design world june 2016

How to choose

an industrial lubricant

June 2016www.designworldonline.com

Think

Allie

d for

Autom

ation

& Co

ntrol

APR15-A&C Snipe_Snipe 3/13/15 2:39 PM Page 1

INSIDE:

MOTION CONTROL: Why is preload necessary in some bearing applications? PAGE 56

MATERIALS: Make the right choice for metal coating for the right application PAGE 70

64

MECHATRONICS: Five keys to mechatronic success PAGE 80

JUNE DW COVER 2016_fit for gatefold_FINALFINAL.indd 1 6/2/16 11:11 AM

We also o er FREE 2-day shipping and a 30-day money back guarantee for any of those last-minute modi cations.

Field-friendly Features for LESS!Field-friendly Features for LESS!

Dont forget that our eld-experienced and highly-trained technical support specialists are ready to help, FREE of charge. Give us a call at 1-800-633-0405, were available 9am - 6pm ET on weekdays.

Trouble-free Troubleshooting The standard OLED message display on the P2-550 CPU gives you instantstatus on your controller and can be used to display system faults.Also, each analog I/O module includes a high-contrast OLED so you can view fault conditions and analog values such as voltage, current, andtemperature without having to disconnect signal wires to get a reading with a meter.

Con gurable Hot Swappable I/O Dont lose production for simple I/O module changes. The Productivity2000CPU can remain in the RUN mode without the user-selected I/O modulesinstalled. Choose to allow any module to be removed or con gure eachmodule separately.

ZIPLink Pre-wired Solutions The Productivity2000 I/O modules have multiple wiring options available. Use standard terminal blocks, or our ZIPlink pre-wired cables and connector modules (available for most modules). ZIPlinks not only provide tremendous wiring time savings but can also provide fused isolation from eld devices, clean wireways with easy, eld-traceable connections, and con dence that your panel wiring is correct.

the #1 value in automation* See our Web site for details and restrictions. Copyright 2015 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 www.AutomationDirect.com

We have designed many eld-friendly features into the Productivity2000 PLC because we understand the pressure that can come with eld installations and start-ups. We want you to have everything you need to keep your install on track and your startup on schedule. From OLED displays to QR codes, thefeatures listed here are just a few examples of the many ways Productvity2000 can save you time in the eld, which also saves you money!

To get the whole story and see even more ways to save, head on over to www.Productivity2000.com

Convenient QR Codes When the pressure is on, dont waste precious time searching for needed documents. Get wiring diagrams, installation instructions and speci cations by simply scanning the QR code tab on each Productivity2000 I/O module.

1606-DesignWorld-P2Features-inside-Gatefold.indd 1 5/4/2016 7:30:49 AM

Gatefold LHP_AutomationDirect 6-16.indd 1 6/2/16 11:43 AM

We also o er FREE 2-day shipping and a 30-day money back guarantee for any of those last-minute modi cations.

Field-friendly Features for LESS!Field-friendly Features for LESS!

Dont forget that our eld-experienced and highly-trained technical support specialists are ready to help, FREE of charge. Give us a call at 1-800-633-0405, were available 9am - 6pm ET on weekdays.

Trouble-free Troubleshooting The standard OLED message display on the P2-550 CPU gives you instantstatus on your controller and can be used to display system faults.Also, each analog I/O module includes a high-contrast OLED so you can view fault conditions and analog values such as voltage, current, andtemperature without having to disconnect signal wires to get a reading with a meter.

Con gurable Hot Swappable I/O Dont lose production for simple I/O module changes. The Productivity2000CPU can remain in the RUN mode without the user-selected I/O modulesinstalled. Choose to allow any module to be removed or con gure eachmodule separately.

ZIPLink Pre-wired Solutions The Productivity2000 I/O modules have multiple wiring options available. Use standard terminal blocks, or our ZIPlink pre-wired cables and connector modules (available for most modules). ZIPlinks not only provide tremendous wiring time savings but can also provide fused isolation from eld devices, clean wireways with easy, eld-traceable connections, and con dence that your panel wiring is correct.


We have designed many eld-friendly features into the Productivity2000 PLC because we understand the pressure that can come with eld installations and start-ups. We want you to have everything you need to keep your install on track and your startup on schedule. From OLED displays to QR codes, thefeatures listed here are just a few examples of the many ways Productvity2000 can save you time in the eld, which also saves you money!

To get the whole story and see even more ways to save, head on over to www.Productivity2000.com

Convenient QR Codes When the pressure is on, dont waste precious time searching for needed documents. Get wiring diagrams, installation instructions and speci cations by simply scanning the QR code tab on each Productivity2000 I/O module.

1606-DesignWorld-P2Features-inside-Gatefold.indd 1 5/4/2016 7:30:49 AM

Gatefold LHP_AutomationDirect 6-16.indd 1 6/2/16 12:09 PM

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Built-in Cost SavingsThe Productivity2000 PLC is designed with

many built-in cost savers. The CPU comes standard with on-board data logging

and more communication options than anyone else (5 comm ports). It also

includes three of the most widely used protocols in the industry (Modbus

RTU, Modbus TCP/IP, EtherNet/IP)so no separate communication

modules are needed!

FREE Intuitive PLC SoftwareThe FREE Productivity Suite PLC software works hand-in-handwith many eld devices and third party software. Thisintegration gives this PLC a clear advantage, and gives you a head start with system development. Here are just a fewexamples:

Built-in Function Blocks: Specialized, ll-in-the-blank style function blocks for many operations

including communication with EtherNet/IP devices and servo/steppermotor control.

Shared Tagname Database: Export the tagname database from the software and easily import it into

C-more HMIs, Point of View SCADA software or other 3rd party databasesoftware to jump start your project development.

Auto-discovered Hardware: The Productivity Suite PLC software will automatically con gure installed

I/O modules - your system is recognized and con gured without anymanual setup. Up to 16 GS Series AC drives can also be auto-discoveredand their parameters stored in the CPU for future reference.

Own It, Dont Owe On It!Buying direct with us saves you money. With Productivity2000,you get many standard features that you would paythousands for elsewhere. Our P2-550 CPU is priced at $255and I/O modules start at just $40 (P2-08NE3). We arent atraditional PLC company - we are here to serve YOU! So checkus out!

and LATER...

PLC CPU and I/OComparison

AutomationDirectProductivity2000

Allen-BradleyCompactLogix

All prices are U.S. published prices. AutomationDirect prices as of 4/27/2016. Allen-Bradley retail prices taken from www.plccenter.com 4/18/2016.

Power Supply

Base (if required)

CPU

8 Relay Outputs

ASCII Comm Module

Modbus RTUComm Module

Total System Price with USB, Ethernet and Serial

8 Analog InputChannels (mA)

16 24VDC Inputs

16 AC Inputs

$69.00P2-04B

$69.00P2-01AC

$255.00P2-550

$105.00P2-16NA

$69.00P2-16NE3

$51.00P2-08TRS

$0.00Built in to CPU

$0.00Built in to CPU

$817.00

$199.00P2-08AD-1

N/AN/A

$427.001769-PA4

$3,220.001769-L33ER

$264.501769-IA16

$222.001769-IQ16

$275.501769-OW8I

$752.001769-ASCII

$736.001769-SM2

$6,694.00

$797.001769-IF8 Visit: www.productivity2000.com

1606-DesignWorld-P2Features-1stpage-Gatefold.indd 1 5/4/2016 2:21:05 PM

Outside Front Gate_AutomationDirect 6-16.indd 1 5/23/16 12:00 PM

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

Electrical Hook-up / Building WireAt AutomationDirect we want to save you money on every aspect of your system design, even down to the wire! Thats why we have invested in a huge selection of electrical wire and cables, o ered at prices that provide substantial savings to you. Not only can you get quality wire at unbeatable prices, but in most cases you can get it shipped for FREE. So, if you havent looked at us for your wiring needs, then youre probably paying too much!

MTW Machine Tool Wire Primarily used in control cabinets, machine tool applications and appliance wiring applications. Available in 10, 12, 14, 16, 18 AWG sizes, in a variety of colors and in 500 or 2500 ft. reels. Starting at $35.00 (500 ft.)

TFFN Fixture WirePrimarily used as xture wire as speci ed by the National Electrical Code (NEC). Available in 16, 18 AWG sizes, in a variety of colors and in 500 or 2500 ft. reels. Starting at $33.00 (500 ft.)

THHN General Purpose Building WireIntended for general purpose applications including new construction or 600 volt rewiring needs. Available in 4, 6, 8, 10, 12, 14 AWG sizes, in a variety of colors and in 500 or 2500 ft. reels. Starting at $33.00 (500 ft.)

Bulk Multi-Conductor Cable Flexible Portable Power Cord, Bulk Data Cable, Flexible Control Cable and Instrumentation Cable for industrial applications. Available in a variety of conductors, gauges and lengths.Starting at $13.75 (20 ft.)

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AutomationDirect 6-16 (not gatefold ad).indd 1 5/23/16 11:55 AM

Offset Couplings from Zero-Max reduce space requirements for parallel offset shafts in large system applications. These specialized couplings provide machine designers with an important option for reducing overall machine size and footprint.

Compact in design, Schmidt Offset Couplings transmit constant angular velocity and torque in a wide range of parallel shaft misalignments. Handling high amounts of parallel offset up to 9 inches, they are available with torque capacities up to 459,000 in-lbs.

Schmidt Offset Couplings can be mounted to shaft hubs or directly to existing machine flanges. They are available for shaft displacements of 0.156 inches to 17.29 inches and torque capacities from 55 to 459,000 inch-pounds. Many design configurations are available including specials.

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I n s i g h t s

4 DESIGN WORLD June 2016

Reshoring continues to make inroads in the American manufacturing sphere. While speaking with a robotics expert recently, he remarked how the cheaper and easier-to-program industrial robots now available are bringing production costs much lower. Low enough, in fact, that in some industries, smaller manufacturers can effectively compete with the low labor cost countries overseas.

The International Economic Development Council recently interviewed senior leaders of American firms about why they were reshoring. Reasons included: Labor turnover, training, and costs Practical economics Quality assurance Companies found that it was easier to manage a domestic staff as they were able to be more involved in company operations instead of relying on managers in other countries. Conversations can occur more regularly with fewer communication obstacles. Theres also an ability to decrease the mount of time that management spends traveling and managers are able to work closer with and train new employees more easily. Another factor was an increase in expenses related to manufacturing overseas. These companies found cost-competitiveness of production offshore had declined based on increased costs to ship products, the decline in the cost of gas, and increasing labor wages demanded by workers. As companies experienced a decline in the tax rebates offered by other countries, low-interest rates, competitive exchange rates, and attractive incentives became attractive to companies considering reshoring, said Gene DePrez, Managing Partner of Global Innovation Partners and Visiting Senior Fellow of IEDC. Some of the companies interviewed indicated that they experienced issues with quality controls for products manufactured offshoreand there were some inaccuracies in the products. Not surprisingly, the reshored products were found to be of higher-quality meeting expectations. The IEDC also noted that the movement of goods faces many potential delays from the time the product leaves the factory to the time it is received by the end user. Natural disasters can delay the delivery of products for significant periods of time just as man-made delays can occur including labor disputes and human error. A product is produced to its customer leaves less room for delays and faster turnaround times from order to delivery, said DePrez. For companies thinking about returning operations to the U.S., there are some free tools that the government and NPOs have created several. Check out Access Costs Everywhere (acetool.commerce.gov), U.S. Cluster Mapping Tool (www.clustermapping.us), the National Excess Manufacturing Capacity Catalog (www.edastayusa.org) and the Reshoring Initiatives Total Cost of Ownership Estimator (http://www.reshorenow.org/TCO_Estimator.cfm). IEDC also said that a conversation with the economic development organization located in your community or state can be a good starting place. DW

More on the reshoring trend

Pa u l J. H e n e y - Ed i to r i a l D i re c to rp h e n e y@w tw h m e d i a .co m

On Twitter @ DWEditor

Speed to market Flexibility in inventory, and Customer demand.

Insights 6-16_Vs2_PH.indd 4 5/27/16 8:40 AM

Facts about BlowersEnergy conscious plants might think a blower to be a better choice due toits slightly lower electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of fi lters, belts and bearings.Here are some important facts:Filters must be replaced every one to three months.Belts must be replaced every three tosix months.Typical bearing replacement is at least once a year at a cost near $1000.

Blower bearings wear out quickly due to the high speeds (17-20,000 RPM) required to generate eff ective airfl ows.

Poorly designed seals that allow dirt and moisture infi ltration and environments above 125F decrease the one year bearing life.

Many bearings can not be replaced in the fi eld, resulting in downtime to send the assembly back to the manufacturer.

Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air volume and velocity are often diffi cult to control since mechanical adjustments are required.

To discuss an application, contact:

EXAIR Corporation11510 Goldcoast DriveCincinnati, Ohio 45249-1621(800) 903-9247Fax: (513) 671-3363email: [email protected]

www.exair.com/58/423a.htm

See the Super Air Knife in action.www.exair.com/58/akvideoa.htm

Compare these Blowoffs ere are a variety of ways to blow the water from the bottles shown in the photo below, but which method is best? To decide, we ran a comparison test on the same application using four diff erent blowoff methods: drilled pipe, fl at air nozzles, Super Air Knife (each using compressed air as a power source), and a blower supplied air knife (using an electric motor as a power source). Each system consisted of two twelve inch long air knives. e following comparison proves that the EXAIR Super Air Knife is the best choice for your blowoff , cooling or drying application.

e goal for each of the blowoff choices was to use the least amount of air possible to get the job done (lowest energy and noise level). e compressed air pressure required was 60 PSIG which provided adequate velocity to blow the water off . e blower used had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM. e table at the bottom of the page summarizes the overall performance. Since your actual part may have an odd confi guration, holes or sharp edges, we took sound level measurements in free air (no impinging surface).

Drilled Pipe is common blowoff is very inexpensive and easy to make. For this test, we used(2) drilled pipes, each with (25) 1/16" diameter holes on 1/2" centers. As shown in the test results below, the drilled pipe performed poorly. e initial cost of the drilled pipe is overshadowed by its high energy use. e holes are easily blocked and the noise level is excessive - both of which violate OSHA requirements. Velocity across the entire length was very inconsistent with spikes of air and numerous dead spots.

Flat Air NozzlesAs shown below, this inexpensive air nozzle was the worst performer. It is available in plastic, aluminum and stainless steel from several manufacturers. e fl at air nozzle provides some entrainment, but suff ers from many of the same problems as the drilled pipe. Operating cost and noise level are both high. Some manufacturers off er fl at air nozzles where the holes can be blocked - an OSHA violation. Velocity was inconsistent with spikes of air.

EXAIR Super Air Knife e Super Air Knife did an exceptional job of removing the moisture on one pass due to the uniformity of the laminar airfl ow. e sound level was extremely low. For this application, energy use was slightly higher than the blower but can be less than the blower if cycling on and off is possible. Safe operation is not an issue since the Super Air Knife can not be dead-ended. Maintenance costs are low since there are no moving parts to wear out.

The Super Air Knife is the low cost way to blowoff, dry, clean and cool.

If you think compressed air is too expensive and noisy - read this. The facts will surprise you!

Blower Air Knife e blower proved to be an expensive, noisy option. As noted below, the purchase price is high. Operating cost was considerably lower than the drilled pipe and fl at air nozzle, but was comparable to EXAIRs Super Air Knife. e large blower with its two 3" (8cm) diameter hoses requires signifi cant mounting space compared to the others. Noise level was high at 90 dBA. ere was no option for cycling it on and off to conserve energy like the other blowoff s. Costly bearing and fi lter maintenance along with downtime were also negative factors.

The Truth About Compressed Air!

Blowo Comparison

Type of blowo PSIG BARComp. Air Horsepower

Required

SoundLevel dBA

PurchasePrice

Annual Electrical

Cost*

Approx. Annual Maintenance Cost

First Year CostSCFM SLPM

Drilled Pipes 60 4.1 174 4,924 35 91 $50 $4,508 $920 $5,478

Flat Air Nozzles 60 4.1 257 7,273 51 102 $208 $6,569 $1,450 $8,227

Blower Air Knife 3 0.2 N/A N/A 10 90 $5,500 $1,288 $1,500 $8,288

Super Air Knife 60 4.1 55 1,557 11 69 $576 $1,417 $300 $2,293*Based on national average electricity cost of 8.3 cents per kWh. Annual cost re ects 40 hours per week, 52 weeks per year.

Exair 6-16.indd 5 6/2/16 8:36 AM

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

It is trendy to speak of bringing back manufacturing jobs to the U.S. Almost

every politician on the stump does so. Manufacturing is coming back. Its now our challenge to figure out how .... we can have a renaissance in manufacturing, says one presidential candidate. Were going to bring our jobs back. Were not going to be losing our jobs to Mexico and all of these other places, says another. Look around Indiana and you will find once vibrant and strong manufacturing towns ........shattered by abandoned factories, shut down steel mills, sky-high poverty rates and foreclosed homes...We need to end the race to the bottom and enact trade policies that demand that American corporations create jobs here, and not abroad, says a third. So can we really expect more U.S. manufacturing jobs if one of these blowhards get elected? Doubtful. Heres whats more likely to happen, based on forecasts from the U.S. Bureau of Labor Statistics: Production occupations will have little or no growth for at least five years. Employment for manufacturing is projected to decline 4.6% by 2022. The BLS attributes declines in manufacturing employment in part to foreign competition, but mainly to improvements in efficiency.

L e l a n d Te s c h le r - Exe c u t i ve Ed i to rlte s c h le r @w tw h m e d i a .co m

The romantic notion of manufacturing jobs

On Twitter @ DWLeeTeschler

And better education, another favorite topic of presidential candidates, is unlikely to change this picture much. The large majority of production jobs typically require a high school degree or less, the BLS points out. The few manufacturing occupations requiring a postsecondary education are all projected to have declining employment. The romantic notion that the American working class can someday be made up of well-paid factory workers is about as plausible as the Cleveland Browns winning this years Super Bowl. The reality is that most occupations in the U.S. categorized as working class are not well paid, and that situation wont change for the foreseeable future. Individuals who dont have to campaign for votes are more prone than politicians to admit this reality. One in that camp is Tamara Draut, Vice President of Policy and Research at think tank called Demos. While Americas public intellectuals wax eloquently, and even idolize, the innovation and ideation done by tech workers, the reality (is) that most Americans actually work in a bargain-basement economy.....Today, the U.S. has one of the highest percentages of working people earning low-wagesone out of four employed Americansof 26 advanced countries surveyed by the Organization for Economic Co-operation and Development. she says.

Draut is right. The BLS expects the occupations that will grow the most in the next few years will be mostly in the low-wage category. They include office managers, home health care workers, food prep workers, janitors, and construction-related jobs. The only high-growth job category demanding a post-secondary education is healthcare, where the BLS envisions a mushrooming need for nurses. So when you hear campaign rhetoric in the upcoming months about helping the working class, bear in mind who politicians are really talking about: Not people who work in factories. That is a vestige of a by-gone era. Todays working class largely consists of individuals for whom a bump in the minimum wage brings a meaningful improvement in life style. And that situation is unlikely to change regardless of who takes the oath of office in January. DW


Lee Teschler Column 6-16_Vs1.indd 6 5/25/16 10:18 AM

2016 Helical Products Company | www.heli-cal.com

Helical 6-16.indd 7 5/23/16 12:05 PM

Te c h n o l o g y F o r w a r d

L e s l i e L a n g n a u - M a n a g i n g Ed i to rl la n g n a u r @w tw h m e d i a .co m

The Internet of Thingsits about security

On Twitter @ DW3Dprinting


The IoT juggernaut continues: Forecasters like Gartner Research predict

that the typical home will have nearly 500

networked devices by 2020 (not me; Im

still wondering why bother?). Big name

companies like GE and Siemens pitch their

IoT successes at various conferences. The much-hyped Internet of Things concept promises to tackle common problems: such as the complexities of managing product life cycles and the lack of interoperability between information technology and operational technology. (Back in my day, operational technology (OT) was better known as industrial control, as in PLCs, SCADA systems, CNCs, and so on.) One concern, however, is bubbling up to the tophow will all the gathered data be secured from hackers?

According to a report from Argus Insights, the conversation is shifting from what cool things can we connect to the IoT, to how do we secure all the data? In fact, security is becoming more of a concern than privacy, as well it should. Privacy implies a user has control over when and how data are shared. Security says a user doesnt. Security concerns for consumers are definitely on the rise and this goes double for any enterprise deployments. Security issues are a real roadblock for IoT product acceptance, said John Feland, CEO, Argus Insights. Unfortunately, tested, viable security solutions are scarce. Typical solutions like a secure boot or encrypted connection only cover a few vulnerabilities. Noted the Argus Insights report, the lack of good security software approaches among software vendors forces engineers to integrate a confusing array of components from many sources only to find they do not play well together or impose an unwieldy demand on scarce system resources. This is a problem.

The unpopular reality is that we dont really understand how to secure devices; this is new territory. At the recent Disrupt New York 2016 conference, experts weighed in. The best way to lock down data is to not have access to it in the first place suggested Nate

Cardoza, an attorney for the Electronic Frontier Foundation. If you collect data, interested parties, such as hackers, organized crime, law enforcement (the recent FBI request to Apple, for example) and others will want access to it. Guaranteed. So some are suggesting a zero knowledge model, where vendors (example: Apple) dont have access to the data. As engineers and vendors navigate security, this model may become the preferred approach. The bigger question, though, may be: Why are we networking everything? What, exactly, is the point? In some situations, the data may be useful. But everything? Just because we can? Thats sloppy thinking. But vendors will continue to explore anything that can be connected to the internet. Martin Mickos, CEO of security firm HackerOne, has a suggestion for better security. In your design, shift to the open source model where you can invite others to help find vulnerabilities. Thats an interesting approach. At the heart of the IoT concept is the idea that technology will solve all of our problems. If we just have enough data, we can figure it all out. What if that concept is backwards? What if its people, in the form of a neighborhood watch, rather than technology, that is the best way to ensure security? DW

Leslie Column (Technology Forward) 6-16 Vs2.LL.indd 8 5/27/16 8:42 AM

Proto Labs 6-16.indd 9 5/23/16 12:06 PM

IS THE ANSWER TO MY DESIGN CHALLENGE ALWAYS A PART NUMBER?

Ask Smalley. We know that theres really no such thing as a standard design. So we deliver a level of technical collaboration and customization far beyond what youd nd in a typical parts catalog.

Smalley engineers are always ready to share their expertise with youtailoring a high-performance Smalley wave spring, Spirolox retaining ring or constant section ring to meet your unique application requirements. So dont settle for ordinary. Talk to a Smalley engineer today.

Smalley retaining rings eliminate the protruding ears that interfere with assemblies, while providing a 360-degree retaining surface. And their unique design means no special tools are required.

Visit smalley.com for your no-charge test samples.

THE ENGINEERS CHOICE

IS THE ANSWER TO MY DESIGN CHALLENGE ALWAYS A PART NUMBER?

Ask Smalley. We know that theres really no such thing as a standard design. So we deliver a level of technical collaboration and customization far beyond what youd nd in a typical parts catalog.

Smalley engineers are always ready to share their expertise with youtailoring a high-performance Smalley wave spring, Spiroloxretaining ring or constant section ring to meet your unique application requirements. So dont settle for ordinary. Talk to a Smalley engineer today.


Visit smalley.com for your no-charge test samples.

THE ENGINEERS CHOICE

engineer today.


Visitno-charge test samples.

Stamped RingConstant Section Ring

Spirolox Ring

38139_Smalley_BrandAd_PartNumber_DesignWorld.indd 1 10/9/15 1:46 PMSmalley 11-15(new).indd 10 5/23/16 12:07 PM

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

June 2016 DESIGN WORLD 1 1

BILL WATSONDirector of Application Engineering

Klber Lubrication NA LP

64

70 ALAN CAIN

Group Leader/Research ChemistChemline Inc.

Make the right choice for metal coating for the right application

Alan has been involved with polyurethane and polyurea

product development for 25 years. He is also a NACE

Level III Certified Coatings Inspector.

JEAN THILMANYContributing Editor

Sweet Freedom

In the next 20 years, Jean expects to see more virtual

reality and holograph applications used in surgery

and long-distance diagnosis and treatment. I hope technological

innovations are pushed out to developing countries, in

appropriate and humanitarian ways, she said. Sadly, I also

expect to see the greater effects of global warming and war and

combat. But despite all that, Jean hopes more people will be able to find ways to slow down

the world in their private lives so theyre not connected around

the clock. Her favorite book is Excellent Women by Barbara

Pym, a funny, post-war English novel about a spinster.

my advice

Enjoy the little things because the big things are complicated to

maneuver.

How to choose an industrial lubricant

Bill joined Klber Lubrication in 1989 and

has held several positions within sales and

marketing. He currently leads the marketing

and application engineering department. Bill

received his Bachelor of Science degree from

the College of William and Mary in Virginia.

88

Contributor Page 6-16_vs1.indd 11 6/2/16 10:30 AM

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Multi-Axis Communications Just Got Simpler.

1

www.animatics.com+1 408 965 3320 | [email protected]

3

READY. Use our free SMI software to auto detect motors.

SET. Set CAN addresses and baud rate.

GO. Send commands; start talking.

2

Same for 2 or 120 motors. Thats all there is. Simple!

When Performance Really Matters

Staff page 6-16_Vs1.indd 12 5/27/16 12:17 PM

Altech 6-16.indd 13 5/26/16 8:39 AM

2015

3

Co n te n t s | J u n e 2 0 1 6 v o l 1 1 n o 6 | d e s i g n w o r l d o n l i n e . c o m

MOTION CONTROL

Why is preload necessary in some bearing applications?With ball bearings, preload is often a misunderstood concept and overlooked by designers and bearing users alike. Heres what you need to know.

56

F E A T U R E S

70

2015

revenue over $3 million

MATERIALS

Make the right choice for metal coating for the right applicationMetals make it possible to have a variety of products, such as industrial production equipment, automobiles, aircraft, or consumer electronics. The corrosion metals are subject to, however, is a problem. Preventive measures, such as the right coating, can delay or eliminate corrosion.

64 MECHATRONICSFIve keys to mechatronic successDecades of exposure to the realities of keeping farm equipment running have provided FireFly Equipment with insight to the problems, and the solutions, needed to making highly automated agricultural machinery a reality.

2015ONLINE

80

88 3D CADSweet FreedomFree, open-source 3D CAD systems are finding their place.

1 4 DESIGN WORLD

MOTION CONTROL

How to choose an industrial lubricantChoosing the right lubricant for an industrial power-transmission design can be a tricky task, because industrial lubricants come in many varieties and formulations, and many industries require lubricants to adhere to specific regulations and standards. Here are some tips to make the selection easier.

ON THE COVERLubricants help chain and other power-transmission components last for years, even in harsh environments.

Courtesy Klber Lubrication NA LP.

CONTENTS JUNE 2016_first page_Vs3.LL.indd 14 6/1/16 4:14 PM

160429_1_3Mill_DW_US.indd 1 4/28/16 1:39 PMDigi-Key 6-16.indd 15 5/23/16 12:08 PM

Co n te n t s

D E P A R T M E N T S

04 Insights

06 Teschler on Topic

08 Technology Forward

1 1 Contributors

18 Green Engineering

22 Design For Industry

28 Design Notes

38 Coupling Notes

42 CAE Solutions

46 Internet of Things

94 Products

96 Ad Index

6. 2 0 1 6


18

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

SIKO MagLine Absolute:

High-precision, optical measurement Accuracy up to 5 m Repeat accuracy up to 0.05 m 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

www.sorbothane.com

800.838.3906

MADE IN THE U.S.A.

Depiction of Frequency Waves

SHOCK & VIBRATION

SOLUTIONSINNOVATING

22

Contents JUNE_second page_Vs2.LL.indd 16 6/1/16 4:04 PM

WITTENSTEIN one with the future

www.wittenstein-us.com

WITTENSTEIN alpha

Since our origination as Alpha Gear in 1984, WITTENSTEIN alpha has set the bar for excellence in motion control systemsright from the heart of the Midwest. Today our North American headquarters sits on a six-acre campus in Illinois, where we exceed customer expectations daily:

Ship more than 5,000 products each month, and average 99% on-time delivery.

Deliver engineering and technical support that helps optimize application performance.

Provide on-site service and maintenance for WITTENSTEIN alpha gearheads.

The quality of WITTENSTEIN alpha gearheads is renowned. Today that quality is more accessible than ever. For providers near you, email [email protected].

WITTENSTEIN one with the future

www.wittenstein-us.com

WITTENSTEIN alpha

Since our origination as Alpha Gear in 1984, WITTENSTEIN alpha has set the bar for excellence in motion control systemsright from the heart of the Midwest. Today our North American headquarters sits on a six-acre campus in Illinois, where we exceed customer expectations daily:

Ship more than 5,000 products each month, and average 99% on-time delivery.

Deliver engineering and technical support that helps optimize application performance.

Provide on-site service and maintenance for WITTENSTEIN alpha gearheads.

The quality of WITTENSTEIN alpha gearheads is renowned. Today that quality is more accessible than ever. For providers near you, email [email protected].

Wittenstein 6-16.indd 17 6/1/16 9:17 AM

Getting past wasted energy

G r e e n E n g i n e e r i n g

At this years Hannover Fair in Germany, an executive panel touched on the importance of using energy properly. According to the U.S. Energy Information Administration, industry accounts for about one-third of energy used in the U.S. This means that there is an

estimated $60 billion in waste. The panel was asked what industry can do to fight this and what may change over the coming decade.

n Paul J. Heney Editorial Director

citys power system that transfers power during an outage event so electricity can continue to flow. The technology was successfully installed and even after a severe ice storm hit the area, Yates said this technology helped transfer power in 90 milliseconds to an alternative source. The Ibuprofen plant was able to avoid costly production shutdowns and keep operations flowing. Anne Cooney, President, Siemens Process Industries & Drives Division, USA, noted that while studies place energy costs at 5-10% of production costs across all industries, in process-based industries, energy costs may comprise the single largest

Kevin Yates, President, Siemens Energy Management Division, USA, said that there is a tremendous shift in how energy is created, transmitted and delivered due to availability of renewable energy, low natural gas prices, the need for greater power reliability and regulatory dynamics. Though the challenges of this changing landscape often focuses on utilities or independent system operators, the industrial market can also pursue the opportunities offered by a 21st century power mix, Yates said. So, even though this shift may seem focused outside of a plants walls, todays energy mix not only can, but is already significantly impacting the way industrial and commercial markets manage and consume energy.


Yates explained how Orangeburg, S.C. is home to the worlds largest Ibuprofen factory, which serves as an economic anchor for the region and has over 300 employees. The plant was plagued with power outages due to sub transmission system issues. Each time the power went out, the plant was required to shut down production, a costly process that resulted in serious production losses and waste generation, he said. The options amounted to either looking for a new site, or working with the local utility to improve power reliability on the grid. Siemens partnered with the Orangeburg Department of Public Utilities to develop a Distribution Feeder Automation System for the

component of total costs, as much as 40%. Consequently, energy efficiency is always on the initiatives list for most of our customers in the process industries, she said. One of the most easily deployed ways that we can help them with that is through energy efficient motors and drives, which can deliver 30% or greater efficiency over older equipment. Depending on the scenario, the gains can be almost astronomical, reaching even 70%. DW

Siemensusa.siemens.com

Green Engineering_6-16_Vs1_PH.indd 18 5/27/16 8:46 AM

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

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

FOR MOTION CONTROL INNOVATION, SOLUTION CITY NEVER SLEEPS.

2015 by AMETEK Inc. All rights reserved.

100 East Erie StreetKent, OH 44240ametekdfs.com

AMETEKPMC 18611_City Never Sleeps Ad_9x10.875.indd 1 7/29/15 9:14 AMAMETEK PMC (Solutions City) 8-15 (NEW).indd 19 5/26/16 8:37 AM

Innovative Hydraulic Fan DrivesDriving Efficiency and Savings

Sponsored Content

ydraulic fan drives are utilized more than ever across multiple markets and applications. To meet the new stringent emission regulations, the engine (charge air) needs more cooling under high load and high ambient temperatures. Sizing a me-chanically driven fan for this condi-tion will be very wasteful because in most applications, the engine does

not run at peak load and highest ambient temperature at most times. By decoupling the engine from the fan drive, hydraulic fan drive speed (power) can be varied to meet the appropriate cooling needs at any working condition. This reduces fuel consumption due to reduced fan power draw and also reduces equip-ment wear and tear. However, all hydraulic fan drive systems are not

equal. Therefore, it is critical for the engineer to select the right system and the right components, as this will directly affect the resulting fuel savings of the machine. This white paper addresses in detail the many benefits of hydraulic fan drives on construction equip-ment, the three different types of systems available, how to size them properly, and the specific types of equipment that benefit most from this technology.

Fixed/Fixed Hydraulic Fan Drive System The simplest and most widely used hydraulic fan drive system is a fixed/fixed system. This consists of a fixed displacement pump with a fixed displacement motor and a pressure controlled bleed-off circuit to vary the fan speed.

Figure 3 Load Sense Hydraulic Fan System

Last is another variable displacement pump with a fixed motor as seen in Figure 4. This system uses Electronic Displacement Control (EDC) of the piston pump with a displacement sensor (X3). This pump would typically be used with a previously mentioned Parker M5A or PGM600R motor. This reduces the system to simply two components and a minimal number of hoses. In this system, the pump is now being controlled using an electronically proportional spool to meter the flow to and from the stroking piston by using the displacement sensor to directly control the pump displacement. Simply put, it no longer uses pressure to control, but the pump displacement. The control based on the displacement feedback has a very high bandwidth and it is robust and stable. This EDC fan drive system could be driven using an existing vehicle control with the right capabilities. Otherwise Parker has many control modules that can control the EDC system, communicate with J1939, and drive other vehicle functions.

Figure 4 EDC Fan Drive System

Parker Hannifin System Engineers can work with each customer to help in the selection of the best system based on their individual application. Whether it is designing the system and troubleshooting through prototypes or just helping with some controls, Parker System Engineers can help every step of the way.

SUBH: SIZING THE SYSTEM

COPY: The first item to address is the amount of cooling power needed at the fan. Typically this is provided by the engine manufacturer. If this is not provided, a general range of 15%-20% of the engine power is needed for cooling. It could be slightly more for machines such as an excavator, or could be slightly less for machines such as backhoes. Wheel loaders generally fall right in that range. So, this means if the vehicle is an excavator with an engine power of 150 hp, it could be estimated that the cooling needed is 30 hp. Once, the power requirement is known, the next step is to size the motor. If the system will use 3500 psi working pressure and a required fan speed of 2000 rpm, the torque can be calculated to 79 ft-lbs. With the pressure and torque, the size would correspond to a


Abstract Load Sense Hydraulic Fan Drive SystemAnother common hydraulic fan drive setup is a variable displace-ment pump with a fixed motor. The first of these variable systems uses a load sensing piston pump. The load sense piston pump adapts the swash plate angle to control the desired fan speed. By adjusting the swash plate angle, the displacement changes to not waste any flow across a relief valve, which minimizes the losses seen within the system. This is the current state-of-the-art system for performance and efficiency.

EDC Fan Drive SystemFigure 4 represents the proposed innovative fan drive system from Parker. This system uses Electric Displacement Control (EDC of the piston pump and position feedback with a displacement sensor (X3). The use of a Parker electric displacement controlled pump allows several advantages.

Different Hydraulic Fan Drive System Options

ENGINEERING YOUR SUCCESS.

Parker enables its partners in the construction equipment

industry to build new schools the world over while increasing

fuel efficiency, minimizing downtime and reducing emissions.

This reflects our commitment to the profitability of our customers

and to helping solve the worlds greatest engineering challenges.

parker.com/buildingbetterlives.

The challenge Constructing a higher quality of life

First, the pump control is much simpler and more stable. Second, the number of hydraulic hoses and connectors is reduced. Third, significant efficiency improvements can be achieved by eliminating the control leakage flow with respect to the current state-of-the-art load sense system.

Download the entire white paper on Hydraulic Fan Drives at www.parker.com/fandrives

Parker Hannifin spread ad 6-16.indd 20 5/27/16 8:48 AM

Innovative Hydraulic Fan DrivesDriving Efficiency and Savings

Sponsored Content

ydraulic fan drives are utilized more than ever across multiple markets and applications. To meet the new stringent emission regulations, the engine (charge air) needs more cooling under high load and high ambient temperatures. Sizing a me-chanically driven fan for this condi-tion will be very wasteful because in most applications, the engine does

not run at peak load and highest ambient temperature at most times. By decoupling the engine from the fan drive, hydraulic fan drive speed (power) can be varied to meet the appropriate cooling needs at any working condition. This reduces fuel consumption due to reduced fan power draw and also reduces equip-ment wear and tear. However, all hydraulic fan drive systems are not

equal. Therefore, it is critical for the engineer to select the right system and the right components, as this will directly affect the resulting fuel savings of the machine. This white paper addresses in detail the many benefits of hydraulic fan drives on construction equip-ment, the three different types of systems available, how to size them properly, and the specific types of equipment that benefit most from this technology.

Fixed/Fixed Hydraulic Fan Drive System The simplest and most widely used hydraulic fan drive system is a fixed/fixed system. This consists of a fixed displacement pump with a fixed displacement motor and a pressure controlled bleed-off circuit to vary the fan speed.

Figure 3 Load Sense Hydraulic Fan System

Last is another variable displacement pump with a fixed motor as seen in Figure 4. This system uses Electronic Displacement Control (EDC) of the piston pump with a displacement sensor (X3). This pump would typically be used with a previously mentioned Parker M5A or PGM600R motor. This reduces the system to simply two components and a minimal number of hoses. In this system, the pump is now being controlled using an electronically proportional spool to meter the flow to and from the stroking piston by using the displacement sensor to directly control the pump displacement. Simply put, it no longer uses pressure to control, but the pump displacement. The control based on the displacement feedback has a very high bandwidth and it is robust and stable. This EDC fan drive system could be driven using an existing vehicle control with the right capabilities. Otherwise Parker has many control modules that can control the EDC system, communicate with J1939, and drive other vehicle functions.


Parker Hannifin System Engineers can work with each customer to help in the selection of the best system based on their individual application. Whether it is designing the system and troubleshooting through prototypes or just helping with some controls, Parker System Engineers can help every step of the way.

SUBH: SIZING THE SYSTEM

COPY: The first item to address is the amount of cooling power needed at the fan. Typically this is provided by the engine manufacturer. If this is not provided, a general range of 15%-20% of the engine power is needed for cooling. It could be slightly more for machines such as an excavator, or could be slightly less for machines such as backhoes. Wheel loaders generally fall right in that range. So, this means if the vehicle is an excavator with an engine power of 150 hp, it could be estimated that the cooling needed is 30 hp. Once, the power requirement is known, the next step is to size the motor. If the system will use 3500 psi working pressure and a required fan speed of 2000 rpm, the torque can be calculated to 79 ft-lbs. With the pressure and torque, the size would correspond to a


Abstract Load Sense Hydraulic Fan Drive SystemAnother common hydraulic fan drive setup is a variable displace-ment pump with a fixed motor. The first of these variable systems uses a load sensing piston pump. The load sense piston pump adapts the swash plate angle to control the desired fan speed. By adjusting the swash plate angle, the displacement changes to not waste any flow across a relief valve, which minimizes the losses seen within the system. This is the current state-of-the-art system for performance and efficiency.

EDC Fan Drive SystemFigure 4 represents the proposed innovative fan drive system from Parker. This system uses Electric Displacement Control (EDC of the piston pump and position feedback with a displacement sensor (X3). The use of a Parker electric displacement controlled pump allows several advantages.

Different Hydraulic Fan Drive System Options

ENGINEERING YOUR SUCCESS.

Parker enables its partners in the construction equipment

industry to build new schools the world over while increasing

fuel efficiency, minimizing downtime and reducing emissions.

This reflects our commitment to the profitability of our customers

and to helping solve the worlds greatest engineering challenges.

parker.com/buildingbetterlives.

The challenge Constructing a higher quality of life

First, the pump control is much simpler and more stable. Second, the number of hydraulic hoses and connectors is reduced. Third, significant efficiency improvements can be achieved by eliminating the control leakage flow with respect to the current state-of-the-art load sense system.

Download the entire white paper on Hydraulic Fan Drives at www.parker.com/fandrives

Parker Hannifin spread ad 6-16.indd 21 5/27/16 8:49 AM

m i l i t a r y / a e r o s p a c e

2 2 DESIGN WORLD June 2016 www.designworldonline.com

01 D e s i g n f o r I n d u s t r y m a c h i n e t o o l

Changeovers of shaft-mounted tools, reels/spools and other objects can be handled more quickly with shaft collars that feature quick-release. One example is the Easylock shaft collars, which install quickly without special tools for non-slip holding of tools and reels on smooth, case hardened (Rockwell > 55) shafts. A new option Easylock positive release assures the collars wont become jammed on shafts. A clamping control wheel on Easylock lets users adjust the holding force from 90 to 1,124 lb. As the clamping control wheel is turned clockwise, the clamping unit is forced against the object being secured, holding it in place. This can generate compression forces that push back against the shaft collar, sometimes interfering with the quick-release mechanism then making it difficult to slide the collar off the shaft. To prevent this situation, it was necessary to advance the clamping control wheel a few turns before sliding the collar onto the shaft. The positive release feature eliminates this step. Positive release is activated when the clamping control wheel is turned all the way in a counterclockwise direction. When the wheel is backed off in this manner, it contacts a stop pin that automatically releases the

Easy release for shaft collars

locking mechanism so that the quick-release functions properly. Easylock shaft collars with positive release reduce downtime. The quick-release feature makes them well suited to high volume production where frequent changeovers of shaft-mounted tools, reels/spools and other objects are required. The positive release feature is standard on sizes 25, 30, 35 and 40, and will soon be included on the smaller sizes 10, 12, 15, 16, 20 and 22. If Easylock is used to hold spools in level winding operations, the pintle points are attached to the face of the unit. As holding force is increased, the points are forced into the spool bore creating a non-slip interface between the shaft and the spool. This permits rapid starts and stops without rotational play of the spool on the shaft. The pintle points also make Easylock useful in processes such as high-speed roll-fed lamination and stretch-wrapping. DW

Amacoil Inc.Amacoil.com

DFI 6-16_Vs4.LL.indd 22 5/27/16 8:51 AM

m a c h i n e t o o l / a e r o s p a c e / m i l i t a r y


Automatically ensure photonics alignment FiberMaxHP is a second-generation 3 to 6 axis photonics alignment platform, built on the ANT nanopositioning product line. The noncontact direct-drive technology can operate in an automated production environment. It is capable of 2 nm linear and 0.05 rad rotary minimum incremental motion, with speeds to 400 mm/s, to align photonics packages. Aerotech controllers work with a variety of smart cameras and machine vision systems to help facilitate first light. Servo scanning algorithms optimize power coupled through the devices. Standard scanning routines include fast align, hill climb, spiral, and raster searches in up to six axes of motion. Kinematics enable a virtual pivot point where rotation can occur at any user-defined point in space rather than the physical rotation point of the systems axes. This feature assists the speed and accuracy of active alignment. The 3 to 6 axes of direct-drive alignment let users specify the exact number of axes needed for an application. Since many applications require manual adjustment of fixtures and parts for a one-time initial alignment, the FiberMaxHP comes with 1 to 3 axes of manual angular alignment with 2 of motion. These manual adjustment axes mount directly to the direct-drive platform. The FiberMaxHP is a modular design and can be customized with special arrangement of axes, fixturing, and mounting patterns to meet specific application needs. DW

AerotechAerotech.com

m a c h i n e t o o l02 D e s i g n f o r I n d u s t r y

The Worry-Free Cable Experience

DFI 6-16_Vs4.LL.indd 23 5/27/16 1:02 PM

m i l i t a r y / a e r o s p a c e

m e d i c a l D e s i g n f o r I n d u s t r y 03

Sensors for medical wearable devices Medical wearable technology continues to be a popular product. Many companies are developing sensors to solve a range of design challenges for these non-invasive body-monitoring devices. One of those challenges is accuracy. Analog Devices Inc. (ADI) and LifeQ plan to design sensors that enable personalized, continuous and accurate tracking of physiological parameters such as heart rate, sleep phases, sleep quality, blood lactate, 24-hour calorie intake as well as stress markers such as salivary cortisol.

Monitoring this type of data can increase early detection of emergency conditions and diseases in patients. ADI will offer its semiconductor expertise and LifeQ will provide the bio-mathematical understanding needed to develop sensors that can make body monitoring devices more effective in preventing, predicting and managing diseases.

Analog Devices Inc. LifeQwww.lifeq.com


2016 Colder Products Company

Smart fl uid handling to take you forward, faster.

Tubing connectors, quick disconnect couplings and fi ttings to meet your needs.

CPC connector solutions add value to your product

designs. We think beyond the point of connection to

help you enhance product performance and your

users experience.

Choose from thousands of proven, standard products

Explore unique and multi-function options

Work with our engineers for a custom design

Watch the video at cpcworldwide.com

RFID-enabled

Fluid/signal hybrid

Non-spill

Innovation ON THELeading Edge OF WHAT IS POSSIBLE

DFI 6-16_Vs4.LL.indd 24 5/27/16 9:02 AM


Avoid restricted substance risks

Risks associated with restricted substance regulations include: legal liability, non-compliance costs, re-design, product recalls, and inability to service products due to material obsolescence. Minimizing these risks is difficult. Companies must keep up with shifting global regulations and gather data from suppliers and throughout their organizations. They must often navigate complex combinations of materials, processes, and specifications, or report on legacy products described by Bills of Materials that are in diverse formats, dispersed, and disconnected from data or tools that could facilitate analysis. The GRANTA MI:Restricted Substances software will helps users navigate the process. It helps eliminate materials and processes risk, helps users design for compliance and analyze products, as well as report on compliance risk for existing products. New developments include extended reference data to fill gaps in in-house information, enhanced tools to manage proprietary knowledge, and fast apps to answer business-critical questions such as which of my specifications contain at-risk substances?

a e r o s p a c e04 D e s i g n f o r I n d u s t r y

Materials and related processes and specifications are the source of most restricted substance issues. So a strength of MI:Restricted Substances is that it is built on GRANTA MI, an industry-leading system for materials information management. In-house information managed in GRANTA MI is then linked to a regularly updated database of 8,000+ substances and 100+ international regulations that restrict their use. Software tools enable users to apply the resulting knowledge base to analyze risk not only for specifications, materials, and processes, but for designs and products.

Features include: Updated data on regulations including the IARC Monographs on the Evaluation of Carcinogenic Risks to Humans and the EU RoHS2, China RoHS2, CoRAP, and CLP Regulation lists Tools supporting the complex process of merging data updates with in-house information Features to account for multiple surface treatments when reporting on product compliance DW

Granta Design Grantadesign.com

2016 Colder Products Company

Smart fl uid handling to take you forward, faster.

Tubing connectors, quick disconnect couplings and fi ttings to meet your needs.

CPC connector solutions add value to your product

designs. We think beyond the point of connection to

help you enhance product performance and your

users experience.

Choose from thousands of proven, standard products

Explore unique and multi-function options

Work with our engineers for a custom design

Watch the video at cpcworldwide.com

RFID-enabled

Fluid/signal hybrid

Non-spill

Innovation ON THELeading Edge OF WHAT IS POSSIBLE

Manchester, New Hampshire , USATel: +1.603.669.4347

www.hca.hitachi-cable.com

Material Science Experts

Industrial Ethernet CablesOptions Available: 600V, High-Flex, Ultra-Limp,

Oil/Gas/Solvent Resistant, Outdoor.

4 x 48 AWG Catheter Cable19000

Actual catheter cable diameter compared to a penny.

Bundle of 128 Micro-Coax Cables(42AWG/85 ohms)

19mm

7.7mm

Actual Micro-Coax cable bundlediameter compared to a penny.

When Size andPerformance Matters

Medical-Industrial

DFI 6-16_Vs4.LL.indd 25 6/1/16 1:56 PM

2016 GAM. ALL RIGHTS RESERVED901 E. Business Center Drive, Mount Prospect, IL 60056

Small Size.Big Performance.

The SPH Flange Gearbox is small in size, but achieves great performance due to a rigid housing,

supported planet carrier, high precision gears, and optimized taper roller bearings. It is produced

to the elevated standard of quality and reliability customers have come to expect from GAMs

high-performance SPH product line.

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

SPH-CSPH-KSPH-WOTHER SPH PRODUCTS:

16_GAM_026_Ad_H.indd 1 5/16/16 12:37 PMGAM 6-16.indd 26 6/1/16 1:57 PM

Stainless steel cylinder handles toughest cleanliness requirements One aspect in the manufacture of drugs is cleanliness; equipment may have to withstand harsh cleaning procedures to prevent contamination. Flat-I is a stainless steel, compact cylinder for applications in which frequent, corrosive wash downs are required to prevent the propagation of bacteria. The cylinder that has mounting holes only where they are needed, with a clean stainless steel exterior. Because of the importance of sterility and the need for cleaning with high-pressure, high temperature sprays applied at close range, this cylinder has the highest possible rating on the Ingress Protection International Scale IP69K, 6 for being dust-tight and 9 for protection against liquids. The Stainless Steel Flat-I comes in a wide range of 8 bore sizes and breadth of cylinder options. DW

Bimbawww.bimba.com


p h a r m a c e u t i c a l s05

WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly.

Visit our websitewhittet-higgins.comto peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local or a good distributor.

33 Higginson Avenue, Central Falls, Rhode Island 02863Telephone: (401) 728-0700 FAX: (401) 728-0703 E-mail: [email protected] Web: www.whittet-higgins.com

POWER TRANSMISSIONRETAINING DEVICES &maintenance & assembly tools

WHITTET-HIGGINS

USA

BEARLOK SHOELOK BEARLOK Shrink Disc

BEARHUG CLAMPNUT TANGENTLOK

PRECISION NUTS & WASHERS ADAPTER SLEEVE ASSEMBLIES

NUTS & WASHERS HARDENED TONGUE WASHERS SPLIT COLLAR

RETHREADING DIES ADJUSTABLE SPANNER WRENCH BEARING ASSEMBLY SOCKET

INCH and METRIC THREADSLEFT HANDED as well as

RIGHT -HANDED

Materials of:CARBON, ALLOY and HARDENED ALLOY

STEELS

Materials of:ALLUMINUM and

CORROSION RESISTANT STEEL

DFI 6-16_Vs4.LL.indd 27 6/1/16 1:56 PM

D e s i g n N o te s

Last year, the Composite Material Laboratory at the Inholland University of Applied Sciences in the Netherlands installed a Moog Portable Test Controller for

single-axis testing of composite materials like fiber-reinforced polymers. The test

machine is a 700 x 300 x 1600 mm, 100-kN hydraulic bench. Manufacturers and

consumers want lightweight materials in all sorts of products and parts, so the lab

had to speed up the number of tests it performs on composite materials.

Historically hydraulics has been used for its combination of high load and velocity.

The Moog test system consists of a hydraulic actuator, test load frame and test

controller. Initially, the lab used the system to perform material tests for aerospace,

but then extended its scope to cover things ranging from car parts to hockey sticks.

The composites lab was now able to use the testing machine for a wider range of

applications.

Edited by: Mike Santora Associate Editor


Portable test controller assists composite materials analysis

The Integrated Test Suite is t

he most

versatile software Inholland ha

s used yet.

The Moog test controller uses

an EtherCAT

fieldbus interface that allows c

onnecting

EtherCAT compatible slave dev

ices with

precise time synchronization.

Design Notes 6-16_Vs3.LL.indd 28 6/1/16 2:00 PM

Here, we see a Moog Portable Test Controller for single-axis testing of composite materials like fiber-reinforced polymers. The test machine is a 700 x 300 x 1600 mm, 100 kN hydraulic bench.

For example, while developing a bio-

composite scooter, the Inholland University

lab was able to conduct full scale testing to

simulate certain road profiles. Another example

was the testing of cargo straps for aviation

to prove compliance with the new EASE

regulations. Also, composite materials require

significant testing for the determination of

material properties. These tests are mainly

static destructive tests; the integrated test

suite allowed Inholland do all these tests on a

single machine. And because the test controller

is portable, the lab can also now integrate more

I/O devices and obtain real-time and realistic

measurements from the labs climate chamber.

The software running on the test controller

gives engineers more options than other

software theyve used in the past, so

researchers can change the force they apply

to a part during a testing sequence. The

Integrated Test Suite is the most versatile

software Inholland has used yet. The Moog

test controller uses an EtherCAT fieldbus

interface that allows connecting EtherCAT

compatible slave devices with precise time

synchronization. The lab is currently using a

Q.bloxx measurement system from Gantner

Instruments linked to the test controller. The

ability of connecting a modular measurement

system to the test controller over EtherCAT

provides flexibility and has become a key

feature to the test lab. DW

Moogwww.moog.com

WHAT DO YOU THINK?

Connect and discuss this and other design engineering issues with

thousands of professionals online

www.designworldonline.com June 2016 DESIGN WORLD 29




Energy efficient signal conditioner saves space


Modern factories need to monitor a range of parameters requiring a high number of signal conditioners. All factories need to be more efficient and

save costs by conserving energy and space wherever possible.

Control cabinets located on a factory floor house many types of equipment

typically mounted on a DIN rail inside the cabinet. Equipment can include PLCs,

signal conditioners, power supplies as well as DIN rail interconnecting blocks;

put simplyspace is at a premium. The larger the signal conditioner the more

space it takes up inside the control cabinet thereby generating increased costs in

cabinet size. Larger cabinets also take up more space on the factory floor.

The need for signal conversion can come in a range of input/output (I/O)

possibilities. Signal conditioners with fixed input/output ranges need a different

module for each input/output combination.

Modern factories need to monitor a range of process parameters requiring a higher number of signal condition-ers. All factories have the need to be more efficient and save costs by conserving energy and saving space wherever possible.


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Non-isolated signal conditioners will not

effectively block ground loops or other spurious

voltages from passing through the signal

conditioner, possibly damaging sensitive

downstream equipment such as the PLC or

data acquisition system.

Signal conditioners with higher power

requirements need larger power supplies

mounted on the DIN rail inside the control

cabinet, which can take up more space and

generate excessive heat.

Older signal conditioners can be up to 25

mm (1-in.) or more in width and require air

gaps in between modules for heat transfer for

cooling. Consequently 50 units can take up

1.25 m (4.1-ft) or more of DIN rail space, which

depending on the size of the control cabinet,

can lead to 1 or 2 rows of signal conditioners.

The DRSL-U isolated universal input DIN rail

signal conditioner offers galvanic isolation

of process signals to SCADA systems or PLC

equipment. It accepts thermocouple, RTD,

linear resistance, potentiometer, voltage or

current input and converts these signals to

linear voltage orurrent output. The unit isolates

between input, output and supply, provides

surge suppression and protects control

systems from transients and noise. The DRSL-U

also offers electrical isolation and eliminates

ground loops and can be used for measuring

floating signals.

The DRSL-U is space efficient and has a

slimline housing that is 6 mm (0.24-in.)

wide. Up to 50 units can be mounted on a

DIN rail in the control panel and occupy only

30 cm (11.8-in.) on the rail. The DRSL-Us low

power design makes the typical 24 Vdc power

requirement for 50 units only 40 W. These

signal conditioners can be stacked vertically

or horizontally and do not require an air gap in

between modules.

The conditioner is configured using the

programming interface in conjunction with the

configuration adapter. The DRSL-DISPLAY has

a 4-line LCD display with scrolling help text in

7 languages (English, French, German, Italian,

Spanish, Danish and Swedish), which guides

users through all the configuration steps. The

DRSL-U is designed with electronic hardware

The DRSL-U is space efficient and h

as

a slimline housing that is only 6 mm

(0.24-in.) wide. Up to 50 units can be

mounted on a DIN rail in the control

panel and occupy only 30 cm (11.8-in

.)

on the rail.

switches, consequently it is not necessary

to open the device to set any internal DIP-

switches. DW

OMEGA www.omega.com

WHAT DO YOU THINK?

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With over 18 years of experience manufacturing for the robotics and automated machinery industry, Jerit Automation,

Inc. is considered a one-stop manufacturer. When their team came

across a palletizing application chassis system involving two robots

requiring more space for the operators to workJerit went to WEISS

to collaborate on designing an octagonal dial plate system.

Palletizing dial plate manages multiple robots

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


WEISS completed two chassis systems featuring an octagon-shaped, 45.68-in. diameter dial plate for this application. The plate footprint was sized to match the WEISS eight station TC220 rotary index table for a medical parts subassembly operation by Jerit.


www.designworldonline.com June 2016 DESIGN WORLD 3 5

WEISS completed two chassis systems

featuring an octagon-shaped, 45.68-in.

diameter dial plate for the application. The plate

footprint was sized to match the eight station

TC220 rotary index table, and was customized

for ergonomic, inertia loading, and index speed

requirements for a medical parts subassembly

operation for Jerit.

The design incorporated two robotsone

SCARA (Selective Compliance Assembly Robot

Arm) robot for glue dispensing, and one 6-axis

robot for part removal, reject, staging, and

placement into preformed trays. This meant

that more space would be needed to work

within than most stations around the dial.

The semi-automated system involved gluing

steel into a small diameter plastic part using

UV glue, then into a subassembly requiring a

tight tolerance of +/- 0.005-in. The pallet-based

production system held four-up nests designed

to allow individual parts to be easilyloaded

by an operator, while keeping parts confined to

hold the tight tolerance addressed above.

These nests were approximately 12-in.

wide, so the goal was to get the pallets closer

to the operators to optimize ergonomics and

work space around the dial. Additionally, the

pallets held clamps, pins, cylinders, and so

on,thatinteract withboth operators as

parts are loaded and indexed to the next

station.

The entire system involves a high-level operation sequence: Operator 1 loads part A, then part A

is clamped.

Dial indexes...Operator 2 loads part B.

Dial indexes...Parts A and B are adjusted

to assembly position in pallet.

Dial Indexes...Glue applied by

Scara robot.

Dial Indexes...Glue drying.

Dial Indexes...Camera inspection of

assemblies for PASS/FAIL.

Dial Indexes...Parts pick and placed with

6 axis robot.

If Fail assembly is present, the robot

moves to reject chutes and discards

failed parts.

If Less than 4 assemblies are present,

Robot moves to staging area and either

places or picks parts as needed, to

ensure it has four assemblies ready for

placement into trays.

The design incorporated two robotsone SCARA robot for glue dispensing, and one 6-axis robot for part removal, reject, staging, and placement into preformed trays.

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Since 1941

Elesa USA Corporationwww.elesausa.comToll-Free 800-374-7686

VD.Original Design

The Industrial Design Award from the IF-Hannover (Germany)

1977

The new innovative machine handwheel VD. made in Italy by Elesa, an original design in Duroplast, was introduced for the first time on the market.

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The first successful exhibition at the Chicago Design Show.

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The new up-to-date and restyled machine handwheel VDN. Elesa Original Design always with the

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Once the robot has 4 passed assemblies, it moves parts to

trays and places into the next position available.

Dial continues indexing back to Operator 1.

Now in its 3rd generation, the WEISS TC220 series heavy duty rotary indexing

tables are robust and fast switching.

Using this rotary table as the heart of the system, Jerit could design the

frame, oversized table plate, and its associated machining. The frame work

and large top plates were designed by the Jerit team to support all their

automation devices for their specific application. Weiss manufactured the

units and shipped them completed. DW

WEISS

www.weissna.com

D e s i g n N o te sThe design incorporated two robotsone SCARA robot for glue dispensing, and one 6-axis robot for part removal, reject, staging, and placement into preformed trays.



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The role of torque limiters for couplings




Co u p l i n g N o te s

When Coupling Tips.com spoke with KTR Engineering Services Manager, Chris Scholz we asked him about some of the common misconceptions about couplings, torque limiters and the integration of the two. Here are some of the highlights from the interview. We kicked things off by asking what topics are being brought up most often when fielding application questions and design inquiries. Here is what he had to say. One of the things that I try to understand first, is whether or not the torque limiter will be used only for catastrophic failure, or if the

customer is looking to slip frequently: are they expecting more slips than usual? That, then, tells me whether I want to use an economical friction style torque limiter, or if I want to use the ball detent designs, where they can slip, catch a limit switch, shut off, and then reset themselves, and begin operating again. They typically can be slipped multiple times through their application, where a friction torque limiter has to be reset every time. I also try to determine whether a zero backlash component is needed, and address other typical industry questions. The biggest misconception that I want to make sure

people understand is that a torque limiter is not a clutch, and therefore theyre not intended to be continuously slipped. They generate a lot of heat, obviously, with those frictional connections, and so once a torque limiter slips we want the system to be shut down as soon as possible. We obviously then want to inspect that torque limiter, and check for any wear, or heat damage. Re-checking the setting torque is also important; it will decrease quite a bit if its been run too long. We want to make sure that were still in the range that we need to be in so were not slipping more and more. The way we do that

Torque limiters are devices that allow the limiting of torque for

high-shock, catastrophic failure

type applications.

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is either with a limit switch, or a proximity switch, and some type of control device. That way when the torque limiter slips, it sends a signal, and shuts the system down so the customer can do whatever it is the torque limiter was designed to catch, or do.Why are torque limiters important? What are they used for?Torque limiters are devices that allow the limiting of torque for high-shock, catastrophic failure type applications. Theyre used

when people dont want to damage their equipment. Engineers will integrate a torque limiter to be set at a certain value of torque, so that if it reaches beyond that torque setting the torque limiter will slip to save higher value equipment, or high-cost shafting, or whatever the case may be. In the basic terms, its limiting torque, based on a predetermined setting, usually using springs, or ball detents. Can you tell us a little bit about idle rotation in torque limiters? When a torque limiter of this style disengages, its outer casing shifts back, and will not re-engage until manually reengaged; so it basically becomes a free-running bearing. Then, once the engineer determines the torque overload issue, they can stop the machine, and manually push the unity back in place to be engaged to run again. We typically see these torque limiter configurations in much larger applications, so theres time to stop a system, and check things out. We see them in shaft-to-shaft applications, large rollers, steel mills etc. DW

KTR

www.ktr.com/us

Here we see an exploded view of KTRs Ruflex torque limiter.

Co u p l i n g N o te s


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