design world december 2015

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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New ISO 15552 (G Series) Non-repairable round

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CONTROL VALVES

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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

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

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

ADVANCEDMATERIALS


Advanced Materials

Congratulations

LEADERSHIP 2015 WINNERS PAGES_Vs2.MD.indd 4 12/7/15 1:37 PM

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.



Digital Manufacturing

LE

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

DIGITAL MANUFACTURING

Congratulations

LEADERSHIP 2015 WINNERS PAGES_Vs4.MD.indd 5 3/3/16 7:55 AM

LE

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

ELECTRICAL & ELECTRONICS



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


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.

LE

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

FASTENING & JOINING



Fastening & Joining

Congratulations


Fluid Power



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

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

FLUIDPOWER

Congratulations


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.



LE

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

MECHANICAL

Mechanical

Congratulations


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

LE

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

MECHATRONICS


Congratulations


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.

LE

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

MOTIONCONTROL

www.designworldonline.com December 2015 DESIGN WORLD 1 1


Motion Control

Congratulations


Networks



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.

LE

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

NETWORKS

Congratulations



Software


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.

LE

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

SOFTWARE

Congratulations


Switches & Sensors


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.

LE

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

SWITCHES & SENSORS

Congratulations



National Instruments


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.

LE

ADERS

HIP IN ENGINEERING

PRESENTED BY

2015 L

eadership Winners

TEST & MEASUREMENT

Test & Measurement

Congratulations



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

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

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


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

@ 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

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


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

Proto Labs 11-15.indd 21 12/2/15 11:55 AM

Follow the whole team on twitter @DesignWorld

WTWH Media, LLC6555 Carnegie Ave., Suite 300, Cleveland, OH 44103Ph: 888.543.2447 FAX: 888.543.2447

NEW MEDIA/WEB/BUSINESS DEVELOPMENT

Web Development ManagerB. David [email protected]@wtwh_webdave

Web Development SpecialistPatrick [email protected]@amigo_patrick

Video ManagerJohn [email protected]@wtwh_jhansel

EDITORIAL

Editorial DirectorPaul J. [email protected]@dw_editor

Managing Editor Leslie Langnau [email protected]@dw_3DPrinting

Executive EditorLeland [email protected]@dw_LeeTeschler

Senior EditorMiles [email protected]@dw_Motion

Senior EditorMary [email protected]@dw_marygannon

Senior EditorLisa [email protected]@dw_LisaEitel

Associate Editor Mike [email protected]@wtwh_Michael

Assistant Editor Michelle [email protected]@wtwh_Michelle

Director, Audience DevelopmentBruce [email protected]

WORLDA DESIGN WORLD RESOURCE

Business Development ManagerPatrick [email protected]@wtwhseopatrick

Online CoordinatorJennifer [email protected]@wtwh_jennifer

MARKETING

Marketing Team LeaderStacy [email protected]@wtwh_Stacy

Marketing and Events CoordinatorNicole [email protected]@wtwh_Nicole

Marketing and Events CoordinatorJen [email protected]@wtwh_jen

Marketing CoordinatorLexi [email protected]@medtech_lexi

Traffic Ma gerMary [email protected]

Production AssociateTracy [email protected]

GRAPHICS

VP, Creative ServicesMark [email protected]@wtwh_graphics

Art Director Matthew [email protected]@wtwh_designer

Graphic DesignerMargaret [email protected]@Meg_CLE

2014 Winner

Crains Cleveland Business Fast 50 2014


2011 - 2015

ControllerBrian [email protected]

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Staff page 12-15_Vs1.indd 22 12/2/15 12:15 PM

SV200 Digital Servo Drives offer a wide range of

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torque or velocity, streaming commands, stored program

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[email protected]

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Applied Motion 12-15_New.indd 23 12/2/15 11:56 AM

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

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.

86

Contributor Page 12-15_Vs2.MD.indd 25 12/3/15 2:55 PM

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

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

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


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

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

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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 ma

fractional horsepower motion control solutions for the medicaff l, packaging, automation, se

energy industries.

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All-in-One brushless DC motor

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Designed in Germany, Over 3 million

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Get prototypes in 24hdunkermotoren.com/express

with EtherCAT interface &

Dunkermotor 11-15 (new).indd 29 12/2/15 12:03 PM

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


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

2015 by AMETEK Inc. All rights reserved.

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

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

100 East Erie StreetKent, OH 44240ametekdfs.com

AMETEKDFS Regen Blower Ad_9x10.875.indd 1 6/1/15 5:03 PMAMETEK 6-15 (NEW AD).indd 31 12/2/15 12:04 PM

with Design WorldDIGITAL ISSUE

Visit designworld-digital.com for our latest issue!

FOLLOW US

Connect with 339,805 engineers at

facebook.com/DesignWorldNetwork.

Grow your network. Join the Design World

group on LinkedIn.

Hot products and topics are streaming at

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See shared slides atslideshare.net/

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

engineeringexchange.com.

Find meaningful links and tweet along with us

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Check the boards and see whats being pinned up at

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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

FACEBOOK

ENGINEERING EXCHANGE

GOOGLE+

YOUTUBE

TWITTER

http://dwo.me/1QPUxa7

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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


Engineering Exchange 12-15_Vs1.indd 32 12/3/15 3:06 PM

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

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


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

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

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


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


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


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

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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



m e d i c a l


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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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

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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


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.


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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

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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

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

design world december 2015

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