Design World February 2016

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

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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


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


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

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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.

72 72

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

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Online CoordinatorJennifer [email protected]@wtwh_jennifer

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 EditorLisa [email protected]@dw_LisaEitel

Senior EditorMary [email protected]@dw_marygannon

Associate Editor Mike [email protected]@wtwh_Michael

Assistant Editor Michelle [email protected]@wtwh_Michelle

Director, Audience DevelopmentBruce [email protected]

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Marketing ManagerStacy [email protected]@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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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.

62

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

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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


32

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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


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

2015-DesignWorld_halfhoriz_precision_OTLNS_FINAL.indd 1 3/6/2015 11:34:56 AMGreen Engineering_2-16_Vs3.MD.indd 19 2/5/16 12:35 PM

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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

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motion solutionsfor demanding applications 54

Two

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What are piezo actuators?

"In time, Onshape will be the system of record for all types of data & meta-data."

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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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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




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

Wherever shafts rotate, youll find RINGFEDER POWER TRANSMISSION. Our broad range of locking devices and couplings will solve your most demanding shaft connection problems wherever they happen to be.

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Connect and discuss this and other design engineering issues with

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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


Wherever shafts rotate, youll find RINGFEDER POWER TRANSMISSION. Our broad range of locking devices and couplings will solve your most demanding shaft connection problems wherever they happen to be.

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WHAT DO YOU THINK?




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


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

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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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Custom coil auger helps save dough


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.


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Empowering Innovation. Engineering Value. www.designworldonline.com February 2016 DESIGN WORLD 35


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.


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




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.

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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

LOW

THIN

HIGH

The

of thermal management

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Linear Slides and Cam Roller Linear Guide Rail System Components

J.W. Winco, Inc. offers high quality, heavy duty linear slides and telescopic linear slides, along with cam roller linear guide rail systems components, suitable for every application. Explore our full line at www.jwwinco.com or contact us with your requirements.

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

To order a catalog, visitphdinc.com/dw216 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.


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


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.



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Dunkermotoren Integrated Intelligence 2-16.indd 39 2/5/16 12:45 PM



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



WHAT DO YOU THINK?




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

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Design World February 2016

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