONGUE WASHERS SPLIT COLLAR
RETHREADING DIES ADJUSTABLE SPANNER WRENCH BEARING ASSEMBLY SOCKET
INCH and METRIC THREADSLEFT HANDED as well as
RIGHT -HANDED
Materials of:CARBON, ALLOY and HARDENED ALLOY
STEELS
Materials of:ALLUMINUM and
CORROSION RESISTANT STEEL
The designed part had to accommodate the fixi g and
assembly components as well as the cover. While the end
product was injection molded, the entire prototyping was
carried out with an X400 3D printer from German RepRap.
Only when we are certain that no more modifications are required do we create the expensive injection mold, said Rene
Schneider, project leader. Up to that time, we do everything with
3D printing. Any faults or changes required by the customer
are easy to rectify and implement. We previously had to wait
several days for a new prototype, such as for CNC milled parts.
But the 3D printed prototype is often already available in a
matter of hours. The printing of this winding body took around
10 to 12 hours.
Thanks to the large build area of approximately 40 40 cm,
Popp is able to print three parts at the same time.
For Popp Group, compared to conventional prototyping,
there are no disadvantages with 3D printing for prototyping.
Prototypes are required to have the same properties as the end
product, both mechanically and functionally, as well as with
regard to their material characteristics. The PLA frequently
used in 3D printing is ideal here for medical technology since
it is non-imaging and is not therefore shown in an MRI scan,
Schneider said.
3D printing has become firm y established in product
development at the Popp Group. Our X400 3D printer runs at full
capacity, Schneider added. DW
German RepRapgermanreprap.com
WHAT DO YOU THINK?
Connect and discuss this and other design engineering issues with
thousands of professionals online
DFI 12-15_Vs4.LL.MD.indd 41 12/3/15 9:06 AM
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4 2 DESIGN WORLD December 2015 www.designworldonline.com
An intelligent steering option incorporates both a steering and a safety
controller into an electrohydraulic actuator,
saving development resources and
accelerating time to market for OEMs across
agriculture, construction, road building,
material handling and specialty markets.
The system connects directly with GPS
to allow automatic steering for an array of
off-h ghway machineryincluding tractors,
combines and sprayers. It also improves
driver comfort with Quick Steering
functionality and enables joystick or mini
wheel steering for all applications. Previous
steering systems used an external safety
controller to monitor the electrohydraulic
section of the steering valve.
The OSPE with PVED-CLS actuator
option is part of the Danfoss Functional
Safety Solution. Designed with the
safety of machine operators in mind, the
flexible software-based system comes preconfigured with a number of steering-specific safety functions informed by comprehensive safety analysis and
customer research. It can be easily adjusted
o f f - h i g h w a y04 D e s i g n f o r I n d u s t r y
Steering system integrates safety
to meet the specific output and safety requirements of each application. It also
includes integrated electrical follow-up
(EFU). EFU aligns the steering wheel with
the tires to ensure precise, unwavering drive
trajectories. With this automation comes
easier operation, higher productivity and
reduced driver fatigue.
With PVED-CLS, system designers no
longer need to ensure that multiple parts
are communicating. Now that the PVED-CLS
is in direct contact with system pressure
and feedback from the LVDT transducer, the
operator is able to react more quickly and
accurately than with an external controller.
When it comes to safety, this fast and
precise reaction is crucial, and the tight
sensor coupling also means less machine
downtime and fewer false alarms. In case of
a fault, the monitor gives operators manual
control within the electrohydraulic safe
state.
In addition to improving functionality,
the integration of the safety controller
into the steering unit reduces the system
complexity.
The OSPE with PVED-CLS is certified by TV SD, the German safety validation
organization, for functional safety of
electronic equipment (SIL2 for IEC 61508)
and functional safety of control systems (PL
d, ISO 13849 and AgPL d for ISO 25119 [EN
16590]).
The PVED-CLS hardware is based
on a fully redundant Category 3 system
architecture. The system takes care of
steering hazards off oad. Additionally,
the PVED-CLS has received the E-mark
stamp from VCA (the United Kingdom
Vehicle Approval Authority). The E-mark
is a general certification regarding EMC (directive ECE R10), which OEMs can use
toward fi al vehicle homologation. DW
Danfoss Power Solutions powersolutions.danfoss.com
DFI 12-15_Vs4.LL.MD.indd 42 12/3/15 9:08 AM
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Precisely synchronize conveyor belts and robots
m a c h i n e t o o l05 D e s i g n f o r I n d u s t r y
An increasing number of processes in production lines require synchronization with
conveyor belts. Ensuring the high levels of speed
and precision needed to accomplish this previously
required highly complex control solutions. Production
lines with conveyor belt tracking have an advantage:
Since the production process never comes to a stop,
they can achieve higher production volumes.
www.designworldonline.com December 2015 DESIGN WORLD 4 3
GREASELESS BEARINGS IDEAL FOR CONSTRUCTION
AND AG EQUIPMENT
The new revolutionary EWS composite bearing offers 300% longerservice life compared to our industry-leading MRP bearings.
Trusted by leading brands, Polygon is the largest producer of composite bearings in the world.
Developed initially for an Ag application, EWS needs no greasing and is designed to handle contaminated environments.
polygoncomposites.com
2015 Polygon Company
DFI 12-15_Vs4.LL.MD.indd 43 12/7/15 11:12 AM
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4 4 DESIGN WORLD December 2015 www.designworldonline.com
m a c h i n e t o o l05 D e s i g n f o r I n d u s t r y
The complexity of these systems is
constantly increasing, for example, as
robots are added to these systems. One
way to reduce the complexity is to use
tools inherent in systems like PLCopen. The
function blocks in PLCopen can be used for
all types of robot kinematics and even allow
robots to be synchronized with multiple
conveyor belts. The interfaces are also
suited for integrating HMI applications for all
types of kinematic systems.
The robot can move freely during the
synchronization phase, which also enables
complex product manipulation. B&R offers a system in which the conveyor belt is fully
integrated into the application. An external
sensor that supplies information about the
current position of the conveyor belt is all
that is needed.
The conveyor belt tracking system
is hardware-independent, which allows
the use of different drive systems with different kinematics. The application can be created quickly and easily upgraded at a
later time. The robot can be replaced or the
conveyor belts can be upgraded at any time
without a significant amount of application engineering work. A large portion of the
software can be used as is. DW
B&R Industrial Automation br-automation.com
WHAT DO YOU THINK?
Connect and discuss this and other design engineering issues with
thousands of professionals online
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With its compact size and flexible installation options, EPCs new 30M Incremental Encoder Module can fit in tight spaces.
Its bearingless design allows the 30M to work at high speeds yet its tolerant of shaft
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encoders in its class.
The magnetic sensor and optional IP69K seal mean it can go into your dirtiest, dustiest, wettest applications and itll keep going.
Call EPC today. Discover how the 30M can tackle your tough application.
The NEW encoder module that gets the job done.
DFI 12-15_Vs4.LL.MD.indd 44 12/7/15 11:17 AM
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AlwAys essentiAlOften invisible
For FreudenbergNOK Sealing Technologies, the power to innovate is key. Our compound portfolio spans hundreds of individual mixtures, each tailored to a specific applica-tion, each capable of staying flexible and operational in
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Freudenberg 11-15.indd 45 12/2/15 5:43 PM
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4 6 DESIGN WORLD December 2015 www.designworldonline.com
D e s i g n N o te s
US Cotton, a domestic manufacturer of cotton swabs, was considering the replacement of the pneumatic cylinders on one of its
major production machines. The application involved picking a layer of
cotton swabs out of the assembly section of the machine and placing it
in a stack before going into the retail package.
The company was looking for better control and reduced
maintenance. Control, because operators had to make frequent
adjustments to the machines to compensate for changes in air
pressure. Maintenance, because the air cylinders in each of the several
dozen machines had to be replaced every one to two months. The
company needed an actuator that would last much longer.
The search led the engineers to linear motors made by LinMot. These
linear motors differ from others in that they are tubular-style linear
motors, as opposed to open, track-style linear motors. The tubular-
style linear motor actually looks and acts somewhat like a pneumatic
Electric linear motors picked for swab application
cylinder. The motors are sealed so they can operate in dirty environments
and dont require any moving cables.
Cost is always a factor in design, but its important to balance cost
over benefit. In this case, energy savings can justify the price of the linear
motors. But the staff t US Cotton needed convincing.
The company said that it would volunteer machines to use test beds
(along with some personnel) if LinMot would provide the equipment
needed to perform a test. LinMot agreed. US Cotton chose one of the
systems (linear motor and drive) and installed it on a machine to evaluate
the technology. After running for more than 18 months, there were no
adjustments required and no replacements needed.
For the fi al test, LinMot and US Cotton enlisted two production
machines to perform a side-by-side comparison between a pneumatic
cylinder and linear motor. The air for the pneumatic cylinder (and only the
single pneumatic cylinder) was supplied from a separate, free-standing air
Edited by: Mike Santora Associate Editor
Design Notes 12-15_Vs4.LL.MD.indd 46 12/3/15 3:36 PM
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December 2015 DESIGN WORLD 47
compressor connected directly to the cylinder.
Test administrators used a standard
compressor rated at 150 psi, 1.5 hp, 120 Vac,
3.5 cfm (at 90 psi), with a 15 gal tank. The
regulator on the compressor was set to 80 psi
to match the normal running pressure used on
the machine.
To measure the energy used, an Allen-
Bradley PowerMonitor 5000 was chosen. This
revenue-accurate instrument detailed data
about energy usage.
The machines were each run for 30 min at
a rate of 48 operations per minute. The energy
consumed was recorded by the PowerMonitor.
For that time, the compressor consumed 1.875
kWh hours of energy. The machine equipped
with the linear motor consumed 0.060 kWh.
This meant that the linear motor equipped
machine consumed only 3.2% of the energy of
t