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February 2016www.designworldonline.com
LINEAR MOTION: Selecting linear actuators for valve automation PAGE 62
SENSORS: Key standards to know when specifying sensors PAGE 82
3D CAD: If you draw it, can you print it? PAGE 78
creative
INSIDE:
Think
Allie
d for
Autom
ation
& Co
ntrol
APR15-A&C Snipe_Snipe 3/13/15 2:39 PM Page 1
motion solutionsfor demanding applications 54
Two
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Our manuals, help les, software updates and access to online resources such as forums, articles, and FAQs are always FREE and available 24/7 on our website. There you will also nd our FREE programming software. Download as much as needed or try before you buy:
CLICK Software - FREE Do-more Designer - FREE Productivity Suite - FREE
And dont forget we o er FREE two-day shipping on any purchase over $49. We also o er a 30-day money-back guarantee which can be useful for any last minute changes or modi cations.
FREE Programming Software and Tech Support for Life!Its amazing how we t so much functionality into such a small package, with such a low price! Starting at $69, the CLICK micro-brick PLC is a simple, cost-e ective solution for your application.
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And our newest programmable controller line . . .
Weve never been traditional . . . . . . and neither have our prices.
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more Do
the #1 value in automation* See our Web site for details and restrictions. Copyright 2015 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 www.AutomationDirect.com
See for yourself, and get more than you paid forat www.AutomationDirect.com/plcs
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I n s i g h t s
4 DESIGN WORLD February 2016
Theres a classic stereotype about engineers that many of them started as tinkerers, tearing apart dusty old radio sets, fixing equipment on the farm, or helping an older relative rebuild a classic car
in the family garage. But Im beginning to wonder if, in another generation or so, the stereotype will be that
most engineers got their start in the Maker community.
Weve seen an interesting convergence over the past few yearsa growing awareness of the need to
get kids interested in STEM careers, the explosion of 3D printing technology, and hands-on programs like
Dean Kamens FIRST robotics competition. The Maker movement seems to be at the intersection of a lot of
this. Even the government has taken noticelast June, the White House hosted its first ever Maker Faire to
highlight the importance of this trend.
At the Maker Faire, more than 150 U.S. colleges and universities committed to support Maker
education. A recent report by these MakeSchools found that:
The experience is being driven by a spirit of creativity and kids excitement in doing
something concrete.
Schools are putting money into incorporating Making into their curricula, as well as creating spaces
on campus specifically for this activity. (See my recent Insights column on CWRUs Sears
think[box].)
Making is a cross-disciplinary educational activity and its often being used to solve
real-world problems.
The Maker movement can also teach students about entrepreneurshipa needed skill in a
country that is creating fewer and fewer new companies each year.
For a long time, Ive heard older engineers fret about the next generation of college graduates. Theyre too
dependent on everything from handheld calculators to the Internet. Next it was mobile phones and even
FEA software. The argument was that they wont know how to get their hands dirty. Theyll be overly reliant
on computers to do their thinking for them. Its a compelling argumentand Ill admit, the worry was
starting to creep into my mind, too.
But, as the saying goes, the pendulum is swinging back, and we may have a far different future ahead.
What an interesting turnabout it would be if the engineers of the next few decades turn out to be more
hands-on, more intuitive and more cross-disciplinary than the previous generation of designers. I cant wait
to watch these kids innovate. DW
The hands-on engineer returns
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
Whats your take on the Maker movement?Comment on Pauls blog on
Pneumatic Tips, www.pneumatictips.com/blogOn Twitter @ DWEditor
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Te s c h l e r o n To p i c
There is an apocryphal tale about intellect that took place in the 1920s.
Thats when a psychologist by the name
of Lewis Terman identified and began
tracking 1,500 children he considered to
be geniuses based on IQ tests. Terman
figured a number of them would make big
contributions to society. Many of them did,
in fact, graduate from college years ahead
of their peers and wound up in professional
occupations. But as a group, they never lived up to Termans expectations. Some couldnt hold jobs, and they had a much higher-than-average suicide rate. None of them went on to win a Nobel prize, though two kids who Terman surveyed and excluded eventually mounted the stage in Stockholm.
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
Recipe for a bad boss:Too smart, too gritty
On Twitter @ DWLeeTeschler
The lesson, or course, was that basic intelligence cant really predict success. Fast forward to modern times, and this lesson-learned seems to have been lost, at least until recently. Thats one conclusion from looking at how executive recruiters and head hunters have been hiring executives and managers. Take for example Russell Reynolds Associates, a search firm that recruits at the CEO level. There, the emphasis has long been on recruiting candidates with high intelligence, according to Dean Stamoulis, a principal at the firm. But the sands of top management recruiting have shifted, quite possibly as aftermath from hiring smart people who turned out to be cruddy managers. High IQ is now out, replaced by something Stamoulis calls results intelligence. He loosely defines this quality as being similar to grit: The ability to get beat up and bounce back when faced with difficulties without blaming or rationalizing away mistakes. Among management recruiters, it has become stylish to search for job candidates with grit-like qualities. The trend may have started with a 2013 TED Talk by research psychologist Angela Duckworth. While teaching seventh-grade math, she noticed her best students werent necessarily the smartest, but rather those who worked hard and maintained their focus. The mental leap made by hiring managers seems to be that grit is just as important for managers as for seventh graders. Now, however, there is a grit backlash. It
may be that grittiness, like intelligence, is a poor predictor of management success. The problem is that bosses who are too passionate about their goals can burn out the people who work for them. And they may not know when to quit though its obvious to others involved that the goal is unachievable. Someone who has seen the problem first hand is Mary Herrmann, managing director of executive coaching at BPI Group. Herrmann estimates about 35% of the firms coaching assignments involve bosses with grittiness issueseither too little or too much. Those who are too passionate about their goals are often new to the job, Herrmann said, and want to see quick wins. So they may not listen too well to subordinates, particularly when there is unwelcome news. Another failing of the too-passionate boss: Moving too fast before sufficient facts are in. But sometimes the difficulty is simply cultural. A lot of successful managers think what worked in one place will work as well in another, she said. And sometimes the too passionate label gets put on executives who are brought in as change agents when the reality is the organization isnt ready for it. Herrmann has advice for professionals finding themselves suffering burn-out from an overly gritty manager: Im a big believer in direct feedback. A leader needs to hear feedback about this, and an evolved leader will ask for it. Maybe so. But heres my own advice for individuals bringing this kind of message to their boss: Be ready to duck. DW
6 DESIGN WORLD February 2016
Lee Teschler Column 2-16_Vs3.LL.MD.indd 6 2/5/16 11:57 AM
2016 Helical Products Company | www.heli-cal.com
Helical 2-16.indd 7 2/5/16 12:09 PM
Te c h n o l o g y F o r w a r d
All too frequently, hype and inaccurate claims still replace facts about 3D printing
(3DP) and Additive Manufacturing (AM)
systems capabilities. You could easily
make the case that hype is to blame for
3DSystems recent decision to shut down
its Cube business. Many still claim (or hope) that 3DP/AM systems will become mass production machines, producing hundreds of thousands of parts and objects with the efficiency of traditional manufacturing equipment, like CNCs. The implication is that 3DP/AM will replace CNCs. But just what is meant by mass production? What number comes to mind? One to three hundred parts an hour? OK, 3DP/AM can do that, depending on the part size, complexity and 3D printing technology used. How about 1,000 parts an hour? Depending on the part size, part complexity and the 3DP/AM technology, it could happen. What about 500,000 parts per minute? Not yet. Thats still CNC, injection-molding territory. Ignorance sets up impossible-to-fulfill expectations. And if you dont meet customer expectations, they stop buying. It has happened before in the 3DP/AM industry.
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
How to set up 3D printing for failure in 3 steps
On Twitter @ DW3Dprinting
8 DESIGN WORLD February 2016
So, heres how to set up 3DP/AM for failure:
1. Insist on 3DP/AM doing what it is not designed to do. If you are making very small, simple geometry parts, say in., you can produce about 50 or so on a typical 3D printer build table (19 19 19 in.) in an hour, maybe less, depending on the 3DP/AM technology you use. CNC machines can mass produce several thousand parts in under a minute. Its no comparison. Even if HP succeeds in delivering its Multi-Jet fusion system with its supposedly faster build capabilities, it wont be as fast as a CNC.
2. Insist that 3DP/AM will supersede a trillion dollar machine tool industry. According to various reports, the global machine tool industry is worth about a trillion dollars. In 2014, China reported an export value of $11.63B in machine tool sales. China reported an import value of $17.78B in machine tools. Japan reported imports of $5.16B, and Germany of $4.29B. Those figures are just a few of the countries buying and selling machine tools. Various market research firms claim that the number of 3D printers sold globally in 2014 is around 158,000. Sales are expected to grow from $1.6B in 2014
to $4.8B by 2018. 3DP/AM has a bit of a way to go before it becomes a trillion dollar industry.
3. Fail to educate yourself about 3DP/AM strengths and weaknesses. 3DP/AM vendors may eventually figure out a way to speed up part build. They may develop material with faster flow rates through a nozzle, or test the limits of mechanics to move axes faster with repeatable accuracy and minimal vibration, or fuse powder together with even more lasers without overheating the build chamber or vaporizing the powder. It can happen. But not this year. Probably not next year. Or the year after that even. For years, manufacturing has been looking for a tool that will produce custom one-off or small production runs inexpensively. Its herethe 3D printer/additive manufacturing machine. 3DP/AM fills the gap that has long existed between mass and custom production. DW
Leslie Column (Technology Forward) 2-16 Vs3.MD.indd 8 2/5/16 11:58 AM
Proto Labs 2-16.indd 9 2/5/16 12:10 PM
IS EDGEWINDING THE NEXT BIG THING?
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THE ENGINEERS CHOICE
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IS EDGEWINDING THE NEXT BIG THING?
Ask Smalley. Edgewinding is our precision forming operation that offers unique advantages. Unlike the conventional stamping process, Smalley edgewinding delivers maximum strength, effectively eliminates material waste, and offers No Tooling Chargesto make prototyping or custom designs easier and affordable.
Our experienced engineers can show you how edgewinding gives our wave springs, Spirolox retaining rings and constant section rings a real performance edge. Its a combination of manufacturing innovation and technical expertise that only Smalley delivers.
The edgewinding process coils pre-tempered at wire on edge to give Smalley products strength and stability far superior to stamped retaining rings.
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section rings a real performance edge. Its a combination of manufacturing innovation and technical expertise that only Smalley delivers.
THE ENGINEERS CHOICE
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l C o n t r i b u t o r s S p o t l i g h t
Two positioning components speed OEM product development
ROBERT GLOECKNERAdvanced Engineering GroupMICROMO
RYAN KLEMETSON
Target Markets ManagerTolomatic
February 2016 DESIGN WORLD 1 1
Selecting linear actuators for valve automation
Ryan has worked on multiple custom actuator design projects in a variety of industries, including oil and gas, medical, commercial, and industrial printing applications. Prior to joining Tolomatic, Ryan spent five years in the mobile hydraulics industry. He obtained an AAS degree in Manufacturing Engineering from Alexandria Technical College. While Ryan looks forward to the continued integration of technology into
Robert Gloeckner is an R&D Engineer with the Advanced Engineering Group at MICROMO. Robert was born and raised in Dresden, Germany, and he attended the Dresden University of Technology. His specialties are mechatronics, robotics and electrical drives, and he built his engineering experience with various companies in Sweden, Germany, California and Oregon before joining MICROMO. Outside of his career, Roberts passions include technology, photography, tennis and surfing.
Ted has more than 25 years of sensor technology experience with previous positions in sales, business
development and strategic marketing. He earned his
B.S. in Electrical Engineering from the University of
Illinois at Chicago and MBA in Marketing from the
Illinois Institute of Technology.
our everyday lives, he also likes to think about what life would be like in the past, particularly the mid to late 1800s. [It was] a very interesting time as the U.S. experienced its industrial revolution. Some of the early ingenuity, which helped us evolve into a more modern society, truly offered individuals the chance to become whatever they wanted to be and for some, made a significant impact on the rest of the world.
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TED TOMITAGlobal Product Marketing Manager
Honeywell Sensing & Productivity Solutions
Key standards to know when specifying sensors
82
PAVEN PATELGeneral ManagerEpoxyset
7 tips to get the best adhesive
Paven Patel graduated Boston University with a degree in Chemistry and Biochemistry and began working for Epoxyset in 2010 upon graduation. With a strong understanding of needs of customers and the market, he has implemented a stronger web presence and has begun developing a global network to build the Epoxyset brand internationally. His efforts over the least three years have benefited Epoxyset in increased sales, wider target audience, and increased brand recognition. Paven plans on continuing to work for Epoxyset helping its growth and also intends to pursue an MBA.
BARRY SIROKABusiness Development ManagerEpoxyset
7 tips to get the best adhesive
Barry Siroka began his career in the adhesives and specialty polymers industry in marketing and technical support with W.R Grace (Emerson & Cumming) before becoming VP of Tra-Con/National Starch. After a successful 11 years at Tra-Con/National Starch, Barry became head of Business Development of Polymers at The Fiber Optics Center where he expanded product offerings into new diverse markets and brought on and managed suppliers, including writing product specifications for new offerings. Barry began at Epoxyset in June of 2015 bringing over 35 years of experience. His extensive career lends him to give this advice: Learn everything you can and network throughout every industry. You can learn from everybody. And his predictions for what the future holds? Its going to get warmer and hotter and there will be new innovations that we cant even imagine yet. 20 years ago I couldnt even tell you some of the things that we have now.
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Contributor Page 2-16_vs4.MD.LL.indd 11 2/5/16 12:03 PM
Follow the whole team on twitter @DesignWorld
WTWH Media, LLC6555 Carnegie Ave., Suite 300, Cleveland, OH 44103
Ph: 888.543.2447 FAX: 888.543.2447
2014 Winner
1 2 DESIGN WORLD February 2016
2011 - 2015
NEW MEDIA/WEB/
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EDITORIAL
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Senior EditorMiles Budimirmbudimir@wtwhmedia.com@dw_Motion
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Marketing ManagerStacy Combestscombest@wtwhmedia.com@wtwh_Stacy
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Co n te n t s | F e b r u a r y 2 0 1 6 v o l 1 1 n o 2 | d e s i g n w o r l d o n l i n e . c o m
MOTION CONTROL
Two positioning components speed OEM product developmentInnovative components help OEMs revolutionize their designs.
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F E A T U R E S
72
2015
revenue over $3 million
LINEAR MOTION
Selecting linear actuators for valve automationA comparison of conventional and emerging technologies for valve actuation and automation in process industry applications reveals more options than ever for designers.
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ON THE COVERZero-backlash actuators and integrated gearhead encoders give designers multiple options for demanding applications.
Photo courtesy of MICROMO
FASTENING & JOINING
7 tips to get the best adhesiveThe process of evaluating and choosing an adhesive is easier when you consider a few key parameters.
2015ONLINE
78 3D CADIf you draw it, can you print it?3D printing delivers a number of benefits to manufacturing. But to truly take advantage, engineers need updated, intuitive, easy-to-learn CAD tools.
82 SENSORSKey standards to know when specifying sensors Everything from an excavator to a thermostat is getting smarter and the demand for more intelligent and connected systems is driving more demand for sensors in nearly every industry. A report by market research firm BCC Research anticipates the sensor market will grow by more than 10% by 2020.
1 4 DESIGN WORLD
CONTENTS FEBRUARY 2016_first page_Vs4.LL.indd 14 2/5/16 12:16 PM
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
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Co n te n t s
D E P A R T M E N T S
04 Insights
06 Teschler on Topic
08 Technology Forward 11 Contributors 18 Green Engineering
20 Engineering Exchange
22 Design For Industry
32 Design Notes
42 CAE Solutions
48 Internet of Things
88 Product World
92 Ad Index
2 . 2 0 1 6
1 6 DESIGN WORLD February 2016
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Contents FEBRUARY_second page_Vs1.indd 16 2/8/16 9:32 AM
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Minimizing production losses in the food and beverage industryn Jean-Pierre Berlan Director of Processing Tetra Pak U.S. and Canada
G r e e n E n g i n e e r i n g
1 8 DESIGN WORLD February 2016
Food and beverage companies have the power to make a difference in reducing waste, which occurs throughout the entire supply chain.
Doing so not only affects a companys bottom line (reduced waste equals
lower costs), but benefits the planet through the conservation of natural
resources and reduced levels of greenhouse gases. Waste can happen
anywhere on the value chain, and producers can take action to reduce it or
even eliminate it in their parts of the process.
By looking at their processing and packaging operations, both of which
offer opportunities to pare waste, food and beverage producers can start
addressing this issue. Here are some ways to take action.
The processing sideInefficient lines, formulation changes and maintenance can cause product
losses in large-scale food manufacturing plants. Plant managers can cut
waste by employing strategies to prevent product loss and maximize
production efficiencies.
They should start with the easiest issue first: inefficient plant designs.
In the U.S. dairy industry, milk losses can average 2 to 3% from the time the
raw milk enters the factory to when the finished product is packaged and
shipped. Although this may sound insignificant, it adds up to approximately
1.4 billion pounds of milk per year in the U.S., and that number more than
doubles if it includes cheese production.
These losses happen for various reasons. In one case, when
large-scale equipment is used to process food,
the machines must be cleaned for food safety. During those cleanings, milk
is lost. A typical plant processing 500,000 gallons can lose 3%, or 15,000
gallons, a day. One solution is employing equipment designed to run much
longer between cleanings, maximizing efficiency and minimizing product
loss.
Inefficient equipment design results in further losses, as well as the
diverse range of products consumers currently demand, which challenges
plants to produce a broad number of SKUs. On a daily basis, producing
products that require many different ingredients and format changes incurs
multiple line changes, which leads to production stops and starts and
additional cleaning cycles. Inevitably, this leads to more losses.
Processing plants should be designed in the most efficient way possible,
which means they should be compact and have equipment that can fulfill
more than one function. Tetra Pak has developed a number of technologies
aimed at making liquid food processing plants more efficient and compact.
These include the OneStep technology that significantly cuts processing
timeand the loss associated with itby giving processors the ability to
change fat contents more quickly.
Water consumption is another area where food and beverage
manufacturers can reduce waste. For example, processing a gallon of milk
takes 2 to 3 lb of water, and inefficient plant design can send that figure
higher. This is water used primarily to clean and rinse the equipment, which
can be reduced by installing equipment that requires
fewer cleanings and offers other efficiencies. For the
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U.S. dairy industry, which produces about 23 billion
gallons of milk per year, its easy to see that it is
critical to diminish losses to conserve water.
The packaging sidePackaging also plays an important role in preventing
food and beverage waste. For starters, the choice
of package affects environmental impact, shelf life,
and resource consumption during transportation and
storage. Consider milk in aseptic cartons. It remains
safe to drink for up to six months after packaging
without refrigeration until opening. Chilled milk
lasts only about two weeks and requires electricity
during transport, retail display and home storage.
Containers that protect product without refrigeration
reduce waste along the chain by averting energy
consumption needed for chilled transport and
can avoid waste by making packages easier
to open and more efficient in closure and
storage to keep unused portions intact. Testing
packages usability among various age groups,
ranging from young children to seniors, is key,
said Rendina. If they can handle the packages
capably, they are less likely to fumble, drop,
spill and waste product.
Taking a holistic view of packaging and
processing elements throughout the food and
beverage manufacturing value chainand
enacting changes where possiblehelps
prevent waste, which ultimately benefits
businesses, the environment and society. DW
Tetra Paktetrapak.com/us
storage. Further, storing goods in ambient
condition reduces spoilage risk, said Antonio
Rendina, Tetra Paks aseptic performance
management director.
Producers also must consider packaging
that strikes a balance between protecting
product to ensure its sale and consumption,
rather than waste, and using an economical
amount of material to produce the container.
Reducing packaging weight also uses fewer
resources in transportation and leaves less
material at the end of the packages lifecycle.
Ergonomic packaging design can also
help producers reduce waste that occurs
after a product leaves the store. For example,
by considering how people open and close
packages during the design phase, companies
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LINEAR MOTION: Selecting linear actuators for valve automation PAGE 62
SENSORS: Key standards to know when specifying sensors PAGE 82
3D CAD: If you draw it, can you print it? PAGE 78
creative
INSIDE:
Think
Allie
d for
Autom
ation
& Co
ntrol
APR15-A&C Snipe_Snipe 3/13/15 2:39 PM Page 1
motion solutionsfor demanding applications 54
Two
FEBRUARY DW COVER 2-16.indd 1 2/8/16 10:37 AM
What are piezo actuators?
"In time, Onshape will be the system of record for all types of data & meta-data."
ENGINEERING EXCHANGE
2 0 DESIGN WORLD
YOUTUBE
http://dwo.me/1NMcLmO
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It's about time: the evolving time-sensitive networking standard for the Industrial IoT
Top 5 coolest technologies at CES 2016
connect
http://dwo.me/1RVOPoW
http://dwo.me/1NMeh8C
IoT adoption promises increased amounts of data over widely distributed networks. This change will require new standards for sharing and transferring critical information. One approach will be Time-Sensitive Networks, a new standard from the IEEE 802 committee
Innovative trends in robotics, Part 3
by Todd Walter, NI, AVnu Alliance Industrial Segment Chair
The topic I wanted to talk about is Soft Robotics and if
you havent heard about Soft Robotics, you can think
of it as a new approach that fits in with a lot of other
segments and branches of overall robotics taxonomy
where you can get, for example, industrial robots.
Here's our list of the top five gee-whiz developments
we saw at CES 2016. They range from svelte heads-up
displays to a hoverboard that turns sidewalks into land-
surfing opportunities.
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Engineering Exchange 2-16_Vs1.indd 20 2/8/16 10:38 AM
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D e s i g n f o r I n d u s t r y
2 2 DESIGN WORLD February 2016 www.designworldonline.com
Gearmotors enhance material handling energy efficiency
m a t e r i a l h a n d l i n g
The two-stage bevel drives are available in a range of ratios. Features include UNICASETM, a quiet, leak-free housing design, along with wear-free infinite life gearing. Installation, for replacement or other need, involves using the companys worm replacement footplate and universal shaft. The footplate, which drops into all standard worm mounting footprints, is available with either threaded or through holes and an optional extended design. DW
NORD Drivesystemsnord.com
Energy efficiency is an ever growing concern and a focus point in the manufacturing and material handling portions of the supply chain industry, not only to reduce cost and time, but also to help protect the environment. Gearmotors, electric motors, speed reducers and ac vector drives play key roles in improving the energy efficiency of material handling operations. For example, NORD Gear has a two-stage bevel seriesthe SK92.1 and SK93.1with gear efficiencies up to 97%. These helical bevel gearmotors can deliver 30% energy savings. Typical right angle worm reducers range in efficiency from 40 to 90% depending on size, ratio and output speed.
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D e s i g n f o r I n d u s t r y
Capacitive sensors measure low forces
02
www.designworldonline.com February 2016 DESIGN WORLD 2 5
m e d i c a l
Consumer electronics, medical devices and other applications are spurring the development of sensors to measure a range of parameters. One of the latest is a capacitive-based miniature force sensor that can accurately, and with high repeatability, measure forces as low as 1 g. This sensor lets you measure applied force at discreet points, even at low levels. It is suitable for a number of applications, including medical devices, electronics robotics and others. Although capacitive sensors have largely supplanted resistive for touch screens, until recently, resistive sensors were the main option available for measuring force. Resistive sensors are often limited in sensitivity at low levels of pressure. Capacitive sensors, on the other hand, have two electrodes separated by a compressible dielectric structure. When pressure is applied, the gap decreases and capacitance rises. Consequently, capacitive sensors are less susceptible to wear or failure even if subjected to multiple repeat loads. Capacitive sensors are typically stable in terms of repeatability and durability, and can measure low levels of pressure accurately. Thus, developers of wearable technology and products are evaluating capacitive sensors for these applications. By integrating capacitive tactile sensors in the testing and development of wearables, manufacturers could capture and quantify the amount of pressure experienced by customers at specific spots to optimize fit and function, said Jae Son, founder of Pressure Profile Systems (PPS). Comfort, after all, plays a large role in determining whether someone will like a product or not. There are also many applications in medical equipment design. According to Son, such applications include an advanced catheter
system that provides clinicians with more useful and detailed data to aid in diagnosis of esophageal problems, and a screening clinical breast exam called SureTouch that detects breast lumps and, essentially, quantifies the sense of touch. One manufacturer wanted to use a miniature force sensor to control the amount of force used when injecting insulin using a syringe. Capacitive miniature force sensors are being evaluated for this application. The technology is also well suited for monitoring blood pressure and could be used to create an alternative to pressure cuffs or embedded into future fitness and smartwatches that currently only measure heart rate. Even within the realm of capacitive sensors, there are different methods to detect a persons data. In the most familiar use, capacitive touch screens in smartphones use a layer of capacitive material to hold an electrical charge. Touching the screen changes the amount of charge at a specific point of contact.Capacitive sensors from PPS use two built-in electrodes separated by a compressible gap, eliminating the need to use the electrical charge delivered by the human finger. Thus, the sensors can be activated by someone wearing a glove, for example medical or laboratory personnel, or any object that can apply force. The miniature force sensor is available in two sizes, each with three force options, and comes with a small microcontroller that performs the capacitance conversion. For more sophisticated applications, up to 128 single-element sensors can be daisy-cained together with a single interface. DW
Pressure Profile Systems singletact.com
2 4 DESIGN WORLD February 2016 www.designworldonline.com
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www.designworldonline.com February 2016 DESIGN WORLD 2 5
D e s i g n f o r I n d u s t r y 03m e d i c a l
When it comes to measuring high rates of shock and angular velocity for crash, blast and impact testing, the 6DX PRO may fit the need. These sensors come in a shock-hardened enclosure thats as small as the diameter of a penny. Weighing only 12 g, they terminate to a single triaxial connector. The six degrees-of-freedom sensor includes three accelerometers (2,000 or 20,000 g) and three angular rate sensors (300, 1500, 8K, 18K or 50K deg/sec) in a rugged enclosure that is less than 34 in3 (19 x 19 x 14.5 mm). Focused on human injury assessment testing, the sensor is shock rated up to 20,000 g and is IP67 rated. Testing applications include: helmet testing, automotive safety, airplane seats, parachutes, amusement rides and blast testing. The 6DX PRO is delivered calibrated with pigtail or adapter cables to support a variety of termination options. Its repairable if damaged and meets NHTSA, FAA, ISO 6487 and SAE J211 data acquisition requirements. DW
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Small sensor with six degrees of freedom
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Sterilizable brushless dc-slotted mini motors for surgical power hand tools
m e d i c a l D e s i g n f o r I n d u s t r y 04
Its always best to use components designed for specific industries or applications. This line of motors was designed for surgical powered hand toolsarthroscopic shavers, ENT microdebriders and large bone drills. Plus, they withstand up to 1,000 cycles of autoclaving. Arthroscopic shaver brushless dc mini motors drive powered surgical hand tools used in minimally invasive joint surgery; surgical procedures that are responsible for repairing joints such as hip, knee, and shoulder joints. No-load speed of the arthroscopic shaver motors ranges from 4,000 to 7,000 rpm, while maximum continuous torque is 117 to 119 mNm. Large, bone-drill brushless dc mini motors consist of a cannulated gearbox and motor to allow for in-line pin
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WHAT DO YOU THINK?
Connect and discuss this and other design engineering issues with
thousands of professionals online
and k-wire driving and provide high torque at operating speed. These battery-powered systems meet extreme torque demands without stall during joint replacement surgeries such as those of the knee, hip, and shoulder. The large bone-drill motor offers a no-load speed of 950 rpm with maximum continuous torque of 818 mNm. Ear, nose, and throat (ENT) brushless dc mini motors have the high speed and high torque required by powered surgical hand tools used in minimally invasive surgical procedures of the ear, nose and throat as well as arthroscopic surgeries of small joints. With no-load speeds of 11,800 rpm and a maximum continuous torque of 39 mNm, these motors perform precise cutting of tissue and clean burring of bone. For high-speed drilling in spine, cranial, maxiofacial,
and otologic (ear) surgery, a spine drill will provide 90,500 rpm of no-load speed and 9.2 mNm maximum continuous torque. DW
Portescapportescap.com
www.designworldonline.com February 2016 DESIGN WORLD 2 7
Wherever shafts rotate, youll find RINGFEDER POWER TRANSMISSION. Our broad range of locking devices and couplings will solve your most de- manding shaft connection problems wherever they happen to be.
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2 8 DESIGN WORLD February 2016 www.designworldonline.com
o f f - h i g h w a y05 D e s i g n f o r I n d u s t r y
February 2016 DESIGN WORLD 2 9
Heres a sensor that can handle the harsh or extreme environments off-highway equipment experiences. The RSX-7900 series of angle sensors provides up to IP69K ingress protection, extremely long life of more than 100 million movements and ISO13849 PL-d safety compliance in a non-contacting design. The sensor is available in six standard measuring ranges with angles from 0 to 60 to 0 to 360 with unrestricted rotation. Resolution is 12-bit across a 4 to 20 mA output with linearity to 1% at 90. Repeatability is 0.2 and update rate is 5 kHz. Single and dual redundant versions are available and the life specification is valid even under high shock and vibration conditions up to 50 and 20 g respectively. The RSX-7900 series is available with a CANopen interface. The sensors offer anodized aluminum housing with a stainless-steel shaft for enhanced corrosion protection with salt and spray resistance. Axial and radial shaft loading is
Angle sensor for extreme environments
up to 300 N thanks to a double-row, angular contact ball bearing design. The 70-mm diameter sensor has a nominal length of only 35 mm and is available with a wide choice of shaft styles for maximum installation flexibility. The RSX-7900 series angle sensors operate from 9 to 34 Vdc supply for 12 and 24 V off-highway vehicle and construction equipment applications. DW
Novotechniknovotechnik.com
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s a f e t y
February 2016 DESIGN WORLD 2 9
WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly.
Visit our websitewhittet-higgins.comto peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local or a good distributor.
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06Online change for safe automation now possibleThe function non-persistent online change now means that individual changes in user programs can be transferred to the control system. This function is available in Release 13 of the automation system PSS 4000 for safety applications. User programs and software blocks of a control system are often only put through final testing during commissioning, when they undergo multiple modifications. The non-persistent online change function allows individual changes to be fed into one or more control systems of the automation system PSS 4000 without it being necessary to compile and load the entire program, which saves time during commissioning. The changes are fed in without stopping the control systemthe new program becomes active on the head modules with the next clock cycle after downloading. The changes apply for a maximum of 12 hours or until the control system is restarted, so they are not permanent (non-persistent). If the changes are not accepted, the control system re-establishes the status of the last complete download. As well as simplifying and accelerating commissioning, the function improves the handling of safety in hectic commissioning processes. DW
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These ReelFast surface mount fasteners have a variety of attachment options for printed circuit board applications. Depending on type, the fasteners can be specified to mount, stack, or space boards; attach components to boards; create right-angle attachment points on boards; or enable repeated access without requiring loose screws. All types are supplied on tape and reel compatible with existing SMT automated installation equipment and install permanently where designed in the same manner and at the same time as other surface mount components prior to the automated reflow solder process. Where necessary, a polyimide patch affixed to the end of the fasteners allows for vacuum pickup. These fasteners reduce board damage and scrap due to improper secondary installation operations by offline equipment. The line includes Type SMTSO steel nuts and spacers/standoffs and Type SMTSOB brass versions with or without threads for board mounting, stacking, or spacing applications; Type SMTRA fasteners introducing re-usable threads at right angles to boards for mounting board to chassis, chassis to board, or component to board; Type SMTPFLSM all-metal, spring-loaded captive panel screws; and Type PSHP captive panel screws with color plastic caps for subsequent access to assemblies without the use of loose screws or the risk of compromising thread integrity over time. They are available in a range of unified or metric thread sizes and lengths. DW
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D e s i g n f o r I n d u s t r y s e m i c o n d u c t o r07
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Custom coil auger helps save dough
3 2 DESIGN WORLD February 2016
D e s i g n N o te s
Newcomb Spring recently supplied large, custom coil auger components to a national food distributor. Working on-site at the distributors facility, Newcomb analyzed dough-mixing machinery and previous auger
components, created drawings and customized their manufacturing process for the new parts.
Previous parts in the customers dough mixing
machinery often failed, did not fit properly
and required maintenance. The mixing augers
are vitally important to the dough preparation
processwhen they broke, not only did dough
production stop, but total output was affected.
The old replacement augers just didnt fit right,
said Donald Jacobson III, technical salesperson,
Newcomb Spring. OEM replacements were not
available, so the customer had to make do with
what they could buy through distributors.
The design team travelled to the customers
facility during a scheduled maintenance day, when
all relevant equipment was shut down for cleaning.
Us going on-site, seeing the machinery and
working with the customers maintenance and
production personnel provided us with a unique
insight into how these parts needed to work,
said Jacobson. Our ability to plan this on a
maintenance day also saved the distributor a lot of
money.
The engineering team created plans for the new
parts based on the dimensions of the previous
augers and the augers position when mounted
in the mixing machinery. The application and
operating conditions of the parts were factored as
well, which helped the team alter the design and
recommend materials.
In a traditional order process, engineers would
receive specifications and a CAD file. The company
would then custom manufacture the order to meet
requirements. While the company often provides
design assistance, in this project, staff were involved
from the initial design phase. They were presented
with a problem part, then collaborated to identify the
needed specifications.
It was a really interesting challengemuch more
than just reverse engineering the old parts, since
the old parts didnt work properly, said Jacobson.
We worked with the distributor and reviewed their
production processes to the design of these augers,
which are really just giant compression springs.
The new components have significantly reduced
downtime and unscheduled maintenance. Order
specifications for these parts are now stored in the
engineering teams archives, and the customer is
able to easily obtain new replacement augers when
they are needed. DW
Newcomb Spring newcombspring.com
Edited by: Mike Santora Associate Editor
Design Notes 2-16_Vs5.LL.MD.indd 32 2/5/16 1:38 PM
www.designworldonline.com February 2016 DESIGN WORLD 33
Mixing augers are vitally important to the dough preparation processwhen they break, dough production stops and total output is affected. The engineering team created plans for the new parts based on the dimensions of the previous augers and their position when mounted in the mixing machinery.
Design Notes 2-16_Vs5.LL.MD.indd 33 2/5/16 1:38 PM
ORIGINAL
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Empowering Innovation. Engineering Value. www.designworldonline.com February 2016 DESIGN WORLD 35
D e s i g n N o te s
Computer-controlled fiber aligners help
boost throughput in photonics-packaging
applications. Before the telecom boom at the
end of the millennium, fiber alignment in the
manufacture of photonics products was a
tedious manual task. Heres a summary of the
first designs to automate the job and whats
possible with todays technology.
3 4 DESIGN WORLD February 2016 www.designworldonline.com
stages of the dayslow and low-resolution
devices with limited synchronization compared
to todays piezoelectric nanopositioners. But
these setups were flexible, and their massive
motorized positioners worked for the emerging
industrial era of photonics.
Note that analog gradient search and
digital alignment algorithms didnt address
angular alignment, and new photonic devices
made angular alignment a mainstream
concern. First, planar waveguides became
key to switching and modulating in photonic
networks. Second, angular alignment needed
automation, as optical switches based on
steering of collimated beams necessitated
throughput-optimized gimbaling alignment of
collimators and other optical elements. Third,
confocal optical trains (COTs) in new photonics
need relatively precise angular alignment.
These needs, in addition to unabated
alignment requirements for high-throughput
transverse alignment, drove the introduction
of the F-206 hexapod 6-axis fiber alignment
system. This instrument combined six
actuators with a stictionless kinematic
Edited by: Mike Santora Associate Editor
Two-part stage aligns fibers in photonics
Analog gradient search: The analog-phase demodulation hill-climbing technique worked
(and in some cases, still works) for clean,
quasi-Gaussian couplings already near
optimal alignment. But it locks in on local
maxima and flat spots in multimode couplings
and imperfect devices with misalignment.
Instrumentation based on this principle was
popular, though bulky and with too little travel
for fully automated fiber alignment.
Digital alignment algorithms: The first digital-gradient search technique in the 1990s aligned
fiber-optic devices with the motorized linear
Design Notes 2-16_Vs5.LL.MD.indd 34 2/8/16 1:47 PM
www.designworldonline.com February 2016 DESIGN WORLD 35
3 4 DESIGN WORLD February 2016 www.designworldonline.com
flexure coupling. This component integrated a
fast photodetector and a flexible assortment of
digital algorithms for autonomous fiber alignment
automation in up to six degrees of freedom.
A key advantage of the hexapod parallel
kinematic approach is the ability to cast the
rotational pivot point anywhere in space.
Conventional stage-stacks are limited to rotating
about the fixed mechanical centerpoint of their
rotation stages and goniometers. This is defined
by their bearings and fixturing structures and
cannot readily be moved around. With the
hexapod, process engineers could place the
rotation point about an optical sweet spot with a
single software command. Examples include:
for multichannel waveguide alignments,
the rotation can be about the first optical
channel
in collimator-collimator alignments, the
rotation can be centered on either
collimators face
for COT alignment, the alignment can pivot
about its focal point, which might be buried
inside a package and only blindly
accessible by tweezers.
New hexapod options, new fiber-optic alignment powerRecent advances in hexapod design and
controls have now enabled a host of robust,
high-load, long-travel hexapods to be deployed
for high-throughput industrial alignment
applications. Building on previous high
stiffness designs and triangulated geometries,
these systems offer travel ranges of several
centimeters while accommodating loads of
many kilograms. These designs are suitable
for use in any mounting orientation and offer
up to 50% higher acceleration than previously
possible. In addition to integrating optical
metrology with the hexapods six degrees of
freedom plus two additional linear or rotary
axes of motion, their new controllers integrate
data recorders for correlation of optical power
with position. 100-x-100-m scans can be
achieved in as little as 650 msec with these
speedy mechanisms.
Interfacing options have also expanded
and improved, with standard TCP/IP and USB
ports offering high-speed communications
and compatibility with factory automation
By integrating six degrees of freedom, F-206 facilitates complex alignments like this 10-DOF waveguide MUX/DEMUX packaging.
ORIGINAL
ISO 9001:2008 Made in the USA
Learn more at: www.mw-ind.com(847) 349-5780
Springs for Control, High Pressure, Safety Relief, Poppet, & Actuators
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Comprehensive Testing & SPC Analysis on Final Reports
SPRINGS & MACHINED COMPONENTS
Developing & Manufacturing Custom Products
VALVE MARKET
Empowering Innovation. Engineering Value.
Design Notes 2-16_Vs5.LL.MD.indd 35 2/8/16 1:48 PM
D e s i g n N o te s
architectures. New, optional remote-control pad/
displays offer hands-off manual operation.
Modular piezofiber alignment engine for transverse alignment and trackingAs the telecom boom crested in the early 2000s,
a manufacturer asked the design team at Physik
Instrumente to create a cost-effective fiber-alignment
platform for coarse-to-fine transverse alignment. The
company wanted a simple stack of stages with the
NanoCube XYZ nanopositioning stage (for 100 m of
travel in three orthogonal axes with 2-nm resolution).
Three motorized stages would allow many
millimeters of coarse positioning to accommodate
different devices in the companys production. The
system was software-based (to leverage new fast
analog I/O interfaces), modular, open-
source and based on LabVIEW. Two
main challenges were that the
machine had to handle fiber-
through-tube designs
(which complicate the
search for first-light) and
irregular coupling cross-
sections, which can impede
gradient searches. In the
end, PI engineers built a
machine with a two-step
sequence. First, a compact
double-spiral scan uses
a motorized long-travel
stage for first-light capture
The F-206 HexAlign hexapod micro-alignment system provides six degrees of freedom of 0.1 m precision motion in a more compact and responsive package.
3 6 DESIGN WORLD February 2016 www.designworldonline.com February 2016 DESIGN WORLD 37
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Design Notes 2-16_Vs5.LL.MD.indd 36 2/8/16 9:56 AM
and rough optimization. Then a fast raster
scan (previously impossible without modern
piezoelectric positioners and advanced
controls), combined with synchronous
data acquisition to compile the transverse
coupling cross-section and identify the global
maximum. This approach would literally align
virtually anything in a flash.
The raster-scan approach is insensitive to
local maxima. The global maximum can always
be observed and selected. This option had
been unavailable a decade earlier due to the
limitations of the motion devices of that day.
Since piezo devices are so fast, why not collect
data to localize the global maximum directly
rather than inferring the vector to it from the
limited data older architectures could provide?
Recently this architecture, called
CyberAligner, has enjoyed many advances,
including an upgrade to updated versions
of LabVIEW and leveraging I/O capabilities
provided by todays multifunction analog/
digital hardware. DW
Physik Instrumente
physikinstrumente.com
Pre-production bench for silicon photonics chip manufacturing and inspection: The system integrates several hardware components and software for automating
assembly and alignment, such as pick-and-place robotics, machine vision or precision positioning devices.
February 2016 DESIGN WORLD 37
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Design Notes 2-16_Vs5.LL.MD.indd 37 2/8/16 9:56 AM
The automotive industry is fiercely competitive. Tier-one car manufacturers are constantly looking for
breakthroughs in areas such as performance, safety
and design, all of which place ever stricter requirements
on the processing of metal components. SuperAlloy
Industrial (SAI) is a supplier of lightweight forged
metal products. The forged wheel and car chassis
components SAI produce are used by several car manufacturers.
SAI uses Renishaw machine tool probe systems, including the OLP40, RMP60, OMP60
and the NC4.
SAI came to Renishaw because it needed to enhance product quality and reduce the
amount of rework and corrections during processing to achieve high-quality levels.
The production of aluminium forged wheel rimsThe forged wheel production process is complex, particularly for low-volume, high-diversity
production. Strict standards are applied to workpiece setting, reference measurements
and key dimension detection during metal processing, as the precision requirements
for machining wheel mounting surfaces exceed the requirements of even the aerospace
www.designworldonline.com February 2016 DESIGN WORLD 39
D e s i g n N o te sEdited by: Mike Santora Associate Editor
Machine tool probes help forge wheel and car chassis
Production times for car chassis are relatively short, and can be
kept within 20 to 25 minutes. The machine tool probe systems provide
the operator with turnkey solutions for real-time positioning and
measurement and in-process control measurement.
3 8 DESIGN WORLD February 2016 www.designworldonline.com
Design Notes 2-16_Vs5.LL.MD.indd 38 2/8/16 1:56 PM
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4 0 DESIGN WORLD February 2016 www.designworldonline.com
industry. SAI currently has 600 CNC machine
tools working on wheel rim production,
including 150 Victor Taichung lathes and 450
YCM milling machines. So how does SAI ensure
that the precision and stability of 600 machine
tools remains consistent?
To increase production precision and reduce
scrap, SAI equipped the lathes with Renishaw
OLP40 touch probes, which use optical signal
transmission and are adapted for turning
processes. The CNC milling machines were
equipped with RMP60 machine tool probes,
which use wireless radio transmission to
measure workpiece position and reference
height, as well as providing in-line key
dimension detection, thereby increasing
production performance.
Y. C. Kao, senior manager of SAIs Wheel
Production Dept., said: The automated
workpiece setup, enabled by Renishaw machine
tool probes, allows us to ensure that the cutting
To increase production precision and reduce scrap, SAI equipped the lathes with Renishaw OLP40 touch probes, which use optical signal transmission and are adapted for turning processes.
dimensions remain stable and consistent
when we are producing wheel rims, as well
as reducing human error. For example, the air
valve hole cutting thickness Process Capability
Index (CPK) rose from 0.71-1.13 to 1.35-1.43
when using Renishaw machine tool probes.
3D appearance modelling for forged wheelWheel styling design has moved from flatter
surfaces toward more 3D effects in recent
years, causing wheel rims to become even
larger, and placing increasingly stringent
demands on processing precision. Until 2011,
SAIs acceptable tolerances for wheel rim
production (with the flatter designs used at
the time) were 0.05 to 0.10 mm. However,
the tighter tolerance requirements of the
current 3D designs has gradually increased
cutting times and processing; wheel rim
appearance processing takes as long as 180
www.designworldonline.com February 2016 DESIGN WORLD 41
Design Notes 2-16_Vs5.LL.MD.indd 40 2/8/16 9:57 AM
WHAT DO YOU THINK?
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www.designworldonline.com February 2016 DESIGN WORLD 41
to 240 minutes, with the result that any rework
imposes considerable pressures in terms of
both production time and cost.
OLP40 probes carry out in-process
measurement control to achieve tolerance of
less than 0.02 mm, and can replace human
measurements and updates to workpiece
coordinates. This greatly improves cutting and
efficiency for surface precision processing
after coating. Even more importantly, it reduces
rework by 80%, as before the introduction of in-
line measurement systems wheel produ