motion systems applications handbook

SystemsMotion

November 2015designworldonline.com

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Precision Gearboxesfor Servomotors

the #1 value in automationOrder Today, Ships Today!

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

SureGear PrecisionServo GearboxesThe SureGear series of high-precision servo gear reducersis an excellent choice for applications that require accuracyand reliability at an exceptional value.

These planetary gearboxes, available in right-angle, inline,and now hub-style versions, have a thread-in mounting style, along with precision and torque capacity that is best in class.

NEW hub-style models are perfect for applicationsrequiring high-speed, high-precision indexing movement

Industry-standard mounting dimensions

Best-in-class backlash

Multiple gear ratios available (5, 10, 15, 25, 35, 50:1)

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Maintenance free: no need to replace the grease for thelife of the unit

At nominal speed, service life is 20,000 hours

Can be positioned in any orientation

5-year warranty

Starting at: $398.00 (70mm Frame - PGA070-05A1)

Use SureGear with our practicalSureServo systems

The SureServo family of brushless servo systems from AutomationDirectis fully digital and o ersa rich set of features atdynamite prices.Beginners to experienced users can take advantageof this easy-to-use familyfor as little as $986.00**(100W system).

start under $1,000**brushless servo systems from AutomationDirectis fully digital and o ersa rich set of features atdynamite prices.Beginners to experienced users can take advantageof this easy-to-use familyfor as little as $986.00**(100W system).

Eight standard systems from 100 W to 3 kW

Use with most AutomationDirect PLCs or any other host control

Drives feature on-board indexer and adaptive tuning modes

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Mates easily toSureServo motors

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Servo Systems

AutomationDirectPrice/Part Number

Allen-BradleyPrice/Part Number

All prices are U.S. list prices, AutomationDirect prices as of October 2015.The Allen-Bradley 100W system consists of part numbers shown in table above with prices from

www.wernerelectric.com, www.rexelusa.com 5/25/2015.

100W Servo Motorwith connectorized Leads

10 MotorFeedback Cable

10 MotorPower Cable

Configuration Software

Digital Servo Drive

Breakout Board Kit forCN1 Control Interface

$488.00SVA-2040

$325.00SVL-201

$94.00ASD-BM-50A

$49.50SVC-EFL-010

$29.50SVC-PFL-010

FREESV-PRO*

$1,340.002098-DSD-005

$558.00TLY-A130T-HK62AA

$263.002090-U3BK-D4401

$90.002090-CFBM6DF-CBAA03

$101.002090-CPBM6DF-16AA03

$82.002098-UWCPRG

*SureServo Pro software is FREE when downloaded and is also available for $9.00 on a CD

Complete 1-axis 100W System $986.00 $2,434.00

$674.00(PGB070-05A1)

$398.00(PGA070-05A1)

Examplemodelsshown

$722.00(PGD047-05A1)

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BEI Sensors rotary encoders are well-sealed, shock and vibration

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performance. Put a working class hero on the job and see what a

difference real reliability can make.

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Aerospace: Showcasing motion excellence

LISA EITEL @DW_LisaEitel

NASA engineers and scientists saw years of design work come to fruition when the Mars rover Curiosity, a 2,000-lb feat of excellence, settled onto the red planet in a gentle touchdown of glory.

But it wasnt just the efforts of NASA personnel that gave humanity that momentand every other win in the thousand-plus days that Curiosity has successfully documented Mars terrain. Scores of suppliers (among them many motion-component manufacturers) also saw their designs succeed.

In our inaugural edition of this Design World Motion Casebook, we profile applications that showcase this kind of engineering excellence. Read through this Casebook, and youll discover how smart bearings could soon improve rail and wind-turbine applications ... and how custom-engineered conveyors and robots

are leading warehouse automation in packaging. Youll also see how smart

motors power next-generation peristaltic pumps to circulate blood without pulsations.

Reconsider Curiosity. As details about its design (including some of its bearings, actuators, and software) continue to go public, we cover the technical details.

For example, we now know that tubular piezo stacks from Physik Instrumente (PI) are on the rover and still working perfectly, currently helping in the collection of soil samples from the red planets Gale Crater. The solid-state actuators go on a Chemistry & Mineralogy (CheMin) instrument to help scoop Mars dirt into test chambers and dump it out when tests are done. Conventional polymer-insulated piezo actuators wouldve been too sensitive to humidity and temperature extremes on Mars. But PIs ceramic encapsulation (cofiring that puts piezo-elements in monolithic blocks) makes the actuators more durable. In fact, PI PICMA actuators with the same design now work for nanopositioning systems in

This is the recovery of SpaceXs Dragon spacecraft off the coast of southern California in early 2015 after a parachute-assisted splashdown. Thanks to durable components, Dragon can repeatedly return supplies and experiments back to Earth.

2 DESIGN WORLD 11 2015 designworldonline.com

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This NASA Robonaut uses 26 Harmonic Drive component sets in its arm, leg, head and torso joints.

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Whatever keeps you up at night, weve got a solutionthe largest selection of motors, pumps and air-moving devices available. Plus, one-of-a-kind solutions ready to be

custom-engineered for your precision industrial, commercial, combustion or transportation application. If you can dream it, youll nd it at Solution City.

FOR MOTION CONTROL INNOVATION, SOLUTION CITY NEVER SLEEPS.

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AEROSPACE SHOWCASES MOTION EXCELLENCE

semiconductor test and inspection, super-resolution microscopy, and bio-nanotechnology.

Even simpler power-transmission components on Curiosity demonstrate design merit. Consider the DU metal-polymer bearings in Curiositys soil drill. GGB Bearing Technology made the self-lubricating bearings to function in Mars temperatures from -328 to +536 F. Thats important because DU bearing segments function as the main drill-spindle component.

Curiosity engineers tapped motion-industry resources on the software side as

well. They used Adams multi-body dynamics software from MSC to design Curiositys descent and landing. Simulating of touchdown details helped them prevent flight hardware from banging during breakaway of a Descent Rate Limiter and bridle deployment.

Other aerospace projects exhibit motion-design brilliance. Just turn to page 61 of this Casebook, where we detail how encoders on a Sentinel-1A satellite support inter-satellite laser communications. Or consider how the European space probe Rosetta recently landed on the comet Chury, and an array of dc motors from maxon motor helped the craft do its job.

Even seemingly futuristic technologies in recent Hollywood blockbuster The Martian already exist. The movie dramatizes a Mars habitat that strongly resembles the real Human Exploration Research Analog (HERA) at NASAs Johnson Space Center. HERA is a simulated deep-space habitat for ISS-bound astronauts. Its complete with two stories of living quarters, hygiene module, workspaces and airlock. Other technologies in the movie for water recovery, rovers, space farming, oxygen generation and ion propulsion also exist.

To be sure, aerospace applications are challenging, so are subject to failures. An experimental NASA cubesat recently showed altitude-control issues; the SpaceX CRS-7 mission earlier this year (to resupply the ISS) failed after an explosion originating from a liquid oxygen tank; defective pressure gauges recently delayed the launch of the European Space Agencys ExoMars 2016 mission.

Despite such challenges and in celebration of those averted, may we let todays applications in aerospace and other motion industries bring us inspiration, and let us welcome the technologies they kindle tomorrow.

Starring in The Martian are Matt Damon ... and emerging aerospace technologies. In fact, many of the movies dramatized rover, camera, and solar-panel actuating systems incorporating motion components already exist. Photo courtesy Aidan Monaghan and Fox Films

After passing extensive NASA tests, PIs PICMA actuators got into Curiosity and still work in the sample-analysis system of the CheMin sample-collection instrument. (The tests confirmed PICMA actuators deliver 96% of their original stroke after 100 billion cycles.)

MR encoders from maxon motor work in Curiositys electromechanical joints. The magnetic sensors mount on the drive shafts and help drives control motors.

DU metal-polymer bearings from GGB Bearing Technology go into the spindle of Curiositys soil-grinding drill, which the rover uses in getting samples.

NASAs Curiosity rover took of itself with its robotic Mars Hand Lens Imager camera arm on October 5, 2015 (its 1,126th in service). In the background is Mars Gale Crater. Image courtesy NASA

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

Call: [email protected]

WHEN SPEED MATTERS THE MOST. And

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

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

Power from 10 to 450 Watts

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

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

dunkermotor.com/express

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DESIGN WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. DESIGN WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care.

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motioncontroltips.comM O T I O N CASEBOOK

P02Aerospace showcasesMotion excellenceActuators ........................................................ 10

Ballscrews ........................................................16

Bearings .........................................................20

Brakes, clutches & torque limiters .................. 24

Cable management ........................................ 26

Cabling ...........................................................30

Chain .............................................................. 32

Compression springs ...................................... 34

Controllers Motion, servo & PLC ................. 35

Conveyors ......................................................40

Couplings .......................................................42

Drives AC .....................................................48

Drives DC .................................................... 52

Encoders ........................................................ 56

Gears Speed reducers,

gearboxes & servo gearing ...............62

Gearmotors ................................................... 72

Grippers ......................................................... 74

Human machine interface (HMI) hardware ..... 76

Human machine interface (HMI) software ...... 78

Leadscrews .....................................................82

Linear guides, rails, slides & ways ..................84

Motors AC ...................................................90

Motors DC ................................................... 93

Motors Integrated ....................................... 97

Motors Linear ..............................................98

Servomotors ................................................. 102

Stepper motors ............................................ 106

Networks ......................................................108

Positioning stages & tables ...........................112

Retaining rings...............................................114

Shaft collars Locking devices ......................116

Shocks & vibration-damping components ....118

Wave springs ................................................ 122

2015 PTDA Summit recap:

The industrys future ...................................... 124

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2015 by AMETEK Inc. All rights reserved.

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

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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 EditorMike [email protected]@DW_MikeSantora

Assistant Editor Michelle [email protected]@wtwh_Michelle

2011, 2012, 2013, 20142014 Winner

Crains Cleveland Business Fast 50 2014

VIDEO

Integrated Media SpecialistJohn [email protected]@wtwh_jhansel

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Director, Creative ServicesMark [email protected]@wtwh_graphics

Visual Design Manager Matthew [email protected]@wtwh_designer

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

Traffic ManagerMary [email protected]

MARKETING

Marketing ManagerStacy [email protected]@wtwh_Stacy

Marketing & Event CoordinatorNicole [email protected]@wtwh_Nicole

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NEW MEDIA/WEB/BUSINESS DEVELOPMENT

Web Development ManagerB. David [email protected]@wtwh_webdave

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M O T I O N CASEBOOK

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www.catalystmotiongroup.com

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

of simple-to-sophisticated automation systems.

At Catalyst Motion Group

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

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

Your Catalyst to InnovativeMotion Control Solutions

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

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At Catalyst Motion Group, we are able to congure motion systems by utilizing our own component level supply. What this means for our clients is full accountability for customized solutions while realizing the improved eciencies of a reduced supplier count and receiving fully tested and delivered solutions.We can provide you with the ultimate solution for almost any application, while managing scheduling demands, technical requirements and nancial considerations. We are able to accomplish this through coordinated utilization of our extensive engineering resources and vertically integrated manufacturing resources.We put it all together customized motion systems that include stepper motors, brush and brushless DC motors, linear mechanics, drives, electronics and an extensive array of peripheral system components. Our considerable and wide-ranging in-house manufacturing capabilities allow us full control of the entire process, from development of prototypes to delivery of fully tested production units. And, with our engineering capability, if we don't have it ...we can develop it! We have successfully developed and taken to production fully customized motion solutions for a wide variety of advanced technologies including: Medical devices for diagnostics, surgical procedures, therapeutics and pharmaceuticals Laboratory and analytical instrumentation and equipment Industrial automation including robotics and production line processing operations We are innovative, exible and most importantly a secure, reliable, and knowledgeable resource ready to respond to your most challenging motion control needs.




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Electric actuators: Versatility in motion

E lectric actuators range from syringe-sized units in medical applications to those that drive truck-sized industrial presses. These ubiquitous muscles of precision motion usually incorporate an electric motor and rotary-to-linear device for conversion of torque to linear force.

No matter the application, electric actuators deliver precision and repeatabilityindispensible for repeatedly moving loads to a given location or locations. In some cases, theyre also more controllable than fluid-power options, giving engineers a viable way to shape the speed, force and acceleration of machine-axis moves.

Another benefit for applications that must deliver different outputs over time is that many electric actuators are programmable, so can adapt to changing conditions. Exceptions abound, but

In this conveyor setup, SFP, SD and SE slides from PHD, Inc. route products off a conveyor line, while optical sensing identifies routed pieces. Such setups quickly and effectively separate product for packaging and distribution.

Series SFP slideSeries SD slideSeries SE slide

applications with similar dynamics generally make use of similar actuatorsthose that pair motors with ballscrews; incorporate brushless dc motors; use leadscrews; come in a rod style; integrate belt-and-pulley setups; use motors paired with planetary roller screws; or are fully integrated actuators with built-in guides.

Note that electric actuators that work closed-loop or with a micro-stepping motor can match force and speed output commands best using feedback to overcome most of the mechanical limitations of rotary-to-linear devices.

Some application tips: No matter the application, establish the designs power draw. Determine if the machine needs continuous or intermittent power draw, as that will dictate actuator size and type. Remember that overly large electric actuators can be less responsive than properly sized units.

On the other hand, appropriate safety factors ensure that electric actuators run coolly. Plus, lighter loads on the mechanical components can extend life. Halving load on a leadscrew can extend its life eightfold, for example.

Also account for the application environment and any dirt, chemicals and liquids that will contact the actuator. O-rings and seals must be made of materials that withstand the applications suite of contaminants. Finally, ensure that the electric actuator can handle the applications side, radial and axial loads.

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The PITTMAN Difference

When evaluating DC motor choices, its whats inside that matters.

Special brush formulation for use in a very low humidity environment Bearing system to handle higher than normal axial loads Very tight balancing spec to minimize audible noise and vibration at high speeds Unique magnet charge pattern to minimize cogging at low speeds Specially chosen surface-mount components inside the motor to meet an aggressive EMC requirement Whats Inside

Matters

On the outside, this looks like an ordinary DC motor. In fact, this particular motor is not a standard off-the-shelf part, but designed exactly to a customers specific technical requirements. PITTMAN provided an experienced team of engineers to work directly with the customer to design the perfect motor to meet a demanding motion application

Special brush formulation for use in a very low humidity environment Bearing system to handle higher than normal axial loads Very tight balancing spec to minimize audible noise and vibration at high speeds Unique magnet charge pattern to minimize cogging at low speeds Specially chosen surface-mount components inside the motor to meet an aggressive EMC requirement

www.PittmanMotors.com343 Godshall Drive, Harleysville, PA 19438USA: +1 267 933 2105Europe: +33 2 40 92 87 51Asia: +86 21 5763 1258

24 -HR SHIPPING / E-COMMERCE




At Catalyst Motion Group

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

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




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Matching actuators to design demandsElectric actuators for automation applications must deliver set levels of speed and force requirements. Here, better feedback and controls can increase responsiveness to overcome any mechanical limitations while boosting output-motion accuracy. OEMs and end users can pick from a vast array of actuators to get the right level of accuracyfor everything from lumber-processing machines to those medical applications that need accuracy to a few micrometers. Electric-motor actuators that use belts and acme screws for rotary-to-linear conversion of motion abound. That said, the majority of general motion applications (including

positioning tables, workpiece-pivoting stations, robotic end effectors and machining axes) make use of actuators that integrate ballscrews. With precision of down to micrometers, these satisfy designs that need thrust to thousands of pounds-force or linear positioning speeds to several feet per second.

Elsewhere, on injection-molding applications, packaging machines, machine presses and other setups

that need high thrust, actuators that pair the electric motor with a roller screw (sporting a nut loaded with roller bearings that work like planetary gears around the screw) is a newer and increasingly common option. Typical stroke is 2 m with acceleration to a few gs.

This five-axis CNC foam-cutting gantry system was designed and built by a faculty and student project team at the University of California, Davis Engineering. Its for the fabrication of aerostructures, such as foam-core wings, and for the production of forms for composite layup.

The machine was built from standard configurations of Bishop-Wisecarver LoPro linear actuators featuring ballscrew drive mechanisms. The designers configured the actuators in to an X-X-Y gantry using T-slot aluminum framing members and aluminum brackets to create a work envelope of 1 x 2 x 0.7 m. The fourth and fifth axes are custom designed and fabricated to accommodate the cutting spindle.

More specifically, on the X axis, there are two

aluminum-beam-mounted LoPro actuators with Size-2 ballscrews and a basic wheel plate with lubricators for 1,000 mm of travel. The Y Axis has one LoPro with a Size-4 ballscrew for 2,000 mm of travel. The Z axis has a LoPro Size-2 ballscrew and travels 700 mm.

ACTUATORS


To order a catalog, visitphdinc.com/dws1115 1-800-624-8511

Complete Motion SolutionsPneumatic, Electric & Hydraulic Actuators

PHD offers an extensive line of pneumatic actuators that are known for long life and high quality. Over our 55 years of innovation, we have extended our product offerings to include built-to-need components, price alternative components, electric actuators, specialty workholding clamps, and motion control robots. From single actuator solutions, to multi-unit systems, PHD and Yamaha Robotics

can provide complete solutions for practically any application requirement.

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Common actuator types Benefits and potential limitations Typical uses

Actuators pairing motors with ballscrews

High axial output force for given torque input (mechanical advantage) Speed and stroke limits

Industrial, transportation, aerospace and defense

Actuators with brushless dc motors

None of the wear of brush motors; long life More costly initially and potentially complicated drive

General-purpose applications; axes run at high speed; appliances; factory automation

Actuators with leadscrews (or Acme screws)

Simplicity and (in some versions) integration of guide function Variable life due to sliding wear

Ruggedized equipment; lower-cost consumer products; machine-tool transport

Rod-style actuators High force output (especially screw-driven types); hygienic Seals can increase costMedical applications needing sealed motion components; sorting and food processing

Actuators with belt-and-pulley setups

Extremely high speeds and long strokes; short design lead times Limited precision without guides

Horizontal and vertical designs; small conveying to large SCARA transport

Fully integrated actuators (with built-in guides)

Simple installation Less design freedom

Consumer products to medium-volume industrial machines

Linear motors Fast and accurate More costly than alternativesUltra-high-precision applications in semiconductor, medical and more

Motor paired with planetary roller screw

Fast, accurate and precise More demanding installation requirements

Precision applications in aerospace and semiconductor

Actuatorfor welding

Robot controller

Welder controller

7th-axis resolver or encoder feedbackenclosed within protective housing

This is one example of how manufacturers often build actuators to specific requirementshere, an actuator on a spot-welding robot used in automotive body-in-white spot welding applications. These GSWA ServoWeld actuators from Tolomatic, one of a myriad of job-specific offerings from the company, offer faster spot weld cycles and higher quality, more repeatable welds than pneumatic robotic spot welding equipment. The lightweight actuators have an enclosed anti-rotate assembly and are ideal for P (pinch), C, X, or Euro guns, offering superior performance and lower lifetime costs. A hollow-core servomotor pairs with either a ball or roller screw to output efficient, repeatable high force, lasting more than 10 million cycles and eliminating the need for couplings, adapters, belts and gears.

ACTUATORS


Want us to make you a hero?

Power and economy

Low-cost ERD electric rod cylinder Replace

pneumatic cylinders, automate manual processes

USDA- and 3A-approved hygienic design

IP69K/IP67 options Force range to 4,500 lbf (20 kN)

High-force RSA actuator

High performance Mounting exibility High thrust up to 12,900 lbf

(57 kN)

Heavy-duty IMA linear servo actuator

Compact package Ball and roller screw Forces up to 6,875 lbf (30 kN)

www.tolomatic.com

Visit www.tolomatic.com/electric-rod

Electric rod actuators

Powerful linear motion solutions that help you save the day (and simplify your machine design).

Build your next machine exactly as you envision it. With Tolomatics broad line of electric linear actuators and motion control systems, you can conquer virtually any application adversity with ease. Youll fi nd the speed, force and accuracy that precisely fi t your machine goals, plus expert specifi cation help through our online tools and customer support.

Face your linear motion challenges with Tolomatic at your side. Contact us to fi nd out how easy it is to get the job done.Visit www.tolomatic.com or call 877-385-2234.

Be heroic! Sign up to receive Tolomatics blog and register to win a GoPro HERO camera.www.tolomatic.com/Heroic

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Ballscrew applications: From mainstream to extreme

Ballscrews are a tried and true linear motion component. They best suit applications needing light, smooth motion; applications requiring precise positioning; and when heavy loads must be moved. Examples include machine tools, assembly devices, X-Y motion and robotics.

Ballscrews are usually classified according to factors such as lead accuracy, axial play and preload, and life/load relationship. Lead accuracy refers to the degree to which the shafts rotational movements are translated into linear movement. With lead accuracy and axial play determined by the manufacturing method of the ballscrew shaft and the assembly of the nut, high lead accuracy and zero axial play is generally associated with relatively higher-cost, precision ground ballscrews, while lower lead accuracy and some axial play is associated with lower-cost, rolled ballscrews. Fabricated by rolling or other means, these ballscrew shafts yield a less precise, but mechanically efficient and less expensive ballscrew.

When specifying a ballscrew, understanding the application criteria that the component needs to satisfy is essential. There are several factors to consider and each one plays a role in the decision-making process. The most important factors to consider when selecting a ballscrew are:

loadincluding the mass being moved and the forces involved in the machines processes

orientationfor example, horizontal or vertical, which affects the need for load-bearing support

speedvelocity and acceleration travelthe stroke length precisionincluding positional accuracy and requirements for

repeatability environmentspecial considerations for rugged or unique

environments duty cyclecycle rate

Recently, advances in manufacturing and materials have improved ballscrew performance so machine designers today can get better linear motion at lower cost. Some improvements include the fact that the latest generation of ballscrews has more load density than ever, giving designers higher capacity from a smaller package. There is also a trend toward more miniaturization, as well as faster

Shown here is a Skyfire SVM-0 CNC milling machine. It has linear rails from HIWIN for all three axes of motion; the ballscrews that drive the axes are P7 single or double-nut rolled or C3-class ground ballscrews.

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nsk k1TM lubricaTion uniTExperience long-term, maintenance-free operation with NSK K1 Lubrication Units. These patented units provide fresh, continuous oil flow onto the rail or shaft during operation, making them ideal for environments where grease replenishment is undesirable or where grease is easily washed away. Available on NSK linear guides, ball screws, Monocarrier actuators and Robot Modules, K1 Lubrication Units prolong life for up to 5 years or 10,000 km operational distance.

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ballscrews using both rolled and ground screw manufacturing methods.

In addition to higher load capacities and miniaturization, there is also a move toward more integration. For example, ballscrew-based linear actuators are readily available as all-in-one packages. The benefit here is that such integrated packages significantly reduce design time as well as time required for assembling a system and programming the actuator itself.

Actuator stabilizes worlds fastest motorcycleA recent example illustrates how ballscrew-based actuators play a key role in stabilizing the worlds fastest motorcycle called the Top 1 ACK Attack Streamliner. Since it broke the motorcycle land-speed record in 2006, engineer Mike Akatiff and his design team have been working to make the Top 1 ACK Attack Streamliner surpass 400 mph, setting a new motorcycle land-speed record.

Training-wheel-type stabilizers for starts and stops, as well as rear stabilizing flaps for coast-down, are critical safety features. To move these safety components, Akatiff and his team chose Motion Systems 1,000-lb-rated Model 85199 actuator. Ballscrew-based actuators have better efficiency than those with acme screws, so they consume less energy to move the same amount of load.

The Top 1 Ack Attack Streamliner Motorcycle could become the first bike to exceed 400 mph. Actuators are key to its safe operation.

Motion Systems Corp.s 1,000-lb-rated Model 85199 Ball Drive actuator is efficient and takes less energy to move a given load.

This in turn lets engineers use smaller power supplies, which reduce size and weight, critical parameters when attempting to break a land-speed record. Ballscrew-based actuators also have better speed characteristics.

For the motorcycle, engineers modified the 0.979-in.-diameter 85199 to withstand g forces during acceleration and deceleration. So the actuator freewheels at stroke ends to eliminate limit switches and prevention of over-travel at stroke ends. Initiating freewheeling and linear advance stops is a ball cage within the nut ID that hits stop pins at each travel end. Factory-installed top pins mount in the screw thread for the specified stroke, which eliminates the need for limit switches. Screw, nut and ball cage are made of heat-treated alloy steel to resist wear. These mechanical design elements keep the motorcycle rider and others safe.

BALLSCREWS

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Bearings abound in myriad applications

Some applications excel with custom bearing designs. Shown here is the bearing in a blade pitch control on a wind turbine. Designed by Plymouth Machine Integration, it includes two concentric bearing rings fitted with one-way sprag clutches oriented in opposite directions. Small relative oscillatory motions of the inner race alternately lock and unlock the two clutches, in opposite phase. The middle (common) race is advanced in a single direction by an angle equal to the amplitude of the oscillatory motion. The average motion within each bearing is non-zero, promoting movement of the lubricant within the rolling elements.

Bearings are ubiquitous and essential components for reducing friction between moving parts. Their primary function is to give moving parts something to roll on rather than slide over. Their secondary function is to transmit loads. Bearing loads are either radial (perpendicular to the shaft), axial (parallel) or a combination of the two. Depending on the type of loads expected and the likelihood of extreme temperature, pressure and contaminant exposure, there are different bearings specialized for certain applications.

Consider the bearings and slewing rings in wind turbines. These can reach 2 m in diameter and must, in some cases, bear hundreds of tons. At the opposite end of the size spectrum (but only slightly less demanding) are bearings for medical applications. These often take the form of compact equipment necessitating bearings of just a couple millimeters in diameter, with rollers that are smaller. Some going into equipment subject to washdown have treated steel subcomponents; others for disposable or quiet designs are made of plastic. Likewise, industrial machines that are particularly hot, fast, or starved of lubrication under normal design conditions benefit from the use of hybrid bearings, which are those that use steel raceways and rollers or balls made from ceramic. No matter the design, each bearing type satisfies specific parameters.

Ball bearings use balls to provide a low-friction means of motion between two bearing races. Ball bearings are usually inexpensive and, when selected properly, require little maintenance. These characteristics, along with limited heat generation make them one of the most common types of bearings. They are found in everything from skateboard wheels to turbine engines in aerospace applications, medical equipment and home appliances.

Roller bearings use rollers of varying shape (spherical, spherical thrust, cylindrical) instead of balls to transmit loads and reduce friction. Thanks to this shape, roller bearings have greater surface contact than ball bearings, so handle larger loads without deforming. Their shape also allows for a moderate amount of thrust load because the weight is distributed across cylinder line contacts instead of sphere point contacts.They are common in conveyor belt rollers, turbine engines, transmissions and gearboxes, as well as the mining, food and beverage, pulp and paper, waste-water and marine industries.

A needle roller bearing is a roller bearing with rollers whose length is at least four times their diameter. The large surface area of a needle roller

bearing allows them to accommodate high radial loads in a limited ammount of

space. Needle bearings often go in compressors, rocker-arm pivots,

pumps, transmissions and other automotive designs.

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Affordable, lightweight, and modular in design, with motorized self-lubricating slewing ring joint technology. For robotics manufacturers, automation engineers, and a multitude of applications.

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The drive shaft of a rear-wheel drive vehicle typically has at least eight needle bearings (four in each U joint) and often more if it is particularly long, or operates on steep slopes. They are also found in construction and agricultural equipment, two-cycle engines, outboard engines and paper moving equipment.

Thrust ball bearings go in applications with mostly axial loads and can handle shaft misalignment. These bearings also excel in high-speed applications in aerospace, automotive, and oil and gas industries. Thrust ball bearings are also often found in machine tool tables, fluid control valves and spindles.

Thrust roller bearings transmit load from one raceway to the other to accommodate radial loads. Bearings like these also have a self-aligning capability that makes them immune to shaft deflection and alignment errors. Typical applications include: crane hooks, pulverizers, cone crushers and other heavy-load, medium-speed applications.

Tapered roller bearings have tapered inner and outer ring raceways with tapered rollers between them. The rollers are angled so their surfaces converge at the bearings axis. These bearings are unique in that, unlike most bearings that can handle either axial or radial loads, they can handle large amounts of load in both directions. Common applications include helicopter transmissions, fuel pumps and agricultural uses.

The principle difference between plain bearings and roller bearings is that plain bearings do not have any rolling elements. Plain bearings are usually compact, lower-cost bearings that are relatively simple in design. They can be found in many applications, but automotive and construction are some of the most common. Plain bearings are used in steering cylinders, front and rear struts, dump cylinders and on hydraulic excavators.

Intelligent bearing technology trialed in railway and wind energy sectors SKF is now using a bearing health-management technology called Insight in several industry applications. The design puts a self-powered intelligent wireless sensor in a bearing to get condition-monitoring data through the Internet. In fact, the setup is already undergoing trials in challenging wind-turbine and railway applications.

It goes beyond current sensorised bearing technology by integrating more sensors and ... self-powering and wireless technology, said Ronnie Spolidoro, business development manager, SKF Insight. These bearings connect to the Cloud, giving customers access to a range of diagnostic and support services.

SKF Insight monitors dynamic parameters such as temperature, lubrication condition, vibration and load, and informs operators when conditions are abnormal or threatening. When launched at Hannover 2013, SKF Insight was a just a concept for maintenance engineers to track bearing health. But now its a functioning

Timken pinion bearings were selected for the opener hubs on this P51C Mustang opener because of their ability to handle extreme radial and axial loading. Common double Timken pinion bearings are rated at 3,300 lb. Image courtesy of Timken

Split roller bearings, like this one from Revolvo SRB, are completely split to the shaft. This design feature makes installation easier and is an alternative to solid bearing replacement.


BEARINGS

23DESIGN WORLD 11 2015 designworldonline.com

After a bearing failure in the rotating element of this sludge thickener tank, engineers chose this custom cross roller slewing ring from Revolvo. This bearing is over 1,800 mm in diameter and is designed for long term reliability in harsh conditions.

Here, a True-Tech technician installs a high-speed pinion/bearing assembly in Valmet/Bonus Model SL3H-500 wind turbine gearbox.

In this image we see True-Tech technicians installing low-speed gear, shaft and bearing assembly into a lower housing bearing bore in a Valmet/Bonus Model SL3H-500 wind turbine gearbox. Image courtesy of True-Tech Industries Co.

solution running in customer pilots to supply data directly to diagnostic centers for condition monitoring using SKF aptitude. From here, dashboards and reports go to plant operators, machine manufacturers, SKF and anyone else authorized online. Users can even access the data on mobile devices.

Now using dynamic bearing data provided by SKF Insight, bearing health management will let operators see how actual conditions are affecting bearing health and spur corrective actionautomatic lubricant application or shifting speed, for example.

One promising application for SKF Insight is wind-turbine monitoring. Sometimes changing a turbines main bearing is so expensive that it negates the turbines overall viability. Here, Insight could monitor loads and lubrication conditions in service, giving plenty of time to prevent damaging conditions.

In fact, SKF is already helping a wind turbine customer develop such a system to measure dynamic bearing information in the true operating state, then wirelessly communicate it to monitoring centers and maintenance crews. Ultimately, the system will monitor bearing speed,

vibration, temperature and lubricationeven as a retrofit to enhance operational potential of thousands of turbines already in operation worldwide.

The company is developing a similar solution in the railway sector for wheel-end bearingscritical components usually changed at set intervals, regardless of condition. Here, Insight could soon let operators change the bearings based on real conditions.



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Brakes, clutches and torque limiters in motion

Here, a ROBA guidestop on a carriage clamps directly to a profiled rail.

Brakes, clutches and torque limiters serve similar functions in packaging machinery, medical equipment, industrial hoists and installations. Essentially, brakes stop and hold loads while clutches and torque limiters disengage and engage power-transmission outputs to transfer torque from an input. Torque limiters usually modulate power transmission to protect mechanical equipment from overload.

When selecting brakes, clutches and torque limiters for a given application, engineers must pick between mechanical, electric, fluidic or self-actuation. Electric brakes are easy to control and cycle, even to a couple thousand cycles per minute. In contrast, common air-actuated brakes and clutches run coolly and maintain hold with minimal power. Friction brakes with disc, drum and cone morphologies work well as emergency brakes because of their failsafe holdingessential on conveyors, escalators, airport-baggage handlers, elevators and other safety-critical designs.

The size and type of brake most suitable for a given design depend on whether the machine needs emergency stops or softer stops that sacrifice brakes to protect loads from shock. Then, other application criteria (including the machine envelope, thermal capacity, cycle rates, and inspection and repair schedules) dictate the final selection. In other machines, its more important that brakes prevent shifting loads and misalignment.

In most cases, its best to size brakes and clutches to the motor torque of the machine axis. But especially for axes where the brake must stop a vertical load, engineers should account for the fact that motors can temporarily draw added current to output more than their rated torque. Helpful resources include published performance curves from brake and clutch manufacturers. These list dynamic torque ratings for various operating speeds to help engineers match brakes and clutches to peak motor-output torque.

Beyond these general guidelines, fast, hot and other extreme applications require extra evaluation. Some tips:

Spring-set brakes benefit motion designs that slow loads with the motor before the brake engages; theyre also suitable as holding mechanisms.

Machinery that runs beyond a few hundred cycles per minute may require brakes and clutches that are larger than performance curves indicate.

Industrial designs that operate in hot environments may benefit from friction brakes with specialty friction-surface geometries and materials (such as phenolic resin or ceramic). Motion applications that dont get a lot of maintenance also benefit from the longer life these friction materials get.

Brakes that use permanent magnets for operation automatically adjust for wear, so they excel in industrial machines subject to slow but steady on-and-off cycling.

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BRAKES, CLUTCHES & TORQUE LIMITERS


One brake example: Safety for linear motionIn machine tools and machining centers, rail brakes can boost safety while improving accuracy and performance. Consider how suspended loads present a hazard in machines and systems, especially if people are below. During falls or crashes, the design must stop the load as quickly as possible to protect people and the machine.

So, some safety brakes (in the form of clamping units that engage profiled rail guides) brake movements safely

and quickly by rigidly clamping the axes while running. Case in point: Backlash-free ROBA-guidestop profiled rail brakes from Mayr Corp. now come in eight sizes for nominal holding forces from 5 to 34 kN. The designs are dimensioned for four rail sizes made by established linear guide manufacturers. A

short constructional design and the integrated switching-condition monitoring

use a contactless proximity switch.The guidestop brakes mount directly to masses,

which is especially useful for gravity-loaded axes that pose a risk to nearby workers. Drive elements between the motor and moving mass (spindles and nuts, shaft couplings or gearboxes) dont affect overall machine safety as in motor brakes that rely on drive elements to transmit braking torque to the load. Another drawback of the motor-brake setup (not to mention pole brakes or band brakes) is that everything between the brake and carriage degrades rigidity. ROBA-guidestop safety brakes avoid this issue.

The ROBA-guidestop safety brakes work as fail-safes, as they close when de-energized. Tensioned cup springs press brake shoes onto the profiled rails middle (to clamp it). Then hydraulics release the ROBA-guidestop with nominal pressure of 70 barlow compared to the holding force. The brake mechanism is for relatively long stroke paths, so compensates for profiled rails manufacturing tolerances without losing braking force. Two brake circuits work independently to either double holding forces or provide redundancy.

The backlash-free clamping of guidestops directly onto profiled rails also boosts the rigidity of the NC axis (for more accuracy) and minimizes vibrations (for better workpiece surface quality). Whats more, when the axis is at a standstill during machining, the ROBA-guidestop brake takes over the load, so the drive motor switches off and disconnects from the controls. This eliminates the control movements and relieves the ballscrew spindle; the closed brake absorbs axial forces.

Mayrs safety brake applies stopping force directly to moving vertical-axis masses. This makes for safer operationwith the right controls, minimizing the hazard risk to people, according to safety standard DIN EN ISO 13849-1.

Backlash-free safety brakes (as this ROBA-guidestop from Mayr Corp.) maximize functional safety while boosting the rigidity of an NC axis and overall machine performance.

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Cable and hose carriers in use

Cable and hose carriers may be installed as a component on new or existing equipment, but it is often possible to simplify and expedite their installation with a complete turnkey assembly from the manufacturer. Such an assembly may incorporate other system components that include the hoses or cables, fittings, manifolds and special brackets, which add value by simplifying installation and minimizing errors.

Instead of having to install the cables or hoses into a carrier on-site, the end user often can obtain preloaded carrier assemblies or complete harnesses with connectors and fittings from the carrier manufacturer for plug-and-play installation. Cables, hoses and fittings can either be furnished to specifications or drop-shipped to the carrier

manufacturer from a customers supplier and installed before shipping. The end result is a drop-in assembly, ready for quick installation when it arrives.

A turnkey engineered carrier assembly may integrate a range of other system components to meet specific application requirements. Some examples include special mounting brackets to allow drop-in replacement, as well as manifolds, junction boxes, tow-arm assemblies, guidance and support systems, safety mechanisms, shrouds and enclosures, or other associated components.

Nylatrac NP Series cable carriers are installed on a gantry crane designed to offload product to an automated cart-shuttling system. Photo courtesy of Dynatect Manufacturing

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Move cables, hoses, and more with ease

Rol E-ChainAll media in one chain & from one source: power, hoses, data, and more. Corrosion-free and resistant against chemicals and other liquid media. Long travels up to 2,700 ft. and speeds up to 20 ft./s possible with up to 57% lower required drive force. Light and modular.

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This value-added system from the Gortrac Division of Dynatect Manufacturing for a military dynamometer includes multiple cable and hose carriers and a structural support.

This Nylatrac carrier system from the Gortrac Division of Dynatect Manufacturing is preloaded on reels for easier shipping, handling, storage and quick installation.

Dynatect Manufacturing supplied Gortrac steel-nested cable carriers for this Universal 360 Vertical Drill Rig developed by Robbins HDD, one of the first companies to pioneer this type of equipment.

Cable and hose carrier applicationsFor a military application on a dynamometer carrying cables and hoses, the manufacturer furnished a structural support system on which multiple carriers ride. The metal Gortrac carriers, which hold a total of 10 cables and hoses, are approximately 40 ft long. As a result, the end user was able to simply bolt the system in place instead of building the support system.

Cable carriers made for an offshore oil rig were shipped on storage reels so they were easier to ship, handle, store and install. In this case, cables specified by the customer were included, and brackets also were included for easy assembly. The Nylatrac carriers for this application were 54 ft long and carried eight cables.

For a pontoon bridge at the Hood Canal on Puget Sound, the supplier of the Nylatrac carrier system designed and manufactured a stainless-steel support and guide tray system for the carrier. Other value-added components included the cables, clamps, auto-alignment brackets and fixed-end mounting structure. Stainless steel was used for the support and tray system to resist corrosion in the salt air environment. The cable carrier was constructed of a

heavy-duty, fiber-reinforced nylon. The self-aligning brackets were designed to accommodate lateral misalignment up to 2 in. over more than 300 ft of travel to reduce stress on the carrier.

When its necessary to provide optimum cable separation and ensure that cables ride on the neutral axis of the carrier, machined bars with a series of holes through which the cables pass can be added to a carrier design. This helps reduce stress on the cables and extend their life.

A hose carrier for a Las Vegas water show was supplied with a stainless-steel water manifold, as well as hoses and PVC guides, so it could be installed as a complete system. The large Nylatrac carrier handles four 5-in. diameter hoses and is 48 ft long. Cable or hose carriers with long travel requirements can be supplied with a carriage system equipped with rollers to support the carrier and allow it to extend smoothly beyond its self-supported travel limits. End brackets, clamps and other components also can be furnished to provide a complete bolt-in-place system.

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CABLE MANAGEMENT

29DESIGN WORLD 11 2015

A manufacturer also may be able to incorporate other items into a turnkey package customized for the application. These may include such diverse products as protective expanding/telescoping covers, roll-up doors, slip clutches and motors, and ball- or leadscrews. Discussion with the manufacturers application engineers may open up new possibilities for saving time and reducing costs by combining multiple components into complete turnkey assemblies.

Along with turnkey solutions, the carrier manufacturer also may be able to help minimize inventory requirements for OEM users by customizing a Kanban or JIT program. Another possibility is a vendor-managed inventory and tool crib replenishment program that integrates directly into the manufacturing process.

Thank you to Mark Cunningham, Sales Manager at the Gortrac Division and Mark Zanolla, Engineering Manager at the Gortrac Division of Dynatect Manufacturing for this information.

GORTITE PROTECTIVE COVERINGS Customized bellows; steel covers,

roll-up covers and doors; walk-on covers; way wipers

GORTRAC CABLE/HOSE CARRIERS Metal, plastic & hybrid;

open- and enclosed-styles;modular and custom designs

POLYCLUTCH Continuous mechanical and

pneumatic slip clutchesmodular and custom designsmodular and custom designs

(800) 298-2066 / dynatect.com

VISIT US ONLINE OR CONTACT US FOR OUR FULL-LINE CATALOG. [email protected] / 262-786-1500

VISIT US AT DYNATECT.COM FOR MORE CUSTOM-ENGINEERED PRODUCTS AND SERVICES.

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Cables in motion: Common applications

More than any other component, cables come in customized versions to satisfy specific application requirements. The number of conductors and strands to transmit power to motors and feedback to and from sensors and controllers are just a couple cable features designers match to designs.

Usually requiring UL listing, cables in motion-control applications must be able to handle tight bending radii, abrasion, flexing and possibly even torsional movements. Some must also isolate the effects of strands conducting power. In VFD cables, for instance, a symmetrical ground design with three grounds and three power conductors offers a small outer diameter and less EMI. However, a four-conductor design with three power conductors and one ground is better for continuous flex applications. The latter are common in machine tools, assembly lines and industrial-production applications.

Jacket material must also be compatible with the application. The cable jacket protects conductors and insulation and may also provide a level of shielding. For example, cables used in harsh environments, such as on mobile machinery and machine tools, require special jacketing to withstand chemicals such as cutting fluids and oils and abrasion. Cables used in these tough environments or in welding applications may also require a flame-retardant jacket or low-smoke, zero-Halogen design.

Cables used in flexing and rotating applications, such

as those on robots, must have high tensile strength and abrasion and flammability resistance. These are most often manufactured of polyvinyl chloride (PVC), chlorinated polyethylene (CPE), polyurethane (PUR) and thermoplastic elastomer (TPE).

On the other hand, cables used in medical applications must be biocompatible. The most common material used in cables for medical equipment is silicone, as it is durable and can be easily sterilized, disinfected and cleaned without disintegrating. Other medical-grade materials include thermoplastic elastomers, thermoplastic polyurethanes and PVC. Still other cables are manufactured with anti-microbial jacket materials to prevent bacterial growth.

As mentioned, shielding and insulation are also application-specific. Shielding protects the cables from outside electromagnetic interference, but also protects users and machines from voltage spikes and other internal interferences. For cables that will be inside cabinets or machines, or those with light to medium loads, unshielded designs may be used, as they usually are smaller and offer a tighter bend radius. But cables installed on machines that are in motion require shielding, especially when they connect to a motor or drive enclosure.

Cables used on robotic arms, left, must have high tensile strength, abrasion and flammability resistance. At right, cables are tested for abrasion resistance, a critical feature required of any industrial motion cable. Photos courtesy of igus

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CABLING


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Chains for every environment

chain, curved-attachment chain and plastic-sleeve chain. The attachments accommodate special fixtures or blocks for specific conveyor functions.

Accumulating conveyors are one subtype of conveyor chain that suit applications that need more control over product flow, such as packaging or assembly.

Self-lubricating chains excel in harsh environments or where regular maintenance is difficult. They are useful in applications in food and beverage, paper product or wood-processing industries where traditional lubrication presents too much of a contamination or clogging risk.

Chains are also available with specialty coatings for rugged environments. Stainless steel is a good choice in applications exposed to corrosion, but because this material cannot be hardened in the same manner as carbon steel, it doesnt have the same load carrying capacity. Nickel-plated chains are another alternative, providing some protection for mildly corrosive environments.

Factors that can limit chain life are corrosion, wear and fatigue. If a chain application requires long life without contamination, pick chain with self-lubricating subcomponents. If the roller chain application requires high precision, pick chain with precision roller bearings at each link connection.

W ith recent advances in precision, designers can use chains in more applications than ever, including remote installations thanks to lubrication technology. Chains are versatile and reliable components used primarily to transmit

power in machinery or convey products. Roller chains are mainly used with drives. But they can also be found in applications with harsh environments that subject chain to weather, water or chemicals, where other options would fail. Most drive applications use an ASME/ANSI roller chain wrapped around a driver sprocket that is connected directly to the motor or reducer. This sprocket is usually connected to a machines conveyor head-shaft.

Conveyor chains are used in applications that require moving product horizontally, vertically or around curved radii. Most common conveyor chains are ASME-style (ANSI-style) attachment chains. Types include single-pitch attachment chain, double-pitch attachment chain, hollow-pin

Shown here is a mobile chain application, a trencher from Shelton Sportsturf Drainage. Its digging chain runs off the tractor power takeoff; twin augers flanking the chain move dirt away. Called the Shelton CT150, the vehicle uses laser-guided grading to evenly install drainage pipes. Hydraulics control trench depth; a pipe layer lifts out of the ground for easy starts.

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

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AN UNBEATABLE PACKAGE: QUALITY, DEPENDABILITY, & ENGINEERING SUPPORT.Crafted to excel in the toughest environments, including high-speed, wash down, vacuum sealing, high-temperature, food grade and many more. From standard chains to highly customized solutions, Tsubaki has the right chain for your packaging industry application. We understand the importance of your lines uptime so save time and money by trusting in Tsubaki. And dont forget Tsubakis full line-up of complementary products. Bundling options provide the flexibility to ensure optimum quality along your entire production line. At Tsubaki, weve got you covered.

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

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Compression springs are typically used to resist linear compressing forces (such as a push force) where space is limited, where uniform bearing pressures are required, or to reduce buckling. Thus, they are ubiquitous motion components. In the automotive industry, they are common in seats, pedals, transmission springs and windshield wipers. Building automation uses compression springs for industrial doors, fasteners and

dampers. In electric-distribution applications, they are indispensible for the function of contact switches and other electromechanical components. Medical uses for compression springs also aboundin simple mechanical equipment, such as beds, to those in advanced actuators for precision medical devices. In consumer devices, they are found in major appliances, lawn mowers, cell phones and so on.

Compression springs in motion

Shown here is a compression spring inside the ball of a Dyson vacuum cleaner. The spring helps a flexible changeover valve-hose assembly engage with the floor-vacuuming mechanism or the wand, depending on how the user moves the handle.

This application example from Jacquemet Group shows compression springs in an engine.

Compression springs are also common in shocks and runaway bumpers on high-speed trains. Image courtesy Jacquemet Group

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motioncontroltips.comControllers in motion:

Applications advance

This gabletop case packer is one version of a line of stainless-steel case packers from Schneider Packaging Equipment that allows for sanitation washdown. Theres even an additional sleeve around open spaces in the support frame between the bolts and frame interior.

The extra sleeve makes a more hygienic environment by preventing contamination from microbiotic organisms inside the frame itself, said Pete Squires, VP of Schneider Packaging.

Quick changeovers let the machine go

from two-pack convenience cases to three, four, six and eight-pack cases. Similar Schneider machines accommodate half-pint, pint, quart and gallon sizes. A complete end-of-line automation solution is easy thanks to simple integration with accumulator sand loaders for gabletop cartons, carton lane-dividing and transport conveyors, and robotic palletizers. Standard features include touchscreen operation and Allen Bradley Logix controls.

Motion controllers range from single-axis smarts to programmable automation controllers (PACs) that synchronize hundreds of axes and plant IT. These brains of precision motion are at the heart of todays motion-system innovation. But controls are increasingly advanced in mobile applications as well.

Consider just one example: Trust Automation Inc., known for standard and custom motion and motor controls, is helping design and develop a multi-mission launcher (MML) for a U.S. Army Indirect Fire Protection Capability program. The Development and Engineering Center of the U.S. Army Aviation and Missile Research is leading the project.

The design is a truck-based system thats fixed or semi-fixed. It holds 15 launch tubes that can fire simultaneously at threats, for 360 protection against unmanned aircraft, cruise missiles, artillery, mortars and rockets. Trust Automation is developing elevation controllers for the MML to give them precise positioning. The controller interfaces with heavy-duty electro-mechanical actuators for motion control to the

MML elevation axis. In short, digital signal processing and advanced algorithms enable synchronous control of twin actuators that raise and lower the MMLs pallet.

These platforms are critically important to national defense, said Craig Von Ilten, business-development VP for the defense industry at Trust Automation.

Food and beverage example: Controllers make it simpleConsider another example: Opelkas new continuous pastry fryer is more versatile and easier to clean and service than its predecessor. Called the MagicBaker CleanFlex, it uses B&R automation components for a modular architectureso end users can use the machine without programming, even after a shutdown to replace parts.

PowerLink allows line or star topology on the equipment, and users can remove networked components without disconnecting the power or worrying about disrupting bus communication. Central data storage speeds up commissioning.


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CONTROLLERS

Here, a ROBA-guidestop on a carriage clamps directly to a profiled rail.

Data coding, motion control, PLC tasks and HMI functions are all on a single CompactFlash card in the controller. When the equipment restarts after maintenance, the controller automatically copies the software (including changes) to related B&R components. More specifically, Opelka leverages integrated PLC/HMI functionality from the B&R Power Panel 500, which has a 10.4-in. touch screen, X20 I/O and ACOPOSmulti drives.

The fryers versatility arises from the new control architecture, which allows changes through the HMI panel to accommodate different configurations for different bakers, said Stefan Weng of Opelka. ACOPOSmulti servodrives replaced pneumatic drives on the previous version to eliminate design and operation constraints. Here, a key advantage over pneumatics is that controls can implement new paths during operation at the push of a button without major modifications.

So now, pastries go through the machine more gently and with greater precision. That in turn means that users can customize the machine for different pastry types ... simply by picking recipes on the HMI. So the machine can now float or tip pastries into the oil bath.

The new machines drives are synchronized electrically, which means the oil bath can extend as needed without making the engineers modify the power-transmission system. Theres also a Power Panel 500 in a control cabinet within the machine body. The drives for other machine modules (including one for loading separate raw-dough forms into rows and another at the end of the line that injects jelly into the pastries) are in distributed control cabinets.

Opelkas new continuous pastry fryer, the MagicBaker CleanFlex, uses a B&R controller.

All of the automated functions on the new MagicBaker CleanFlex from Opelka use B&R technology, and Opelka set up the PLC and HMI in B&Rs Automation Studio software. Seamless integration makes programming, diagnostics and maintenance more efficient.


us.MitsubishiElectric.com/fa/en

You wouldnt believe the things we do.Mitsubishi Electrics One-Touch Auto-tuning for the MR-J4 Series Servo System

ensures every servo in a machine is always perfectly tuned from commissioning

to end-of-life. Maintain peak performance and accuracy and reduce downtime,

even as equipment wears. That is the beauty of One-Touch Auto-tuning:

oneclick,one time.

No tweaking, no maintenance, just the sweet sound of productivity.

What if you never had to worry about servo tuning?

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Space is limited in the distributed cabinets, so the compactness of the ACOPOSmulti and X20 modules was key, said Weng. A two-axis variant of the ACOPOSmulti was the biggest space saver of all. Opelka saved even more cabinet space by replacing dedicated power supplies with 24-V modules from the X20 system. The X20 system also provided digital and analog I/O slices, as well as PT100 input terminals for PID temperature control.

The X20 modules also control stepper motors that move pushers and other small machine axes. The X20s three-part construction has a terminal block, electronics module and bus module. This simplifies installation and allows electronic-module replacements without the hassle of rewiring, said Weng.

X20 modules and drives communicate with each other and the central controller through PowerLink.

Another improvement is that the user can configure components without needing to connect each to a PC first. To prepare the components for bus communication, the engineer just sets their node numbers with DIP switches before install.

During operation, PowerLink and the electronic drives also make decoupling machine modules easier. The user simply disconnects the power and PowerLink cables, both of which handle repeated plugging and unplugging much better than compressed air hoses. Then machine modules can go to a washdown room for cleaning.

An IDEC Pentra PLC controls two VFD drives that open and close a hangar door. The hangar has eight doors, each with its own PLC controller.

In this defense application, controllers from Trust Automation synchronize actuators that position a multi-mission launcher (MML). The design is part of an Indirect Fire Protection Capability (IFPC) program led by the U.S. Army.

PLCs control San Fran hangar doorsDoor motors, controls and gear drives of the Superbay Maintenance Hangar at the San Francisco International Airport needed a retrofit. Previous controls were built in 1969 with relays, contactors, timers, antiquated power tracks and miles of wiring requiring continuous maintenance. The massive hangar has two 130-x-90-ft doors, weighing 74,000 lb, on either side. Each door consists of an inner and outer panel for a total of eight independently functioning doors. The door sections mounted on rails offset so that adjacent doors can open and close without interfering with neighboring ones.

MicroSmart Pentra PLCs from IDEC now control and monitor the doors, letting airplanes as large as a 747-400s in and out of the hangar. Engineers from San Francisco International Airports Design and Construction Dept. used IDEC PLC programming and PLCs for their simplicity and expandability. Twin drives power the doors halves. A VFD drives each motor door, in turn capable of moving the entire door (though airport engineers made each drive redundant).

An IDEC MicroSmart Pentra PLC connects to each doors two VFDs through Modbus, and communicates in ASCII through an RS485 connection. The PLC also has inputs for switches and sensors for preventing operation when people or objects are in the way. From the IDEC HG4Gs HMI, operators open and close the doors.


CONTROLLERS


The eight centralized PLCs controlling the eight doors simplify operation; soon a master PLC could control all the doors and command the PLCs as slaves. Wireless connection will soon provide fire control. In the current design, anytime a door stops, its PLC analyzes the problem and displays a troubleshooting protocol on the HMI.

The IDEC MicroSmart Pentra PLC has floating-point math functions, supports 32-bit processing, Modbus master and slave capabilities, up to 512 digital I/O and 56 analog I/O. The PLC also connects to the Internet (to allow for mobile access). IDEC Automation Organizer software comes in WindLDR for programming in ladder logic and function blocks (and online editing and simulation) or WindO/I-NV2 for programming HMIs. WindO/I-NV2 has tools for programming HMIs with a 5,000-symbol library (to save design time).

The hangar engineers used Automation Organizer to program touch-screen controls, status and troubleshooting displays, alarms, feedback processing and drive operating hours for maintenance purposes.

Simulation with the IDEC system let the engineers start and fine-tune the first doors operation in less than a day (with the others in operation within a few hours). It also let the engineers add interlocking man-doors to the giant hangar doorsstandard doors are embedded in the hangar doors for aircraft mechanics to enter and leave the hangar. Then the engineers programmed the PLC and HMI to interlock these man-doors with the larger hangar doors. If any man-doors are open, the HMI indicates that and prevents operation.

IDEC PLCs control 37-ton hangar doors to let airplanes in and out of the hangar.



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Conveyors: A variety of uses

R anging from discrete product transport to bulk-material carriage, conveyor functions are as varied as the places in which they work. Engineers make conveyors meet specific applications by tailoring about a dozen conveyor design elements: belt or chain size, morphology and material; bases and support frames; controller, drive, and motor or motors; mode of belt or chain engagement with the drive; encoder, vision, and switch feedback; tracks, bumpers, and gates; and HMIs and plant-level IT integration.

Consider the warehouse-automation industry. Sorting and tracking tasks are paramount, but speed is often critical. Such applications need conveyors with servomotor functionality integrated with inspection stations fitted with machine vision. Or consider pharmaceutical manufacturing. Its grown to a trillion-dollar industry, even while standards such as the FDAs Current Good Manufacturing Practice (CGMP) regulations are more stringent than ever. Here, conveyors must have all the functions of those for warehouse-automation, plus need to be stainless and aluminum, posing no risk of contamination, while quickly and cleanly transporting expensive pharmaceutical products to and from stations for bottle filling, pill compressing, sorting and inspection.

In the same way, the manufacture of medical devices must adhere to FDA regulations that dictate equipment-sterilization schedules and methods. Here, only conveyors withstanding regular harsh cleaning last.

Collectors buy and sell coin proof sets to enjoy the currencies precise level of detail and overall presentation in durable packaging. Heres a robot and Dorner conveyor that help automate the exacting packaging process.

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CONVEYORS


Packaging application:Conveyors support coordinated robot tasksMounting coin proof sets into hobbyist commemorative cases sounds easy, but its challenging when the application calls for precisely placing several thousand coins on moving inserts every day. This was a challenge engineers at Farason Corp. recently solved with conveyors from Dorner Manufacturing and vision-guided robots.

Farason designs and builds custom machinery for assembly, manufacturing and packaging processes (mostly in cosmetics, food and confections, medical, pharmaceutical and manufacturing industries).

For the coin-setting application, a system picks and orients coins in case inserts, then encloses the inserts with top and bottom lenses, said Joe Hurley, president,

motion systems applications handbook

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