design world march 2016
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March 2016www.designworldonline.com
Fivekey electrical
design concepts for mechanical
engineers 58
INSIDE:
LINEAR MOTION: Picking the right accumulation chain for conveying PAGE 66
INTERCONNECT: PCB connection technology keeps pace with power demands PAGE 100
TEST & MEASUREMENT: Oscilloscope designs change with the times PAGE 80
Cover_DW_MARCH 2016_FINAL.indd 1 3/4/16 4:58 PM
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I n s i g h t s
4 DESIGN WORLD March 2016
Were just about a month away from the annual Hannover Fair, the worlds largest industrial tradeshow. The German tradeshow is pretty hard to comprehend, with 30-ish
trade halls, 200,000 visitors, and 6,500 exhibitors. Its definitely a show you have to plan a
strategy for, not to mention packing some comfortable shoes.
This years Fair will focus on the concept of Integrated Industry Discover Solutions.
Fair organizers say that exhibits will inform the international audience how to transform
their production facilities into smart factories for the digital age and how to build intelligent,
networked systems for energy generation, distribution and storage.
Im personally interested to see who will win the Hermes Award, which is given out at the
Fair each year. The award is given in honor of a technologically innovative product making
its debut at Hannover. Products entered for the award must have undergone industrial
trials and/or already be used in industrial applications, and must be particularly innovative
in terms of technical and economic impact. Last year, Wittenstein AG won for its Galaxie
product, a new type of mechanical gearhead that features Industry 4.0 connectivity.
Each year, Hannover Fair chooses a partner country; last year it was India, in 2014
it was The Netherlands, and in 2013 it was Russia. The Fair encourages all exhibitors to
focus on their businesses within the partner country, as well as invite customers from that
country. Traditionally, the partner countrys head of state conducts the ceremonial opening
ceremonies with the German Chancellor.
For the first time, the United States will be the partner country at Hannover.
Approximately 250 companies from the U.S. will present industrial solutions at the Fair,
scheduled for April 2529. President Obama will appear at the Fair with Chancellor Merkel,
and well be there to cover all of the news and innovations. In fact, for the first time, Design
World will be sending two editors to the Fair, to provide you information on all of the latest
products and innovations across the mechanical and electrical engineering spaces. Please
follow myself and Executive Editor Lee Teschler on Twitter at @DW_Editor and
@DW_LeeTeschler to keep up with the latest on Hannover. DW
Partnering up with Germany
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
Will your company be sending engineers to the Hannover Fair?
Comment on Pauls blog on Pneumatic Tips, www.pneumatictips.com/blog On Twitter @ DWEditor
Insights 3-16_Vs2.MD.indd 4 3/3/16 1:32 PM
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Te s c h l e r o n To p i c
I once worked at a company where the human resources department had
run amuck and perfected a performance
review process pretty much guaranteed
to be discouraging. Every six months,
we were ostensibly graded on a one-to-
four scale on each of a laundry list of
goals. But this grading scale was only in
theory. For some reason, no one could
earn the highest score. Managers who
gave one of their reports a four got the
evaluation bounced back for a redo, often
accompanied by a back-handed reprimand.
Thus, no matter what you managed to accomplish, you could never be outstanding. To make matters slightly worse, the goal-evaluation process was such that even strong performers could end up, on paper, looking like bumbling fools. The reason: The computerized evaluations demanded numerous goals in numerous categories. So managers were
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
Performance review is another way of saying morale killer
On Twitter @ DWLeeTeschler
forced to come up with inconsequential objectives just to make the evaluation look complete in the eyes of HR. Even superbly performing employees couldnt meet them all. So there were always lots of unimportant things left uncompleted. The theory among employees was that managers used the uncompleted tasks as an excuse to keep salaries down. The upshot of the evaluation process was that top management came across as two-faced: During company meetings, we were all part of a great team. During individual evaluations, we were all idiots. I once thought my brush with this evaluation nightmare was just bad luck. But there is a lot of evidence that counterproductive employee evaluations are the norm in U.S. business rather than the exception. For a classic example, consider the evaluation process in place at Microsoft prior to 2012. Called stack ranking, it forced managers to declare a certain percentage of their reports as being poor performers, no matter how well they were actually performing. As related by author Kurt Eichenwald in Vanity Fair magazine, Every current and former Microsoft employee I interviewedevery onecited stack ranking as the most destructive process inside Microsoft, something that drove out untold numbers of employees. Stack ranking, he said, gave engineers incentives not to work with other engineers who were outstanding for fear of ending up on the bottom of the ranking scale.
Microsoft engineers also told Eichenwald that the politics around stack ranking slowed company decision making dramatically. People planned their days and their years around the review, rather than around products. You really had to focus on the six-month performance, rather than on doing what was right for the company, one engineer told him. Indications are that Microsoft was embarrassed by Eichenwalds portrayal of its review process. Though it never said why, the company scrapped its stack ranking scheme shortly after publication of the article. And there is ample evidence that nobody likes performance reviews. Consider the findings of Texas A&M researchers. They hypothesized that people who thought their abilities developed mainly through effort and experience would take negative feedback better than others who mainly tried to avoid negative judgments. Nah. In studies the researchers ran, nobody liked negative feedback. Those researchers could have saved themselves some effort if they had simply referred to the works of quality guru W. Edwards Deming. As far back as the early 1950s, Deming was teaching Japanese manufacturers to evaluate groups rather than individuals. In so many words, he claimed that individual performance reviews create chaos rather than order. A lot of companies every day prove that Deming was right. DW
6 DESIGN WORLD March 2016
Lee Teschler Column 3-16_Vs2.MD.indd 6 3/3/16 1:29 PM
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Te c h n o l o g y F o r w a r d
When designing products for the Internet of Things (IoT), research is showing that the user experience with
software is often more important than the experience
with the IoT device itself. While most of the studies focus
on consumers and consumer targeted IoT products, the
point is valid for industrial IoT designers too.
The study focused on IoT products for the smart
home. This idea consists of hardware devices and
software apps that, when combined, should make an
efficient system for consumers. But a new report from
Argus Insights shows that consumers are overall more
frustrated with the applications that dictate, schedule
and manage each device than with the actual devices
themselves.
According to data compiled from nearly 50,000
Smart Home device and app reviews from August
2015 to the present, a number of developers apps lack
features users want. Users indicate that they are more
frustrated with the software applications than with the
actual devices.
It appears as though end users look at the hardware
and software experiences differently. Once the hardware
is installed, which should be an easy process, the
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
Mind the gap
On Twitter @ DW3Dprinting
8 DESIGN WORLD March 2016
hardware functions in the background. Users have
much more interaction with the software app. Thus, they
are looking for the best functionality of the software
possible. In many cases, this functionality means fast
video streaming, short load times, and minimal video
blackouts. Its here users find a gap in expectations
among IoT products.
One company that appears to be an exception is
Honeywell, which offers a more synchronized hardware
and software ecosystem and is doing well among
consumers. Research shows it has beaten Nest with an
overall better experience.
The analytics from IoT implementation are supposed
to help make it easier to shrink the gap between user
expectation and product operation. But this study
shows that simply buying into the concept of the IoT
is not enough. If the IoT really delivers on valuable,
useful information that can aid design, its still up to
designers to use that information appropriately. The
other companies mentioned in the research, AT&T, ADT
and Comcast, illustrate what happens when IoT data are
not used, or not used well to aid designloss of market
share. DW
Leslie Column (Technology Forward) 3-16 Vs3.LL.MD.indd 8 3/3/16 1:31 PM
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Proto Labs 3-16.indd 9 3/3/16 11:19 AM
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IS THE ANSWER TO MY DESIGN CHALLENGE ALWAYS A PART NUMBER?
Ask Smalley. We know that theres really no such thing as a standard design. So we deliver a level of technical collaboration and customization far beyond what youd nd in a typical parts catalog.
Smalley engineers are always ready to share their expertise with youtailoring a high-performance Smalley wave spring, Spiroloxretaining ring or constant section ring to meet your unique application requirements. So dont settle for ordinary. Talk to a Smalley engineer today.
Smalley retaining rings eliminate the protruding ears that interfere with assemblies, while providing a 360-degree retaining surface. And their unique design means no special tools are required.
Visit smalley.com for your no-charge test samples.
THE ENGINEERS CHOICE
engineer today.
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l C o n t r i b u t o r s S p o t l i g h t
PCB connection technology keeps pace with power demands
JIM DUNBARProduct Marketing ManagerPhoenix Contact
GERHARD HARTINGER
Key Account Manageriwis Drive Systems
March 2016 DESIGN WORLD 1 1
Picking the right accumulation chain for conveying
Gerhard brings more to the table than supplier support and strategic purchasinghes had advanced training as a time-and-motion studies technician, and completed an apprenticeship as a toolmaker in Munich, Germany, where he currently resides. In addition, he has practical experience in all production departments at iwis including head of production of special rollers, bushes and special parts. Like a lot of engineers,
Jim, who holds a BSEE and MBA from Penn State University, believes that in 20 years, 3D printing will play a big role in everything we do, from printing food in restaurants to manufacturing buildings. As someone whose previous jobs include development engineering, product engineering and engineering supervision in a manufacturing facility, Jim said it drives him crazy when people assume that engineers can fix anything that breaks. At one time, I had stereos, microwaves, refrigerators and more lined up in my garage because people assumed that since I was an engineer I could repair it all for them.
fun factJim is inspired by the movie Jiro Dreams of Sushi. Its about an
85-year-old guy who dedicated his life to perfecting sushi and making it better each day. Amazing.
Brig joined Agilent Technologies in 2005 as a Technical Support Engineer. During his time with Agilent, he has held the following positions: Marketing Operations Manager, where he oversaw the marketing budget and managed the technical support and learning products teams, and Technical Support Engineer, where he helped solve numerous customer problems. Before Agilent, Brig worked at Micron Technologies as a Test Engineer. He graduated with an MBA from Northwest Nazarene University and BSEE from the University of Wyoming. In his spare time, Brig runs marathons and climbs the mountains of Colorado with his kids.
fun fact Brig is a published technical author.
Gerhard wishes he had learned more practical aspects of his career, such as chain technology, that werent part of his college curriculum.
fun fact Gerhard has his travel sights set on the U.S. or South America. It sounds strange, he said, but so far, I havent had the
opportunity to go to either one. On the other hand, I travel to Asia a lot on business.
66
BRIG ASAYProduct Manager High-Performance OscilloscopesKeysight Technologies
Power delivery and the Type-C revolution 94
GEORG GRUNENBERGProduct Marketing, Business Unit, Device ConnectorsPhoenix Contact
Georg earned his degree in engineering from the Bochum University of Applied Sciences. Advances in technology, he said, will continue to make peoples lives easier. Simple tasks such as mowing the lawn and vacuuming the living room wont remain the sole domain of robots. In ten years, robots will start to take on jobs for people in need of help, like doing the laundry, cooking, and grocery shopping. In 1990, Georg wrote a thesis paper investigating the operation of a solar-powered inverter that was directly connected to the grid. He began working in product marketing at Phoenix Contact in 1997 and in 2012, he became Group Manager for the Combicon power product range. If technology is used with peoples needs in mind, it can only be to our advantage, Georg said. Im primarily concerned about the misuse of peoples data, not to mention internal corporate data and information. When hes not at work or home, Georg can most likely be found taking a jog or spending time with friends.
my advice People should always take a central role!
PCB connection technology keeps pace with power demands
100
100
Contributor Page 3-16_vs2.MD.indd 11 3/4/16 3:21 PM
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Follow the whole team on twitter @DesignWorld
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1 2 DESIGN WORLD March 2016
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Web Development SpecialistPatrick Amigopamigo@wtwhmedia.com@amigo_patrick
Digital Marketing SpecialistAndrew Zistlerazistler@wtwhmedia.com
Digital Media ManagerPatrick Curranpcurran@wtwhmedia.com@wtwhseopatrick
Online CoordinatorJennifer Calhoonjcalhoon@wtwhmedia.com@wtwh_jennifer
EDITORIAL
Editorial DirectorPaul J. Heneypheney@wtwhmedia.com@dw_editor
Managing Editor Leslie Langnau llangnau@wtwhmedia.com@dw_3DPrinting
Executive EditorLeland Teschlerlteschler@wtwhmedia.com@dw_LeeTeschler
Senior EditorMiles Budimirmbudimir@wtwhmedia.com@dw_Motion
Senior EditorLisa Eitelleitel@wtwhmedia.com@dw_LisaEitel
Senior EditorMary Gannonmgannon@wtwhmedia.com@dw_marygannon
Associate Editor Mike Santoramsantora@wtwhmedia.com@dw_MikeSantora
Assistant Editor Michelle DiFrangiamdifrangia@wtwhmedia.com@wtwh_Michelle
Director, Audience DevelopmentBruce Spraguebsprague@wtwhmedia.com
VideographerJohn Hanseljhansel@wtwhmedia.com@wtwh_jhansel
VideographerKyle Johnstonkjohnston@wtwhmedia.com
VideographerAlex Barniabarni@wtwhmedia.com
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Digital Marketing SpecialistJosh Breulerjbreuler@wtwhmedia.com@wtwh_joshb
Digital Marketing InternAly Ryanaryan@wtwhmedia.com@wtwh_aly
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VP, Creative ServicesMark Rookmrook@wtwhmedia.com@wtwh_graphics
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2015
3
Co n te n t s | M a r c h 2 0 1 6 v o l 1 1 n o 3 | d e s i g n w o r l d o n l i n e . c o m
MOTION CONTROL
Five key electrical design concepts for mechanical engineersMechanical engineers often overlook important electrical issues when specifying their respective parts of an electromechanical system.
58
F E A T U R E S
74
2015
revenue over $3 million
INDUSTRIAL ETHERNET
A hint of things to come in the IoTIn some respects, the Internet of Things is still heavy on the buzz and promotion and light on actual products that help design engineers. A few helpful aids are emerging.
66
Make Parts Fast Supplement 107-124
TEST & MEASUREMENT
Oscilloscope designs change with the timesFrom portable scopes to a wide array of testing tools, oscilloscope design keeps up with the times.
2015ONLINE
80
ELECTRONICSPower delivery and the Type-C revolutionUSB-C cords promise to be all-in-one cables for the next decade thanks, in no small part, to the way this new spec handles electrical power.
88 MECHANICALWhen are custom couplings the best choice? If it aint broke, dont fix itan old phrase appropriate in reference to the coupling selection of a design. However, there are circumstances where a custom coupling is the difference between a good choice and the perfect choice.
1 4 DESIGN WORLD
LINEAR MOTION
Picking the right accumulation chain for conveyingFor logistics and material-handling applications, chain engineered for accumulating discrete pieces of product is efficient and durable.
94
INTERCONNECTPCB connection technology keeps pace with power demandsAs developers of power electronics devices compete to make these devices more compact, it is up to PCB connector manufacturers to fit within these space constraints while increasing efficiency.
100
ON THE COVERA clean design balances mass and motion. Lighter-weight components help reduce mass and enable the use of smaller motor/drive components.
Courtesy of Bosch Rexroth.
CONTENTS MARCH 2016_first page_Vs3.LL.MD.indd 14 3/4/16 10:15 AM
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Co n te n t s
D E P A R T M E N T S
04 Insights
06 Teschler on Topic
08 Technology Forward 11 Contributors 18 Green Engineering
20 Design for Industry
29 Engineering Exchange
30 Design Notes
42 Coupling Notes
44 CAE Solutions
50 Internet of Things
126 Product World
136 Ad Index
3 . 2 0 1 6
1 6 DESIGN WORLD March 2016
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44
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Canted coil springs can improve wind turbine seals, connectors
n Jim Harty Global Market Manager Energy Bal Seal Engineering
G r e e n E n g i n e e r i n g
1 8 DESIGN WORLD March 2016
Wind turbines must withstand harsh internal and external conditions, including temperature and weather fluctuations, turbulence
caused by wind gusts, variations in rotor speed, and repeated strokes of
the blades. For the components that make up the turbine, durability is
essential. Even the smallest components, such as seals and connectors,
must endure changes in pressure and temperature while minimizing
friction and wear inside the nacelle.
Proper sealingSealing and protecting turbine parts is a small job but an important one. When choosing a product, designers should consider materials that offer a proven ability to last and withstand the tough conditions inside wind turbines.
Friction and wear. When used in pitch-drive gears and other similar applications, seals need to facilitate a certain level of mobility. Because blades rotate millions of times, they must resist continuous wear. Low-friction sealing materials such as a polymer-filled polytetrafluoroethylene (PTFE) can minimize wear, providing excellent sealing performance and an extremely low dynamic coefficient of friction. An energized seal will ensure that the lip retains an ability to contact the housing, while securely and consistently sealing around the edges.
Chemical and media compatibility. For proper protection, its important to choose a sealing material that exhibits chemical compatibility with the greases and lubricants commonly used in the turbine. PTFE is chemically inert and offers high resistance to solvents, chemicals, and other materials over time. By contrast, materials such as elastomers struggle with long-term exposure to UV rays.
Contact stress. Machined large-diameter seals have no weld, and therefore no hard spots or areas of potential weakness. This results in an ability to provide consistent contact pressures along the entire diameter of the sealing lip. Machined seals can also withstand much harsher conditions than welded ones, increasing service life of the seal and minimizing turbine downtime for maintenance or repairs.
Shelf life. Longevity is an essential turbine design consideration, and this holds true for all of the turbine components. Minimizing the need for repairs or replacements of a seal means fewer maintenance visits and lower material costs. The design of a seal and the choice of material used will affect its shelf life. The length of time that seals can be stored is often dependent on the material. For example, materials such as PTFE can be stored for years without impacting their sealing performance.
Thermal stability. In areas where ambient heat is excessive such as in a turbines gearbox, its important to use seals that provide protection and thermal stability. The seal should withstand high and low temperatures (up to 140 F and as low as to -65 F) without compromising the sealing contact stress.
Connecting turbinesMuch like the requirements for proper sealing, connecting turbine parts deserves special consideration for the best and safest results. Connecting presents specific challenges inside the small confines of a turbine nacelle.
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Tight spaces can make it difficult to achieve adequate torque and high vibration can easily loosen cables. In a worst-case scenario, this can lead to increased turbine temperatures, rising heat, and potentially hazardous conditions. When choosing connectors, these characteristics are critical:
Latching and locking forces. Connectors should provide wind-turbine engineers with a means of dictating forces with which connections are made and broken. Fasteners such as canted coil springs offer controllable mating and unmating forces. Such controlled forces make it easy to connect and disconnect control, and provide an alternative to traditional technologies, such as threaded connections that require tools.
Conductivity. In wind systems, its necessary to dial in the current-carrying capacity based on application need by specifying physical properties of contact (type of plating and wire diameter, for example). Although copper braids
March 2016 DESIGN WORLD 1 9
are often used to carry current, other options such as canted coil springs placed on each end of a rod can improve current transmission. Because the spring maintains consistent contact forces on the conducting element, it can ultimately improve turbine performance.
Heat safe. Connectors should allow maximum current management with minimal heat build-up in the turbine. Capacitors, transformers, generators, electrical controls, and transmission equipment are all subject to fire. To minimize risk in wind turbines, operating temperatures must remain at a minimum. Typical requirements include a heat run during which the heat rises to no more than 63 C. Operating temperatures should not exceed 110 C at 2,900 A CC (amps of constant current). The short circuit current must be able to withstand 1.6 kVA for two seconds. Canted coil springs help minimize heat-to-current carrying capacity in high-temperature conditions.
Compression resistant. Its important that connectors in wind turbines are resistant to compression set, which refers to the permanent deformation of a material after release of stress or force. They should be comprised of material with physical properties that ensure consistent, multi-point contact for maximum efficiency of current flow. A resistance to compression set provides for consistent service over thousands of cycles.
Space-saving design. To ensure maximum efficiency, each connector should provide an excellent size-to-current capacity ratio, allowing designers the opportunity to decrease overall device size and build in more functionality where necessary.
As wind-energy systems supply a greater percentage of power worldwide, minimizing downtime and decreasing maintenance and service is critical. Conditions such as temperature, vibration and corrosion demand components that are efficient and reliable even in tough environments. DW
Bal Seal Engineeringbalseal.com
Green Engineering_3-16_Vs3.MD.indd 19 3/3/16 1:37 PM
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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
2 0 DESIGN WORLD March 2016 www.designworldonline.com
a e r o s p a c e / m i l i t a r y
over-voltage shutdown and surge capability. Operating temperature is -20 to 75 C, with -40 C as an option. Optional features include: ac/dc inputs and ac/dc outputs; multiple output voltages; remote on/off through various inhibit configurations; input inrush and surge protection; mains synchronization; input reverse polarity protection; output voltage adjustment potentiometer; output voltage and frequency monitoring; increased mechanical strength; tropical (conformal coating) protection; low and high IP rated; liquid or air-cooled; and parallel and redundant operation. Heavy industrial and military versions are available. Safety and construction protection
These inverters and frequency converters use new communication interfaces for heavy industrial and military applications. The CI, IT, IV, and K series of single or three-phase Heavy Industrial and Mil Inverters and Frequency Converters with CAN, Ethernet, Modbus and Analog communication interfaces are for mission critical applications. These reliable, customizable built-to-project pure-sine-wave inverters offer 10 to more than 1,000 Vdc input voltage and 200 VA to 3 MW output voltages. Some of the designs feature an integrated UPS function, static switch(SS series), battery charging (B series) and parallel capabilities (N+1). Features include continuous short-circuit protection, automatic restart after
meets EN 60950-1/EN 50178. EMI to EN 61000-6-4, class A, option class B available. Optional: Mil-Std-1399 type 1 and type 3; Mil-Std-461; Mil-Std-1275; Mil-Std-1332; Mil-Std-810; Mil-Std-901; Mil-Std-167, Mil-Std-704; and so on. COTS, MOTS and custom-tailored to meet your specific application requirements. DW
Schaeferschaeferpower.com
Communication options for inverters/converters
DFI 3-16_Vs3.LL.MD.indd 20 3/3/16 3:30 PM
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90 Taylor Drive, P.O. Box 748North Tonawanda, NY 14120-0748Phone: 716.694.0800Fax: 716.695.6015
www.taylordevices.com
High precision, lightweight tension/compression
Extremely long life
Made from a wide variety of materials including high strength steel, stainless steel, aluminum, and titanium
Exact/consistent spring rate
Precise alignment
Up to 16 inches in diameter
Contact us today to see how we can provide a better solution for your engineering application.
A N A T O M Y O F A G R E A T I D E A
MACHINED SPRINGS FROM TAYLOR DEVICESAvailable in virtually unlimited configurations, Machined Springs
from Taylor Devices offer unique capabilities to solve your
application challenges. Examine the difference.
TAYOR-006170-4 MachSprg_9x10_875 DesWorld_MARCHMech.indd 1 1/29/16 3:47 PMTaylor Devices 3-16.indd 21 3/3/16 11:32 AM
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D e s i g n f o r I n d u s t r y 02 p a c k a g i n g
Some material handling and packaging applications have special handling needs, such as requiring perfect seal during pickup, or handling hot injection-molded plastics, or uneven surfaces. One option for these applications is the SP-BX Series Varioflex bellows suction cups. These cups deliver a perfect seal on surfaces ranging from oil-free metal sheets to hot injection-molded plastics, and even rough or uneven surfaces. Made of oil-, ozone-, and wear-resistant polyurethane composite material, FIPAs SP-BX Series Varioflex bellows suction cups have a dimensionally stable body (60 shore) that prevents buckling over a range of shear forces, and a soft, low-marking sealing lip (30 shore) that delivers a perfect seal on surfaces ranging from oil-free metal sheets to hot injection-molded plastics, and even rough or uneven surfaces, including cardboard and wood. Available with either 1.5 folds (SP-BX1) or 2.5 folds (SP-BX2), the suction cups also function over long lifecycles to reduce machine downtime. Other features include holding force, recovery force, stability, and reset capabilities to accommodate systems with short cycle times.
Available in diameters spanning 16 to 160 mm, the suction cups have 1.5 bellows to compensate for material height differences, and stabilizing cleats that both enable fast acceleration and prevent the deep drawing of thin materials like sheet metal. Available in diameters spanning 16 to 77 mm, these bellows suction cups have 2.5 bellows to accommodate material handling applications that require both height and angle compensation, such as the de-molding of injection-molded parts, and feature an optional filter disk between the bellows for 26 to 53 mm diameter suction cups. Filter disks are included with suction cups with diameters of at least 77 mm, and rated operating temperatures for both SP-BX series span 50 to 122 F. DW
FIPAfipa.com
2 2 DESIGN WORLD March 2016 www.designworldonline.com
Suction cups handle a range of product shapes and sizes
DFI 3-16_Vs3.LL.MD.indd 22 3/3/16 3:30 PM
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Take the work out of integration
March 2016 DESIGN WORLD 2 3
03m a c h i n e t o o l
Responding to industry demand for integrated machine and plant control, the iQ-R series incorporates sequence, motion, safety, process and C language control into one platform. The control platform is for applications requiring integrated motion and safety control, tight synchronization between various processes and high production throughput. Applications include automotive, food and beverage, material handling, life sciences, and electronics manufacturing industries. The integrated design allows machines or production lines to consolidate control in one rack. The system can have up to 4 CPUs per rack for various combinations of motion, sequence or process control.
Key features include: 0.98 nsec execution speed high-speed bus GX Works3 programming software with built-in functions and configuration screens CC-Link IE field network with deterministic performance over industrial Ethernet built-in SD memory card database
This scalable control fits many application needs, whether it involves coordinated motion, integrated safety, C language programming or PID control. It easily integrates with other automation products such as the GOT2000 series HMI and MR-J4 series amplifiers through pre-created templates and function blocks. A machine designed on the iQ-R series is set up for synchronization at every levelamong PLCs, I/O modules and network stations for fast, reliable PLC performance. The clean control design allows communication between controllers across the backplane, eliminating the need for complex wiring that can add points of error. It also offers a variety of security features to protect intellectual property and ensure system integrity, including a security key feature to prevent unauthorized execution of OEMs programs. DW
Mitsubishi Electric Automationus.mitsubishielectric.com
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: info@whittet-higgins.com 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
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SCARA robots for small parts assembly
r o b o t i c s D e s i g n f o r I n d u s t r y 04
This small SCARA robot handles a range of needs in applications requiring fast, repeatable and precise movements. The IRB 910SC SCARA (Selective Compliance Articulated Robot Arm) robot has a maximum payload of 6 kg, and is available in reaches of 450, 550 and 650 mm. The single arm robot operates in a confined space and is tabletop mountable. All variants are modular by design, with differing linking arm lengths allowing end users to specify the optimal reach required for a specific application. Target applications include small parts assembly, material handling, tray kitting, component placement, parts inspection, laboratory automation, prescription drug dispensing and other applications requiring rapid cycle times, high precision and unmatched reliability. Each SCARA variant is IP54-rated for optimum protection against dust and liquids and a Clean Room ISO-5 option is under development. DW
ABBabb.com
2 4 DESIGN WORLD March 2016 www.designworldonline.com
DFI 3-16_Vs3.LL.MD.indd 24 3/3/16 3:31 PM
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Altra Industrial Motion
Vol. 5 | No. 1 | 2016
The Power Brands in Power TransmissionPower Review
For more information contact us at: info@altramotion.com or visit www.altramotion.com
Featured in this Edition...
Find Altra Industrial Motion on:
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Get Connected with Altras Newsroom
Browse featuredstories and stayupdated on the mostrecent Altra news
Download literatureand share via varioussocial media sites
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How-To Video Series
Explore the helpfulHow-To Video Serieson a variety of industrialapplications
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Couplings, Clutches & BrakesCouplingsAmeridrives CouplingsAmeridrives PTBibby TurboexGuardian CouplingsHuco DynatorkLamiex CouplingsTB Woods
Belted DrivesTB Woods
Electric Clutches & BrakesElectric Clutches & BrakesInertia DynamicsMatrix InternationalWarner ElectricWarner Linear
Linear ProductsWarner Linear
GearingGear DrivesBoston GearDelroyd Worm GearNuttall Gear
Gear MotorsBauer Gear Motor
Engineered BearingAssembliesKilian Manufacturing
Heavy DutyClutches & BrakesIndustrial ClutchSvendborg BrakesTwiex LimitedWichita Clutch
Overrunning ClutchesFormsprag ClutchMarland ClutchStieber Clutch
Couplings, Clutches & BrakesCouplingsAmeridrives CouplingsAmeridrives PTBibby TurboexGuardian CouplingsHuco DynatorkLamiex CouplingsTB Woods
Belted DrivesTB Woods
Electric Clutches & BrakesElectric Clutches & BrakesInertia DynamicsMatrix InternationalWarner ElectricWarner Linear
Linear ProductsWarner Linear
GearingGear DrivesBoston GearDelroyd Worm GearNuttall Gear
Gear MotorsBauer Gear Motor
Engineered BearingAssembliesKilian Manufacturing
Heavy DutyClutches & BrakesIndustrial ClutchSvendborg BrakesTwiex LimitedWichita Clutch
Overrunning ClutchesFormsprag ClutchMarland ClutchStieber Clutch
Couplings, Clutches & BrakesCouplingsAmeridrives CouplingsAmeridrives PTBibby TurboexGuardian CouplingsHuco DynatorkLamiex CouplingsTB Woods
Belted DrivesTB Woods
Electric Clutches & BrakesElectric Clutches & BrakesInertia DynamicsMatrix InternationalWarner ElectricWarner Linear
Linear ProductsWarner Linear
GearingGear DrivesBoston GearDelroyd Worm GearNuttall Gear
Gear MotorsBauer Gear Motor
Engineered BearingAssembliesKilian Manufacturing
Heavy DutyClutches & BrakesIndustrial ClutchSvendborg BrakesTwiex LimitedWichita Clutch
Overrunning ClutchesFormsprag ClutchMarland ClutchStieber Clutch
Power Transmission and Motion Control Products
Couplings, Clutches & BrakesCouplingsAmeridrives CouplingsAmeridrives PTBibby TurboexGuardian CouplingsHuco DynatorkLamiex CouplingsTB Woods
Belted DrivesTB Woods
Electric Clutches & BrakesElectric Clutches & BrakesInertia DynamicsMatrix InternationalWarner ElectricWarner Linear
Linear ProductsWarner Linear
GearingGear DrivesBoston GearDelroyd Worm GearNuttall Gear
Gear MotorsBauer Gear Motor
Engineered BearingAssembliesKilian Manufacturing
Heavy DutyClutches & BrakesIndustrial ClutchSvendborg BrakesTwiex LimitedWichita Clutch
Overrunning ClutchesFormsprag ClutchMarland ClutchStieber Clutch
Couplings, Clutches & BrakesCouplingsAmeridrives CouplingsAmeridrives PTBibby TurboexGuardian CouplingsHuco DynatorkLamiex CouplingsTB Woods
Belted DrivesTB Woods
Electric Clutches & BrakesElectric Clutches & BrakesInertia DynamicsMatrix InternationalWarner ElectricWarner Linear
Linear ProductsWarner Linear
GearingGear DrivesBoston GearDelroyd Worm GearNuttall Gear
Gear MotorsBauer Gear Motor
Engineered BearingAssembliesKilian Manufacturing
Heavy DutyClutches & BrakesIndustrial ClutchSvendborg BrakesTwiex LimitedWichita Clutch
Overrunning ClutchesFormsprag ClutchMarland ClutchStieber Clutch
Couplings, Clutches & BrakesCouplingsAmeridrives CouplingsAmeridrives PTBibby TurboexGuardian CouplingsHuco DynatorkLamiex CouplingsTB Woods
Belted DrivesTB Woods
Electric Clutches & BrakesElectric Clutches & BrakesInertia DynamicsMatrix InternationalWarner ElectricWarner Linear
Linear ProductsWarner Linear
GearingGear DrivesBoston GearDelroyd Worm GearNuttall Gear
Gear MotorsBauer Gear Motor
Engineered BearingAssembliesKilian Manufacturing
Heavy DutyClutches & BrakesIndustrial ClutchSvendborg BrakesTwiex LimitedWichita Clutch
Overrunning ClutchesFormsprag ClutchMarland ClutchStieber Clutch
Altra Industrial_#1_3-16.indd 25 3/3/16 11:33 AM
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Get Connected with Altras Newsroom
The Altra Newsroom is updated weekly with the latest brand, product, and market news. The Newsroom makes it quick and easy for you to get the news you need when you need it. From new literature releases to trade show schedules, the news is at your fingertips 24 hours a day.
Browse featured stories on the home page and stay updated on the latest on tradeshows, articles, application profiles, news releases and innovation spotlights. PDFs of literature are available for download.
Search news stories by brand, literature type and products or browse the news archives by month.
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Explore the most recent news stories in each category. Additional stories are listed below.
Literature can be downloaded and shared via various social media platforms.
I N N O V A T I O Nfrom the brands of Altra Industrial Motion Corp.SPOTL IGHT
The wind turbine market has been slowly recovering since the 2008 global financial crisis. While there was significant improvement in 2012 and 2013,
global wind power grew by a record 50+ GW in 2014. There are currently six countries that have an installed wind capacity of more than 10,000 MW, with
China, the U.S. and Germany leading the world. The U.S. alone produces enough wind energy to power more than 16 million homes.
Europe has been experiencing substantial growth in offshore wind capacity, with 408 turbines added in 2014. This brings the cumulative total of installed
and grid-connected offshore turbines to 2,488 in 11 European countries.
The small wind and distributed wind segments of the market (turbines from 5 kW to 500 kW) are also growing. In the U.S., 40% of distributed wind
(power which is primarily consumed at the point of generation) is deployed in residential applications, while agriculture accounts for 26% and
industrial/commercial uses 20%.
SUPERIOR ROTOR AND YAW BRAKING TECHNOLOGIES
As they meet the worlds growing demand for wind energy, global wind turbine OEMs rely on Svendborg Brakes and Twiflex Limited for innovative hydraulic
caliper braking solutions. The braking systems control the speed of wind turbine rotors as well as the 360 degree yaw rotation of the turbines nacelle as
it follows changing wind directions. These two Altra brands work closely with major turbine OEMs as they develop new turbine models of various designs
and capacities, while improving efficiency, performance, and cost-effectiveness.
www.altrawind.com
CALIPER BRAKE SOLUTIONS FROM ALTRA PROVIDE RELIABLE PERFORMANCE ON WIND
TURBINES AROUND THE WORLD
99BillionDollars invested in global wind power in 2014*
Custom Precision Bearing Assemblies
Poultry Processing Equipment
Product
Application
Highlights
Application Profile
P-7951-KM 12/15 Printed in USA
Asia PacificFor a list of our AP sales offices:altramotion.com/contactus
US (Sales/Engineering)1-315-432-0700 kilianbearings.com
Shielded 303 stainless steel housings
Sealed stainless steel ball bearings
Washdown and corrosion resistant
Smooth movement
Integral stud for easy installation
A leading poultry and food processing equipment manufacturer needed a stainless steel bearing assembly for use on its line of chicken vicera harvesters. The machines removes various internal organs from chicken carcasses as they rotate on an overhead-driven carousel. Multiple bearing assemblies, positioned over each of the carcass stations allow the carousel to rotate smoothly.
Kilian engineers designed a custom stainless steel ball bearing assembly to meet the tough washdown application requirements. The units feature a 303 stainless steel shielded housing containing precision stainless steel ball bearings sealed to protect against bacteria and withstand harsh washdowns. An integral stud was added to allow for easy installation.
AltraMotion.com/Newsroom
Altra Industrial_#2_3-16.indd 26 3/3/16 11:34 AM
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Altras How-To Video Series on YouTube
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 includes troubleshooting and installation instructions for a variety of products.
Share Videos
Share your favorite videos via email or various other social media sites. Videos can also be added to custom playlists or saved to a Watch Later list.
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
YouTube.com/AltraIndMotion
Altra Industrial_#3_3-16.indd 27 3/3/16 11:34 AM
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Our new Sure-Flex Plus EPDM and Neoprene sleeves are best-in-class for coupling performance and value. Heres why:
For more information on Sure-Flex Plus call 1.888.TBWOODS or visit www.TBWoods.com
High Torque Rating
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Provides longer service life in demanding applications, reducing required maintenance and associated replacement cost.
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Extensive testing shows our sleeves outlast the imitators. More uptime means less costly downtime.
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The increased rating of the Sure-Flex Plus sleeves lets the user choose a one-size-smaller coupling for over 50% of common applications. This lowers the cost of both initial purchase and future sleeve replacement.
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No need to replace the full coupling The Sure-Flex Plus sleeve design is 100% compatible with the current industry standard that TB Woods created over 50 years ago.
TB Woods Incorporated
Scan to WatchSure-Flex Plus Video
NEW Sure-Flex Plus EPDM & Neoprene Sleeves
Altra Industrial_#4_3-16.indd 28 3/3/16 11:35 AM
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with Design World
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March 2016www.designworldonline.com
Fivekey electrical
design concepts for mechanical
engineers 58
INSIDE:
LINEAR MOTION: Picking the right accumulation chain for conveying PAGE 66
INTERCONNECT: PCB connection technology keeps pace with power demands PAGE 100
TEST & MEASUREMENT: Oscilloscope designs change with the times PAGE 80
Cover_DW_MARCH 2016_FINAL.indd 1 3/4/16 4:58 PM
Basics of frequency mixing and mixers
If you draw it, can you print it?3D printing enables you to reduce part weight, raw material used
and cut total energy used in production. But to truly take advantage
of 3D printing, engineers need updated, intuitive, easy-to-learn CAD
tools. by Jean Thilmany, Contributing Editor
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The capability to design, test and validate in the digital world helps get products to market faster for less money.
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The process of evaluating and choosing an adhesive is
easier when you consider a few key parameters.
Design World's Editorial Director Paul J. Heney and
Senior Editor Miles Budimir introduce the Spartan Robot,
which has 26 motor, servo and sensor ports, allowing
programs to interact with the robots environment.
Coupled with the company's MATRIX building system,
Spartan can complete endless challenges.
GOOGLE+
by Paven Patel, General Manager and Barry Siroka, Business Development Manager, EpoxySet
www.designworldonline.com March 2016 DESIGN WORLD 2 9
Engineering Exchange 2-16_Vs2.indd 29 3/7/16 10:19 AM
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Lost in space: biomedical harness finally makes it home
D e s i g n N o te s
Almost 50 years after an Apollo space walk, a long-lost flat cable harness returned back home to Cicoil. The Bio-Harness assembly, built by the company for the 1969 Apollo 9 space flight, was returned in a NASA Apollo Space Program
Auction. Considering its age and the number of miles it has travelled, the harness looked virtually brand-new.
Edited by: Mike Santora Associate Editor
3 0 DESIGN WORLD March 2016
This cable was worn under the astro-nauts garments and enabled continuous monitoring of vital signs, such as blood pres-sure, respiration, body temperature and pulse rate for each astronaut during flight, orbit and spacewalk operations. The harness looks virtually brand-new, considering its age and the number of miles it has traveled.
The 26-in.-long electrical biomedical harness was worn by Commander
Jim McDivitt during the Apollo 9 flight that launched into orbit on March
3 and returned to Earth 10 days later. Typically, the Bio-Harness was
worn underneath the intravehicular constant wear garment when in the
spacecraft, and under the extravehicular pressure suit during spacewalk
activities. The assembly enabled continuous monitoring of vital signs, such
as pulse, respiration, body temperature and pulse rate for each astronaut
during flight, orbit and spacewalk operations. In addition to Commander
McDivitt, Astronauts David Scott and Rusty Schweickart also used Bio-
Harnesses on the Apollo 9 space mission as well.
The space flight approved Bio-medical Instrumentation and Telemetry
Harnesses were chosen for their highly flexible and lightweight materials;
high reliability in mission critical applications; resistance to UV light,
radiation and vibration; high efficiency
in dissipating heat between inner cable
components; strong performance when
exposed to temperature extremes (-65 to
260 C); and ability to separately encase
shielded signal pairs to eliminate electronic
interference and provide uninterrupted signal
integrity during the harsh rigors of space flight.
Flat cable harnesses were also there to
help John Glenn (Mercury-Atlas 6) become the
first American to orbit the earth, Edward White
(Gemini 4) to be the first American to walk
in space, Neil Armstrong (Apollo 11) to take
his historical First Step on the surface of the
moon, and Buzz Aldrin (Apollo 11) to take his
second walk on the moon.
In addition to every Apollo space flight, the
design team from Cicoil has manufactured cable
assemblies for the Mercury and Gemini Space
missions, Skylab, Mercury Voyager, the Space
Shuttle, Tri-ATHLETE Lunar Vehicle, the Mars
Rover; and myriad space transport rockets and
satellites. DW
Cicoil cicoil.com
WHAT DO YOU THINK?
Connect and discuss this and other design engineering issues with
thousands of professionals online
Design Notes 3-16_Vs7.LL.MD.indd 30 3/3/16 3:57 PM
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m e m o ry p r o t e c t i o n d e v i c e sMPD M P D i s a g l o b a l m a n u f a c t u r e r o f b a t t e r y h o l d e r s a n d o t h e r e l e c t r o n i c c o m p o n e n t s . W e b e l i e v e t h a t o u r c o m p o n e n t s s h o u l d f i t e a s i l y i n t o y o u r d e s i g n s , w h i c h i s w h y w e a r e a l w a y s c r e a t i n g i n n o v a t i v e n e w p r o d u c t s .b a t t e r y h o l d e r s . c o m
M e m o r y p r o t e c t i o n d e v i c e sF l u s h e s o ut t h e c o m p e t i t i o n* *
MPD DEV ICES CAN BE FOUND INMULT IPLE R F ID DEV ICES INCLUDING
TOLL TAGS AROUND THE WORLD
MPDKEEPS YOU
MOV INGQUICKLY, S EAMLESSLY
AND E F F ICIENTLY
Memory Protection Device 3-16.indd 31 3/3/16 11:36 AM
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ORIGINAL
ISO 9001 AS9100 FAA, DoD, NASA Compliant Quality Management System (QMS) ITAR Compliant DFARS Materials Member of NBAA Boeing DPD Approved
for CATIA Files Made in the USA
Lightweight, Heat-Resistant Products Including Components for Engines, Flight Controls, Propulsion, Landing Gear, Interiors, Avionics, & Space
Exploration Vehicles
In-House Engineering, Development Processes, & Metallurgy Expertise
Mission Critical Safety & Performance Standards
SPRINGS, METAL BELLOWS, MACHINED SPRINGS, COUPLINGS,
FASTENERS, & ASSEMBLIES
Designing and Manufacturing Custom Products for
AEROSPACE
Empowering Innovation. Engineering Value.
Learn more at: www.mw-ind.com(847) 349-5780
MADE IN THE USA www.designworldonline.com March 2016 DESIGN WORLD 33
D e s i g n N o te s
Motion control is essential for the digitization and automation of equipment, and bearings
are at the core of frictionless movement. In
1956, just distributing bearings in California
was viable, even on a small scale. For many
small distributors, with growing globalization
through the end of the 20th century, it was
change or die. This is where the entrance of
strong engineering skills came to the rescue of
such distributors.
Bearing Engineers, one such distributor,
recently changed its name to Motion Solutions
to reflect their evolution into custom designers
3 2 DESIGN WORLD March 2016 www.designworldonline.com
of motion solutions. How this distributor
became a manufacturer is illustrated by the
development of their newest product.
A company who needed a better linear
motor table for positioning laser surgery
equipment brought this challenge to the
engineering team. According to Shawn
Hakim, mechanical engineering supervisor at
Motion Solutions, The client came to us with
the complaint that their Lasik eye surgery
equipment was not performing smoothly
enough and its running parallelism was not up
to their standards. The problem was caused by
Edited by: Mike Santora Associate Editor
Anti-cage creep mechanism helps bring Lasik surgery equipment into focus
Design Notes 3-16_Vs7.LL.MD.indd 32 3/3/16 3:58 PM
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ORIGINAL
ISO 9001:2008 Made in the USA
Learn more at: www.mw-ind.com(847) 349-5780
V Springs, U Springs, Helical Springs, Full Contact Springs, Spring Bands,
Detached Leg Spring, Slant Coil Spring, Garter Springs,
Expander Springs for the Spring Engergized Seal Industry
Sizes from 100 ft. to Annual Quantities Exceeding 100,000 ft.
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Empowering Innovation. Engineering Value. MADE IN THE USAwww.designworldonline.com March 2016 DESIGN WORLD 33
3 2 DESIGN WORLD March 2016 www.designworldonline.com
linear bearing cage slippage. Though positioned
horizontally, at full operating speed, the bearing
retainer would creep as the momentum of the
bearing movement was transferred to the cage
(also termed the retainer). An anti-cage creep
mechanism was the logical solution.
The term anti-creep describes the method
of eliminating any slippage of the retainer
holding the crossed rollers between the two
V-grooved rails of the slideway. In addition
to maintaining precise movement, without
creepage, downtime is reduced lowering the
cost of maintenance.
An anti-creep device eliminates this
creeping of the retainer, so the slideway
can be used in any mounting direction and
with lower momentum motors such as linear
motors. Several complex anti-creep devices
have been developed. To prevent cage creep/
slippage, manufacturers have used a few
different approaches, such as a rack and pinion
mechanism; an external attachment made of
plastic gears outside of the rail; and a metal gear
inside of the rail. Some of these devices are quite
expensive.
After comparison tests, Hakim settled on one
mechanism that does not use a gear. It is an
anti-cage creep mechanism that uses a roller
with round balls studded around its surface. It
has the smoothest tracking motion and therefore
is quieter than an externally attached toothed-
gear type anti-creep device. In this Studroller
mechanism, creepage is prevented because the
raceway has depressions that track the studs or
In this Studroller anti-creep slideway from NB Corp., creepage is
prevented because the raceway has depressions that track the studs or
nodules, preventing slippage in any position.
Design Notes 3-16_Vs7.LL.MD.indd 33 3/3/16 3:58 PM
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D e s i g n N o te s
3 4 DESIGN WORLD March 2016
nodules, preventing slippage in any position.
By placing studs in the center roller and
machining a path along the rail, this retainer will not
slip. It is suitable for high acceleration, vertical or
horizontal mounting and uneven load distribution.
The engineering team saw that the improved
linear motor table held great promise as a
proprietary product. However, they had commercial
concerns; cost was their number one concern.
Costs vary for crossed roller bearings with anti-
creep mechanismsdepending on the complexity
of their design and whether the application has to
be custom designed to accommodate them. The
Studroller, being the simplest non-slip design, uses
a studded roller, as opposed to a gear or exterior
control, so its cost is almost the same as a standard
slideway.
We were able to make the product more cost
competitive. Our product lowered the clients cost
by 17%. We gave them an equivalent product that
is lower cost, has better running parallelism, better
smoothness and with about 30% more force, said
Hakim.
Secondly, long lead timessay, six to eight
weekscould doom the product. We established
processes that would allow us to shorten the lead
time to somewhere between two and three weeks,
he added.
Cage creep is prevented by the studs that roll into the raceways depressions. The resin retainer fits around the roller in the Studroller.
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Design Notes 3-16_Vs7.LL.MD.indd 34 3/3/16 3:59 PM
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The linear motor table, which initially was incorporated into Lasik eye
surgery systemsfocusing optics and lasers on the eyehas a level of
precision that is also good for other applications.
That challenge also led to the development of a line of precision
positioning tables that meet the requirements of liquid-crystal related
equipment, measuring instruments, assembling systems and material
transfer equipment.
The design teams Linear Motor Table is powered by an ironless core
linear motor. This smooth, non-contact drive system prevents force ripple
(attraction force or cogging), unlike an iron core motor. Designed for high
speed positioning, the linear motor tables allow speeds up to 2,550 mm/
sec. A compact, lightweight aluminum alloy enclosure houses a linear
encoder that precisely positions down to 10 nm resolution. DW
NB Corp. nbcorporation.com
3 4 DESIGN WORLD March 2016
In this image we see technicians working in the Motion Systems assembly area and cleanroom.
www.designworldonline.com March 2016 DESIGN WORLD 35
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Cures in 75 minutes at 80C
LOW EXOTHERM UPON CURING
Design Notes 3-16_Vs7.LL.MD.indd 35 3/3/16 3:59 PM
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While most bike enthusiasts have come to know Vance & Hines for its exhaust systems, the riding community also knows the company for its Fuelpak FP3. This aftermarket
motorcycle part is the most capable and cost-effective fuel management system currently
available for Delphi-equipped Harley-Davidson motorcycles.
This modification can impact fuel economy and performance as it alters the air/fuel ratio,
causing the bike to run much leaner. Our classic Fuelpak devices solved those issues. With the
new FP3, we added functionality like increased horsepower, quicker throttle response, and
increased fuel efficiency, said Larry Hinds, manufacturing manager at Vance & Hines.
As the current generation of fuel management systems neared end of product life, demand
grew for a solution with exciting new feature sets. The challenge for Vance & Hines then
became how to optimize fuel economy and upgrade the user interface.
www.designworldonline.com March 2016 DESIGN WORLD 37
D e s i g n N o te sEdited by: Mike Santora Associate Editor
Pushing performance and fuel management
The smartphone integration gave us the ability to not only fix perfor-mance issues, but also enhance the rider experience. That meant the FP3 would use Bluetooth technology and more robust, complex PCBs, said Larry Hinds, manufacturing manager at Vance & Hines.
3 6 DESIGN WORLD March 2016 www.designworldonline.com
Vance & Hines had the idea of linking the
FP3 with the users smartphone over Bluetooth
to provide a more dynamic interface.
The smartphone integration gave us the
ability to not only fix performance issues, but
also enhance the rider experience, said Hinds.
That meant the FP3 would use Bluetooth
technology and more robust, complex PCBs.
Even though the FP3 is a fairly high volume
product, we use a just-in-time (JIT) style of
manufacturing, he added. This production
Design Notes 3-16_Vs7.LL.MD.indd 36 3/3/16 3:59 PM
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D e s i g n N o te s
method called Kanban, or blank card, requires a
PCB supplier to commit to a predictable production
turnaround. We set aside six weeks of board
inventory and put a card on it, said Hinds. When
we crack open that box, it signals us to place a PCB
order that can easily be delivered within six weeks.
For this, the Vance & Hines design team chose
Sunstone.
In addition to collaborative prototyping services
and capacity for high volume PCB production,
communication lines were kept open at all times.
We dont feel like were sending our orders into a
black hole, said Hinds. Theres someone on the
other end who cares.
Instead of robotically manufacturing boards,
Sunstone had a thought process behind their work,
he continued. That process in its simplest form
is taking every measure necessary to ensure
quality before production begins. Anything
that can interfere with quality or performance
raises a red flag and a proactive call to Hinds
himself.
For example: A new employee accidentally
sent over some specs that called for a tin-lead
finish, rather than the silver RoHS we normally
use, he said. That anomaly raised the alarm at
Sunstone, who contacted Hinds to confirm the
unusual order. It had been made in error. That
www.designworldonline.com March 2016 DESIGN WORLD 39
email saved an entire production run.
The commitment is to build the right board
the right way, every time. No exceptions. For
Hinds, this meant focusing on expanding
the FP3 feature sets, not worrying about
supporting basic functions. DW
Sunstone sunstone.com
In addition to collaborative prototyping services and capacity for high volume PCB production, communication lines are always kept open to ensure every measure is taken to make certain of quality before production begins.
l i n m o t . c o ml i n m o t u s a . c o mu s a s a l e s @ l i n m o t . c o m 2 6 2 - 7 4 3 - 2 5 5 5
Industrial Linear Motors
Optimal components for your design
C
M
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CM
MY
CY
CMY
K
precision half page.pdf 1 2/4/2016 10:17:35 AM
Design Notes 3-16_Vs7.LL.MD.indd 38 3/3/16 3:55 PM
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Bishop Wisecarver 9-15.indd 39 3/4/16 8:54 AM
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D e s i g n N o te s
The sound of air leaking from ageing pneumatic actuatorsnails on a chalkboard for your bottom line. Sixty years ago,
when Raaco International started manufacturing plastic
drawers and mobile storage solutions in Nykbing Falster,
Denmark, pneumatic actuators were the technology of
choice for injection molding and semi-automatic welding line
automation. Weve since learned that pneumatic cylinders
are susceptible to pressure loss and leakage. This issue was
precisely the case for the company recently. With an increased
need for performance and rising energy costs, Raaco engineers
sought out electric actuators from Thomson Industries.
To help them get started, the Raaco engineering team
contacted AVN Teknik, a Danish distributor, from which it
had previously sourced industrial components. In reviewing
specifications, AVN Tekniks product specialist, Flemming
Blauert, analyzed the problem and compared actuation
alternatives.
Edited by: Mike Santora Associate Editor
Electric actuation helps save energy in automation applications
Lower maintenance costs
and requirements influenced
Raacos decision to switch to
electromechanical actuation.
4 0 DESIGN WORLD March 2016 www.designworldonline.com
perfection in stainless
Eagle has the expertise and the specialized
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Design Notes 3-16_Vs7.LL.MD.indd 40 3/3/16 3:57 PM
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Electric actuation helps save energy in automation applications Raaco knew the actuators needed to
be replaced, and were prepared to pay the
cost360 per cylinder to upgrade to a newer
pneumatic actuator, or 1,800 per cylinder for
electromechanical actuators.
Using a sizing and calculation tool that
factored in the required dimensions, torque,
price of energy, ambient conditions, number
of cycles and the duration of operation, the
cost of operating a pneumatic cylinder was
estimated at 739 per year, compared to 63
for the electromechanical cylinder. Pneumatic
actuators consume more energy because
each cylinder operation requires compressors
to be operating 24/7. Also, the efficiency
rate of electrical energy for pneumatic
cylinders is only 15%, compared to 80% for
electromechanical actuators.
But energy savings were only part of the
value. Raaco chose to go with Thomsons PC
series. The PC series offered improvements in
performance, productivity and maintenance.
Raaco agreed to a preliminary test.
The test involved replacing the pneumatic
cylinder on a trapezoidal welding machine
used for fixing metal parts. Although it was not
a direct production application, it was enough
to demonstrate the speed, safety, loading and
energy saving capabilities of electromechanical
actuators.
The next step involved replacing the
pneumatic actuator controlling the arm of
a key injection molding application with the
electromechanical actuator. The actuators
function was to extend a robot arm down into
the machine to grab a part from the mold,
raise it up, move it sideways and drop it onto a
conveyor belt for processing.
Expecting a certain amount of downtime for
the transition, Raaco planned to hold factory
production for up to two days; the actuators were
up and working in a couple of hours.
Energy savings met expectations. Annual
energy costs for operating this particular
machine fell from 179 to 19. Along with
the low energy consumption came a boost in
performance. The electromechanical actuator
proved to be 3x faster than its pneumatic
predecessor, saving Raaco up to 1.2 sec for each
cycle. For every two parts fetched and placed
before, the system was now handling three. With
an average machine running 2,880 cycles a
day, this was a significant boost in productivity.
Maintenance for the electromechanical actuators
is a squirt of grease into the lubrication ports
three times per year.
There is also a safety advantage. If the
power fails while the system is in operation,
the controlling pneumatic force goes away and
the arm can drop rapidly, potentially harming
anything that might be beneath it. This is not an
issue for electromechanical actuators because
they have an electric brake on the motor. If the
power goes down, the actuator stays in position.
Convinced of the potential value across
the rest of its production line, Raaco ordered
electromechanical replacements for its
pneumatic cylinders on the whole of its
injection molding line during the next scheduled
maintenance turnaround, and is evaluating
applications throughout the rest of its plant. DW
Thomson Industries thomsonlinear.com
The PC-series
precision linear
actuator delivers
extended life,
repeatability and
quiet operation.
www.designworldonline.com March 2016 DESIGN WORLD 4 14 0 DESIGN WORLD March 2016 www.designworldonline.com
perfection in stainlessEagle has the skills and the technology required to produce
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Design Notes 3-16_Vs7.LL.MD.indd 41 3/3/16 3:57 PM
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How to avoid common coupling installation mistakes
www.designworldonline.com March 2016 DESIGN WORLD 4 3
Edited by: Mike Santora Associate Editor
4 2 DESIGN WORLD March 2016
Co u p l i n g N o te s
Initial coupling selection aside, the prevention of premature component failure begins with installation. Installing the right part the wrong way is badseems obvious. Yet, nearly all coupling manufacturers we speak with have similar tales
of installation nightmares. Mike Parzych, product marketing manager at GAM, gave us the three most common installation
mistakes he encounters.
Clean up your act Another common mistake we see is when customers do not check to make sure the shafts and bores are cleaned and free from oil to prevent premature slippage.
GAMs EASY clamp system opens up the bore slightly to
allow for installation without
damage to the coupling or
mating shafts.
Tighten Up The most common mistake we have seen is when our customers do not tighten the clamping bolts to the recommended torque values. Rather than using a torque wrench, they estimate when the correct torque has
been reached. In some cases, they do not tighten the clamping bolt enough and the coupling slips. On the other end of the spectrum, they over tighten the clamping bolt which can damage the bolt or even cause hub fracture.
Coupling Notes 3-16_Vs3.MS.LL.MD.indd 42 3/3/16 3:01 PM
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www.designworldonline.com March 2016 DESIGN WORLD 4 3
The Force is not with you The last mistake we see is often due to difficult assembly conditions (confined space) or tight shaft/hub tolerances; customers force the coupling onto the shaft, which compresses the bellows and can damage the coupling. To account for these scenarios, many couplings have the EASY clamp system which opens up the bore slightly to allow for easy installation without damage to the coupling or mating shafts.
Out of sight, out of mind One of the worst coupling installations Ive seen was for an application where the parallel misalignment between shafts was actually visible. Normally it takes a precision gauge to measure the misalignment as we are generally talking distances of 0.3 mm (0.0118 in.). So being able to visually observe the misalignment gave us a clear diagnosis. We also had some questions for Parzych about couplings when your design will likely experience large loads. Here is what he had to say: When expecting large loads for a motion system design, a few things need to be
A metal bellows was evaluated using FEA. The specific loads in the corrugation valleys of the
metal bellows are in red because of higher stress.
This means that the corrugation val
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