design world july 2015

INSIDE:

July 2015www.designworldonline.com

Designingslides into electronic

enclosures TEST & MEASUREMENT: 6 ways to benefit from EMC testing PAGE 90

MOTION CONTROL: IP65 rating and what it means for your application PAGE 70

MECHANICAL: New material for radial shaft seals increases uptime PAGE 84

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I n s i g h t s

4 DESIGN WORLD July 2015

A few months ago, I wrote about the new paradigm of engineering education that’s happening at Olin College and the University of Illinois. I was pleased to receive so much positive feedback from across the spectrum. Engineers, manufacturers and educators all seem to be on board with the idea of making an engineering education more broadly based, with a focus on creativity and real-world problem solving skills.

Dr. Gary Maul is the Director of Systems Engineering for Otterbein University, and he shared what this Ohio liberal arts school has done in creating a new engineering program, slated to start this Fall. Otterbein’s program exists in the liberal arts environment and is multidisciplinary in that it combines mechanical, electrical and industrial engineering. Students will have a good dose of liberal arts courses, including the new History of Technology course, as well as a series of writing intensive courses. Maul said the program focuses on design of products and processes and teaches students how to manufacture things—as well as how to design processes that manufacture things.

“We focus on the ramifications of poor design, impacts of design on cost, quality and manufacturability,” said Maul. “Our core essence is on solving real world engineering problems by approaching them as a system. In each engineering course, we will have students work in teams to do a term design project. We want and encourage students to collaborate by both teaching others at times, and at other times learning from other students who are teaching them. I think you often learn more by teaching someone what you know.”

Maul presents students with open-ended design problems, ones where opinions may prove to be wrong and do not correctly define the core issues at stake. Students draft a situation appraisal and then figure out what they need to know. Exercises are designed to make them think about information they need, how to get that information, and how much of it to get. Then they have to formulate their problem statement, come up with alternatives—all while under the constraints of time and money.

Engineering education still on the move

Pa u l J. H e n e y - Ed i to r i a l D i re c to r

p h e n e y@w tw h m e d i a .co m

Do you think engineering education is changing quickly enough?

Comment on Paul’s blog on Pneumatic Tips, www.pneumatictips.com/blog On Twitter @ DW—Editor

“They then have to actually solve their problem,” said Maul. “This means design and build. I think the building part gives students a sense of being real engineers and teaches them by letting them make mistakes and then teaches them to persevere to get a good result.”

Industry, too, has a role to play. A traditional university setting isn’t ideal for many students, and trade schools and apprenticeships should be encouraged and supported—not just by parents and guidance counselors, but by local manufacturers across the country.

I love what Gilman Precision is doing to fight the manufacturing skills gap. The Wisconsin company works with GPS Education Partners, a company that connects school districts with industry partners. Through the program, local high school juniors and seniors aspiring to pursue a technical career in the manufacturing industry are matched up with companies like Gilman. Students can gain industry credentials, employability skills and transferable post-secondary college credits; they engage in two hours of classroom learning, followed by working at their designated intern locations.

Bosch Rexroth has been supporting work in this area, too. Thanks to a founding grant of $80,000 by the company, the Charlotte-Mecklenburg public school system has opened the Bosch Rexroth Advanced Manufacturing and Technology Center. The new 2,839-sq-ft facility will support a new Advanced Manufacturing Hub and provide students with hands-on experience using state-of-the-art manufacturing technologies. It includes the latest in metal-cutting and finishing technology, with multiple lathes, milling machines, saws and grinders, along with metrology and quality-control stations.

Changing half a century’s worth of educational inertia in engineering and manufacturing isn’t going to be a quick fix. But change is coming—and for this country’s industrial future, it can’t come quickly enough.

Insights 7-15_Vs2.MD.indd 4 6/30/15 11:40 AM

A bad choice could cost you thousands!Look Familiar?When hot weather causes the electronics inside a control cabinet to fail, there is a panic to get the machinery up and running again. � e operator might choose to simply open the panel door and aim a fan at the circuit boards. In reality, the fan ends up blowing a lot of hot, humid, dirty air atthe electronics and the cooling e� ect is minimal. If the machinery starts functioning again, the likelihood of repeated failure is great since the environment is still hot (and threatens permanent damage to the circuit boards). Worse yet, that open panel door is an OSHAviolation that presents a shock hazard to personnel.

The Real Solution!Stop electronic downtime with an EXAIR Cabinet Cooler® System! � e complete line of low cost Cabinet Cooler Systemsare in stock and can ship now. � ey mount in minutes through an ordinary electrical knockout and have no movingparts to wear out. � ermostat control to minimize compressedair use is available for all models. All Cabinet Coolers are UL Listed to US and Canadian safety standards.

NEMA 4 and 4XCabinet Coolers

NEMA 4 and 4X Cabinet Coolers for large heat loads up to 5,600 Btu/hr. � ey are ideal for PLCs and modular controls.

• Enclosure remains dust-tight, oil-tight and splash resistant

• Suitable for wet locations where coolant spray or hose down can occur

Type 316 Stainless Steel Cabinet Coolers

Type 316 Stainless Steel Cabinet Coolers for NEMA 4X applications are available for heat loads up to 5,600 Btu/hr. • Resists harsh environments

not suitable for Type 303/304

• Ideal for food and chemical processing, pharmaceutical, foundries, heat treating and other corrosive environments

Mini NEMA 12, 4, and 4X Cabinet Coolers

� e mini NEMA 12, 4 and 4X Cabinet Coolers for small heat loads up to 550 Btu/hr. are ideal for control panels, relay boxes, laser housings, and electronic scales. • Measures 5" (127mm) high

• Mounts top, side or bottom

• Enclosure remains dust-tight and oil-tight

High TemperatureCabinet Coolers

High Temperature CabinetCoolers for NEMA 12, 4 and 4X applications are available for heat loads in many capacities up to 5,600 Btu/hr.

• Suitable for ambients up to 200°F (93°C)

• Ideal for mounting near ovens, furnaces, and other hot locations

Non-Hazardous PurgeCabinet Coolers

NHP Cabinet Coolers keep a slight positive pressure on the enclosure to keep dirt from entering through small holes or conduits. For use in non-hazardous locations.• Uses only 1 SCFM in

purge mode

• For heat loads up to 5,600 Btu/hr.

• NEMA 12, 4 and 4X

NEMA 12Cabinet Coolers

� e NEMA 12 Cabinet Coolers for large heat loadsup to 5,600 Btu/hr. areideal for PLCs, line control cabinets, CCTV cameras, modular control centers, etc. • Measures 8" (203mm) high

• Mounts top, side or bottom

• Enclosure remains dust-tightand oil-tight

The Secret To Keeping Electronics Cool!

If you would like to discuss an application,Contact:11510 Goldcoast DriveCincinnati, Ohio 45249-1621(800) 903-9247 / fax: (513) 671-3363

www.exair.com/58/440.htmJe� Hauck, Lasercraft Inc. Cincinnati OH

“It took us three days to get a replacement computer cabinet and we didn’t want to risk another heat failure. Fans weren’t an option since they would just blow around a lot of hot air. Freon-type air conditioners like those on some of our other machines were a constant maintenance project of their own. We purchased EXAIR’s Model 4330 NEMA 12

Cabinet Cooler System since it was easy to install and requires no maintenance.”

The only compressed air powered coolerthat is CE compliant!

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Watch The Video!

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Exair 7-15.indd 5 6/30/15 8:36 AM

Te s c h l e r o n To p i c

The popular press is filled with

caterwauling that bemoans a lack of

technological innovation in the U.S. The

idea that seems to have taken hold in the

public’s imagination is that entrenched

corporations often squelch novel ideas.

According to the popular narrative,

corporate managers look like either

dunderheads or villains. They spout

bromides about the short-term bottom

line to a degree that somehow blinds

them to spending money on promising

new ideas that take time to blossom.

L e l a n d Te s c h le r - Exe c u t i ve Ed i to r

lte s c h le r @w tw h m e d i a .co m

Can’t innovate? Don’t blame the dunderhead syndrome

On Twitter @ DW—LeeTeschler


The manager obsessed with short-term results is a convenient stereotype to explain why businesses don’t invest in more cutting-edge technology. There’s also reason to believe that it is also completely wrong. The real culprit, surprisingly, might be the way industry does its accounting. This insight comes from Peter Martin, a vice president and Fellow at Schneider Electric. Martin describes his role at Schneider as that of a futurist who discerns trends and then helps his employer get in front of them. Martin’s experiences have led him to conclude that a key obstacle preventing many industrial firms from innovating is their own bookkeeping methods. To understand why, consider this scenario: Suppose your engineering team has come up with an idea that makes your production line super productive. But the improvements involve new technology that costs money. Being prudent, you pick one particularly troublesome station as a test case. The changes get made. Big success! Your team figures that over a year, they can add a half-million dollars to the company bottom line for each station that incorporates this innovation. With proof in hand, you approach upper management about going plant-wide. And that’s where the trouble begins. “There may be 40 process points in the facility and you’ve fixed one of them. But cost accounting systems are often set up to look at entire plants, not at individual

process units. Moreover, they only look at them monthly,” said Martin. “When you examine the operation through the eyes of the cost accounting system, you might see an improvement, but you won’t be able to tell the improvement is in the unit you fixed. The accountants will look at the whole plant and say it has improved a little bit, but they don’t know why.” This isn’t just a hypothetical example. Martin says he’s seen it unfold numerous times during the 40 years he’s been working with clients in industry. “The accountants who study the books will say they can’t attribute anything explicitly to specific improvements that have been made. The best they can say is that the plant had a good month, but that could have been because of better feed stock, a more competent machine operator somewhere, or from any number of other causes,” he said. The picture that emerges from Martin’s observation is that stubborn managers are less of an obstacle to spending money on technological innovations than accounting schemes rooted in the last century. “You need accounting software that shows the specific financial performance of individual units. And managers need to see it in real time, not monthly. Do that, and you’ll know how each single improvement drives the bottom line,” Martin said. “Fortunately, there is accounting software today that gives that kind of visibility.” And with this visibility, we might add, could come the end of the cliché of the dunderhead manager. DW

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Follow the whole team on twitter @DesignWorld

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2011, 2012, 2013, 2014

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HOW DO I KNOW IF I’M TALKING TO AN ENGINEER OR A SALESMAN?

Ask Smalley. We have nothing against sales people. But when it comes to differentiating Inconel from Elgiloy or overcoming dimensional variations within a complex assembly, wouldn’t you rather work with an engineer?

Our customers would. That’s why they collaborate directly with our world-class team of Smalley engineers—experienced professionals whose only focus is helping you specify or design the ideal wave spring, Spirolox® retaining ring or constant section ring for your precision application.

Smalley wave springs reduce spring operating height by 50%, saving space and weight, fi tting tight radial and axial spaces. We offer more than 4,000 stock sizes in carbon and stainless steel.

Visit smalley.com for your no-chargetest samples.

THE ENGINEER’S CHOICE™

HOW DO I KNOWIF I’M TALKING TO AN ENGINEER OR A SALESMAN?

Ask Smalley. We have nothing against sales people. But when it comes to differentiating Inconel from Elgiloy or overcoming dimensional variations within a complex assembly, wouldn’t you rather work with an engineer?

Our customers would. That’s why they collaborate directly with our world-class team of Smalley engineers—experienced professionals whose only focus is helping you specify or design the ideal wave spring, Spirolox® retaining ring or constant section ring for your precision application.

Smalley wave springs reduce spring operating height by 50%, saving space and weight, fi tting tight radial and axial spaces. We offer more than 4,000 stock sizes in carbon and stainless steel.

Visit smalley.com for your no-chargetest samples.

THE ENGINEER’S CHOICE™

38139_Smalley_BrandAd_DesignWorld.indd 1 6/11/15 9:51 AMSmalley 7-15_NEW AD.indd 10 6/30/15 8:46 AM

July 2015 DESIGN WORLD 1 1

l C o n t r i b u t o r s S p o t l i g h t

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DUNSTAN POWER ByteSnap Design

Pre-compliance EMC testing: 6 ways your project will benefit

Choose the best linear positioning device for your application

TONY KLIBEREngineering Director of Precision Motion ControlNexen Group

Tony Kliber’s primary focus at Nexen is new product development for the precision motion control sector. In the next five years, Kliber said he would like to see more products that offer simple links between electrical and mechanical systems. Being involved in product development comes with its own frustrations; Kliber points to motion drive systems in particular. “In my experience, it seems selecting components and programming a servo drive is difficult for common users. There are so many dependent variables, it becomes overwhelming.” He also said he sees junior engineers relying too much on pre-made tools to do their work for them. “If you want to grow as an engineer … knowing the base math, concepts and logic behind what you are doing will allow you to grow faster.” Outside of work, Kliber’s two daughters (ages 5 and 2) keep him busy. “It’s amazing watching them grow and learn, especially when they join me in my other hobbies, like golf and car building.”

fun fact Kliber would like to have dinner with the early American settlers. “I think it is amazing that people got on a ship, sailed for three months to a new land, got off the ship

with nothing, and found a way to survive in the new world!”

BRIAN TAYLOR

Application Engineering ManagerSchneider Electric Motion

IP65 rating and what it means for your application

Having graduated with a degree in engineering from Cambridge University, Dunstan Power has been working in the electronics industry since 1992. Of his college experience, Power said his coursework had little content that was relevant to real-world electronic engineering. “It was mostly advanced math, which, in reality, most engineers use very little day-to-day, and very little practical experience. That was some time ago, and I hope that courses have become more relevant.” In 2004, Power founded electronic consultancy Diglis Design, then in 2008, established ByteSnap Design with a former colleague. He cites job security as a major issue facing engineers today. “The days of cradle-grave jobs have gone and the market is much more dynamic. You need to keep on top of your skills to avoid becoming institutionalized.”

fun fact Power could not live without his electronic drum kit. “I can play in venues large and small without deafening the audience and the rest of the band.

Though it isn’t as much fun as a ‘real’ kit!”

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Designing slides into electronic enclosures

STEVEN M. ROBERTSONR&D Engineering Group LeaderAccuride International

Purdue University graduate Brian Taylor says time is one of the biggest issues facing most engineers today, “specifically how to make the most efficient use of their day with all of the additional responsibilities now on their plate.” Taylor, who received his B.S. in Mechanical Engineering Technology, hopes to see engineers impacting energy conservation in a major way over the next decade. He points to solar panel development and transportation, the latter with respect to using renewable energy to drive vehicles rather than fossil fuels.

fun fact If Taylor hadn’t become an engineer, he would have loved to have been a full-time musician. “I currently can say that I am a musician, and a professional

one, as people do pay me to play. However, the pay does not offset the cost of living in Connecticut, so I need a day job!”

Steven M. Robertson has been designing myriad industrial products for more than 42 years. As a child, he enjoyed trying to figure out how things worked. Robertson said he started college studying graphic design, but became more interested in the technical aspects of drawing and engineering technologies. Over the last 18 years, Robertson’s focus has been on developing and designing products for the electronic enclosure accessories market. Like Taylor, Robertson hopes our dependence on oil reserves will diminish over the next 20 years and renewable energy will become the norm. “By then, we should be able to tap fresh water reserves of the ocean, to considerably reduce the dependence on the ever-changing weather and to provide consistent water supplies around the world.”

fun factWhen he’s not at work or home, Robertson can be found running or cycling in the hills or streets around Orange County, Calif., or off-roading in his Jeep Wrangler with

family and friends.


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Co n te n t s | J u l y 2 0 1 5 • v o l 1 0 n o 7 | d e s i g n w o r l d o n l i n e . c o m

1 2 DESIGN WORLD

MOTION CONTROL

IP65 rating and what it means for your applicationIP ratings have very specific definitions. Here we explain exactly what kinds of water and dirt exposure IP65-rated motion components can withstand.

2014

3

2014

3

70

F E A T U R E S

84 MECHANICAL

New material for radial shaft seals increases uptimeA reduction in design elements and a new material lays the foundation for radial shaft seals for roller bearings in steel mills. This cost-effective approach is a distinct advantage for manufacturer and customer in a price-sensitive market.

2014

3

LINEAR MOTION

Choose the best linear positioning device for your applicationReviewing the basics about the most popular linear positioning devices will help users properly specify them in their

applications.

76

ON THE COVERSlides can handle 1U to 4U chassis in multiple rack configurations.

Photo: courtesy of Accuride International Inc.

ELECTRONICS

Designing slides into electronic enclosuresEquipment that usually sits in standard 19-in. racks has gotten heavier in recent years, and that complicates the task of selecting hardware for managing server electronics and test instruments.

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90 TEST & MEASUREMENT

Pre-compliance EMC testing: 6 ways your project will benefitAdopting pre-compliance EMC testing removes the risk of product failure and avoids costly re-testing after design.

CONTENTS JULY 2015_first page_Vs3.LL.MD(1).indd 12 7/1/15 8:13 AM

Altech 7-15.indd 13 6/30/15 8:55 AM

Relay or Transistor Outputs

10A contact relay output, 300mA per channel transistor output

Digital, Analog and High-speed Inputs

• Eight built-in digital inputs of which two can be configured as 0-10VDC/4-20mA analog inputs

• 4 high-speed inputs (up to 10kHz)

RS232C and RS485 ports

• Serial and PLC communication• Driver to communicate with other PLCs

USB-A Port

For data logging, recipe data and performing program updates

Embedded USB Mini-B Port

3 Bezel Colors

• Silver• Light gray • Dark gray

Screens

• STN monochrome (740cd/m2)• 65K TFT color (400cd/m2)

RJ45 Ethernet Port

• Supports remote Ethernet communication and Modbus TCP• Driver to communicate with other PLCs

Flexible and Stress-free Programming

• 5MB screen-editing memory• Over 7,000 symbol factory images

800.262.4332

Analog Expansion Cartridges

Add up to two analog expansion cartridges for an additional four analog I/O

Analog Outputs

Two 0-10V DC/4-20mA analog outputs

High Environmental & Safety Ratings

• IP66f (water and oil tight) • NEMA 4X (indoor) and 13 • Class I, Division 2 for hazardous locations

HMI + PLC in One

Extreme Operating Temperature

-20° C to 55° C

www.IDEC.com/usa

Smart Products... Simple Solutions

By combining PLC and HMI functions in one, the FT1A Touch makes it faster and easier to build smart machines. This integration reduces initial design and maintenance costs by eliminating extra components and duplicate programming. Just one HMI+PLC unit optimizes efficiency and productivity by providing the complete functionality of a separate PLC and HMI system.

For more details and to read our Tech Note, visit www.IDEC.com/Touch

The Most Efficient Automation Solution

IDEC spread 7-15.indd 14 6/30/15 8:49 AM

Relay or Transistor Outputs

10A contact relay output, 300mA per channel transistor output

Digital, Analog and High-speed Inputs

• Eight built-in digital inputs of which two can be configured as 0-10VDC/4-20mA analog inputs

• 4 high-speed inputs (up to 10kHz)

RS232C and RS485 ports

• Serial and PLC communication• Driver to communicate with other PLCs

USB-A Port

For data logging, recipe data and performing program updates

Embedded USB Mini-B Port

3 Bezel Colors

• Silver• Light gray • Dark gray

Screens

• STN monochrome (740cd/m2)• 65K TFT color (400cd/m2)

RJ45 Ethernet Port

• Supports remote Ethernet communication and Modbus TCP• Driver to communicate with other PLCs

Flexible and Stress-free Programming

• 5MB screen-editing memory• Over 7,000 symbol factory images

800.262.4332

Analog Expansion Cartridges

Add up to two analog expansion cartridges for an additional four analog I/O

Analog Outputs

Two 0-10V DC/4-20mA analog outputs

High Environmental & Safety Ratings

• IP66f (water and oil tight) • NEMA 4X (indoor) and 13 • Class I, Division 2 for hazardous locations

HMI + PLC in One

Extreme Operating Temperature

-20° C to 55° C

www.IDEC.com/usa

Smart Products... Simple Solutions

By combining PLC and HMI functions in one, the FT1A Touch makes it faster and easier to build smart machines. This integration reduces initial design and maintenance costs by eliminating extra components and duplicate programming. Just one HMI+PLC unit optimizes efficiency and productivity by providing the complete functionality of a separate PLC and HMI system.

For more details and to read our Tech Note, visit www.IDEC.com/Touch

The Most Efficient Automation Solution

IDEC spread 7-15.indd 15 6/30/15 8:50 AM

Co n te n t s

D E P A R T M E N T S

4 Insights

6 Teschler on Topic

11 Contributors

18 Green Engineering

22 Engineering Exchange

24 Design For Industry

32 Design Notes

46 CAE Solutions

56 Internet of Things

64 Robotic Trends

111 Product World

120 Ad Index

7. 2 0 1 5

1 6 DESIGN WORLD July 2015

32

56

32

46

■ Measuring length of up to 20 m with a large reading distance■ Contactless and wear-free■ Accuracy up to 10 µm■ Simple and fast installation

SIKO MagLine Absolute:

■ High-precision, optical measurement■ Accuracy up to 5 μm■ Repeat accuracy up to 0.05 µm■ Large reading distance

SIKO OptoLine:

Measuring length of up to 20 m with a

SIKO MagLine Absolute:

open flyeropen flyer

visit websitevisit website

SIKO Products Inc., Phone +1 (734) 426-3476, www.siko-global.com

Contents JULY_second page_Vs1.indd 16 7/2/15 11:41 AM

All roads lead toSOLUTION CITY

© 2013 by AMETEK Inc. All rights reserved.

SOLUTION CITY

Welcome to Solution City, where you will find the largestselection of Precision Motion Control solutions for air andfluid movement, drive systems, linear motion technology,and brush/brushless DC servo motors.

AMETEK's market leading, high-quality brands offer engineeredsolutions to match your specific application requirements.Whether your need utilizes existing technology or requires a

customized solution leveraging our growing list of microprocessor based capabilities, we work closely with you to evaluate your application needs,and to assure you a fully compliant or tailor-made solution unique to your system requirements.

To put your ideas for precision motion control into action, contact your local AMETEK technicalsales and application expert, or visit us at ametekpmc.com.

Drive Systems& Motors

Linear Motion

Air & Fluid Movement


AMETEKTIP 14152-PMC Solution City-9x10.875_Design World 02/20/15 12:11 PM Page 1

AMETEK 3-15 (NEW AD).indd 17 6/30/15 12:43 PM

Smaller robots help increase efficiency

Comau has introduced a high-speed, 6-axis articulated robot that features a

payload of 3 kg and a reach of 630 mm. The third robot within the Racer family, the

Racer3 is the company’s response to the market demand for fast, cost-effective

robotic automation within small- to medium-sized companies and emerging

countries. With a streamlined design and brushed metal exterior, the robot unites

speed with absolute precision and repeatability.

Built from high-strength aluminum, the Racer2 weighs 30 kg and can be easily

mounted on benches, walls, ceilings or on inclined supports. Preliminary prototype

tests indicate that it will be the fastest in its class. Field-proven technology and

enhanced dexterity allow for a focus on safety, design and product aesthetics.

Features include: compact design, aluminum construction, exceptional stability and

user-friendly control interface.

Racer3 can adapt to any environment, meaning that SMEs in virtually any

industry can easily automate, with extreme accuracy, precision and intelligence,

even the most delicate manufacturing processes. It was created for general

industry sectors, including food and beverage, electronics, plastics and

metalworking. Rigid construction ensures higher precision and repeatability,

whereas the hollow body construction optimizes the fluid transition of cables.

Racer3 can be easily transported, guaranteeing maximum deployability. DW

Comaurobotics.comau.com

» G r e e n E n g i n e e r i n g


n Paul J. Heney • Editorial Director

Variable speed drive pump enables energy savings for industrial machinery

Eaton’s Hydraulics Group has announced a new

variable speed drive (VSD) pump solution that can provide

up to 70% energy savings for equipment in the machine

building, manufacturing, oil and gas and marine industries,

depending on the machine duty cycle. The industrial pump

solution, available in open- or closed-loop motion control

configurations, reduces operational costs by allowing

quieter machine operation, reducing or eliminating cooling

needs and allowing for pump downsizing.

n n

Green Engineering_7-15_Vs2.MD.indd 18 7/1/15 8:17 AM

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

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Dunkermotor 3-15.indd 19 6/30/15 9:05 AM

» G r e e n E n g i n e e r i n g


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MADE IN THE U.S.A.

Depiction of Frequency Waves

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The solution can include one or more pumps,

selected from an offering of PVM variable piston

pumps, Hydrokraft variable piston pumps or

VMQ fixed vane pumps. Together with the smart

control of variable speed drives, the system

can be controlled to match the precise load

requirements of the current duty cycle.

“Energy consumption plays a significant

role in overall machine operating costs, and

as energy costs increase, Eaton has worked

to provide more efficient solutions without

sacrificing safety or power,” said Wayne Wang,

product strategy and planning manager,

Industrial Product Portfolio, Eaton’s Hydraulics

Group. “By combining the proven reliability

and availability of Eaton’s Hydraulic and

Electrical solutions, we are helping enable

more sustainable, cost-effective industrial

operations.”

Running pumps at a variable speed also

reduces noise pollution, protecting operators

hearing while meeting noise regulations. As

equipment efficiency increases, oil coolers can

be downsized, limiting the amount of oil used

and extending the life of seals and oil. DW

Eatoneaton.com/VSD

WHAT DO YOU THINK?

Connect and discuss this and other design engineering issues with

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Green Engineering_7-15_Vs2.MD.indd 20 7/1/15 8:19 AM

The PITTMAN Difference

When evaluating DC motor choices, it’s what’s inside that matters.

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

Matters®

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

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

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PITTMAN 7-15.indd 21 6/30/15 9:06 AM

CONNECT with Design World

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INSIDE:

July 2015www.designworldonline.com

Designingslides into electronic

enclosures TEST & MEASUREMENT: Turning to captive panel screws PAGE 90

MOTION CONTROL: IP65 rating and what it means for your application PAGE 70

MECHANICAL: New material for radial shaft seals increases uptime PAGE 84

96

How 3D printing can be used for tooling applications3D printing enables manufacturers to test tool

designs before committing to metal—saving both

time and money.

5 mechanical considerations for electrical engineers Trying to size and space the electrical components before the mechanics are defined can lead to wasted time and

rework. Edited by Paul J. Heney, Editorial Director

How is Industry 4.0 affecting the cable industry?

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» D e s i g n f o r I n d u s t r y

2 4 DESIGN WORLD July 2015 www.designworldonline.com

Fresenius Medical Care SMAD uses a smart system to handle uneven stacks of dialyzers. This system consists of a robot that uses two 2D sensors to detect the position of dialyzers and move them to a conveyor without human intervention 24 hours a day, 7 days a week. Fresenius Medical Care SMAD specializes in kidney disease treatment, offering a comprehensive range of services and products for patients with chronic kidney failure. Operations are primarily focused on the production of two main types of product: dialysis filters (aka dialyzers) and bags of dry or liquid concentrates. Concentrates are salts that are used to prepare dialysis fluid, which is similar in composition to blood plasma. The dialyzer production line at its plant in east-central France is equipped with the robot. “In 2009 we decided to automate our dialyzer handling unit, which is located between a conveyor system and a processing unit. Automating the unit was an obvious solution. The main challenge was that the dialyzers are stacked unevenly and their positions vary along three dimensions. We had to find a system that could recognize their positions,” said Mouloud Ifri of Fresenius Medical Care SMAD’s Manufacturing Dept. Automating the line was necessary for two reasons: it is installed in a controlled environment—problematic for human intervention—and it operated at high speed 24/7. The feed system consists of two conveyors, each with two rows of dialyzers. The robot is equipped with a tool that allows it to pick up two dialyzers per cycle. The tool is fitted with two Keyence LJ-G080 laser sensors, one per dialyzer, so that the dialyzers are correctly picked up one after the other. The robot thus simultaneously removes dialyzers from each stack on a conveyor. It takes dialyzers from the two conveyors in turn. When a row (diagonal) is emptied, the conveyor moves forward until the stack reaches the unloading position. The robot routinely “scans” the theoretical positions

depending on the type of product. It uses the Keyence sensors to detect products and correct its pickup position accordingly. If no products are detected, the robot moves to a different stack. It also uses the sensors to correct its X- and Z-axes. To compensate for dispersion along the robot’s Y-axis, the robot’s tool is fitted with a homing cylinder for each type of dialyzer. The maximum height and slope of the stacks are always the same for the same type of product. However, these stacks may be uneven. “We first considered installing an industrial vision system. However, the cost and complexity involved led us to scrap that idea. We then looked at a 2D laser measurement sensor provided by a competitor, but found it to be complicated to implement.” Ultimately, the installation team chose the LJ-G080 sensor by Keyence. Its user-friendly settings menu means that experienced and novice users can configure settings easily and quickly. The setting support software (LJ-H1W) supplied with the device makes it easy to save and analyze data with a PC. Configuration is also made easy by several adjustment functions. For example, position adjustment ensures accurate measurements even when targets are not perfectly arranged or positioned. The tilt

r o b o t i c s

Automated handling of uneven stacks

The main challenge in automating a dialyzer handling unit was that the dialyzers are stacked unevenly and their positions vary along three dimensions. An automation system needed to recognize the individual dialyzer positions.

DFI 7-15_Vs5.LL.MD.indd 24 7/1/15 8:26 AM


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.

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» D e s i g n f o r I n d u s t r y

correction function simplifies installation of the sensor head and eliminates measurement errors. A number of functions make measurements to the surface properties of targets (shiny, dull, for example). “We also place high demands on the robustness and reliability of equipment,” said Ifri. The LJ-G sensor delivers reliable detection over time, offering repeatability of 1 µ along the Z-axis and 10 µ along the X-axis. It is protected inside an IP67 housing and withstands vibrations tested from 10 to 55 Hz, with an amplitude of 1.5 mm, for two hours along X, Y and Z. It weighs 350 g and has a detection range of 80 mm. DW

Keyencekeyence.com

The robot routinely “scans” the theoretical positions depending on the type of product. It uses the Keyence sensors to detect products and correct its pickup position accordingly.



02 » D e s i g n f o r I n d u s t r y r o b o t i c s

Size and weight restrictions limit the kind of sensors that can be used in compact applications, such as robotic end effectors. The SuperShorty inductive sensor line fits applications with space restrictions. These sensors weigh about 0.7 g, and have diameters as small as 6.5 mm and lengths as short as 6 mm. The electronics are self-contained, making remote amplifiers unnecessary, and are placed in stainless-steel housings, making them suitable in a range of challenging applications. DW

Balluffballuff.com

Inductive sensors fit tight spaces

P114

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Cables ensure power and control

03 » 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 r

Several processes in semiconductor Wafer Fab Class 1 Clean Rooms are operationally critical and need equipment that is absolutely reliable. When it comes to cabling, one option is flexible flat cables. The crystal-clear designs are free of halogens and contaminants, and are an alternative to PVC, Polyurethane and Teflon cables, especially in continuous motion and long-term flexing operations.

The flat cables from Cicoil are made from a unique extrusion process that combines multiple power conductors; shielded signal pairs; fiber optics; Ethernet; coax; thermocouple wires and flexible tubing for air, wire placement or fluid transfer; and StripMount fastening strips to be placed in a single flat cable, precisely controlling the inner component spacing, jacket thickness and the overall cable shape.

The durable outer Flexx-Sil rubber jacket is self-healing from small punctures and will not wear, crack or deform during a lifetime of more than 10 mil flexing cycles or long term exposure to vibration, de-ionized water, cold temperatures (-65° C), alcohol, extreme heat (165° C), stress, UV light and many chemicals.

Standard “off-the-shelf” cables are available, complete with connectors offered in 3, 6 and 12 ft lengths.

These cables for semiconductor applications are UL Recognized, CE Conforming, RoHS & REACH Compliant, Class 1 Clean Room Rated and exceed the outgassing requirements of ASTM E-595. DW

Cicoilcicoil.com

DFI 7-15_Vs5.LL.MD.indd 28 7/2/15 12:45 PM


04 » D e s i g n f o r I n d u s t r y

Custom materials for semiconductor applicationsBetter component or easier assembly performance often requires polymers, sometimes in custom blends. This can be true when designing fluid delivery systems, as well as in many static or dynamic applications. Minnesota Rubber and Plastics molds miniature components using custom blends of PEEK, polycarbonate, polysulphone, Nylon, polyethylene, polypropylene, FKM and EPDM elastomers.

Many of these components are as small as 1 mm in diameter and weigh under 0.018 g. Often these components must handle sterilization, chemical compatibility, biocompatibility, toughness and durability and show hydrolytic stability at elevated temperatures.

These miniature components can be combined into assemblies that include specialized seals and sealing devices. DW

Minnesota Rubber and Plasticsmnrubber.com

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» D e s i g n f o r I n d u s t r y 05

www.designworldonline.com June 2015 DESIGN WORLD 3 1

Simpler machine tool designA mechatronic design tool will help you size a motion system within a single platform. Finally, some companies are cooperating together to make it easier to design a whole system.

Tolomatic and Rockwell Automation have announced that you will be able to specify electric rod actuators and rodless electro-mechanical actuators on Rockwell’s Motion Analyzer web-based software, making it easier to specify, design and validate complete motion control systems that use Allen Bradley controls.

The mechatronic design tool, with its cloud-based architecture, promotes collaboration among mechanical, electrical and controls engineers to create prototype machines. The Motion Analyzer combines application requirements with product

WHAT DO YOU THINK?



m a c h i n e t o o l

ratings and specifications to provide solutions that exactly meet needs.

Tolomatic’s featured electric rod actuators (ERD, RSA) can meet most budget and performance requirements. ERD electric actuators are a low-cost alternative to pneumatic cylinders. The RSA high-thrust actuator offers mounting flexibility. Tolomatic rodless electro-mechanical actuators (MXE, MXB) are available in both screw- and belt-drive designs and a variety of bearing styles and options. Products can be built-to-order in 15 days or less. DW

Tolomatictolomatic.com

PiMotion®

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Automation Direct 7-15.indd 31 6/30/15 9:07 AM

Optical encoder takes over for LVDT

Conventional servo-hydraulic test

instruments use a linear variable differential

transformer (LVDT), a type of inductive absolute

encoder, to determine the linear direction of travel

and position of the actuator. But when Instron was

designing its ElectroPuls fatigue testing systems,

it knew the limitations of LVDT technology would be

problematic.

ElectroPuls is driven by a linear synchronous

motor and requires additional velocity feedback

due to the challenges of driving linear motors with

lower inherent damping than traditional rotary

designs. While suitable for position control, an

LVDT suffers from relatively poor signal stability,

and therefore, cannot produce accurate velocity

measurements. LVDTs are also susceptible to

magnetic fields produced within a linear motor and

exhibit increasing non-linearity over longer axes.

Optical encoders, on the other hand, have

better signal stability and higher accuracy, making

them better in this application. The Instron design

» D e s i g n N o te s


Mike Santora • Associate Editor

Design Notes 7-15_Vs3a.LL.MD.indd 32 7/1/15 9:17 AM


The Instron E3000 uses a T-slot table for regular and irregular grips and specimins


July 2015 DESIGN WORLD 35



team determined that an absolute optical

encoder, capable of providing absolute position

information without homing, would be the

best solution for their bi-axial systems. The

encoder offers several advantages over servo

mechanisms that use optical linear incremental

encoders in conjunction with an LVDT.

The engineering team needed an absolute

optical encoder that was compatible with

BiSS serial communications, easy to set-up

and install, and non-contacting to eliminate

the friction and wear that leads to mechanical

hysteresis errors. They chose Renishaw‘s

RESOLUTE, which offers linear resolutions of 1

nm and speeds beyond 20 m/sec.

“We previously used an LVDT to supply

the absolute position feedback needed

to commutate a linear motor, and an

incremental optical encoder to provide

the required measurement and control

accuracy,” said Graham Mead, principal

mechanical engineer for Instron ElectroPuls.

The absolute linear encoder gave the design

Instron’s E3000 has a twin column configuration with the actuator in the upper crosshead and is electrically powered from a single-phase main supply.

MADE IN USA

TAKE A CLOSER LOOK

Design Notes 7-15_Vs3a.LL.MD.indd 34 7/1/15 5:03 PM


WHAT DO YOU THINK?



team functionality and accuracy from one device.

The ElectroPuls E3000 linear-torsion machine

requires both linear and rotary absolute encoders for

the linear and rotational axes respectively. The linear

position is provided by a RESOLUTE readhead and RTLA

tape scale with ±5 µm/m accuracy and 5-nm resolution.

A second RESOLUTE reading a 115-mm diameter RESA

ring determines angular position, offering a resolution

of 0.019 arc second and an encoder accuracy of ±2.5

arc second.

The behavior of dynamic materials-testing machines

must be precisely controlled with either strain feedback

from an encoder or stress feedback from a load cell.

Standards body ASTM International tolerates a deviation

of up to 2% of the maximum applied load before a

test becomes invalid. RESOLUTE’s high accuracy and

excellent dynamic performance permit more detailed

analysis of samples at failure, contributing to the

accuracy of drawn conclusions. DW

Renishaw

renishaw.com

MADE IN USA

TAKE A CLOSER LOOK

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Mike Santora • Associate Editor

Even the highest quality metrology equipment

can’t truly shine without a motion controller

that functions with the same level of precision.

H2Optx’s mPAT LAB multiplexed Raman and Optical

microscope system needed a motion control

platform that was easy to use and would allow quick

integration during the prototyping stage of the design

cycle. H2Optx Inc. provides the pharmaceutical, food

and fine chemical industries with multi-spectral,

online measurement devices. The devices can be

used in end product situations or as a device within

a larger, more complex laboratory or production

system.

Because H2Optx is a small team of specialists

working to develop products for highly specific

industries, its ability to integrate components

for a particular system quickly and efficiently is

important. Specifically, its ability to move samples

and then do a detailed scan of the samples depends

on complex underlying motion control capabilities.

The mPAT incorporates a laser ScanHead as well

as an optional material handling accessory, such

as either the company’s Pillerator or Powderator

product. That means that a controller must work right

out of the box, and the software must be easy to

Step motor control ensures accurate scanning

integrate into pre-existing system components. In

addition, the controller had to have high levels of

overall integration (like a four channel controller

in a single, compact, printed circuit board).

Raman microscopes are laser-based devices

that are used to identify and quantitate samples

by measuring and evaluating the scattering

properties of materials.

The underlying capabilities of a Raman

Scanning Microscope are enabled by the ability

to move an optical block that houses a laser,

microscope, digital camera and spectrometer

interface together on a three-axis stage. The three

axes are driven by accurate and repeatable linear

stepper motor actuators. The system is controlled

using a personal computer over a standard USB

port. Therefore, the H2Optx needed a controller

that was USB based. Plus, it needed to handle

multiple axes simultaneously. “The only solution



we found that would meet all of our needs was

the AllMotion EZ4AXIS controller,” said company

spokesperson Scott Tandy.

To accomplish the scanning function, the

controller had to have a flexible enough interface

to allow it to execute pre-programmed actions on

its own, without the PC involved. At 2.25 x 2.25 x

0.6 in. (57 x 57 x 15 mm), the EZ4AXIS is one of

the smallest controller/drivers on the market—

and one of the most powerful in its size. It is a four-

axis position controller with built-in power drivers.

It also incorporates dual encoders as an integral

part of the package.

H2Optx required a controller with at least 16

microstep resolution and 1 A drive current. The

controller provided these capabilities for four

outputs (one more than was needed). In addition,

the design called for the use of hardware limit

switch capability, something that came as part of

the controller package.

The H2Optx design team was also happy

The mPAT LAB Inverted Raman Microscope

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with the way the controller easily integrated

with other components of the system. Its

flexibility helped make interfacing easier. Each

independent axis functions through a 1 A (2 A

peak) PWM chopper driver.

According to Tandy, “AllMotion provided all of

the motion control capabilities we needed in a

compact package. We integrated the EZ4AXIS

directly into our ScanHead design using it as a

daughter board to our main printed circuit board.

This allowed us to use all of the features of the

controller, but pick and choose the connectors

and interconnects that we wanted for our form

factor.”

As far as ease of use was concerned,

H2Optx engineers found that the EZ4AXIS’

software was based on industry standard

serial interfaces. Thus, direct

interaction with the product

was easy to incorporate

during the investigation and

early prototyping phases of

the design—all while using

the software application

that AllMotion provided. “For

the final product integration

into our Microsoft C#/.Net

environment, the serial port

interface meant that there

were no additional software modules to integrate into

our mPAT system software,” Tandy said. DW

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The AllMotion EZ4AXIS controller is a critical component of the mPAT microscope system. It is shown here mounted on the

ScanHead electronics.

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Guaranteeing packaging results every time, even when product

characteristics vary and product types change often, is one of the greatest

challenges facing a machine builder. This was the primary consideration

for Alpenland Maschinenbau (ALPMA) when designing its new MultiSAN

film wrapping machine. The machine packages round and rectangular soft

cheeses, as well as cheeses in karospar, cylindrical and half-moon formats.

“There are cheese makers today that make only a few types of cheese,

but nevertheless change over their production every two or three hours

because they produce every order by the truckload,” said Helmut Eitermoser,

the designer of the MultiSAN. The reasons for smaller and smaller batches

are typically the same as in other industries: customer-specific product

requirements, shorter product life cycles and increasing product variety.

ALPMA’s film wrapping machine called the MultiSAN can process a range of products with no changeover with use of LinMot linear motors.

The total package: How to design a film wrapping machine with direct-drive technology

Until now, cheese makers used packaging systems in which a

mechanical master shaft with cam drives mounted on it drove the

synchronous motion of the individual mechanisms.

“These cam machines were, and continue to be, the right solution

for packaging just one type of product. They are precise, cost-effective

and durable,” said Eitermoser. Two similar format shapes—such as

round and half-moon—and different sizes with the same shape can

also be processed on these machines with a reasonable effort. This

does, however, require a compromise; the packages for each product

version are less than optimal. “When several different products are to

be packed in a folded or wrapped package on the same machine with

rapid changeovers, the cam machine reaches its limit. Reconfiguration


C

M

Y

CM

MY

CY

CMY

K

DesignWorld_MDrive_ad_2015.ai 1 4/28/2015 9:33:15 AM

Schneider Electric 7-15.indd 39 6/30/15 11:38 AM



or even machine replacement is required before

a product changeover.

For the MultiSAN, the ALPMA design team

used direct-drive technology in combination

with a virtual master shaft and electronic

cams, which have completely replaced their

mechanical counterparts.

The envelope folds under the cheese, typical

for wrapped packaging, are now produced by

means of four horizontally mounted LinMot

linear motors that each drive one shutter blade

through a linkage. Once the cheese has been

wrapped in the packing film by the machine,

and has been fixed in place on a round plate

by a gripper, the shutters press the protruding

film together on the bottom of the product in

rapid succession, thus producing the desired

fold pattern. Another linear motor axis moves

the cheese off of the round plate onto a belt that

transports the cheese to the next station.

For this specific application, the design team

suspected early on that only linear motors would

have the power density that they needed. “Demo

units have shown that rotary servomotors are

not well suited for this task because they take

up too much space,” said Eitermoser. He chose

model PS01-23x160H-HP-R motors for the

MultiSan. The motors have a diameter of 23 mm

(stator)—not including the plug connection on

the end—but nevertheless are able to produce

a peak force of 130 N when coupled with the

E1130-DP-HC controller.

The matching sliders are available as

standard products in many variants, for strokes

from 20 to 780 mm. The version selected for the

MultiSAN has a stroke of 120 mm.

The space-saving form factor of the linear

motor also allows the new design to take up the

same floor space as the comparable version

with a mechanical master shaft. The cycle time

also match: both run at up to 80 cycles.

The commonalties end there, however. To

create a much more modular construction, the

ALPMA design team combined the mechanical

unit with the shutter drives into one module that

is used in several places on the machine. It is

designed to function as a heat sink for the linear

motors as well. These features all helped lead to

a product with consistent and repeatable results

every time.

“We have also made use of the sensitive

and direct reaction performance of the linear

motors to give the operator an instrument for

reacting to variations in product consistency,”

said Eitermoser. “The responsible parties on-site

can thus set their own parameters for various

consistencies, so that the machine operator

can adapt the machine settings to changes

in product characteristics just by pushing a

button.” DW

LinMot

linmot-usa.com

By using direct-drive technology, the MultiSAN has been decoupled mechanically so that sensitive com-ponents can be folded back out of the foam cleaning area.


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to the machine to let it know it should finish its task. The signal can be

sent by the operator, usually with a black pushbutton.

For times when an operator needs to deliberately stop the machine

as quick and safe as possible, an emergency stop is used. This type of

stop is performed using a red mushroom shaped device with a yellow

background.

Machines require at least one category 0 emergency stop, which is

the immediate removal of power. On occasion though, the removal of

power creates more hazards, so category 1 emergency stops may be

suitable for additional emergency stop buttons. This is a controlled stop

before the power is removed.

How do you stop your car as you approach a red light? Is it a gentle

release of the gas pedal so it can coast, slamming on the brakes or

somewhere in between?

With both methods, each way of stopping has a practical purpose.

Most people like to glide to a stop. It’s easier on the passengers and

it saves on gas and brake pads. However, sometimes you have to

stop the car as soon as possible. The same is true with machines. For

engineers there are other practical considerations when designing an

emergency stop system than the obvious primary function.

A normal stop allows the machine to glide to a smooth stop at the

end of a sequence. In most cases, this will be done by a signal sent


» D e s i g n N o te sEdited by: Mike Santora • Associate Editor

How using a programmable safety rated controller can increase the life of your machine

Viewing the Omron Delta Robot as

it uses different stopping methods

between emergency stop and

protective stop (light curtain).



Careful consideration should be applied before using

a category 2 emergency stop, a controlled stop with the

power still available. Because it’s quite possible that the

operator may not be aware of the hazard, a protective

(safety) stop uses a control system to stop a machine

if anything accesses a hazardous area. There are many

types of this technology including light curtains, non-

contact switches, safety mats, bumpers and edges,

area scanners and mechanical switches.

Every machine needs to have an emergency stop.

However, the machine does not need to have immediate

stops with protective devices. The only way they can

stop differently is if the controls are separated.

Depending on the load, motor size and speed, the

number of braking stops could be greatly reduced

before the disk in the mechanical brake is worn out.

It is difficult to separate the stopping method with

relays because they are hard-wired and share the

outputs. However, with a programmable safety rated

controller, the logic can be separated so a signal can

be sent to the machine during the activation of a

protective stop device. This signal separation gives the

machine a chance to stop on its own before the safety

system “slams on the brakes.”

Like the need for emergency stops themselves,

some design considerations are necessary but easily

overlooked. When adding any type of delay, remember

to include the additional time to the safe distance

calculation. When using a time delay, the length of

time for the motion to stop may be dependent on the

machine age, condition of contacts, speed, load, and

motor size. Using the dynamic braking settings may

also affect the machine’s stopping time. If no more

space exists to extend the safety zone, a common

solution is to use a guard interlocking switch.

One advantage of considering a servo drive or

inverter is the safe torque-off function. It has a faster

response time than using the traditional force guided

relays for the EDM (External Device Monitoring) since it

has one less connection.

For small systems, turning off the power through

a breaker box may be a suitable substation for an

emergency stop pushbutton. The breaker box must be

located by the machine and easy to activate. According

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to the ANSI RIA 15.06-2012, section 5.6.4,

stop control device(s) shall be placed near

each start control device.

It is important to reference the specific

emergency stop requirements in your area.

In the U.S., the primary emergency stop

requirements are found in the NFPA 79: 2015

Edition (Electrical Standard for Industrial

Machinery). The Canadian standards refer

to NFPA 79:2015. ISO 13850:2006 (Safety

of Machinery—emergency stop function—

Principles for design) covers international

standards.

Specific requirements just for emergency

stops include: • be continuously operable and readily

accessible

• red with yellow background

• positioned so readily available and capable of

non-hazardous actuation by the operator and

others who may need to actuate it

• positive mechanical action, direct opening

(NC contacts)

• (be either) stop category 0 stopping by

means of immediate removal of power to

the machine actuator(s) OR Mechanical

disconnection (declutching) between the

hazardous elements and their machine

actuator(s), and if necessary, braking

The robotics standard, ANSI RIA 15.06-

2012, section 5.3.8 states the system

shall: • have a protective stop and independent

emergency stop

• lead to a protective stop when entering

the safeguarded space in automatic

mode

• have manually initiated emergency stop

function. DW

Omronomron.com


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Baldor 7-15.indd 45 7/1/15 9:48 AM

»»» C A E S o lu t i o n s

46 DESIGN WORLD July 2015 www.designworldonline.com

»»» C A E S o lu t i o n s

Around the clock solar power

Situated on the east coast of Sicily, this innovative industrial demonstration plant uses Parabolic Trough CSP technology to generate electricity during sunny hours as well as under overcast conditions or at night. Jointly developed by Italian utility ENEL and the Italian National Agency for New Technologies ENEA, it began operating in July 2010 and is named after the mathematician and engineer Archimedes who lived in the nearby town of Syracuse.

Valerio Marra • Technical Marketing Manager • COMSOL

Thermal modeling enabled the optimization of a critical drainage system for Archimede, the first Concentrating Solar Power (CSP) plant in the world to use molten salt for heat transfer as well as storage, and to be integrated with an existing combined cycle gas facility.

Drainage system and detail of conic shape drain.

Archimede incorporates 30,000 m2 of reflective parabolic mirror surface in the shape of troughs. The sun’s rays are concentrated onto long thin tubes, which together make up a receiver pipeline running along the inside of the curved surfaces and stretching for 5,400 m. This pipeline contains a heat transfer fluid made of 60% sodium nitrate and 40% potassium nitrate, commonly

used as fertilizer. During the start-up of the power plant, this mixture is heated to at least 240° C (464° F) so that it melts and can pass into the tubes. Once it is molten, it is heated further by the sun and channeled to a dedicated steam generator, where it produces high-pressure steam that drives a turbine in the adjacent combined-cycle power plant.

CAE Solutions_Simulations 7-15_Vs3.LL.MD.indd 46 7/1/15 10:44 AM

» C A E S o l u t i o n s


The molten salt advantageMainly located in the U.S. and Spain, there are several CSP plants already in operation. They all depend on pipes filled with diathermal oil to absorb solar heat; older CSP plants can only operate in the daytime under direct sunlight. Newer plants have extended their operating hours through the use of molten salt as a medium for storing heat in large, well-insulated tanks. Using molten salt for heat capture as well as storage has several advantages over pressurized oil. Molten salt operates at 550° C (1,022° F) compared with oil at 390° C (734° F), so power output goes up, maximizing energy efficiency and potentially reducing the consumption of fossil fuels. The annual solar-to-electricity conversion efficiency is more than 15% better than other CSP plants. Because no oil-to-salt heat exchangers are required, the solar field is completely integrated with the energy storage system and there is minimal heat loss. This means that the tanks are less than half the size of competing parabolic trough CSP technologies with the same storage capability, yet they provide seven hours of thermal storage. The cold storage tank of both technologies works at 290° C (554° F). The temperature of the hot storage tank in oil-based CSP plants is 390° C (734° F), a difference between hot and cold tank of 100°. The temperature of the hot

COMSOL simulation of the conic shape drain (the temperature field expressed in °C is shown).

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storage tank in the Archimede plant is 550° C (1,022° F), a difference between hot and cold tank of 260° C. Comparing the Archimede plant with oil-based CSP plants the temperature difference between the two storage tanks is 2.5 times higher. Salt is clean, and one big advantage is that once it has been cooled, it can be reused. Oil degrades, is flammable and, as a toxic substance, needs to be disposed of carefully. In addition, molten salt allows the steam turbines used in the CSP process to operate within the standard pressure and temperature regulations at which fossil fuel plants run. This provides the potential for conventional power plants to be integrated easily with CSP plants like Archimede.

Conjugate heat transfer simulationUnfortunately, the advantages of molten salt also present a technical challenge: to maintain the salt’s liquid state. Daniele Consoli, project engineer in the Engineering and Innovation Division of ENEL, explained, “At 220° C (428° F) salt is frozen. It melts at 240° C (464° F), and for it to remain liquid, it must be kept at 290° C (554° F). When molten salt acts as the heat transfer fluid circulating in


» C A E S o lu t i o n s» C A E S o lu t i o n s

the tubes in which irradiation is concentrated, the pipes must be able to withstand constant heat up to 300° C (572° F) to prevent the salt solidifying and causing an obstruction. An electrical trace system is therefore required to preheat the pipeline and to facilitate the emptying of the circuit, which drains the solar collector.” Accordingly, the Research Division of ENEL chose to make the pipeline from a stainless-steel alloy to withstand extremely high temperatures. “This is an experimental power plant and there have been some critical points throughout the project,” said Consoli. “COMSOL Multiphysics has helped us to solve technical issues as they arose, for example when we needed to analyze temperature and heat loss throughout the drainage circuit and optimize both its geometry and insulation properties.” The team created a model of the drain within COMSOL Multiphysics and the results were quickly validated by a physical investigation of thermography and thermocouple measurements. “To begin, we undertook two kinds of simulation. First, we created a stationary

IR Thermography of the conic shape drain.

model and used it to determine the level of heating power that needed to be applied by cable to ensure that the temperature in all areas of the drainage system remained above the point at which salt solidifies. We carried out a 3D solid-fluid conjugate heat transfer simulation where both the conic drain part and the surrounding air were modeled. We considered heat transfer by conduction in the former, while both conduction and convection were taken into account in the latter. All the material properties were temperature dependent. We simulated heat loss in the remaining part of the drain by using COMSOL’s built-in library of local heat transfer coefficients. Thanks to such coefficients, we

saved both computational time and resources without affecting the accuracy of the simulation,” Consoli said. The team then created a second dynamic model to study the transient heating of the drain and check the time required to achieve the desired temperature. Another example of COMSOL application in CSP plant analysis has been the development of a model of the storage system to assess how, after validation, it could be optimized for plants of a larger size. This may incorporate several thermal bridges, which would have to be assessed to avoid the potential for significant and costly thermal power losses. Consoli explained how heat transfer was

Archimede project; Priolo Gargallo, Italy.


FOR PRECISE LINEAR POSITIONING The DCH Series combines an AC to DC switching power supply with a regenerative PWM drive, creating an all-in-one solution for applications requiring control of 12 or 24 VDC motors when only

115 or 230 VAC power is available. The microprocessor design allows the drive to be programmed for custom applications or

routines to meet OEMs needs.

www.amcntrl.com | 1.844. AMCNTRL (262-6875) Designed and Assembled in the USA

ACE HAS THE ANSWERThe DCH Series combines an AC to DC switching power supply The DCH Series combines an AC to DC switching power supply with a regenerative PWM drive, creating an all-in-one solution for with a regenerative PWM drive, creating an all-in-one solution for applications requiring control of 12 or 24 VDC motors when only applications requiring control of 12 or 24 VDC motors when only

routines to meet OEMs needs. routines to meet OEMs needs.

ACE HAS THE ANSWERACE HAS THE ANSWERThe DCH Series combines an AC to DC switching power supply with a regenerative PWM drive, creating an all-in-one solution for applications requiring control of 12 or 24 VDC motors when only

ACE HAS THE ANSWERACE HAS THE ANSWER

• Accurate to within 1/1000th of command position

• Designed for positioning control

• Regenerative stepping / reversing

• Microprocessor-based for custom programming

• Ideal for rapid starting and stopping



modeled: “We considered heat transfer by conduction along the thickness of the wall (steel, insulation, aluminium sheet) and the foundation of the tank. We took both conduction and convection into account for the fluid (molten salt) and convection and radiation for the surrounding air outside the tank.”

Reliable process operationGiven the over 50 million Euro ENEL total investment in the Archimede project, it was not difficult for Consoli to propose a business case for COMSOL Multiphysics. “Being able to simulate plant operation related to design choices on critical components was extremely important. In the case of the drainage circuit, simulation may significantly reduce the risk of potential damage to the power

plant and the consequent costs in case of failures. COMSOL Multiphysics represented an appropriate tool for those analyses.” From the operating and maintenance point of view the drain represents a single point of failure. “If it failed, we would have to stop one branch of the plant from producing energy while we repaired the failure. Then we would need to follow complex procedures to reactivate the affected branch, a process that takes at least two working days. All this would result in the loss of man-hours, significant operational income, and above all, clean energy. In addition, being aware of the thermal stresses that the drain and the whole plant are subjected to, we can schedule the preventive maintenance in a more effective way.” According to Consoli, another way to

have sized the heating cables would have been through an iterative process based on experience and on monitoring the effectiveness of incremental changes in an empirical way. “With COMSOL we quickly discovered the exact amount of thermal power required and then validated the results directly.” The Archimede project has attracted great interest from utility companies within Europe and around the globe. “We were building the first power plant in world to use this technology and we needed to get the first plant right and then go on to improve it. There are many potential opportunities for solar thermodynamic technology and the next Parabolic Trough CSP may be much larger,” said Consoli. DW

COMSOLcomsol.com

www.designworldonline.com July 2015 DESIGN WORLD 4 9

FOR PRECISE LINEAR POSITIONING The DCH Series combines an AC to DC switching power supply with a regenerative PWM drive, creating an all-in-one solution for applications requiring control of 12 or 24 VDC motors when only

115 or 230 VAC power is available. The microprocessor design allows the drive to be programmed for custom applications or

routines to meet OEMs needs.

www.amcntrl.com | 1.844. AMCNTRL (262-6875) Designed and Assembled in the USA

ACE HAS THE ANSWERThe DCH Series combines an AC to DC switching power supply The DCH Series combines an AC to DC switching power supply with a regenerative PWM drive, creating an all-in-one solution for with a regenerative PWM drive, creating an all-in-one solution for applications requiring control of 12 or 24 VDC motors when only applications requiring control of 12 or 24 VDC motors when only

routines to meet OEMs needs. routines to meet OEMs needs.

ACE HAS THE ANSWERACE HAS THE ANSWERThe DCH Series combines an AC to DC switching power supply with a regenerative PWM drive, creating an all-in-one solution for applications requiring control of 12 or 24 VDC motors when only

ACE HAS THE ANSWERACE HAS THE ANSWER

• Accurate to within 1/1000th of command position

• Designed for positioning control

• Regenerative stepping / reversing

• Microprocessor-based for custom programming

• Ideal for rapid starting and stopping

CAE Solutions_Simulations 7-15_Vs3.LL.MD.indd 49 7/2/15 12:59 PM


» C A E S o lu t i o n s

The newest version of FloTHERM XT software offers advanced thermal management capabilities for electronic systems, printed circuit board (PCB) and packages of any geometric complexity. This software includes CAD-centric technology and a mesher that simulates complex geometries with ease, speed and accuracy. It also supports transient analysis, Joule heating, parametric studies, extended EDA integration capabilities and new modeling options, including a cutting-edge ability to represent copper in detail for complex PCBs. These capabilities suit thermal simulation of electronic devices used in a range of markets including automotive, transportation, consumer electronics, industrial automation, aerospace and defense. “We can now take raw mechanical and electrical design data for an electronics system through to a viable thermal model appropriate for advanced parametric analysis. The improvements offered by FloTHERM XT enable us to work more efficiently and to build and run models with a significant reduction of engineering time and effort,” said William Maltz, president and founder, Electronic Cooling Solutions. For thermal specialists and design engineers, this software provides early design virtual prototyping and advanced “what-if” analysis for improved product quality, minimial design iterations, and faster time to market.

Key product capabilities • Transient analysis. Time-varying analyses across all industrial applications is enabled with the FloTHERM XT state-of-

FloTHERM XT includes EDA connectivity for

better thermal management

the-art solver and intuitive user interface (UI). • Component and board manipulation. Time is saved by importing any board and component layout and easily modifying data for position, size, orientation, shape and modeling level prior to transfer to the FloTHERM XT product. • Joule heating. Comprehensive analysis platform predicts current density, electric potential and associated Joule heating effects in complex electronics systems, PCBs and other high-power devices—a valuable feature for automotive and power electronics applications. • Parametric study. A new integrated environment for defining, solving and analyzing results for parametric variations of geometry, attributes (such as material, thermal) plus solution parameters significantly enhances the design optimization process. • EDA tool connectivity. A new ODB++ interface for non-Mentor Graphics layout tools supports Cadence, Zuken and Altium and helps users save time by providing increased user flexibility and use of existing EDA data. • Modeling options. PCB copper nets and traces are represented in full 3D detail, critical for higher-fidelity solutions or high-power applications using Joule heating effects for critical devices on a board. • Enhanced UI. Easy-to-use interface and enhanced functionality enables efficient use of the FloTHERM XT software for an improved intuitive user experience. DW

Mentor Graphicsmentor.com

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Siemens launches Solid Edge App Marketplace Siemens launched an online store that will help customers easily search for, compare and purchase partner developed apps for Solid Edge software. The Solid Edge App Marketplace mobile app provides a one-stop shop for add-on solutions that extend the capabilities of Solid Edge. The open architecture of Solid Edge gives partners access to a product development platform to create apps that support the user community.

“Innovative features enabled by apps allow customers to choose how they want to extend their use of Solid Edge technology,” said Michelle Boucher, VP of Tech-Clarity. The Solid Edge App Marketplace allows customers to instantly find complementary partner apps to meet their specific needs. Customers will be able to research and compare a variety of apps, select the one that best meets their requirements and purchase the app online to start realizing value right away. DW

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» C A E S o lu t i o n s

To ensure drilling platform stability, elongation measurement sensors contribute data as part of a long-term finite element analysis of pipelines, derricks, moorings and other critical high-stress members on offshore oil platforms. These platforms must be constantly monitored to ensure their stability. These sensors are typically a type of LVDT linear position sensor made for offshore applications. Specific features include high accuracy and long-term reliability when operating in water. In addition to providing measurement from micro inches to two feet with repeatability and precision, some offshore sensors can operate for at least 20 years, even when exposed to seawater. One such

Linear position sensors support finite element analysis of pipelines

WHAT DO YOU THINK?



»»

sensor is the Macro Sensors Offshore LVDT Linear Position Sensor. Reliability is a demanded feature of these sensors in offshore applications because of the high cost associated with replacing underwater hardware. These LVDTs are hermetically sealed, constructed with a subsea connector and gold-plated pins, and rated up to 7,500 psi to survive and perform accurately when submerged in the ocean for indefinite time periods. Dependent upon ocean temperature and depth levels, the LVDT casing is typically composed of special alloy that supports long-term operation. As sensor housings and core carriers made from stainless steel do not survive well in shallow warm waters, the Offshore

LVDTs are made with exotic material, such as Inconel, titanium and Hastelloy, for pressure and corrosion resistance. LVDTs have no moving parts. DW

Macro Sensorsmacrosensors.com


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“We are now at a point where the line between electronic and mechanical design is blurred, and PCBWorks is the first PCB design product to address the need for electrical and mechanical design teams to collaborate in a natural way,” said Ben Jordan, product man-ager at Altium. PCBWorks is a PCB design tool specifically for collaboration with mechanical designers in SOLIDWORKS. It is available globally through a certified network of SOLIDWORKS resellers. With PCBWorks, the collaboration process between electrical and mechanical design teams is now a seamless process with linked design data between both environments.

Designers can maintain their own distinct workflows with support from the following features: • ECAD/MCAD collaboration server. SolidWorks users can make changes to component placement, board shape and mounting holes on a PCB, and then push those changes to PCBWorks as a managed Engineering Change Order (ECO) to keep design data in sync. • Separate component lifecycles. Lifecycles for components can now be separately managed in their respective design

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environments. This allows an electrical designer to place a component without waiting for mechanical models to be complete, while linked data allows the component to be updated when the 3D model is finished. • Parasolid support. PCBWorks support for SOLIDWORKS Parasolid file format allows the electrical designer to link directly to native mechanical models for enclosures and component bodies.

PCBWorks includes a number of PCB design features that allow electrical designers to complete their PCB designs in one unified design environment, tying together the schematic capture and layout process with support from the following features: • Interactive and differential pair routing. PCBWorks includes a number of routing options to make the board layout process easier. Differential pair routing helps the designer to route high-speed designs with properly tuned lengths between signal pairs. • Library management. Schematic templates and components can be stored within a central library in PCBWorks, providing electrical designers with a number of design re-use options for future design projects. • Supplier links. With supplier links,

electrical designers have direct access to supplier databases,

including real-time information on component pricing and availability. DW

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» I n te r n e t o f T h i n g s

How the IoT really affects manufacturing


Frank Blasé • CEO • igus International

Internet of Things 7-15_Vs5.LL.MD.indd 56 7/1/15 11:41 AM

Recently, Editorial Director Paul J. Heney had the opportunity to tour the igus International

Headquarters and speak with company CEO Frank Blasé. The tour included an opportunity to

see the 350 injection molding machines that put out more than 3 million pieces per day. igus

runs approximately 10,000 mechanical and temperature tests per year on its products, as well

as chemical tests that are done off-site. There are 600 customer-specific tests on the bearings

product line alone.

The Internet of Things (IoT) appears to be new to many companies. However, if you have

worked in manufacturing, the IoT is more of an evolution of data collection and connectivity

that has been around for several decades. What’s new this time is using IoT to automate the

processes that surround manufacturing—order entry, ERP systems and other parts of the total

manufacturing system. Here are the comments from Blasé and how igus is using IoT concepts

to further improve manufacturing.

DW: How do you personally see the Internet of Things affecting igus?

Blasé: A little bit facetiously, on the one

hand, as we have been doing it for many

years. Not all the aspects, not all digitalized,

but part of what the Internet of Things means,

according to us anyway, is that customers

can order online any kind of configuration or

any kind of one-off and get it, quickly. That has

been part of our business … for decades, and

also online tools started early, but we have to

make huge efforts, and we are doing that.

We invest in an unprecedented amount of

IT right now, to digitalize the whole process.

We call it “from contact to claim.” From the first

contact that the customer has with us, on the

Web, or we have with the customer, all the way

to a possible claim, and digitalize everything in

between, as much as is possible or adequate.

[Imagine] making a CAD drawing that can be,

should be, automated, with a few configuration

tools; it should automatically go to the ERP

system and then automatically go to the

supplier, where automatically the CNC machine

starts turning that part. We need to digitalize,

quickly, and we have am ambitious plan for

the next two years.


We see three aspects of the IoT: the one-

to-one online ordering, the smart factory and

the smart products.

For online ordering, we see ourselves

quite well prepared. Smart factory, inside,

we made a lot of preparations to do the

one-to-one, and we need to digitalize more,

for our customers. We have the cable

developments, CAD 7 and so on, to make

the data communication safe. Once it’s in

motion, we believe, we can make some good

contributions there. From the smart products

point of view, we think that we will do more.

We have some smart products, a chain

that tells the customer if it has worn to a

certain point, and the new Web-based control

might be interesting, but we think that we

can do more. We need the overall investment

in IT, like the Big Data foundation, so that

we can do something with data if we want

to. It is so difficult to integrate a sensor into

something, but the software and what IT

does with it and tells the customer what to

do with it, is, we believe, a big part of the

investment. DW

igus

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How to select wireless networks

Like other wireless networks, wireless

sensor networks eliminate the costly

labyrinth of dedicated cabling to hardwire

devices, enable flexibility in organizing

operations, and expand opportunities for

keeping tabs on plant-floor conditions and

performance.

Selecting the right wireless sensor network

for your applications is still a challenge.

To help manufacturers make confident

decisions, the National Institute of Standards

and Technology (NIST) has developed best-

practice guidelines for evaluating wireless-

sensor-network performance and selecting

the option that best meets requirements.

“Our goal is to develop a tool that will

enable manufacturers and their technology

suppliers to design, assess, select and deploy

secure, integrated wireless platforms that

perform dependably in factory conditions,”

NIST’s Rick Candell said during the

International Instrumentation Symposium.

Candell, head of NIST’s Wireless Platforms

for Smart Manufacturing project, noted

that several standards-based technologies

have been adapted or developed to support

industrial wireless applications. The guide will

include benchmarking tests and metrics for

comparing how well different technologies

meet specific sets of requirements, he said.

NIST is in the early stages of commissioning

a wireless network test bed that will replicate

a smart manufacturing environment. It will

re-create conditions representative of a variety

of industrial settings and support development

of network-performance measurements and

tests. The test bed also will be used to evaluate

the usefulness of NIST network models and

simulations.

To ensure that the test bed accurately

reproduces the messy and challenging

realities of a variety of manufacturing

operations—from chemical processing to

aerospace—the NIST team is making a special

request. They are asking companies to open

their plant doors so that the researchers can

characterize conditions and factors, such

as heat, vibrations, reflections, interference

and shielding obstacles that affect network

performance.

“We want to re-create the factory and

network entirely in the lab,” Candell said. “To

do that, we need to make measurements in

the field to capture channel and environmental

characteristics and to represent the current

state of wireless activity in different types

of manufacturing operations. We want to

assess how the network performs and

how the wireless network impacts factory

performance.”

The NIST team has just completed

gathering needed data at NIST’s own machine

shop and at a U.S. automaker’s transmission

assembly plant.

“We would like to expand our

measurement efforts from discrete

manufacturing to a broader range of

industries, including the process control

industries such as oil and gas, chemical, and

water treatment,” Candell said. DW

NIST

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Analyzing Big Data

One of the key developments to come out of IoT is delivering data analysis as a

service. Siemens has launced Omneo Performance Analytics (PA), the latest application

for its software as a service (SaaS) Omneo offering, which it obtained last year as part of

its acquisition of Camstar.

Omneo PA delivers product performance intelligence from Big Data analytics. It

monitors data across the entire supply chain and customer experience, while analyzing

billions of data combinations in seconds. By revealing the hidden intelligence that

pinpoints the source of product issues, this service delivers proactive analysis for Big

Data.

“Using data from sources including field service, manufacturing, CRM, ERP and the

Internet of Things, Omneo Performance Analytics enables companies to identify and

resolve problems before they reach their customers—the ultimate goal of any business,”

said Steve Bashada, SVP of Cloud Services, Siemens PLM Software.

Omneo PA is the next evolution in product performance intelligence. It delivers on

three major components in a big-data, cloud environment: discovery, monitoring and

dashboards. By rapidly analyzing multiple combinations of all possible data sets, it helps

create insights into Big Data that were previously unattainable. Discovery results clearly

identify and display the highest contributing factors to data anomalies, so that every

value chain decision creates the largest and most positive impact possible on current

and future product performance. Companies can now answer questions they previously

did not know to ask, saving valuable time and resources.

The graphical monitoring capability in Omneo PA provides a complete view of product

performance across the entire value chain and enables companies to consistently

track current and emerging trends related to their products. Now fact-based, data-driven

decisions can be made for the entire value chain.

Omneo PA features a flexible, user-friendly dashboard workspace that users can

customize with data analytics definitions and key performance indicators (KPIs).

Definitions and corporate-wide KPIs are built as “modeling objects” with multi-level

definitions, for easy re-use. This structure enables users to interactively explore custom

data analytics and KPIs or schedule them for monitoring, and view the results whenever

needed.

“Omneo Performance Analytics goes beyond the limits of a traditional business

intelligence tool to take businesses to the next level of performance,” said Rami

Lokas, senior director, Omneo Research and Development, Siemens PLM Software.

“By leveraging Big Data to monitor, discover and display global product performance

for its customers, Omneo PA is already altering the landscape of product performance

intelligence as we know it today.” DW

Siemens PLM Software

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GE has implemented and released a

Global Discovery Server (GDS) based on Part

12 of the OPC UA standards. The GDS, used

in conjunction with GE’s Proficy software,

automatically discovers OPC UA devices

on your network and connects to them; no

configuration is needed. GDS automates the

previously manual and complex processes

associated with connectivity and certificate

management—saving a significant amount

of time and money. The technology supports

both the push and pull of certificates.

“We have been working closely with

the OPC Foundation to help design this

specification so that customers can reap the

benefits of connected systems and the ability

to manage asset performance,” said Jim

Walsh, president and general manager of GE

Intelligent Platforms Software.

GE’s decision to standardize on OPC UA

within its businesses provides a foundation

for cloud-based systems and asset

performance management.

GE’s OPC-UA enabled devices include the

PACSystems RX3i and RXi and controllers.

Other GE products adopting the standard

include: ADAPT3701, GE Oil & Gas’ System 1

condition monitoring software, 8 Series for

primary or backup protection for underground

and overhead medium voltage feeders, and 3

Series multifunctional feeder relays.

“Companies around the world are

working with multiple OS platforms across

their organizations,” Walsh continued. “By

standardizing on OPC UA, GE is alleviating

the issues involved with multiple platforms,

including Windows, iOS and Android.”

“With hundreds of thousands of nodes

needing to migrate from OPC DA to OPC

UA, users are looking for tools to leverage

enterprise connectivity and security in as

close to a plug-and-play fashion as possible,”

said Craig Resnick, VP, ARC Advisory Group.

GE’s OPC UA-enabled software can

also aggregate data from legacy systems

and equipment to eliminate islands of

information. Even for devices that are

unaware of OPC UA, the GE server can still

manage certificates and trust lists for those

devices, using Proficy Agent, which acts on

their behalf. DW

GE

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GE offers an easier way to connect industrial IoT devices


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» R o b o t i c T r e n d s

Software with standard models can now drive motion and robots

Today’s increasingly custom products are leading to smaller production batches, so production machinery is becoming more flexible. Robots are useful here because they’re not tied to rigid motion sequences. No wonder robots are on the rise in industrial manufacturing, especially in the packaging industry. The only catch is that it can be difficult to integrate robots (and their controls and kinematics) into larger automation systems. It’s still standard practice for machine builders to buy kinematic axes and program them from scratch, or to buy proprietary turnkey robots and add them after the fact. For the latter, builders must integrate the robot control with consistently compatible software and communications. In contrast, builders that use free kinematics must do copious programming.

How does modular software for motion work?No matter a machine’s kinematics, the aim is always to produce motion in a multi-dimensional space—either by linear interrelationships (as in a gantry) or nonlinear moves (as from a delta robot). The application dictates which is suitable. Especially for Cartesian robotics, some manufacturers now offer software toolboxes with standardized and reusable software modules to let machine builders set up flexible robot stations more easily. They let builders treat machinery controls and motion functions holistically. The modules adhere to the technical specifications of PLCopen and IEC 61131-3 and include complementary functions for delta-robot controls, electronic camming, conveying, cutting and tensioning.

Machine builders must deliver designs with more flexibility than ever. Standardized motion software helps them go beyond segregated component and drive purchases with efficient programming of even complex robotic movement.

Lenze drive and motion-control systems integrate robots with software using standardized modules represented by the boxed sketches here. The Feasibly Applicable Software Toolbox (FAST) modules use standardized interfaces that combine in myriad ways, even with a designer’s own software. Functions are scalable to meet the requirements of the task in hand.

Detlef Stork Technology Manager, Motion • Lenze

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Shown here is one setup that’s possible with Lenze’s FAST software. It is function-building-block software that lets machine designers virtually assemble predesigned control modules. The software includes interfaces for camera systems that detect objects for the robot to handle.

» Ro b o t i c Tr e n d s

Once a designer picks a general kinematics model, the software runs on automation equipment (including drives and motion controls) from one manufacturer. So, on the hardware side, motion and robot control (traditionally separate) become one. That simplifies physical setup and programming so designers can focus on what specific robotic movements should look like. In the years to come, such hardware and software innovation will put robots in jobs currently done by specialized machines. In fact, modular software can already set multi-axis kinematics to automate tasks too big for standard robots. Machine flexibility reduces efforts in mechanics, electrical engineering

and programming … so small- and medium-sized machine builders can integrate robot kinematics into designs with kinematics tailored to the task at hand.

Breaking tasks down into motion constituentsConsider technology modules for pick-and-place motion functions and corresponding coordinate-transformation functions for alternative kinematics (read: delta or Cartesian robots) based on PLCopen Part 4. The designer sets hardware parameters to define motion functions—including the coordinate system, material speeds and acceleration, radii, and rounding. Then the kinematics model

Lenze’s FAST software speeds the implementation, so machine builders can quickly assemble software for complete production lines like this one.

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Lenze’s FAST software speed implementation so machines builders can more quickly assemble software for complete production lines like this one.


parameterizes the mechanical variables such as arm lengths and distances between parallel struts. In this way, designers can reference, traverse and commission a robot-automation cell without programming. Currently, there are kinematics modules for gantries, belt kinematics, articulated robots, SCARA robots, and two- and three-axis delta robots. Elements for all their tasks are in the technology and kinematics modules. So now, engineers only need to know what a motion task should look like and not how to program a robot to make those moves. What’s more, if the design team needs to add another kinematics system, they only need to mechanically integrate the design, replace the corresponding kinematics model and set the necessary mechanical parameters.

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»»


Some software also has application templates (some quite specific) to implement modularized tasks in the controls. For example, OMAC versions of one template let packaging-machine builders implement applications in accordance with the PackML standard. The template accepts custom program components just as easily as technology modules. As mentioned, some modules let designers implement robotics through simple parameterization instead of programming a controller. Once the controller takes control of the other axes of the machine system and process, programming complex interfaces is unnecessary. In fact, motion-component manufacturers have offered application software for years with dedicated winding, cross-cutting, conveying, separating, grouping or sealing modules. Only recently have some added robotics applications based on PLCopen Part 4 … including those for pick-and-place moves through alternative kinematics … with other modules for more machine applications on the horizon.

Software modules for machines, tooStandard hardware and software also support modularization of machines. Here, builders can use software to break down the complexity of tasks into parts. Then, standardized technology modules let builders create and reuse designs for less engineering to get to machine production. That boosts software quality, so there’s less need for testing as well. Ultimately, the standardized and reusable modules free programmers to concentrate on developing and testing special machine functionalities that give designs unique features to benefit end users. DW

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IP65 rating


IP ratings have very specific definitions. Here we explain

exactly what kinds of water and dirt exposure IP65-rated

motion components can withstand.

and what it means for your application

Brian Taylor

Application Engineering Manager

Schneider Electric Motion

Motion Control 7-15_Vs5.LE.LL.indd 70 7/2/15 10:28 AM

M o t i o n C o n t r o l


and what it means for your application

Brian Taylor

Application Engineering Manager

Schneider Electric Motion

Just like the mysteries surrounding Stonehenge, crop circles, who

shot JFK, and what a self-respecting individual would actually do for a Klondike

bar, some motion-control considerations cause significant consternation,

confusion and debate. No application engineer really wants to deal with these

grey areas of motion, but most are eventually forced to do so during one design

or another. The most heavily debated topics include closed loop versus open

loop versus hybrid technology; sinking versus sourcing I/O; and the load to

rotor inertia ratio. Another grey area is the meaning of IP ratings for industrial

motors and how they relate to specific applications.

To dispel some of this confusion, let’s define IP65-rated components and what they do and don’t mean for applications. That will give us an understanding of how to correctly apply these components.

IP ratings: the true letter of the lawRanging opinions about the meaning of IP ratings is frustrating, but actual definitions are very specific. Published by the International Electrotechnical Commission (IEC) and detailed by IEC standard 60529, IP ratings—also known as Ingress Protection ratings or International Protection markings—rate the protection components provided by mechanical casings and electrical enclosures against intrusion (including body parts such as hands and fingers), dust, accidental contact and water. In other words, an IP rating indicates how well the enclosure of a device shields internal subcomponents. The ratings include two or sometimes three numbers.

IP number

Indicates protection from …

First position

Solid objects or materials

Second position

Liquids (water)

Third position

Mechanical impact (commonly omitted as not part of IEC 60529)

phot

o : is

tock

phot

o.co

m



What IP means for applicationsNow consider the two larger tables that accompany this article. A component with an IP65 rating withstands solid objects (as indicated by the 6) and liquids (as indicated by the 5). So, an IP65 motor is considered dust tight. It also seals against water projected from any direction from a distance of 3 m through 6.3-mm waterjet nozzles for a duration of at least 3 min with pressure not exceeding 30 kPa. Could the authors of this technical specification be any more specific? Probably not. But after reviewing application needs, how does an engineer decide if IP65 is an adequate protection level? To begin, the engineer must consider if the motor will be used outdoors or need to be fully submerged. Also: Will it need to withstand washdown conditions?

7 2 DESIGN WORLD July 2015 www.designworldonline.com July 2015 DESIGN WORLD 7 3

>> This IP65-rated Lexium MDrive from Schneider Electric Motion is an integrated motor for machine builders to use in applications subject to tough environmental conditions. IP65 LMDs include sealed M12 industrial connectors for power, communications and I/O interface.

>> To get the IP65 rating, a component must withstand hosing from nozzles up to 30 kPa.

IP rating’s first number: Denotes protection against solidsLevel Object size protected

againstEffective against

0 — No protection against contact and ingress of objects

1 Anything larger than 50 mm

Any large surface of the body, such as the back of a hand, but no protection against deliberate contact with a body part

2 Anything larger than 12.5 mm

Fingers or similar objects

3 Anything larger than 2.5 mm

Tools, thick wires, and so on

4 Anything larger than 1 mm Most wires, screws, and so on5 Dust protected Dust protected Ingress of dust is not entirely

prevented, but it must not enter in sufficient quantity to interfere with the satisfactory operation of the equipment, complete protection against contact (dust proof)

6 Dust tight No ingress of dust, complete protection against contact (dust tight)


Contrary to some opinions (or because of a general lack of understanding), IP65 specification does not certify that a product will operate in any of these conditions. To be clear: • IP65-rated motors are not certified for outdoor applications without additional protection against the elements • IP65-rated motors are not fully water submersible • IP65-rated motors are not food- grade components that satisfy washdown requirements.So then, what benefits do IP65 motors offer? Many. For example, some integrated motors with an IP65 rating combine motor, drive, controller, I/O, encoder and closed-loop performance to simplify integration and maintenance, improve efficiency, increase profitability and reduce time to market. Applications that benefit from such IP65-rated drives are numerous. These include packaging designs that convey various materials; form, fill and seal machines that dispense and seal product; liquid dispensing and pumping applications in medical and life-science devices; and printing and labeling machines … especially barcode and 2D label applications for tracking and traceability of medical devices. Other applications include 3D printers, assembly and test systems with three- and four-axis pick-and-place gantries, and machine tools that use waterjet cutting, laser cutting, and tool changers.

Testing to ensure IP65 protectionNow that we understand IP rating standards and how they relate to the specific rating of IP65, let’s explore how manufacturers verify that components meet the criteria. In most cases, an independent testing facility places the component in a sealed chamber filled with blowing air carrying fine powder to ensure the component is dust tight. In another chamber, engineers position 6.3-mm nozzles at a distance of 3 m from the component to hit from all directions with powerful water jets (not exceeding 30 kPa) for 3 min. The facility certifies components that pass these tests.


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Non-MagneticBall Slides

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Micrometer Driven Ball &Crossed Roller Stages

Linear SlidesBall & Crossed Roller

These lead screw and ball screw actuators offer the benefits of a space saving design, fast and simple assembly, long life, and a competitive price. The rigid enclosed aluminum box structure provides a compact envelope that incorporates the linear bearing and drive mechanism. Integrating all components into a single unit that includes the motor adaptor saves assembly time and eliminates the need to source additional parts. DL series linear actuators are offered in travel lengths up to 410 mm. The DL ball screw and lead screw actuators utilize recirculating guide technology to provide a low profile and compact design solution. Our DW series (double wide) is engineered to create a wider mounting platform while still maintaining the same low profile height as our standard width DL actuators. This double wide design is ideal for applications that need a greater carriage mounting area or where axial play must be minimized.

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But not so fast. Though components that pass their tests satisfy the IEC standard, some manufacturers go further to replicate real-world challenges. Here, some use IEC standard testing for IP65 certification and then task quality engineers to continue to subject the components to extreme life-testing. So a line of IP65-rated components now for sale as standard product may still be under testing—and have an installation base in the thousands that verifies real-world performance. Consider a typical motor application. Applying an IP-rated motor in a system is no different than applying a non-rated motor, as both require the correct fit for the application to operate successfully. IP ratings do not negate the need to consider the device’s ultimate environment or possible needs for additional protection. However, if engineers work to understand IP ratings, they can make intelligent design decisions to select appropriately rated devices for applications that run as expected. DW

Schneider Electric

schneiderelectric.com

>> To get the IP65 rating, a component

must also withstand a sealed chamber filled

with fine powder.

Mo b i l e I n te g ra ti o n Po w e r e d B y

http://dwo.me/1GMLheF

IP rating’s second number: Denotes protection against liquidsLevel Protected

againstTesting for Details

0 Not protected — —1 Dripping water Dripping water (vertically falling drops)

shall have no harmful effectTest duration: 10 min Water equivalent to 1 mm of rainfall per min

2 Dripping water when tilted up to 15°

Vertically dripping water shall have no harmful effect when the enclosure is tilted at an angle up to 15° from its normal position

Test duration: 10 min Water equivalent to 3 mm of rainfall per min

3 Spraying water Water falling as a spray at any angle up to 60° from the vertical shall have no harmful effect

Test duration: 5 min Water volume: 0.7 L/min Pressure: 80 to 100 kPa

4 Splashing of water

Water splashing against the enclosure from any direction shall have no harmful effect

Test duration: 5 min Water volume: 10 L/min Pressure: 80 to 100 kPa

5 Water jets Water projected by a nozzle (6.3 mm) against enclosure from any direction shall have no harmful effects

Test duration: at least 3 min Water volume: 12.5 L/min Pressure: 30 kPa at distance of 3 m

6 Powerful water jets

Water projected in powerful jets (12.5-mm nozzle) against the enclosure from any direction shall have no harmful effects

Test duration: at least 3 min Water volume: 100 L/min Pressure: 100 kPa at distance of 3 m

7 Immersion up to 1 m

Ingress of water in harmful quantity shall not be possible when the enclosure is immersed in water under defined conditions of pressure and time

Test duration: 30 min Up to 1 m of submersion There are caveats

8 Immersion beyond 1 m

The equipment is suitable for continuous immersion in water under conditions which shall be specified by the manufacturer. However, with certain types of equipment, it can mean that water can enter but only in such a manner that it produces no harmful effects

Test duration is continuous immersion in water. Depth specified by manufacturer, generally up to 3 m


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L i n e a r M o t i o n


the best linear positioning device

Tony KliberLead Design EngineerNexen Group

for your application

Reviewing the basics

about the most popular

linear positioning devices

will help users properly

specify them in their

applications.

Positioning accuracy of roller pinion systems ranges from 30 to 80 µm.Photo courtesy of Nexen Group

Feat_Linear_Motion_7-15_Vs4b.LL MG.MD.indd 76 7/1/15 4:14 PM


The linear drive technology used in a product plays an important role in providing the functionality, performance, durability, energy consumption and other attributes that enable the product to outperform compe-tition. Engineers can choose from a range of linear drive technology choices such as leadscrews, ballscrews, rack and pinion systems, belt drives, linear motors and roller pinion systems. It’s critical to carefully consider all of your options to avoid common problems such as low ac-curacy, backlash/vibrations, high cost, dirty operations, high maintenance, low load capacity, excessive noise, low speed and so on. A systematic selection process can

Linear drive systems have been used for thousands of years, as far back as the ancient

Egyptians who used tree trunks to move heavy blocks of stones, providing the precursor to

linear motion solutions such as ballscrews and roller pinion systems. Today, linear motion tech-

nology is used to support, locate, guide and move machinery components in a range of applications in

the aerospace, machine tool, medical, factory automation and packaging industries, among others. While the

basic requirements of linear motion technology are to provide load-bearing capability and accurate motion, other

requirements are also important in many cases.

ensure that the linear drive technology is selected to match the requirements of the application. Selecting the right technology can also reduce design complex-ity, improve performance and reduce the overall cost of assembly.

LeadscrewsLeadscrews use the helix angle of a thread to convert turning motion into linear motion. The large area of sliding contact between the male and female members of the thread generate relatively high frictional losses. The result is that leadscrews are less efficient and not as



Linear Motion

as accurate as ballscrews. Leadscrews pro-vide relatively high load-carrying capacity, although typically less than ballscrews. A key advantage of leadscrews is low cost—they are typically only one-tenth the cost of equivalent ballscrews. Leadscrews are available in a range of lead sizes, meaning that the lead can be selected to provide the right balance of positioning accuracy and speed. Leadscrews generally produce minimal noise as long as sufficient lubrica-tion is maintained. However, they can be difficult to use in long-distance moves as the screw is typically unsupported between the two ends.

BallscrewsThe ballscrew drive consists of a ball screw and ball nut with recirculating bearings that roll in the grooves formed by the screw and nut. The ballscrew distributes the load over a large number of rolling elements, resulting in a high load carrying capabil-ity. The use of a large number of precision rolling elements also provides high levels of accuracy. In addition, ballscrews provide low levels of friction. This translates into high mechanical efficiency and reduced power require-ments. The duty cycle of ballscrews is quite high because they gener-ate relatively low levels of frictional

heat. However, compared to other linear drive technologies, ballscrews tend to be expensive and they require that lubrica-tion be maintained to provide reasonable life. Finally, ballscrews are prone to noise, caused primarily by ball recirculation.

Belt drive systemsBelt-drive linear motion systems with ball guides are typically selected when high speeds, high rates of acceleration and long stroke lengths are the most important criteria. Belt-driven, slide guided linear actuators offer somewhat lower speed and acceleration capabilities at a correspond-ing lower cost. Linear positioning accuracy of belt drives, as might be expected, is not as great as either leadscrews or ballscrews. The load capacity of both ball-guided and slide-guided belt drives is somewhat lower than ballscrews. Belt stretch and stiffness are other drawbacks. Belt-driven linear motion systems are generally capable of high duty cycles because they avoid con-cerns about frictional heat buildup in the bearing of a leadscrew or ballscrew. Addi-tional advantages of belt-driven systems in-clude the fact that they generate relatively little noise and that they require relatively little maintenance.

Ballscrews are available in rolled or precision ground thread versions. Photo courtesy of THOMSON

Iron Core Linear Motors are designed with coils wound on silicon steel laminations to generate force with a single-sided magnet. Photo courtesy of Kollmorgen


Chain drivesChain drives convert rotary motion to linear motion through a series of chain links that mesh with a toothed sprocket and with a linear slide. Because they are metal, chain drives hold an advantage over belt drives. They also take up less space than belt drives and are not prone to dam-age by oil, grease, sunlight or age. Unlike belt drives, chain drives are also capable of operating in wet conditions. On the other hand, chain drives typically generate more noise and have a greater tendency to vibrate than belt drives and also provide a lower load capacity and service life than gear drives.

Linear motorsLinear motors are based on the concept of unwrapping a conventional rotary servomotor with the stator becoming a forcer and the rotor transforming into a coil or magnet rail. Linear motors make it possible to achieve direct linear motion without any rotary to linear transmission devices. Brushed linear motors use coils in the linear rail and magnets in the forcer. Brushes in the forcer contact a bar running the length of the motor to provide com-mutation. Both the windings and forcer are contained within the forcer of a linear step motor. The advantages of linear motors include high speeds, high levels of accuracy and fast response. The limitations of this

approach include high cost, large pack-age size and generation of considerable amounts of heat. Linear motors also have a low capacity, similar to the comparison of direct-drive motors versus motors with a gearbox—the direct-drive motor must be significantly larger to get the same capacity.

Rack and pinion setsRack and pinion gear sets consist of a circular gear called a pinion that engages the teeth of a linear gear called a rack to convert rotational motion to linear mo-tion. Rack and pinion gears are commonly used as linear actuators in a wide range of machinery. For example, they are used to move the axes of CNC machine tools such as machining centers. Helical racks offer quieter running at high speeds and a higher load carrying capacity due to the higher tooth contact ratio. Lubrication is important to ensure long life for rack and pinion sets. Because rack and pinion sets have relatively few components, they help save time during installation and increase reliability. They also offer high levels of accuracy even over long travel lengths. The disadvantages of rack and pinion sets include their relative high levels of friction, which reduces their efficiency, increases power consumption and limits their life. Plus, rack and pinion drives need to run with clearance so backlash can be a major disadvantage.

Roller pinion systemsAt first glance, roller pinion systems look similar to rack and pinion sets, but instead of spur gear teeth, bearing supported rollers engage the rack teeth. The rollers




Linear Motion

engage a tooth profile designed to match the pinion’s path, providing friction-free meshing that allows the pinion to be pre-loaded into the rack, eliminating mechanical clearance. The rollers ap-proach the tooth face on a tangent path and then smoothly roll down the face. Each tooth is precisely measured relative to the first, eradicating cumulative error and maintaining high positional accura-cy. The resulting smooth rolling friction provides 99% efficient rotary to linear motion conversion. Due to the smooth way the rollers engage the rack teeth, the new approach generates minimal noise and vibration. The system is whisper quiet at low speeds and less than 75 dB at full speed. Positioning accuracy of roller pin-ion systems ranges from 30 to 80 µm. For instance, a given size product in a premium model may deliver positional accuracy of ±30 µm, a life expectancy of 30 million cycles/tooth and a maximum dynamic load of 14,000 N. For medium loads, a universal model can deliver ac-

Application Considerations Belt Drives Chain Drives Rack/Gear & Pinion Roller Pinion/Rack Leadscrews Ballscrews Linear Motors

Accuracy Low Low Low-High High Low Low-High High

Backlash/Vibration A Consideration A Consideration A Consideration Near Zero A Consideration A Consideration Near Zero

Acceleration Medium Low High High Low Medium High

Speed Medium Low Medium High Low Medium High

Load Capacity Low Medium High High Low High Low

Length Shorter Shorter Long Long Shorter Shorter Moderate

High Wear and Short Life A Consideration A Consideration A Consideration Long Life A Consideration A Consideration Long Life

Maintenance A Consideration A Consideration A Consideration Little to none A Consideration A Consideration Little to none

Noise Level Medium High Medium Low High Medium Low

Dust & Dirt Emissions High High Moderate Low to none Moderate Moderate Low to none

Technology comparison chart

CNC machine tools are a key application for linear positioning devices.


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curacy of ±50 µm for 5 million cycles/tooth and carry a maximum dynamic load of 750 N. The RPS system is capable of speeds up to 11 m/sec (36.1 ft) making it the second fastest mechanical linear drive system second only to linear motors. The roller pinion system requires little maintenance. The pinion consists of 10 or 12 needle-bearing supported rollers that are sealed and lubricated for life. The rack is lubri-cated with high performance light grease at installation, then again every six months or 2 mil pinion revolutions. In special ap-plications the roller pinion system can be run lubrication free as long as the speed is less than 30 m/min. Roller pinion systems are offered with both metal and plastic racks. Thermoplas-tic racks offer an alternative that delivers high corrosion resistance, high durability,

Linear Motion

low maintenance requirements, medium accuracy, and load-carrying capacity at a relatively low cost point. Thermoplastic racks are impervious to corrosion. They are made of a self-lubricating polymer so they can withstand dirty environments and outdoor operation without concern over failure due to the loss of lubricant. Their ability to run at full speed without lubrica-tion reduces maintenance requirements and means that these systems can easily withstand washdown, outdoors operations and operation in coastal climates with salty air.

All of these linear drive systems offer their own unique mix of advantages and disad-vantages. To apply the correct type of linear motion technology in a particular applica-tion, the design engineer should carefully


consider the specific capabilities of each alternative. Selecting the right technology can improve performance, ensure long life and reduce the overall cost of the assembly. DW

Nexen Group nexengroup.com


http://dwo.me/1eh7fPp

UPDATED 3/27/2015 4:00 PM Feat_Linear_Motion_7-15_Vs4b.LL MG.MD.indd 82 7/1/15 4:19 PM

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Mechanical 7-15_Vs5a.LL.MD.indd 84 7/1/15 12:30 PM

»New material for radial shaft seals increases uptime

8,000 hours. About a year. That’s the max before seals for work rolls in steel plants need to be replaced. But the wind power industry, for example, demands a service life of up to 20 years or about 150,000 hours. So how do you satisfy the steel plant customers that are not prepared to pay for 19 bonus years of service life?

From your customer’s standpoint, the requirements for a sealing system for work rolls in steel plants are as follows: 1 A reliable sealing effect during the desired period of operation2 A self-retaining fit in the housing3 Easy assembly that protects the housing4 A cost-effective sealing solution5 The option for fast delivery—even for special sizes—in case of repairs

DESIGN WORLD 8 5

A reduction in design elements and a

new material lays the foundation for

radial shaft seals for roller bearings

in steel mills. This cost-effective

approach is a distinct advantage

for manufacturer and customer in a

price-sensitive market.

M e c h a n i c a l

Edited by: Mike Santora • Associate Editor



Avoiding high cost options is the first step for the seal manufacturer in the development of radial shaft seals. One example is the use of a steel ring to ensure the seal’s self-retaining capacity. This option is expensive and inflexible in its accommodation of different diameters. Moreover, the steel rings are more difficult to assemble and disassemble. In some cases, the seals have to be driven into their seat with hammer blows or levered out with special crowbars. Damage to the installation space, which involves costly repairs, is a possibility. Additional O-rings in housing grooves partly compensate for the poor static sealing effect of steel rings. Due to their cost, the current required pretensioning elements for the seal lip are not an ideal solution either. And in the event of the failure of these spring elements, mostly

M e c h a n i c a l

due to defective mounting, the bearings behind them may be damaged. Developing a new radial shaft seal to meet the special needs of the steel industry is an ambitious goal. Freudenberg Sealing Technologies produced such a seal and it is already being used in American steel plants and in Europe. Here’s how they did it. The key element Compared to other applications in heavy industry, the expectations for longevity are low in steel plants. This was the driving factor behind the new design—the springless seal lip. In the project’s launch phase, however, it became clear that this kind of seal design could not be achieved with known materials. The development of a new elastomer material was needed.

Pretensioning elements are traditionally used at the seal lip of radial shaft sealing rings. They are either round springs integrated into slots, formed leaf springs or combinations of the two. The main reason for spring pretensioning is that current materials fatigue too quickly to produce their own stressing force over a long time period. Due to wear on the seal edge, it must also be continuously repositioned. The seal edge needs sufficient contact and pressure on the counter face to achieve the required sealing effect even with slight shaft eccentricity. In addition, this has to occur over the equipment’s entire operating life. Elastomer materials’ compression set is the most important variable affecting the potential for long-lasting elasticity. This material property is a measure of how


Comparison of pretensioning

elements for seal lips on radial

shaft sealing rings

Pressure: 0 barShaft offset: 0 mm

Pressure: 0.5 barShaft offset: 0 mm

Pressure: 0.5 barShaft offset: 0.5 mm

FEM analysis on the

self-retaining ability

of the RPM 41 in the

installation space


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elastomers behave under long-term, constant deformation, under pressure and during subsequent relaxation. To achieve these material characteristics, it was essential to reduce this value to a minimum. The goal was to guarantee a high material elasticity over the required maximum lifespan of 8,000 operating hours. The developers could not allow other material qualities, including high wear resistance and joint strength, to be influenced by a change in the formula. There are already tried and tested formulas for the maximum wear resistance. The newly developed elastomer material walks this tightrope with good elastic capacity and excellent wear behavior. The material’s good joining capacity also provides the desired dimensional flexibility during the manufacturing of the sealing rings. Self-retaining ability in the installation spaceAs retaining elements, metal rings give seals a firm fit in the installation space but with the disadvantages previously mentioned. A self-retaining fit into the installation space is part of the specifications, even if no cover or flange

is used. Once installed, the operation in the work rolls is nearly pressureless. As a result, the required retaining forces are limited. Pure elastomer and rubber/fabric designs are just as poorly suited to the seal’s self-retaining function in the installation space. After several series of tests and FEM analyses, it was clear that a special steel element in the seal’s interior offered an ideal solution. With no material parts on the outside, this meant maximum protection against corrosion. Also, simple assembly and disassembly spared the installation space due to a solid rubber encasing on the adhering piece for the seal with a flexible steel core. With some practice, the seal can be pressed into the housing seat by hand. For disassembly, two fingers are usually enough to pull the sealing ring out of the installation space in a single, obliquely inward movement. Despite this ease of assembly, the new shaft sealing ring sits firmly in the installation space at up to 0.4 bar of overpressure.

Precision joiningFast availability of customer-specific sizes was an important aspect in the specifications.

When it comes to work rolls in steel plants, this availability consists of approximately 15 common profiles in the typical diameter range of 200 to 1,100 mm (approximately). This is an enormous range of different options with several hundred potential combinations. And if the installation space needs to be revised, there are numerous special sizes as well as the typical one-tenth deviations between the metric and imperial dimensions. It is not recommended that this wide variety be produced with individual tools due to concerns about costs and tool procurement. Even a certain level of inventory of completed shaft seals at the customer’s or the manufacturer’s location did not come under consideration due to the wide range of options and high costs. The best option was a shaft seal produced on demand and within 24 hours when necessary, providing assistance immediately in the event of an unplanned equipment stoppage. At the same time, the made-to-order ring must be no more expensive than current solutions. In this phase of the development work, The Freudenberg design team’s experience with joining large sealing rings for the wind

M e c h a n i c a l

CNC precision cutting equipment for basic rubber/steel rings


DESIGN WORLD 8 9www.designworldonline.com July 2015 DESIGN WORLD 8 9

Precision joining using butt vulcanization and molding tools


http://dwo.me/1RQI2If

power industry actually proved to be an advantage. What is possible in the rubber and rubber/fabric field was supposed to be transferable to an elastomer shaft seal with an interior steel element. For a precision joint, however, special devices had to be developed so intersections could be connected and perfectly aligned with one another. The intersections of the interior metal core had to lie precisely against one another so that the necessary pressure in the radial direction is maintained for the ring’s self-retaining ability. That is why a multistep process ensures the constant position of the steel core inside the seal’s adhering piece.A special cutting wheel handles the precise cutting of the ring, producing a plane-parallel intersection in the area of the elastomer as well as the steel core. The sealing ring is guided into a profiled carrier both during the cutting as well as the joining process, which uses butt vulcanization. CNC-controlled peripheral equipment regulates the high-quality level of the production process and ensures maximum reproducibility.

The result is offset-free convergence of all lines and edges and robustness at the joining point of 93%, which surpasses the required level of 75% of the strength of original elastomer material in its sigma 100 value. This means if the material were distorted to twice its length, the joint would show nearly the same strength as the original material. In its installed state, this has only limited importance. However, during the transportation and installation phases, it is expected to show no weakness. DW

Freudenberg Sealing Technologiesfst.com



ways your project will benefit

Dunstan PowerByteSnap Design

6Pre-compliance EMC testing:

T&M_7-15_Vs4.LL.MB.MD.indd 90 7/1/15 12:44 PM

T e s t & M e a s u r e m e n t

Electronic products, such as home appliances, computers, tools and wireless devices, need to be tested for EMC (electromagnetic compatibility). Across the globe, regions and countries have their own standards, such as the CE certification in the European Union or the FCC’s standards in the U.S.

Testing is normally undertaken at the end of a project at a specialty lab. But when tests fail—what then? This is more common than you might think; it’s estimated as many as half of all projects fall at this final hurdle, with radiated emissions often cited as the main stumbling block.

For product designers, the cost of failing compliance testing is a nightmare scenario. The most traumatic phase comes after you have built a product that meets market demands, you are confident that it radiates little energy and is not susceptible to outside interference, yet during the final EMC testing stage, the product fails.

The cost of testing was already high, but re-testing will stretch the planned budget and slow down the entire project. Now the design engineers will need to investigate where the problem is coming from, at a stage in the project when the integration of all the components can make this difficult.

Design engineers can avoid this scenario by building pre-compliance testing into a project from day one. In the software testing industry, there is a move to shift testing and introduce it earlier in the product development lifecycle. Likewise, this thinking is moving to the electronics industry—investigating emissions from your device during each major development stage is the best way to avoid costly re-testing and high failure rates.

What EMC testing actually entailsComplete EMC testing involves a number of different tests, described below:

Radiated emissions testing: This is carried out in a chamber or open field site. An EMC test receiver scans through frequencies up to a multiple of the highest clock frequency used in the device, recording the signal strength at each step. The test is designed to check for unintentional emissions that exceed a given pass band defined by the class of product.


Adopting pre-compliance EMC testing

removes the risk of product failure and

avoids costly re-testing after design.

T&M_7-15_Vs5.LL.MB.MD.indd 91 7/2/15 11:12 AM

the tester, depending on how a failure would be spotted. For instance, at the most basic, you could be staring at a monitor attached to a camera in the chamber. The industrial field strengths are higher than commercial, so if your device was required to be quieter (commercial), it also isn’t required to operate surrounded by the same level of interference, and so it is easier to pass the immunity testing. Conducted immunity: If appropriate, the cables are subjected to conducted noise, scanned across the frequency band. As for the radiated immunity test, the device needs to be operating so that failures can be spotted. ESD testing: ESD (electrostatic discharge) testing is usually carried out last, as it can be destructive. The UUT is subjected to air and direct discharges to any exposed contacts and to the case itself. The device should be in an operating state and should recover to that same state, or be unaffected, by the discharges. Other tests: There are many categories of device and environment, such as commercial, industrial, military, medical, rail and automotive.


Typical classes are for industrial and for residential/commercial. The emissions criteria are more stringent for the latter; the device needs to be quieter. These scans can be slow, particularly if the board has high frequency components on it, as the scan has to run up into the GHz frequency range with a dwell at each step. If you’re wondering where the time goes in EMC testing, this is one of the main areas. Conducted emissions testing: Where the device has long cables attached or operates from the mains, those cables are passed through an LISN (line impedance stabilization network), RF current clamp or artificial mains network, and, again, frequencies scan to search for unintentional emissions. The frequency range is much shorter than for radiated emissions (say, up to 30 MHz). Radiated immunity: This is the reverse of the radiated emissions test and is carried out in an EMC chamber. Here, the UUT (unit under test) is subjected to a radiated field, which, again, scans through the required frequency band, from 30 MHz up into the GHz range. The UUT needs to be operating so that the tester can see if there are any failures at any frequency. This is slow and may require a lot of concentration from

An anechoic chamber, such

as this one used by ByteSnap

design for EMC testing, identifies

radiated emissions from devices

as well as a device’s immunity to

electromagnetic interference.




Understanding all the costs in pneumatic and electric actuators—and recognizing

their very different capabilities—can save tens of thousands of dollars.

Consequently, there are many specialized tests carried out that are just called up for specific device types. For instance, for mains power devices, and those with long cables, fast transient tests and surge tests, both of which can be destructive, can be carried out. They may be simulating lightning strikes or other mains transients. For automotive devices, there are also extended power tests, such as load dumps and high and low voltage tests, simulating such events as a battery being disconnected while the engine is running or the battery being reversed. In our experience, the radiated and conducted emissions tests are the ones that fail most often, they are also time consuming tests, where if there is a failure, working around it and retesting is often a slow process. While we have seen failures in all of these categories, they are not all equal in terms of time to fix the issue. In addition to this, devices that perform well with emissions testing generally perform well at immunity testing also, and the reverse is the case, so by sorting out emissions problems, you are quite possibly also fixing potential immunity issues. To this end, the earlier you can catch these issues, the better.

There are a number of advantages of pre-compliance testing:

1 Project lifecycle accelerated through early error detection The sooner product deficiencies are identified in the development process, the easier it is to rectify any shortcomings. It’s much more costly and time consuming to rectify issues after compliance testing than fixing them during the design stage. Pre-compliance testing allows you to focus on the areas that you have identified as potential causes for concern and find solutions for them early. Generally, the risk to a design failing is relative to how long you delay testing, so designers who schedule testing toward the end of a project are completely reliant on the design team’s skill and experience. Early analysis of the electronics can also help steer system decisions. Apart


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from being about electronics, EMC is also about the system, and mechanical changes, such as adding EMI shields, coating boxes or adding EMC foam to fill any leaks/gaps in an enclosure, may be necessary.

Take the example of the design of an Android tablet. This will have multiple features such as LCD, touchscreen, USB, Wi-Fi, Bluetooth and camera. These are positioned around the architecture of the core CPU and memory. Each of these sub-sections will emit some form of unintended electromagnetic energy, but hopefully all at acceptable levels. You would ideally test the core CPU with each section separately, and when a problem occurred, the source would be apparent. But the reality is that this is rarely a commercially viable approach. However, the use of development boards with pre-compliance testing can do some of this work at a lower cost. This highlights issues early on and allows for remedies to be implemented ahead of the final integration. This is not a substitute for the final testing, but may save some of the pain. In a similar vein, once the target hardware is available, partially populated boards can be used to isolate problem areas.

2 Test products early to compliance standardsUsing an anechoic testing chamber before formal testing can determine whether or not a design will meet relevant compliance standards. Specific standards call up specific measurement limits, and these limits vary widely. If you are not testing to the standard that you will ultimately be judged against, you may be either over or under-testing, or applying the incorrect frequency range. A spectrum analyzer and near field probe can be useful in finding emitters, once they have been identified as presenting radiation above the required limit, but less useful before a calibrated scan at a required distance. What may appear to be a problem at close range

with a probe, can melt away in a chamber, and, of course, the reverse is also true. Testing to a known standard early on focuses attention on real problems.

3 De-risk your electronics design project Early EMC testing can de-risk a project by determining many, if not all, non-compliance issues prior to submitting for formal testing. This is one of the ways the time taken on pre-testing pays back over the course of the project. The end design is much less likely to fail, saving the resulting costs and delays associated with board re-spins and excess test house charges. In addition to EMC, a chamber can be used to measure comparative signal strength for low-power radios to check performance over time, or the effect of modifications. Pre-compliance testing makes certification an overall less stressful experience.

4 Integrated testing means more agile project developmentStand-alone pre-compliance testing can be expensive, especially if a product doesn’t pass the first time, as subsequent rounds of testing will be required after design alterations. However, when testing is integrated into development, a testing chamber and expert advice is available during the entire project lifecycle. Design engineers that offer EMC pre-compliance testing as part of their services will be continuously on the lookout for areas of risk during product development. For instance, testing during development with evaluation or strip boards will provide the designer with the opportunity to add in preventative measures in the form of additional circuitry, such as signal bead filters, to prevent potential issues. Test houses typically charge time in half-day blocks, but often only a single RF emissions sweep is required to see

July 2015 DESIGN WORLD 959 4 DESIGN WORLD July 2015 www.designworldonline.com

if a problem is still there or is probably fixed. The maxim “if you haven’t fixed it, it isn’t fixed” can apply to EMC testing as much as software and hardware design. When you come up with a fix, it’s good to be able to try it out quickly before committing to a re-spin of a circuit board.

5 Eliminate over-engineering for improved efficienciesEarly EMC testing can save money by reducing over-engineering, ensuring that a product can pass compliance tests easily. Before a product is tested, it’s not known where the problems might occur. This can lead to counter-measures being added where they are not required, counter-measures that will be present for the lifetime of the product. As an analogy, Henry Ford used to send engineers to examine Ford cars in scrap yards to understand which components still had lots of life in them due to over-engineering. This helped his engineers to downgrade the specification on these components to achieve a cost saving. The equivalent can be done with EMC testing to optimize the BOM (bill of material) cost. As well as this having an electronic BOM cost impact, there is also an effect on the mechanical constraints (meaning the size of the board in all three dimensions). For a tight design, it’s crucial to optimize the EMC filtering, which can be large, at an early stage, as adding filtering in later on, once mechanical tooling is committed, may prove impossible. This is particularly the case with power line filtering using common-mode chokes or Pi filters.

6 Additional uses of pre-compliance equipmentAs well as EMC testing a product, “look-sees” can be carried out as obsolete parts are replaced or board layout changes. As CE marking is a self-certification process, this data can often be used to justify retention of the CE mark by reference



to comparative measurements on the original unit. Clearly, this depends on the scope and type of any change. Similarly, tests can be carried out on comparative signal strengths of antenna configurations. For example, performance of one of our ZigBee products had markedly decreased on a recent batch, following the move to a new subcontract manufacturer. A new and old board were compared in an EMC chamber to determine the problem. It transpired that the stack-up had not been followed on the PCB, resulting in detuning and losses. To minimize risk of EMC testing failure, at ByteSnap Design, we decided to set up our own testing chamber to allow us to make radiated emissions scans of customer’s products. This provides us with additional ability to eliminate many of the problems prior to formal testing by extending our scope for agile design. After all, adopting a smarter approach to testing can remove a high degree of risk of product failure, not to mention the savings in the bottom line over the course of a project. DW

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into electronic enclosures

Equipment that usually sits

in standard 19-in. racks

has gotten heavier in recent

years, and that complicates

the task of selecting

hardware for managing

server electronics and

test instruments.

Designing slides

Steven M. Robertson R&D Engineering Group LeaderElectronics Enclosure GroupAccuride International

Electronics 7-15_vs6.LL.MD.indd 96 7/2/15 11:06 AM

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The 19-in. equipment rack has long been a standard for enclosures holding

electronic instruments. The basic dimensions on these racks are spelled out in a specification

document issued decades ago by the Electronic Industries Association. With this kind of history, you might think rack hardware from different vendors should all work together without much trouble. Unfortunately, this is not the case. One difficulty comes from factors that standards don’t specify. For example, a rule of thumb has long been that servers that fit in 1U enclosures (where “U” is a nominal EIA unit increment of 1.75 in. high) weigh about 25 lb. Today the average is closer to 60 lb, and 2U servers can hit 90 lb. To handle the additional weight, makers of enclosure hardware have had to beef up or redesign their equipment. Heavier chassis make it more difficult to meet safety standards such as UL 60950, which spells out stability tests as well as levels of steady and impact forces that equipment must be able to withstand.


E l e c t r o n i c s

4U

2U

1U

5U

2907WB

Designing slides

Slide

Chassis

Chassis Front

Mounting Rail

Here’s a typical 19-in. EIA enclosure and server rack

with slides in a four-post configuration. This set up

is commonly used for servers and to store electrical

components, AV equipment and more. The slide shown

(Model 2907WB) can handle 1 to 4U chassis in multiple

rack configurations. This setup was fabricated by Mag-

ma.com, a developer and manufacturer of expansion

systems for servers, desktops and portable workstations.





Enclosure glossaryCabinet Width: the outside dimension (side to side) of a cabinet or enclosure

Panel Width: the outer dimension of the front mounting rails, which is greater than the clear opening between rails

Cable Carrier: accessory item to support and manage wiring behind a chassis when it is withdrawn or inserted into the cabinet

Clear Opening: the innermost dimension between the front mounting rails

Depth: the front to rear dimensions of a cabinet or enclosure

Chassis: a universal term for an electronics drawer; also known as the unit, drawer, module, device, stack equipment, system

Front Panel or Bezel: the front facade of the chassis

Cabinet Rail Upright: also known as mounting rail, column, strut, upright

Slide: mechanism that serves as link between the enclosure and chassis; also known as rail, glide, track, runner, chassis member or suspension.

Slide Mounting Bracket: attachment device between the slide and cabinet

Bar Nut: accessory used in place of hex nuts and washers

Mounting Holes: on cabinet rails, come in a repetitive series as follows: 1/2 in., 5/8 in., 5/8 in., 1/2 in. 5/8 in., 5/8 in., [12.7, 15.8, 15.8, 12.7, 15.8, 15.8 mm]

Makers of enclosure equipment have adopted several tactics to meet such requirements. In some cases, they have had to switch to higher-strength materials for structural elements. Another technique used for handling heavier chassis has been to equip 2U instruments with slides originally designed for 3 and 4U chassis. Racks have also gotten taller and deeper. A standard server rack is 7 ft high and can accommodate 42 units (42U) of rack-mount equipment. It’s possible to find manufacturers today offering enclosures up to 23 in. wide (particularly for telecom equipment) and 9-ft-tall 58U racks. Additionally, server racks are increasingly going to wider 435 to 438-mm chassis designs. Manufacturers such as Accuride have developed special profiles with a width of 7.2 mm to accommodate this demand. These super-narrow slides also have a low profile height that fits 1 and 2U chassis and will carry up to 77 lb. The products are available in partial extension and over travel to offer the access needed to service chassis. Depth wise, original 19-in. racks had a depth between 19 to 24 in. The most typical depth is now about 29 in., but it is possible to find racks with depths in the 40 to 50-in. range.

Enclosure standardsThe EIA standard for enclosures (EIA-310) standardizes several im-portant features of 19-in. racks that include the Rack Unit (RU or U), vertical hole spacing, horizontal hole spacing, rack opening and front panel width. The specification also sets tolerances on each of these dimensions. But there are numerous rack dimensions not spelled out in the standard. For example, the standard doesn’t mention the types of holes permitted, rack mounting depth, front and rear space in the rack, and the possibility of obstructions between front and rear rails.

1

2

3

4

5

6

7

8

9

10

11

12

Slides can be quite versatile as in this setup where a slide is used to attach a

chassis to an enclosure/server rack, but also to allow access to internal components

within the chassis. This setup was fabricated by Magma.com, a developer and

manufacturer of expansion systems for servers, desktops and portable workstations.

Electronics 7-15_vs6.LL.MD.indd 98 7/2/15 3:28 PM

May 2014 DESIGN WORLD 9 9 July 2015 DESIGN WORLD 9 9

All of these are subject to interpretation by equipment vendors. First, a quick review: Electronic instru-ments or servers that slide into the enclo-sure are generally each called a chassis. As previously mentioned, the height of a chassis is based on a nominal EIA unit increment of 1.75 in. (44.45 mm). Each increment is referred to as a U. The minimum measure of a chassis is 1U, with subsequent measures expressed as multiples of this unit: 2U (3.50 in., 88.90 mm), 3U (5.25 in., 133.35 mm), and so forth. The actual height differs from the nominal height. Equipment suppliers sometimes interpret the EIA standard loosely or ignore parts of it. For example, EIA-310 specifies that the horizontal spacing of the vertical rows of mounting holes should be 18 5/16 (18.312) in. (465.1 mm). Some racks don’t adhere to this dimension, complicating installation efforts. Some manufacturers use equipment mounting slots instead of holes to allow for variations in this dimension. Similarly, the EIA standard specifies that the rack opening between the mounting rails is, at minimum, 17.72 in. (450 mm). Racks that aren’t particularly deep, such as 2Post or relay versions, tend to have larger-than-nor-mal openings. Ditto for many other racks with threaded holes. Racks having square holes tend to have an opening quite close to the minimum.

Considerations for rack slidesIndications are that traditional 1 and 2-U server formats will remain widely used for the foreseeable future. These enclosures frequently include slides that make it easy to move instruments around for maintenance or to change connections. But because enclo-sures can have different dimensions and still adhere to EIA 310, there is no such thing as a universal slide that fits all 19-in. racks. There are two main aspects to consid-er when designing slides into electronic enclosures: the cabinet construction and the chassis (or drawer). The attributes of these components affect the overall enclosure con-figuration and the selection of slides, brackets and cable carriers. Cabinets vary according to their intended

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use and the manufacturer. Each manufacturer may use different rail thicknesses, shapes, materials and placement. Because the slides mount to the cabinet rails and the chassis mounts to the slide, the variances in construc-tion can significantly affect the enclosure design. It is helpful to review some of the major provisions for enclosures and dimensions spelled out in EIA 310. The standard dictates cabinets contain four or more rails (columns, uprights or struts). The enclosure may or may not have a surrounding skin. There are front rails, rear rails and optional mid-rails. There

is no limitation on overall cabinet height. A standard 17.72-in. (450-mm) opening is the minimum width between the rails. Rails carry a repetitive pitch pattern of mounting holes. Generally, cabinet rail construction methods fall into three groups: non-adjustable rails, adjustable rails and mid-rails. Non-adjustable rails provide a set distance from front rail to rear rail. Adjustable rails let the end-user relocate front and rear rails to an alternate distance from front to rear. Mid-rails are an additional set of rails, either adjustable or fixed, that provide an alternate mounting distance to accommodate short and deep slide lengths or varying chassis depths. Rails may alternately be referred to as col-umns, uprights or struts. Rails can also have different shapes. There are five shapes that are in wide use: 90° standard, return flange offset,

Enclosure slides in recent years have become slimmer to accommodate the

increasingly cramped quarters in server racks. The difference becomes evident when

comparing the model 2907WB slide and an Ultra Slim model, which is a tenth of an

inch thinner. Both are designed for 1 and 2U chassis.

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Identify whether the rack has round,tapped,or square style holes.

T ype 1

R ound or tapped holes style

T ype 2

Square hole style

1.Determine T ype of E IA R ail

One option for slides is the ability to mount without the use of fas-

teners. The Accuride rotating bracket is designed to mount to square

hole EIA racks without the use of tools. This bracket can also be used

to mount to round and tapped hole racks using thumb screws.

T he mounting bracket is reversible:one side accommodates tapped or round holes,the other side accommodates square holes

2. Match Mounting B racket to E IA R ail T ype

T hread Hole Side for T ype 1

Square Hole Side for T ype 2

3. R otate B racket to Correct Position

Press the button on the bracket

R otate to appropriate hole pattern

L ock intocorrect position

Press the button on the bracket to rotate to the appropriate hole pattern,L ock into position.

6a.Square hole rack installationA lign brackets to desired vertical position on rack andinsert bracket spring-loaded pins into rack holes.T he bracket will lock into place.

6. R ack Installation

1. Determine type of EIA railIdentify whether the rack has round, tapped or square style holes.

Type 1Type 2

Square hole styleRound or tapped holes style

2. Match mounting bracket to EIA rail typeThe mounting bracket is reversible: one side accommodates tapped or round holes, the other side accommodates square holes.

Thread Hole Sidefor Type 1

Square Hole Sidefor Type 2

3. Rotate bracket to correct positionPress the button on the bracket to rotate to the appropriate hole pattern. Lock into position.

Press the buttonon the bracket

Rotate to appropriate hole pattern

Lock into correct position

4. Rack installationFor square hole rack installation:Align brackets to desired vertical position on rack and insert bracket spring-loaded pins into rack holes.The bracket will lock into place.

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return flange flush, U-shaped and extrusion. As previously mentioned, there are sev-eral types of mounting holes and locations. The mounting hole pattern is visually appar-ent on the front face of the cabinet column and often appears on other areas of the col-umn as well. Generally, a given cabinet will use only one style. Different suppliers might use hole styles that include through-hole, countersunk hole, tapped hole and window/square hole.

Selecting the correct slideThe best slide for a given use depends on physical parameters that include the height of the drawer, the cabinet rail construction and configurations, the weight of the chassis, the kind of mounting brackets used to mount the slide to the cabinet, the amount of chassis travel, whether there are accesso-ries on the slide (locking, disconnect, hole pattern), the overall depth of the cabinet, and the chassis width. In particular, chassis width is critical and has been the single most important reason, along with chassis weight, that server slides have gotten thinner over the years. The anticipated chassis load will narrow the range of slide models. Recently, a relatively new IT safety test (UL 60950-1) and the amount of force it specifies for slide loads has greatly affected slide selection. Slide load ratings are based on dynamic loading, defined as continuous motion both

out and into the cabinet. Load ratings for slides in electronic enclosure applications are based on a number of cycles that vary from one vendor to another. Slides used in racks are seldom opened in real life, so ven-dors often specify low figures for cycle life. For example, some OEM enclosure slides have life requirements of as little as 100 cycles. In contrast, load ratings at Accuride are based on 2,000 cycles. Here, one cycle is considered to be the distance from fully closed to fully opened to fully closed in one motion. The cycle speed is generally based on 10 to 12 cycles per minute. Slide makers typically design in a margin of safety to handle overloads. For example, fully extended Accuride slides accept a static overload of twice the indicated load rating. The distance the chassis must travel (the relationship between the back of the chassis and the front of the cabinet) will help estab-lish whether a two- or three-section slide will be necessary for a particular application. Two-section slides provide three-quarter travel. In other words, the chassis opens approximately three-quarters of the total slide length. Three-section slides offer full extension or over travel; the drawer opens the same amount or more than the length of the slide. The chassis length determines the slide length and corresponding travel needed. Ad-justable brackets on these slides determine

The EIA Unit dimensions: basically a U unit is 1.75 in. and U heights are a multiple of this figure.

the range of cabinet depths onto which they can install. On the other hand, cabinet depth can have an impact on the necessary slide length in slides that only have brackets with a limited adjustment range. Slides mount to cabinets by brackets. The mounting depth determines how long the bracket must be. Extension brackets can let a short slide mount on a deep cabinet. The slide is the connection between the cabinet and chassis; the slide will only move properly if the width dimensions are accu-rate. It is important to remember that adding mounting brackets can affect the functional space between the-rail-to-rail opening (450 mm) and the chassis width. Two crucial calculations, functional space and available space, determine the necessary slide width. Functional space is the area between the rail and the chassis side. It includes the overall slide thickness, the thickness of the extending slide member plus the bracket thickness. Available space is the area within the cabinet to mount non-mov-ing portions of slides and/or brackets. Several factors help determine the optimal slide-to-chassis mounting position. For example, the mounting position must allow for the position of internal components (venting, fans, plugs, screws) inside the chas-sis. The chassis center of gravity also has an impact. The center of gravity should remain supported when the slide fully extends. In

www.designworldonline.com July 2015 DESIGN WORLD 1 0 3


Part Solutions 7-15_REVISED.indd 104 6/30/15 10:55 AM

some cases, the chassis manufacturer may have a pre-designated mounting location, so there is no decision to be made. The overall U height is calculated using the bottom of the chassis as a reference. It includes the front panel or bezel, which may have a greater height than the actual chassis. In addition, the slide and bracket location must align with EIA cabinet pattern. The height of the slide should not exceed the specific unit height. The location of mounting holes on the sides of the chassis are usually known when the slide is selected, or the slide’s hole pattern is selected prior to creating a hole pattern on the chassis. The use or non-use of washers plays an important role in determining the fully closed position of the chassis relative to the cabinet front rails. If washers are used, the washer thickness dimension figures into the overall distance when determining the first chassis hole location.


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Open Compute initiativeRack designs could undergo a significant change thanks to what’s called the Open Compute Project (OCP). Announced in 2011 by Facebook, the initiative aims to openly share designs of data center and server farm products primarily for the purpose of better energy efficiency. However, the OCP also covers standards for the mechanical mount-ing systems in server farms. Open racks have the same outside width (600 mm) and depth as standard 19-in. racks, but they are designed for chassis with a 21-in (537-m) width. This wider dimension lets more equipment fit in the same volume and improves air flow. Com-pute chassis sizes are defined in multiples of an OpenU (48 mm), slightly larger than the typical rack unit. The mechanical specifications of OCP were framed with the idea of making it easier for technicians to slide servers out of the rack, snap in new components, and get the unit

back up and running quickly. The mechanical standard also incorporates a power bus running down the back of the rack that lets servers plug into power connections; thus there are no power cables to manage. Because of the snap-out/snap-in nature of OCP server components, it’s likely that OCP servers will do away with some of the mounting and enclosure hardware common to equipment racks today. DW

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Easy on the environmentMany organic adhesive products contain solvents and various diluents, and heat is generally used to drive off these volatiles during the cure process. UV-cure compounds avoid this issue entirely. They cure when radiant energy from a UV light source is absorbed and

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Master Bond

masterbond.com

A d h e s i v e s

July 2015 DESIGN WORLD 1 0 9

Master Bond has developed EP48TC a new two part epoxy

that takes your thermal management to the next level with

exceptionally low thermal resistance. The lower the thermal

resistance, the better it is for heat transfer properties. Thermal

resistance is calculated from the formula: R=t/K (where “R” is

the thermal resistance; “t”, the thickness and “K” the thermal

conductivity of the material). EP48TC features a thermal

resistance of 5-7 x 10-6 K•m2/W and thermal conductivity of

20-25 BTU•in/ft2•hr•°F [2.88-3.60 W/(m·K)]. This material has

a paste consistency and can be applied in bond lines as thin as 10-15 microns.

EP48TC bonds well to a wide variety of substrates and even in thin sections, its strength retention is outstanding. It also

has a low coefficient of thermal expansion, low shrinkage upon curing and excellent dimensional stability. It can be used

in applications in the aerospace, electronic, optical, specialty OEM and many other high-tech industries.

Ad

hes

ive Master Bond Inc.

Master Bond154 Hobart StreetHackensack, NJ 07601+1 [email protected]

How To Achieve Ultra Low Thermal Resistance in Your Bonding Application

Master Bond Feature 7-15_Adhesive Tips Supp_Vs3.MD.LL.indd 109 7/2/15 2:35 PM

Toll Free 888.GAM.7117 www.gamweb.com [email protected]● ●

from

C O N G R A T U L A T I O N S

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Pr o d u c t Wo r ld

Helical in-line reducers

Regal-BeloitRegalbeloit.com

Grove Gear's expanded range of LeCentric helical in-line

reducers features four new cast-iron models that are

torque-rated from 5,974 to 18,587 lb-in., with a maximum

input of 1⁄3 to 40 hp. Units are available with ratios up to

680.03:1, with double and triple reduction designs and

efficiencies as high as 97%. A wide range of removable

bases and mounting hardware makes the new reducers a

drop-in replacement for industry-standard configurations.

The new units are designed and rated for applications

in general material handling and the food and beverage

industries, with options available for washdown and harsh

environments.

Capacitor modules

AltechAltechcorp.com

Altech’s Ultra

Capacitor Modules

DC/UPS can be used

in place of a battery

system to ensure

back up power.

They are DIN-rail

mountable, virtually

maintenance free and carry none of the hazards of a battery.

Voltages include 12 and 24 Vdc from 1,000 to 10,000 W of energy

in a standard unit. Extension modules are available to supply more

energy if needed. In addition, they have five times the life span of a

traditional battery. The modules are environmentally safe, and can

withstand a temperature range

of -40 to 65° C without de-rating.

Ethernet-connected motion controller

Vena EngineeringVena.com

PiMotion

multi-platform,

multi-language,

secure Ethernet-

connected motion controller with integrated linear

amplifier offers complete control of the commutation

waveform from the dual core FPGA. A 16-bit DAC on

each phase drives the amplifiers. PiMotion runs on 24 to

48 Vdc with continuous output up to 3.5 A. Two analog

inputs, auxiliary encoder input and 8 GPIO are available.

With a cast aluminum case, in either panel or DIN-rail

mount, this device is capable of continuous duty in an

industrial environment.


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Foot mount resolvers

Dynapar Dynapar.com

Both of the new Northstar

brand R56 foot/C-Face

mount and RF25 flange

mount resolvers are

designed for maximum compatibility with existing systems and easy user installation.

The R56 resolver features a 5⁄8-in. shaft with NEMA 56C face mount and foot mount

with an industrial 10-pin latching connector standard for quick installation and

enclosure rating of IP65. Large outer bearings isolate shaft loads ensuring heavy-duty

performance and durability. The RF25 resolver includes a 3⁄8-in. shaft with square

flange mounting plate, 10-pin connector and is IP65 rated. The RF25 offers high

integrity seals and a tough package to withstand extreme abuse.

DIN-rail embedded PC

Advantech Advantech.com/ea

Advantech’s UNO-1372G small-size

control DIN-rail embedded automation

computer features three GbE ports for

fast data transfer, two mPCIe slots to

enable connection to third-party

devices, one mSATA connector and one

SATA for a SSD or HDD, two COM ports,

three USB ports, eight digital I/O ports,

and HDMI/VGA ports. The UNO-1372G

has an operating temperature range of

-20 to 60° C and exchangeable RTC

battery so that in the event of failure,

the battery can be replaced and the

mainboard clock will be able to

continue working.

For further information about products on these pages visit the Design World website @ www.designworldonline.com

For more information visit www.hiwin.com

Linear Encoders / Positioning Measurement Systems

AC Servo Motors

Hiwin D1 and D2 Servo Drives

Linear Actuators

Linear Motors

Industrial Robots

Linear Guideways

Ballscrews & Rollerscrews

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Harsh-duty photoelectric sensors

AutomationDirectAutomationdirect.com

AutomationDirect’s new

FM series harsh duty

photoelectric sensors

are IP69K-rated sensors

in three-wire NPN or

PNP styles and are

available in 27 washdown

models. Ideal for food

and beverage applications, the 10-to-30-Vdc rectangular

sensors are fitted with 316L stainless steel housings and are

available in diffuse, diffuse with background suppression,

and polarized retroreflective styles. The sensors have either

an attached 2-m output cable, or an M8 or M12 quick-

disconnect. All models have a selectable light-on/dark-on

output setting; sensing ranges are available up to 10 m.

High-torque dc motor

maxon precision motors maxonmotorsusa.com

maxon motors’ EC-i 40 High Torque series of dc motors are

equipped with three powerful iron-core internal rotor drives,

each with a diameter of 40 mm. Ideally suited for applications

in robotics, prosthetics and industrial automation, the motors

feature high dynamics, a low cogging torque and extremely

high output torque. The strongest motor in this series offers a

maximum nominal torque of 234 mNm and is 56 mm long.

Touchscreen computer for hazardous environments

Sealevel SystemsSealevel.com

The HazPAC R9-8.4 combines a

RISC-based embedded computer

with a bright 8.4-in. TFT LCD

to create a wide-temperature,

ruggedized, flat panel computer

suited for a variety of HMI and

control applications in hazardous area

locations. The system carries the ETL electrical safety mark

and is tested and certified for use in hazardous locations

classified as Class I, Div. 2. Powered by a 400-MHz ARM9

microprocessor, the HazPAC R9-8.4 is available with 128 MB

RAM and 256 MB Flash memory for maximum performance

in embedded systems.

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Conveyor with pallet management

Dorner ManufacturingDornerconveyors.com

With a unique pin tracking system to guide pallets through 90 turns,

and a fast belt change capability without the need to remove the

conveyor from the system, Dorner’s 2200 Precision Move Pallet

Systems are designed to increase efficiency and reduce downtime

in various assembly automation processes. The pallets on this

conveyor range from 160 to 480 mm. During operation,

pallets move on twin dual

strand timing-belt

conveyors.

Electric brake

Miki Pulley Mikipulley-us.com

The compact and light-

weight design of the BXR-

LE electric spring applied

brake optimizes machine

design efficiency. With

accompanying voltage

controller, power

consumption is stepped down to 7 Vdc after a split second of 24 Vdc for brake

actuation. The BXR-LE reaches a maximum rpm of 6,000 and has an ambient

operating temperature range of -20 to 60° C (-4 to 140° F). Its static friction

torque ranges from 0.32 to 1.32 Nm (0.236 to 0.973 ft-lb).


WE Series Linear GuidewayWide Series Ball Type.

MGN / MGW Series Linear GuidewayStainless Steel Miniature Linear Guideway

Size 5 Now Available.

HG / EG / RG Series Linear GuidewaysBall and Roller Type.

PG Series Linear GuidewayIntegrated Magnetic Encoder.



High reliability angle sensors

NovotechnikNovotechnik.com

The Contelec brand of Vert-X

8800 Series of non-contact

angle sensors have an 88-mm,

stainless-steel housing base.

Vert-X 8800 Series sensors

measurement range is 0 to

360° with repeatability of 0.1°

and linearity to ±0.1%. Analog

and digital output versions include CANopen single and

redundant, 0.1 to 10 V, 0.5 to 4.5 V, 4 to 20 mA and 10 to

90% of supply voltage. CANopen versions are CiA certified.

Open-frame stages

AerotechAerotech.com

PlanarDLA XY integrated,

open-frame stages are

optimized for applications

where straightness and

flatness of motion are critical.

High-precision roller bearings,

precision-machined surfaces

and non-contact direct-drive

linear motors driving through the axes’

center-of-stiffness result in a positioning stage

with straightness to ±0.5 µm and flatness to ±1.25 µm. The

PlanarDLA enables high-throughput, high-accuracy processing

with 2-m/sec velocities and 2-g accelerations. It is available in

three positioning performance options. High-performance -PLUS

and -ULTRA options enable accuracies and straightness values to

±500 nm and orthogonality to 5 µrad.

Brushless dc motor and driver package

Oriental MotorOrientalmotor.com

Oriental Motor’s BXII Series Brushless Motor

and Driver Package features speed control

up to 4,000 rpm with a speed regulation

of 0.05%. It is available from 30 to 400 W,

in round shaft, parallel shaft gearheads

or the hollow shaft flat gearhead and

electromagnetic brake options. The new

driver features a digital setting directly on

the face of the drive to use the built-in

speed control, positioning or torque limiting

functions with no additional control module

required. The parallel geared type produces

up to 610 lb-in. (70 N-m) of torque and

the hollow shaft flat geared type products

produces up to 970 lb-in. (110 N-m)

of torque.




Self-lubricating plastic bearing

igusigus.com

With the new iglide L500

material continuous

rotational speeds of more

than 16 ft/sec are possible,

and the L500 material

performs even under extreme

environmental conditions,

such as temperatures ranging

from -148 to 482° F, as well

as media contact. The L500 material is characterized by its low moisture

absorption and thermal expansion. These positive material properties

allow the self-lubricating operation of electric motors, fans and

ventilators, where sintered bearings were previously used.

Linear and curved rail systems

LM76lm76.com

Low-cost, SAIBO SB-LGV Straight and Curved Rail & Roller Block Systems are

available in three widths and two styles to meet load requirements up to 7,200 N

(1,619 lb). These low-profile linear and curved rail systems feature low noise, smooth

travel, high speed, low weight, high accuracy, sealed radial low friction bearings, and

easy installation into new and existing applications. They are available in lengths to

2,000 mm (79 in.) and curved sections with radiuses from 79.5 to 516.5 mm (3.13 to

20.3 in.) in 90, 180 and 360° sections. With operating temperatures of -40 to 120° C

(-40 to 248° F), they are suited for use in robotics,

laser cutting, wafer handling and other

precision applications.

KA Type Linear Actuator / SARBallscrew or belt driven, exible design.

KK Type Linear Actuator / SARBallscrew driven, high accuracy and reliability.

KS Type Linear Actuator / SARBallscrew driven for clean room applications.

Hiwin D1 and D2 Servo Drives for Servo Motors, Torque Motors and Linear Stages.

AC Servo Motors.

LM Linear Actuator / SARLinear motor driven high acceleration

and accuracy, unlimited travel.




Magnetostrictive position sensor

MTS Sensorsmtssensors.com

The RT4 is a linear position measurement

solution that features two independent

sensor elements—each of which has a

measuring length of 50 to 2,540 mm (2

to 100 in.). This fully redundant position

sensing product employs a Synchronous

Serial Interface (SSI), which means

that data transfer is less susceptible

to the presence of electro-magnetic

interference. In addition, the IP68-rated

enclosure protects against the threat

of liquid ingress. The RT4’s detached

electronics can be mounted up to 600

mm (23.6 in.) away from the sensing

environment allowing the electronics to

be kept further from sources of potential

harm. A temperature range that reaches

up to 100° C (212° F) is supported for the

sensor rod and interconnection cables.

New line of motion systems

ETELEtel.ch

ETEL’s DynX line of motion systems consists of three sizes of direct-driven

linear axes, three sizes of direct-driven rotary axes and one high precision

ballscrew-driven axis for vertical applications.

The linear direct-drive axes feature high-precision, recirculating ball

bearings, high-accuracy optical encoders and iron-core motors with zero

backlash, resulting in performance speeds up to 3 m/sec, accelerations up

to 5 g, bidirectional repeatability of ±0.5 µm at ±3 sigma, absolute position

accuracy of ±2 µm after calibration, and position stability of ±50 nm.

The rotary direct-drive axes are equipped with toothless motor

technology to provide zero backlash along with zero cogging force. They

also include a high-accuracy optical encoder, allowing for speeds up to 391

rpm, bidirectional repeatability of ±1.5 arc sec at ±3 sigma,

position accuracy of ±3 arc

sec after calibration, and

position stability of

±0.2 arc sec.


MRI safe linear encoder

MicronorMicronor.com

With 100 µm resolution and 50 µm accuracy, the

MR303 Linear Sensor is suitable for medical, MRI,

robotic and industrial applications. The position sensor

is immune to any electromagnetic interference,

such as magnetic fields, lightning, high voltage and

radiation. Being fabricated from non-ferrous and

non-metallic materials, the sensor is also completely

transparent to electromagnetic fields. These attributes

allow the MR303 sensor to be safely used in and

around the MRI bore and does not produce any

imaging artifacts.



Compact positioning stage

VelmexVelmex.com

The Velmex XSlide Assembly

is a compact positioning

stage suitable for either

high-performance

incrementing or

scanning of smaller loads. Constructed with

hard-coat anodized, aluminum dovetail ways and smooth

motion PTFE bearings, XSlide Assemblies deliver rigidity for longer

life and precise movement. XSlide Assemblies have a load capacity

of 35 lb (15.9 kg) horizontally and 10 lb (4.5 kg) vertically. Straight-

line accuracy is 0.001 in./10 in. (0.076 mm/25 cm). Repeatability

is 0.0001 in. (0.00025 mm). With a cross-sectional profile of 1.88

x 1.22 in. (48 x 31 mm), the XSlide stage comes in eight standard

travel lengths from 2 to 30 in. (50 mm to 76.2 cm).

Submersible pressure transducer

BinMasterBinmaster.com


The PT-500 submersible pressure

transducer is a versatile level sensor that

calculates level based on the amount of

pressure being exerted on the sensor from

the liquid above it. Made of 316L stainless

steel, it can be used in a wide range of

liquids including water, wastewater and

a variety of chemicals. As it has a low

current draw, the PT-500 can be used in

remote locations and for battery powered

applications. Lightning protection is built

into the sensor, eliminating the need for

a separate surge protector. The PT-500

installs simply by dropping it into the vessel.

Infrared thermometer

OMEGAOmega.com

The OS499 Series are fully functional infrared (up

to 760° C [1,400° F]) non-contact temperature

measuring devices and compatibility with Type K

thermocouples. They have dual lasers for better

targeting and a built-in flashlight. Other features

include: distance-to-spot ratio up to 30:1; mini

thermocouple socket up to 1,400° C (2,552° F);

emissivity adjustable from 0.1 to 1.00; and a Hi/Lo

temperature audible alarm.


All Motion ..........................................................4

Allied Electronics, Inc. ............................... 3,87

Altech Corporation .........................................13

American Control Electronics .......................49

AMETEK PMC ..................................................17

AMETEK PMC/Dynamic Fluid Solutions .......23

Anderson Metals Corporation, Inc. ..............43

Applied Motion Products, Inc. ......................27

Aurora Bearing Company ............................ 30

AutomationDirect ..........................................31

Baldor Electric Company ..............................45

Bimba Manufacturing Company ....................2

Bison Gear & Engineering Corp. ..................IBC

C-Flex Bearing Co., Inc. .................................51

CADENAS PARTsolutions ............................ 104

Canfield Connector ........................................54

CGI, Inc. ...........................................................53

CS Hyde Company ........................................ 66

Del-Tron Precision, Inc. ..................................73

Delta Tau Data Systems, Inc. ..................... 102

Design2Parts ...............................................112

Dunkermotor, part of AMETEK .....................19

EXAIR Corporation ............................................5

EZAutomation ..................................................1

FABCO-AIR .......................................................65

Firgelli Technologies Inc. ................................8

GAM ...............................................................110

Graybar .............................................................9

Helical Products Company Inc. ......................7

HELUKABEL USA ............................................33

Hitachi Cable America, Inc ............................57

HIWIN Corporation ........................113,115,117

IDEC Corporation .......................................14,15

igus .................................................................59

IKO International, Inc. ...................................61

Interpower ..................................................... 60

ITT Enidine ................................................... 105

Lee Spring Company .....................................63

Master Bond ...................................................51

MFP Seals ...................................................... 34

Moog Inc., Animatics .................................... 20

Nason ............................................................. 44

National Instruments Corporation ...............41

NSK Precision America .................................83

Omega Engineering, Inc. ..............................29

Omron Corporation ........................................75

Patrick Plastics Corp. ....................................47

PBC Linear ......................................................81

Peninsular Cylinder Co. ................................82

PHD, Inc. .........................................................35

PITTMAN ..........................................................21

Proto Labs, Inc. .........................................37,55

QA1 .................................................................16

R+W ................................................................ 68

Rittal Inc. ..............................................100,101

Schneider Electric Motion USA .......... Cover,39

SEW Eurodrive, Inc. .......................................BC

SIKO Products Inc. .........................................16

Smalley Steel Ring Company .......................10

Sorbothane, Inc. ........................................... 20

THK America, Inc. .......................................... IFC

Tompkins Industries, Inc. .............................69

Tormach LLC .................................................. 95

Trim-Lok, Inc. ................................................ 26

US Digital, Inc. ............................................... 93

U.S. Tsubaki Power Transmission, LLC ....... 99

Vena Engineering Corporation .................... 30

Visumatic Automated Fastening .................67

Whittet-Higgins Company ............................25

Master Bond ................................................ 106

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VP of EE Product Development Mike [email protected]

VP, Business DevelopmentMichael [email protected]@mrference

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Follow the whole team on twitter @DesignWorld

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Business DevelopmentMichelle [email protected]@mflando

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Ad h e s i v e T i p S u p p le m e n t

Ad Index 7-15_Vs1.indd 120 7/2/15 11:55 AM

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To learn more about PowerSTAR® right-angle gearmotors, please visit Bison’s NEW WEBSITE at www.bisongear.com or call 1-800-AT-BISON.

©2014 Bison Gear and Engineering Corp.

AC and DC options available now1/15 - 1/2 HP; 35-1780 in-lbs• AC MOTOR OPTIONS: 115V 1PH, 115/230V 1PH 230V 3PH Inverter Duty, 230/400-460 50/60HZ 3PH• DC MOTOR OPTIONS 720 frame size: 12V, 24V, 90V, 130V and 180V 725 frame size: 12V, 24V, 90V, 130V and 180V 730 frame size: 24V, 90V and 130V• Maximum power density means a compact profile without compromising performance• Ground gearing provides whisper quiet operation, low backlash precision• Latest hypoid gear technology ensures less friction/heat and extends product life• Versatile mounting interchangeability to easily upgrade your installed drives• Exclusive PowerSTAR® EP lubricant for extended life

Runs Cooler & Longer Lasting than Traditional Right Angle Gearmotors

DC

AC

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movigear.com / 864-439-7537

Although independent research has proven that MOVIGEAR® from

SEW-EURODRIVE reduces startup and operating costs by 20-30%,

actual case studies show that many users are experiencing 50% or

more. MOVIGEAR® also substantially reduces your inventory via its

unique ability to replace several gear units of different ratios with a

single unit. Yes...less really is more!

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design world july 2015

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