Design World - October 2013

October 2013 www.designworldonline.
com
INSIDE:
MATeRiALs: Light-curable materials offer designers a fast solution for bonding parts PAGe 58
desiGn FoR indUsTRY: Twin drive system simplies turning table design PAGe 20
sIMpLiFYinG
3D CAD: Silent air cooling is a new approach to thermal management PAGe 66
design
machine
with plug-and-play motion subsystems
PAGe 48
Precision Motion Control

... in stock and ready for same-day shipping.
(TRD-MX500BD)
$99.00
starting at:
(TRDA25RN100RZWDMS)
$175.00
starting at:
(TRD-N3-RZWD)
$119.00
starting at:
TRD-MX series
With small 25mm diameter bodies, rugged solid shafts, and a variety of output types.
Small body with 25 mm diameter and 29 mm depth 4mm diameter solid shaft Resolutions from 100 to 1024 pulses per revolution Open collector output (5 - 12 or 12 - 24 VDC), or line driver output (5 VDC) Up to 100 kHz response frequency 2m cable with tinned ends IP50 environmental rating Mounting bracket and couplings also available
TRDA25 series
are IP65 rated, with military-style connectors for easy installation and replacement.
2.0 in. diameter and 2.15 in. depth 0.375 in diameter solid shaft Removable 2.5 in. round ange Resolutions from 100 to 2500 pulses per revolution Line driver or Totem pole output (has sinking and sourcing capability) Up to 100 kHz (totem pole) or 200 kHz (line driver) response frequency Military-style connector (mating connectors and pre-made cables sold separately) IP65 environmental rating
TRD-N (-NH) and TRD-NA series

oer a wide range of outputs and resolutions.
50 mm diameter and 35 mm depth Splash proof (IP65 rating) 8 mm solid or hollow shaft Incremental models: NEW - High-Resolution versions up to 5000 Pulses Per Revolution Line driver or Totem pole output (sinking and sourcing capability) Up to 100 kHz response frequency Absolute models: Resolutions from 32 to 1024 pulses per revolution, expressed in 5 to 10-bit gray code outputs Open collector outputs Up to 20 kHz response frequency
SAE and metric-dimension encoders are also available in more shaft sizes and resolutions. Also available are hundreds of encoders in mounting frame sizes up to 2.5 inches (SAE) or 78mm (metric).
Also Available
Stepper Systems Servo Systems Drives PLCs
All encoders are in stock for same-day shipping.
Research, price, and buy at: www.automationdirect.com/encoders
Order Today, Ships Today!

* See our Web site for details and restrictions. Copyright 2013 AutomationDirect, Cumming, GA USA. All rights reserved.
1-800-633-0405
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Allied Electronics, Inc 2013. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
Size, Select, & Download...
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NOW, congure your coupling application online with 3D Partstream. Size, select and DOWNLOAD the right ZERO-MAX coupling solution for your application. See models and drawings from all angles. Easily complete your analysis before you go too far. Then download 3D models to your CAD system and GO! www.zero-max.com Check out our FAST deliveries.
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POLARIZED BATTERY HOLDERS
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Available in SMT and THM versions For CR2 & CR123A Lithium batteries Polarized to assure proper continuity and circuit protection SMT versions feature gold-plated phosphor bronze contacts THM versions feature tin-plated phosphor bronze contacts Ideal for low prole, space saving PCB applications Designed for Reow and all PCB soldering applications Suitable for Industrial and Consumer product applications Durable, rugged High Temp Nylon housing Lightweight Quick & easy battery installation/replacement Available in Bulk or on Tape & Reel Optional covers available Request Catalog M60.2
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Insights
Inspiring kids to pursue STEM careers
recent NI Week conference in Austinand a true joy to be able to chat with him afterward. Melvin, who had a brief NFL career, has had a varied and distinguished career with NASA and ew on two shuttle ights in 2008 and 2009. Today, hes busy working to strengthen NASAs student involvement, as well as build public awareness about the administrations scientic goals and missions. In his role as Associate Administrator for Education, he leads the agency in inspiring interest in science, technology, engineering and mathematics, commonly referred to as STEM. Melvin spoke about how critical it is for us to focus on todays students. Those students will be the next generation of explorers, said Melvin. They will be the astronauts walking on Mars one day. They will be building robots that go to other planets. So its endemic to this whole community of engineers, scientists, community leaders, government, and all of us together to give these students everything they need to be empowered to do anything they put their minds to. Melvin encouraged all the engineers in attendance to get their children involved in NASAs newest design challenge for kids, the Exploration Design Challenge. The goal of the Exploration Design Challenge is for students to research and design ways to protect astronauts from space radiation. NASA is working to design the Orion spacecraft, which will take astronauts beyond low Earth orbit and on to asteroids and even Mars. Protecting astronauts from radiation on these long trips is a critical issue that has no easy answers. The Challenge is broken up into different sectionsone for children from Kindergarten through 4th grade, one for 5th through 8th grade, and one for high school students. You can visit http://1.usa.gov/14Ngw5X to learn more about the Challenge. DW
t isnt every day that you get to shake hands with an astronaut. After all, on a planet with more than 7 billion people, fewer than 600 humans have ever reached low Earth orbit. So it was a pleasure to hear NASAs Leland Melvin speak at the
Is NASA doing enough to encourage our kids to pursue STEM careers? Comment on Pauls blog on
Pneumatic Tips, www.pneumatictips.com/blog
4
DESiGN WORLD October 2013
Pa ul J. H eney - Ed i tori al Di rec tor

p heney@wtwhmed i a.com
On Twitter @ DWEditor
Put us to the test.

Get better performance, plus cost savings, and our 50 years of experience is free.
As precision bearing experts, AST recommendations

go beyond bearing type, size, and lubricant. Meticulously focusing on your application from the cutting edge of bearing technology, our engineering team uses custom measures to ensure your best bearing choice. We routinely deliver high quality products and services, better performance, and cost savings, which is why many manufacturers call us.
Put us to the test. Call AST at (888) 906-8366 or visit us at astbearings.com/DWtest and experience value beyond the part.
Value Beyond the Part
2013 . AST Bearings. All rights reserved.
ADDING NEW FRAME SIZES AND MOTOR CAPABILITIES
THE BEST JUST GOT BETTER...
730 725 720
Best-in-class efciency, versatility and value

NEW 720 and 730 FRAME SIZES 1/15 - 1/2 HP; 35-1780 in-lbs 1PH & 3PH INVERTER DUTY MOTORS NEW MOTORS: 115/230V 50/60Hz for ALL FRAME SIZES 230/400-460V 3-Phase for 725 and 730 Series
Maximum power density means a compact prole without compromising performance Ground gearing provides whisper quiet operation, low backlash precision Latest hypoid gear technology for better energy efciency Versatile mounting interchangeability to easily upgrade your installed drives Exclusive PowerSTAR EP lubricant for extended life Bison turns the corner on innovation. The new PowerSTAR line of right-angle gearmotors combines the latest in hypoid gear design with exclusive manufacturing technology, multiple mounting congurations and Bisons Robusticity design philosophy to provide unmatched efciency and complete application versatility. Proudly made in America and available through Bisons dedicated distributor network, PowerSTAR gearmotors are perfect for a multitude of packaging and industrial conveying equipment applications.
To learn more about PowerSTAR right-angle gearmotors, please visit Bisons NEW WEBSITE at www.bisongear.com or call 1-800-AT-BISON.
Gear & Engineering Corp.

2013 Bison Gear and Engineering Corp.
Panasonic Sensors
EKMB & EKMC Series
Passive Infrared Motion Sensors for Smart Home Applications!
Panasonic
Panasonic brings strategic innovations to our customers product development process. We provide the technology and engineering resources to enable manufacturers to plan and build world-class solutions to meet their customer needs.
Relays Capacitors Resistors Connectors

1A low current consumption Simplified circuitry with fully integrated sensor design Lead-free pyroelectric elements Low curvature lens for product designs Robust design prevents false detection
Inductors Sensors Electromechanical Circuit Protection RF Modules Semiconductors

Visit us online at www.panasonic.com/industrial email industrial@us.panasonic.com or call 1-800-344-2112
To learn more about Panasonic Sensors please visit

www.panasonic.com/industrial
...nn wl, toe.

Circuit Protection! Hybrid Capacitors!
New! NN30 Series Synchronous DC/DC Step-Down Regulator
ERZ-E Series ZNRs (MOV)

Zinc-oxide Non-linear Resistor
EEH-ZA & EEH-ZC Series
Panasonics New NN30 Series integrates power MOSFETs that employ a hysteretic control system. This provides a high-speed response that minimizes output voltage uctuations in the presence of load current spikes. Panasonics NN30 Series has a user adjustable output voltage and a maximum current of 10A.
Outstanding performance now one diameter size smaller! Panasonic introduces the New ERZ-E Series Radial Lead Disc ZNR Transient / Surge Absorbers (MOV). The ERZ-E Series offers a ner, more uniform grain structure which facilitates enhanced performance while allowing for size reduction. Available in 5mm, 7mm, 8mm, 11mm and 14mm sizes!
Panasonics New Hybrid design Surface Mount Aluminum Electrolytic Capacitors introduce a new technology that combines the benets of both electrolytic and polymer products producing a capacitor with low ESR, low leakage current, high ripple current and smaller case sizes.
Co ntent s |
October 2013 vol 8 no 10
designworldonline.com
58
F E AT U R E S
MOTION CONTROL 48 Simplifying machine design with plug-and-play motion subsystems
Embedding mechanical motion subsystems into machines improves performance and reduces cost.
70
3D CAD
MECHANICAL VIBRATION
66
Silent air cooling is a new approach to thermal management
78
Atomic force microscope sees more through vibration isolation
MATERIALS
Vibration isolation and better scan size enables atomic force microscopy (AFMs) to see more at A multi-disciplinary team at Tessera Technologies has leveraged simulation to the nanoscale level. develop a new concept for cooling the thin and light tablets used for entertainment, clarification, and communication. MECHANICAL CONNECTION
58
ELECTRONICS
82
At the speed of light

Light-curable materials offer designers a fast solution for bonding parts.
70
Making strong connections

Because of enhanced ergonomics, lightweight and affordable designs, newer plastic quick connect tube fittings are finding their way into an increasing number of mission-critical laboratory and industrial applications, replacing traditional metal quick connects.
Seeing the light

What you need to know about todays energy efficiency lighting standards, the benefits of compliance, and the role of third-party testing labs.
ON THE COVER
Plug-and-play subsystems, such as servobelt linear actuators, help reduce cost and increase performance in embedded motion systems.
Photo courtesy of Bell Evans.
2013
2013
DESIGN WORLD
October 2013
SOLUTION CITY
2013 by AMETEK Inc. All rights reserved.
FANS
PUMPS
BLOWERS
All roads lead to SOLUTION CITY

Welcome Back to Solution City where you always nd the biggest brand names and largest selection of dynamic solutions for air and uid movement.
Our line of variable-speed brushless (electrically commutated) blowers, fans, and pumps as well as our regenerative/ side-channel blowers offer custom-engineered solutions unmatched in the industry. Whether your need is our latest electronic/microprocessor technology, our eld-proven uid motion solutions, or a customized design option, we work closely with you to evaluate your unique application/ specication requirements, assuring a fully compliant product, tailor-made for your application. To put your ideas for dynamic air or uid movement in motion, contact your local AMETEK technical sales and application expert, or visit us at: ametektip.com.
CJM final Ad Heli with bleed2012_DesignWorld_Layout 1 1/3/12 4:4
Co n te n ts
d E PA R T M E N T S 4 Insights
Reliability in a Clutch
...a clutch, brake or power transmission part for that matter. Since 1903 Carlyle Johnson has solved some of historys toughest motion control challenges its what we love to do. Our precision electrical, mechanical, air and hydraulic power transmission products consistently prove reliable and dependable in every application. Underwater, on the ground and in the air, CJM is everywhere.
14 Green Engineering 18 Engineering Exchange 20 Design For Industry 24 Design Notes 32 CAE Solutions 43 Sensor Notes 46 Ethernet World 92 Product World 99 Ad Index 100 Around the Web
20
24
43
Standard and Custom Clutch, Brake & Power Transmission Solutions
291 Boston Turnpike Bolton, CT 06043 Phone: 860-643-1531
www.cjmco.com
10
DESIGN WORLD
October 2013
THE DNA OF MOTION

60+ years partnering with Medical, Factory Automation & Semiconductor OEMs
Rotary Motion Solutions

PMDC, BLDC and iBLDCTM intelligent motors 22mm to 80mm diameter Planetary, Worm & WormetaryTM Encoders, Brakes, up to IP67 CANopen, Profibus, EtherCAT
iBLDCTM Intelligent Brushless DC Motor
Linear Motion Solutions

STA11 series Linear Motor
Actuators, Modules & Gantries Up to sub-micron accuracy Up to IP69K / Stainless steel Compatible with third-party drives 24h Shipping Stock Program
Linear Motor Modules & Gantries
BGE3508 Servo Drive
G30.1 / PLG32
BG65x50Xi / SG80
BG75x25Xi / PLG75
Call on the global quality and value leader.

Now part of AMETEK Precision Motion Control, and recognized since 1950 as the world market leader in customized fractional horsepower motion control solutions for the medical, packaging, automation, semiconductor and renewable energy industries.
Call: 224-293-1300 www.dunkermotor.com info@dunkermotor.com
MOTION CONTROL
INDUSTRIAL ENVIRONMENTS
FOR HARSH, DIRTY, TOUGH
Follow the whole team on twitter @DesignWorld
EdItorIAL Editorial Director Paul J. Heney pheney@wtwhmedia.com 440.234.4531 x104 @dw_editor Managing Editor Leslie Langnau llangnau@wtwhmedia.com 440.234.4531 x113 @dw_rapidmfg Senior Editor Miles Budimir mbudimir@wtwhmedia.com 440.234.4531 x114 @dw_Motion Senior Editor Mary Gannon mgannon@wtwhmedia.com 440.234.4531 x120 @dw_marygannon Assistant Editor Michael Jermann mjermann@wtwhmedia.com 440.234.4531 x111 @dw_MikeJermann
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Web Development Manager B. David Miyares dmiyares@wtwhmedia.com 440.234.4531 x105 @wtwh_webdave Web Development Specialist Patrick Amigo pamigo@wtwhmedia.com 858.603.2984 @amigo_patrick Integrated Media Manager Jessica East jeast@wtwhmedia.com 330.319.1253 @wtwh_MsMedia Business Development Manager Patrick Curran pcurran@wtwhmedia.com 440.234.4531 x109 @wtwhseopatrick Online Coordinator Jennifer Calhoon jcalhoon@wtwhmedia.com 440.234.4531 x119 @wtwh_jennifer Community Manager Lance Brown lbrown@wtwhmedia.com 440.234.4531 x108 @wtwh_SocialGuru Social Media Specialist Stacy Combest scombest@wtwhmedia.com 440.234.4531 x117 @wtwh_scombest Content Associate Heather Centorbi hcentorbi@wtwhmedia.com 440.234.4531 x115 @wtwh_SocialXprt
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VP Sales Todd Tidmore ttidmore@wtwhmedia.com 512.626.8263 @wtwh_ttidmore VP of EE Product Development Mike Caruso mcaruso@wtwhmedia.com 469.855.7344 Key Account Manager Jim Powers jpowers@wtwhmedia.com 312.925.7793 @jpowers_media Regional Sales Manager Suren Sagadevan suren@wtwhmedia.com 310.386.0302 @wtwh_suren Regional Sales Manager Tom Lazar tlazar@wtwhmedia.com 440.234.4531 x106 @wtwh_Tom Regional Sales Manager Courtney Seel cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel Regional Sales Manager Neel Gleason ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason
ROBUST & RELIABLE

SHOCK ABSORBERS / BUMPERS GAS SPRINGS / HYDRAULIC DAMPERS
Enertrols rugged and robust product line provides deceleration and motion control for applications in the most extreme environments. > > > > > > > Heavy-Duty Designs Wide Range of Models and Sizes Reduce Damage and Downtime Increase Productivity Increase Operating Loads Quality-Built ISO Certied Expert Application Assistance
Director, Creative Services Mark Rook mrook@wtwhmedia.com 440.234.4531 x103 @wtwh_graphics Graphic Designer Matthew Claney mclaney@wtwhmedia.com 440.234.4531 x112 @wtwh_designer Traffic Manager Mary Heideloff mheideloff@wtwhmedia.com 440.234.4531 Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com 440.234.4531 x153
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Publisher Mike Emich memich@wtwhmedia.com 508.446.1823 @wtwh_memich Managing Director Scott McCafferty smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty VP New Media Marshall Matheson mmatheson@wtwhmedia.com 805.895.3609 @mmatheson
Applications include: Automotive, Marine, Steel, Foundry, Oil & Gas, Glass & PET, Mining, Defense, and More For further information or product catalog contact us at: customerservice@enertrols.com
WTWH Media, LLC

2019 Center Street, Suite 300, Cleveland, OH 44113 Ph: 440.234.4531 Fax: 216.453.0617
2011, 2012, 2013
DESIGN WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. DESIGN WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care. DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright 2013 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher. Subscription Rates: Free and controlled circulation to qualied subscribers. Non-qualied persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only. Subscriber Services: To order a subscription or change your address, please email: designworld@halldata.com, or visit our web site at www.designworldonline.com DESIGN WORLD (ISSN 1941-7217) is published monthly by: WTWH Media, LLC; 2019 Center Street, Suite 300, Cleveland, OH 44113. Periodicals postage paid at Cleveland, OH & additional mailing offices. POSTMASTER: Send address changes to: Design World, 2019 Center Street, Suite 300, Cleveland, OH 44113
Farmington Hills, MI P: 734.595.4500 l F: 734.595.6410 email: customerservice@enertrols.com
www.enertrols.com
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DESIgn WOrld
October 2013
Small in size, big in performance

The PITTMAN Difference
12.7 mm (0.5-in) diameter. Also available: 9.5 mm (0.375-in); 20 mm (0.8-in); 28 mm (1.1-in)
Many of todays most sophisticated analytical and medical procedures require ultra-compact, high-performance DC motor platforms that deliver responsiveness, maneuverability and extreme precision. Following established stringent design criteria, PITTMAN has developed the micro-motor BI Series slotless, brushless motors for designers, developers and manufacturers looking to achieve high-performance in a confined space.
12.7 mm (0.5-in) diameter with optional gearbox
No load speeds up to 100,000 RPM Output torque range 0.002 Nm (0.3 oz-in) up to 0.105 Nm (14.9 oz-in) Motor diameters - 9.5mm (0.375-in), 12.7mm (0.5-in), 20mm (0.8-in), and 28mm (1.1-in) Stainless steel motor body construction High energy neodymium iron boron rotor magnets Options include custom gearboxes and autoclavable versions
When evaluating DC motor choices, size matters.

Brushless DC Motors
Brush DC Motors
343 Godshall Drive, Harleysville, PA 19438 USA: +1 267 933 2105 Europe: +33 2 40 92 87 51 Asia: +86 21 5763 1258
www.PittmanMotors.com
G ree n E n g i n e e ri n g
Strategic planning can drive sustainability

n Paul J. Heney/Editorial Director
Dr. Ted Duclos, VP and general manager of Freudenberg-NOK Sealing Technologies Fluid Power Division (left) and Roy Schroeder, Lead Center manager, Fluid Power, Automotive, look over a new single cavity press installed at the companys Findlay, Ohio facility.
How does a company sustain itself in a

green fashion through decades of changing business demands? According to Dr. Ted Duclos, VP and general manager of the Global Fluid Power Div. of Freudenberg-NOK Sealing Technologies, this complex question has what amounts to a clear answer. Duclos, who spoke recently at the Center for Automotive Research Management Brieng Seminar in Traverse City, Mich., said that corporate sustainability requires businesses to equally address economic, environmental and social issuesa complex task.
14
DESIGN WORLD October 2013
However, businesses can manage this complexity by establishing clear principles that drive innovation, continuous improvement, nancial accountability, customer and employee consensus, and community support. In short, sustainable knowledge that will drive success. Anyone in business understands that in order for a business to survive and prosper, it must have the capacity to endure, persevere through business cycles and pursue long-range objectives, Duclos said. The ability to endure in business, of course, requires sound nances,
www.designworldonline.com
Here are a few plugs for the industrys first universal voltage blowers, from Windjammer.
Announcing another AMETEK exclusive variable-speed brushless DC motors featuring Universal Drive Systems. Now you can specify a single Windjammer blower design that will operate over voltage inputs from 100 to 240 VAC, and satisfy virtually every voltage standard around the globe! All of our durable 5.7"/145 mm Windjammer blowers feature IntelliGen Controller Design. This electronic control drive integrates a factory-programmed digital signal processor (DSP) and easily accommodates onboard options including remote potentiometer speed control, tachometer or status outputs; even custom cards for specific applications. Plug into our website to learn more about our unique universal voltage design for your products. Then make the whole world your outlet.
ametekpmc.com
2013 by AMETEK Inc. All rights reserved.
A SUPERIOR SENSING SOLUTION
Gre e n En gine e r ing
TIMKEN MAGNETIC ENCODERS

Timken magnetic encoder technology offers clear operational and cost benets over other commonly used technologies. Our superior sensing products provide reliable speed and position data even in harsh operating environments.
To achieve the national goal of 20% wind power in the U.S., wind blades must be 50% longer, an almost impossible gure with current manufacturing methods.
relevant products and an effective means of production. Sustainability is about more than checking a box. It must be founded on the ability to develop new techniques, innovations and knowledge. It is a distillation of the capabilities needed to survive in an evolving business arena. Freudenberg-NOKs guiding principles, drafted by the companys founder, Carl Freudenberg, in 1887, are still in use today. The six guidelines are: Value for customer, responsibility, innovation, leadership, people and long-term orientation. The company says these provide a framework for how it does business and embodies the very denition of sustainability. The guiding principles drive innovation, waste reduction, scal conservatism, collaboration and long-term thinkingall crucial to corporate sustainability, Duclos said. While new business developments, increased global product demands, environmental concerns and economic uctuations have challenged the company, the guiding principles have ensured its survival. Achieving sustainability through these Principles sounds good in theory, but from a practical standpoint, the company has several examples of how it uses the guidelines to drive knowledge creation and longevity: The companys Energy Saving Seals (ESS) reduce friction and heat to such an extent that if every seal on a vehicle (that could be replaced with an ESS) were replaced, it would save the equivalent of three days of oil imports in the United States; The Net Shape Single Cavity Mold Process is a counter-intuitive approach to manufacturing because it produces a nished part in the mold; it improves quality, eliminates waste because there is no trimming or scrap created during production, improves time to market, and lowers inventory requirements; and The TANNER (Travel and Navigate New Exciting Roads) program has sent more than 800 students abroad to experience different countries and cultures. DW Freudenberg-NOK www.fnst.com
timkenencoders.com Visit us at WESTEC 2013 Booth 1218 October 15-17 Los Angeles Convention Center
Discuss This
and other engineering topics at www.engineeringexchange.com
M15
THS25
MPS160 60
MPS512
Custom Solutions
Stronger. Value. | Stronger. By Design.
16
DeSIgN WORLD
October 2013
Bottle packaging equipment requires high performance solutions for transferring power and data across rotating interfaces. Moog offers slip rings that have been developed for Ethernet data communication networks. Models are available in capsule and through-bore configurations. Reliability is built into every product. Extensive life testing means our slip rings are proven to provide long life and less downtime. Learn more about Moogs solutions for automation. Standard slip ring designs are ready for quick delivery or can be tailored for unique projects. Contact us to discuss your applications. Looking for more? Scan to view slip ring specifications.
Ethernet Slip Ring Features:
Continuous 360 rotation Maintenance-free operation Robust performance Compact size Plug-and-play Ethernet connections
Motion Technology +1-540-552-3011
| Fiber Optics | 800-336-2112 (USA)
Electronic Systems mcg@moog.com
www.moog.com/components
CONNECT with Design World

For implants, custom is better
Twenty-seven years ago doctors suggested that Barry Fell have a knee replacement to x his worn out knee. However, I didnt like it, he said. " But with a manmade replica of a knee, in terms of structure, ligaments, and so on, its not even close to what youre giving up.
http://dwo.me/16Nx1mG
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Launching U.K.s First CubeSat Mission

UKube-1 is the UK Space Agencys rst CubeSat mission and Scotlands rst satellite. Its journey into space is expected to launch from the Baikonur Cosmodrone in Kazakhstan later this year.
http://dwo.me/16RLyhm
Building a bridge for wind energy >>

Although offshore wind farms are not common in the U.S., they are increasingly being built overseas, because wind turbines can capture the more consistent winds off the coast while also reducing environmental and visual impacts. But like all wind turbines, offshore designs require vigilant maintenance. So installing them and maintaining them can be a challenge.
Webinar: Essential Steps in Selecting the Correct Hose End Fitting

Extensive information is available regarding polymers utilized in industrial hoses. However, appropriate selection methodologies for choosing the safest and most effective couplings are rarely discussed. Hose leaks, failures and worker safety issues can be avoided by understanding how to select the best coupling for your hose assembly.
What is a Transducer?
1:15/ 2:32
A transducer basically converts some form of energy into another form. Common types of transducers used in industrial applications can include sensors used to measure temperature, pressure, force, strain, liquid levels and ow rates, and electrical conductivity among others. In motion control applications, transducers can refer to any one of a number of sensors such as rotary or linear encoders for position feedback, sensors such as tachometers for speed sensing, and even proximity switches to initiate or halt some action. In applications using hydraulic motion control systems, pressure transducers are a key part of the control.
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Engineers can win a two-day trip and go behind the scenes at NASA
Littelfuse (the circuit protection company) is bringing Engineers behind the scenes at NASA Johnson Space Center. Enter the Littelfuse Speed2Design sweepstakes for a chance to win a two-day trip of a lifetime and go behind the scenes at NASA Johnson Space Center in Houston, TX.
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DESIGN WORLD
Innite Designs, One Platform

with the only complete system design environment
NI LabVIEW is the only comprehensive development environment with the unprecedented hardware integration and wide-ranging compatibility you need to meet any measurement and control application challenge. And LabVIEW is at the heart of the graphical system design approach, which uses an open platform of productive software and recongurable hardware to accelerate the development of your system.
LabVIEW system design software offers unrivaled hardware integration and helps you program the way you thinkgraphically.
>> Accelerate your system design productivity at ni.com/labview-platform
800 453 6202

2013 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 11217
Design for Industry
machine tool
Twin Drive system simplies turning table design
The latest version of MSR TwinDrive simplies the mechanical transmission system on large vertical lathes. As a result, the design of turning tables is easier. The MSR drive is composed of two identical gearboxes (TwinDrive system), sharing the driving torque (50%-50%) during turning operations. With the help of the CNC system, which manages the motor preload torque, the system is able to cancel 100% of backlash while maintaining high accuracy. Thus, it allows the execution of additional functions on the C axis, without any additional mechanical devices. For instance, top accuracy is kept during milling operations with one motor driving and the other
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DESIGN WORLD
motor braking. Before MSR, turning table manufacturers used two different types of drives when a C axis was needed: a main drive for turning operations driven by a big spindle motor and a feedpreloaded gearbox to cancel the backlash during C axis mode that needed to be clutched and unclutched to the crown. In addition, the main drive needed to be shifted to neutral ratio. The MSR drive eliminates the need for developing a complex and expensive gearbox for the C axis, including a complicated system of clutching/unclutching. A system with two motors is less expensive and easy to manage. In comparison to high duty turning tables used in

conventional congurations that require a 160 kW motor, the MSR uses two 80 kW motors, which are more standard and less expensive (despite the fact that there are two of them). When the diameter of the chuck or part to machine is large, conventional homemade kinematics consisted of using a different stage ratio of 1/1, which resulted in high costs and loss of efficiency. MSR kinematics allow the drive to be placed under the chuck directly meshing with the crown. For this MSR drive, the latest generation of MSD twospeed gearbox is combined with the cubic R Series right angle bevel gearbox. Supplied
as a self-contained sub-assembly, this integrated and compact system is ready to be implemented. Depending on machine arrangement, OEMs can use the bevel box as an option. The range improves features of the four sizesMSR330, MSR640, MSR650, MSR660with torque capacity at pinion from 2000/4000 Nm (2 x 40 Kw motors) up to 9000/18000 Nm (2 x 100 Kw motors) with 3 possible ratio combinations of 7.66&2, 9.88&2, 11.49&3. This approach, combined with pinion/ring ratio of about 10 to 15 offers turn table torques from 20 0000 Nm up to 270 000 Nm and global ratios (gearbox + ring gear) of 77/20 and 172/45
ANDANTEX USA Inc. info@andantex.com
October 2013
medical
Design for Industry
2 POWER TRANSMISSION
maintenance & assembly tools
BEARLOK SHOELOK BEARLOK Shrink Disc
RETAINING DEVICES &
BEARHUG
CLAMPNUT
TANGENTLOK
Power unit for wheelchair lifts and other applications

PRECISION NUTS & WASHERS
Even though a component is targeted at a specic market, such as medical, it may be useful in a number of other applications with requirements similar to its primary market. Butler Mobility, for example, uses a high-quality, high-tech power lift for its inclined platform wheelchair lift. That same power unit can also be used for other applications and purposes, including material lifts, low-speed mixing purposes, packaging machinery, conveyors for a high-value product, and also as a control for batch or continuous processes, such as baking or heat treating. The power unit has a rigid, double-decker chassis design that includes thick aluminum plates and durable fasteners. It also features a brake that safely holds the motor without power, as well as a gear box in a sealed unit. The power design also keeps the output from moving. The units chain drive is rated for more than a 6,000 lb capacity. Controls allow the system to operate on a 24-Vdc power supply. With the PLC and expansion module wired to three front-panel connectors, there are three switch circuits, including forward, stop and reverse applications. An emergency stop switch circuit also passes through two of the connectors and disconnects the ac drive from the motor, releasing the brakes to hold the motor. With UL listed electrical components and a battery backup for at least ve minutes of full-load operation, the power unit can be used by a variety of industries.
Butler Transmission, a Division of Butler Dynamics, LLC www.butlertransmission.com
October 2013 DESIGN WORLD
INCH and METRIC THREADS LEFT HANDED as well as RIGHT -HANDED Materials of: CARBON, ALLOY and HARDENED ALLOY STEELS Materials of: ALLUMINUM and CORROSION RESISTANT STEEL
ADAPTER SLEEVE ASSEMBLIES
NUTS & WASHERS
HARDENED TONGUE WASHERS
SPLIT COLLAR
RETHREADING DIES
ADJUSTABLE SPANNER WRENCH
BEARING ASSEMBLY SOCKET
HI
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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 02863 Telephone: (401) 728-0700 FAX: (401) 728-0703 E-mail: info@whittet-higgins.com Web: www.whittet-higgins.com
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Design for Industry
semiconductor
Absolute optical encoders achieve 0.5 m accuracy

In some semiconductor applications, component multitasking can lead to axes collisions. Amicra Microtechnologies, a developer and manufacturer of precision assembly systems that bond and mount active/passive semiconductors, lenses, MEMS and processors for microelectronics and micro-optics applications in the automotive, telecommunications and information technology industries found a way to prevent such collisions. Its NovaPlus series machines handle surface mounting on wafers and stack-die assembly. They use an array of horizontal and vertical axes to perform multiple functions simultaneously. Reliability is critical in avoiding collisions. Incremental measuring systems installed in the companys machines required reference runs upon commissioning or after a stoppage, and the machines were susceptible to axes collisions without excessive operator attention. Both issues created downtimeintolerable in high-production environmentsso the company switched to Renishaws Resolute absolute optical encoders. The encoder system allows the machine axes to deliver absolute measurement without reference runs, and the encoders position detection method eliminated collisions that led to long periods of downtime. The new encoders help the micro assemblers achieve accuracy of 0.5 m and a process capability Cpk of 1.66.
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Surface mounting on wafers and stack die technology are used to construct three-dimensional memory and computer structures. Semi-conductors are mounted horizontally and connected (SoC), as well as mounted vertically in several planes (TSV), and miniaturization of electronic components, a driving force behind their design, is dependent on the ability to achieve high packing densities. Amicras micro assembly machines use linear axes and special grippers from feed stations to pick up components and position them on boards or wafers where they are bonded or soldered, either conventionally or with a laser beam. The machine simultaneously positions a component while a second handling unit picks up the next component from a buffer store, and work tables and other linear axes with lasers and UV lamps move into position to solder and bond. Concurrently, additional axes position the machines integrated process monitoring cameras. These machines have a lot going on at the same time, so process reliability of these installations is particularly important, said Horst Lapsien, managing director of Amicra. More importantly, crashes between the alternate positioning grippers and the linear axes must be avoided. We achieve this through very precise programming of the motions, so the linear axes measuring systems ability to detect current position of the slides
Design for Industry

reliably and accurately is paramount. Incremental position sensors report an incremental change in position and, when powered up, do not report position until they have a reference point. Therefore, starting the NovaPlus production and mounting cycle upon commissioning or after a stoppage took a long time. The readheads of all the linear axes had to rst travel to a reference position to detect the actual position of the axes, and moving to the reference positions from an undened slide position also represented a signicant source of error. If the operator had not rst checked the crash paths and selected the reference travel cycle accordingly, the machines could suffer considerable damage as the result of gripper or gantry collisions. Resolute encoders detect the absolute position immediately at switch-on, without a reference run, so the machines are able to start automated cycles more quickly upon commissioning or after a stoppage. Resolutes single-track optical scale combines the absolute position and the embedded-phase information into a single code to eliminate de-phasing problems associated with dual-track scales. The singletrack scale gives the encoder a wide set-up tolerance and allows for easy installation and long-term reliable operation, even if the axes settle or move over time. An integral set-up LED on the readhead provides a simple visual check that the scale is being read correctly, and further simplies installation and diagnostics. Resolute encoders feature a unique position detection method that operates like a very high-speed digital camera. Highresolution images of the scale are captured and analyzed by a powerful Digital Sensor Processor (DSP) that applies cross checking and error rejection to determine position to 1 nm. The encoder, combined with a built-in position-checking algorithm, also has high immunity to contamination. In a three-shift production operation, our machines have recorded zero stoppages due to reading errors of the system caused by dirty measuring tapes, added Lapsien. The Resolute systems RTLA absolute measuring scale can be bonded directly to the substrate or inserted into a special Fastrack guide, both made from stainless steel. The encoders install easily and compactly in the Amicra machines, achieving 5 m/m accuracy. Another advantage is the encoders use of BiSS-C open serial protocol, which allows it to be integrated into many positioning axes. Many industry-standard servo drives and controls use this interface, added Lapsien. So, the open protocol allows us to avoid getting tied to a single supplier of motion system components. DW
Renishaw Inc www.renishaw.com
October 2013
DESIGN WORLD
23
De s ign Note s
Terry Persun/ Technology Journalist
The Direct Pa rt Marking Mac hine from Totality perform s component m arking using two AllMot ion EZHR17EN st epper controllers and a pneumatic m icro percussion marking te chnique for accu racy and repeatability.
Digital marking meets rigors of manufacturing

Todays successful manufacturing operations need high-performance digital marking
systems that can handle 24/7 operation and integrate well into an enterprise-wide clientserver IT system. A major challenge in the design of such a system is to minimize the maintenance requirements on both the server and the client side. Accomplishing this requires quick adaptation to changing requirements, ready integration with other external systems, scalability toward increased needs, and use of the latest technologies. Totality is a design and manufacturing company that provides high-performance client-server systems that cater to the 24/7/365 production needs of manufacturers in high-volume production. Its primary product, the Direct Part Marking Machine, is used in applications where manufacturers need to mark parts using traceable data such as part numbers, serial numbers, batch numbers, date/month/year codes, and other necessary information. As an example, the automotive industry uses the marking machine to mark vehicles as well as automotive parts and accessories. To advance this technology, Totality wanted to create a more comprehensive and useful digital marking system. Thats when the companys engineers designed the MC2012E SmartMark marking machine, which consists of a Marking Stylus and the Marking Controller. The controller harbors a two-axis carriage, which supports the marking stylus. While each axis is driven by its own stepper motor, the axes operate in a synchronized manner to produce the
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DESIGN WORLD
October 2013
In these component creation and conguration screens, a user gets to select the information required for the particular marking operation from a simple menu.
downloaded character and graphic vectors. The engineering team chose to use stepper motors because they are simple and economical when compared to servomotor systems, and provide more than enough accuracy for the operation, even in openloop operation. For example, addressable accuracy is 1 m at a 256 microstep operation, while the effective accuracy is limited to 25 m due to practical limitations of the mechanical system employed for the operation. This accuracy allows a pneumatic marking stylus, which is attached to the XY carriage, to trace the vectors and make a permanent impression, similar to a pen plotter, directly on the specic part to be marked. The marking machine creates the impressions through a series of indents that are created using high air pressure on the part itself at very high frequency rates. This marking technique is called micro percussion, or dot peen marking. The pneumatic stylus is supplied between 3 and
5 bar air pressure, depending on the required depth of marking and component hardness. The engineers chose AllMotion stepper controllers and drivers because they are efficient, feature-rich, and reasonably priced. The MC2012E SmartMark machine incorporates two AllMotion EZHR17EN highresolution stepper motor controllers and driversone for each axis. The controllers are tightly synchronized so that they can efficiently and accurately align the stylus into position for marking. Designed specically to allow for the rapid implementation of stepper motor solutions in automation products, the controllers provide all the functions necessary for the application in one well-integrated unit. This includes the high-resolution stepper motor control; the axis homing function inputs and outputs that are used to implement functions such as start marking cycle, end of cycle signaling and marking status indications; high current switching for controlling the solenoid valves used to operate the pneumatic stylus; and
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t the ft ware, the markin g data is av a ila ble to downloa d to the AllM o tion EZHR17EN controller. data on th e Totality so
Once the u
ser lls ou
October 2013
DESIGN WORLD
25
De s i g n N o tes
that the MC2012E SmartMark is also installed at the end of the line. The EZHR17EN gets its operational data from a host PC, through easy-to-use marking software supplied by Totality. Marking data includes line conguration so that each line of the manufacturing operation is accounted for; component creation including part name, number, and current serial number; and component conguration, which may include both constants and variable parameters such as plant code, shift code, batch code, date code, line code, and serial number. The marking operation begins by rst performing a homing operation on the X and Y axes, and then proceeding with composing and marking each part for each block of sequential components. Overall, the Direct Part Marking Machine takes only a few minutes to prepare in most cases. Due to the small size of the EZHR17EN, as well as its many capabilities, the marking machine provides the simplest and most accurate marking available, and can be integrated quickly and efficiently into most any industrial application. DW Totality www.totality.in AllMotion www.allmotion.com
an RS485 interface for communications with the host PC. The two EZHR17EN controllers are synchronized to produce the required marking at a very high resolution and at very high speeds of up to 5 characters per second at a 3-mm character height. Each EZHR17EN measures only 1.6 1.6in., and is a fully intelligent motor controller and driver. The controller uses a single 4-wire bus containing two power wires and two communications wires. The controller can be used in a standalone operation or up to 16 of the controllers can be daisy chained together. In most manufacturing environments the marking operation occurs at the end of the manufacturing line after the part has gone through any operational testing. This means
Request
26
DESIGN WORLD October 2013 www.designworldonline.com
D e s ign N o tes
Michael Jermann/ Assistant Editor
Disc spring offers high load capacity in compact design

DEWALTs lead design engineer for drills was
tasked with designing a high power right angle drill that is lightweight, compact, and portable. As is common with hand power tools, the goal with the design was to maximize performance while minimizing the size of the tool. The design would incorporate a mechanical clutch built to limit maximum torque output to 70 ft-lb. Absent the clutch and with a gear reduction of 75:1, the drill would produce a lock rotor torque at the spindle of 175 ft-lb, which would be transmitted directly to the operator of the tool. Compared to conventional coil springs, disc springs offer a higher load capacity in less space. Additionally, the life and performance warranty of the tool were reliant on the disc spring design. Early on in development, DEWALTs engineers were working with a low cost disc spring supplier. They had developed and theoretically calculated the initial disc spring design. The rst prototype built failed, with the new design achieving less than half the targeted cycle life. Analysis indicated premature fatigue failure of the disc spring was due to higher than expected stress, lesser quality material, and a less than ideal manufacturing process by the original supplier. Determined to nd a solution, the lead engineer on the project contacted Spirol to discuss the disc spring design. Spirols Application Engineering team evaluated the design objectives and constraints and determined a standard disc spring could not meet them. The application engineers focused specically on the disc spring portion of the design and recommended a custom disc spring design that had alternate dimensions,
DEWALT te sted SPIR OLs recommen ded disc sp ring and the too l far exceed ed the cycle lif e requirem ent.
material, and secondary operations. For this demanding and high performance application, these features added signicant value and ended up costing only pennies more compared to the product offered by the original supplier. By partnering together, they determined the best disc spring design for the new angle drill, minimizing costly development time for both companies. DW Spirol www.spirol.com
It was determined early on that the clutching thrust required in the space available could only be achieved by a disc spring design.
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DESIGN WORLD
October 2013
5-AXIS + QUICK CHANGE = MAXIMUM UTILIZATION

Use Carr Lanes Quintus quick-change riser to mount vises, xture plates, or your custom clamping device By design, the CL5 system accepts our German-built, extremely accurate vises on precision plates made in the USA Achieve 5-side part access and quick-change exibility Numerous jaw types and sizes available
314-647-6200 www.carrlane.com/featured
D e s i gn N o te s
Michael Jermann/ Assistant Editor
Filtered connectors, where the lter is contained in the device connector, are a higher-performance approach to eliminating EMI/RFI noise.
Tips on ltering out noise

As processing speeds in
electronics continue to rise, and packaging continues to shrink, sensitive internal components are located closer and closer together. Higher clock speeds coupled with increased density of components leads to increasing amounts of electromagnetic interference (EMI) and Radio Frequency Interference (RFI) noise. Failure to address EMI/RFI/EMP protection along with that of transient voltages during the design and test phases of a project usually results in devices failing compliance testing and incurring high costs in redesigning and retesting the electronic systems or components.
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DESIGn WOrLD October 2013
EMI suppression is often handled by lters designed to meet the increased performance demands levied during testing from MILSTD-461, RTCA-DO-160, CISPRE, and CE Mark, and so on. Essentially, there are four ways to address EMI/EMC ltering requirements. Filtering can be designed onto the PCB or in a device during the initial engineering phase. Otherwise, the ltering requirement can be handled by one of three devices after the device has already been designed: (1) lter inserts, which are installed in front of device connectors, (2) ltered connectors, where the lter is contained in the device connector, and (3) lter / Transient Voltage Suppression (TVS) interface modules that are add-ons to an existing device. The lter insert is a quick and simple solution. It allows to you to simply pop a lter into your existing system and see if simple chip cap level of ltering will solve your EMI issues. If
they solve the problem, it wont cost you a lot, said Bob Ydens, President of EMI Solutions Inc. The next tier in EMI Filtering is the lter connector, which is a higher-performance approach to eliminating EMI/RFI noise. This solution is more expensive than the basic lter insert, but has the ability to include chip capacitors, such as what is in lter inserts, discoids, ferrites, TVS components, and Pi tubes, including a broad range of congurations and mounting arrangements. Filter modules are add-on components that are attached to an existing device or box. These modules can include any lter type, with or without transient voltage protection. Some of the advantages include more sophisticated ltration, avoidance of the need to insert additional PCB design integration into your already functioning elded unit, and avoidance of the costly time it takes to re-layout and retest the circuitry.
Sensoray_VSD_October_Ad.pdf
8/29/2013
D e s ig n N o te s
Custom solutions
Custom solutionsincluding design consulting, troubleshooting, device modication, and pre-certication testing may be appropriate when it comes to choosing the appropriate ltering or product modications. Some EMI ltration companies provide design and re-engineering services to expedite any necessary product modications and keep costs to a minimum. Pre-certication testing is performed in a chamber at their facilities so that the customer can evaluate the impacts of changes and modication and achieve a greater condence that the unit will pass when it goes to the certication test lab. The pre-certication testing process at EMI Solutions is an iterative process whereby changes and modications are made incrementally and then tested to determine the results. Additional ltering modications are then applied until testing in their onsite chamber establishes a solution that meets the customers requirements. One of the principal benets of this approach
is that the test lab has the staff and lter technology available on site to implement these modications quickly, which is valuable in terms of the time and costs involved. In some cases the device being tested requires upgrading or modications simply because the original design has been outmoded, or the end-user has specied a special application or environment. We were having multiple EMI issues with units being tested in connection with two government projects, said John Eckland, Test & Integration Engineer at Curtiss Wright Controls. One of the units is a complex, multipurpose computer unit. The other one is a high-capacity, high-throughput Ethernet switch unit. Both have military applications. We had to switch power supplies on both systems, which caused us to have signicant EMI problems, Eckland said. We were unable to do a redesign on the y due to time constrains. So, the only solutions available to us were either to do extensive internal changes within both units, or to contact EMI Solutions and see if they could develop a solution that required only limited changes within the units. In both cases, the solution required only a modication at the connector to the power supply, where lter inserts were placed on the power connectors. DW EMI Solutions, Inc. www.4emi.com
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Although lter inserts are generally

considered the lower end of the spectrum in terms of cost and ltering limitations, they are a practical solution for many applications.
October 2013
DESIGN WORLD
31

New Quick Mate pop-up below the context toolbar
The Curvature Combs of a Style Spline reveal smooth curvature and transitions with minimal inection.
CA E S o lu t i o n s
SolidWorks 2014an upgrade for new and long-term users

Leslie Langnau Managing Editor Adding toor improvingan existing software program that already contains millions of lines of code is a task most engineers approach cautiously; its too easy to introduce code that wrecks havoc on either other parts of the program or on the whole program. So, while some will opine that the latest enhancements to Dassault Systmes SolidWorks 2014 are not impressive, or not enough, those who have written code will be slower to criticize. At the recent introduction of SolidWorks 2014 at the Boston headquarters of Dassault Systmes, CEO Bertrand Sicot emphasized the need to add enhancements to this program, but to do so in a way that does not hinder the millions of already-in-use SolidWorks installations. Throughout the day-long presentation, many mentions of the importance of customer service and customer needs were mentioned. Just what constitutes an improvement in an established product line? Is a marginal increase in performance of 6%, for example, impressive enough? To an engineermaybe. If that improvement translates into 5 more hours to devote to other tasks, then that could be a huge gain. The ability to manage data less and accomplish more can be seen as another terric gain. After all the opinions have been written and posted, it will be users who indicate whether these improvements are good, or good enough. SolidWorks is a bit like Rockwell Automationno one ever got red for choosing Rockwell, goes the saying. SolidWorks 2014 includes 3D CAD, Simulation, Product Data Management, Technical Communication, and Electrical Design functions that further your ability to design with fewer limits. Some of the new enhancements promise to help you re-use data more dynamically, expediting the sharing of design data to accelerate collaboration. This version also includes mobility support for Android and iOS devices, making it easier to connect and experience your 3D designs anywhere and anytime. To maintain customer satisfaction, it is becoming increasingly important to save and track multiple versions and iterations of a design; customers want custom variations of a design, customers want the third version rather than the latest, manufacturing
32
DesIGN WORLD October 2013
MULTIBODY DYNAMICS: A swashplate mechanism is used to control the orientation of helicopter rotor blades.
Verify and optimize your designs with COMSOL Multiphysics.
Multiphysics tools let you build simulations that accurately replicate the important characteristics of your designs. The key is the ability to include all physical effects that exist in the real world. To learn more about COMSOL Multiphysics, visit www.comsol.com/introvideo
Product Suite
COMSOL Multiphysics
ELECTRICAL AC/DC Module RF Module Wave Optics Module MEMS Module Plasma Module Semiconductor Module MECHANICAL Heat Transfer Module Structural Mechanics Module Nonlinear Structural Materials Module Geomechanics Module Fatigue Module Multibody Dynamics Module Acoustics Module FLUID CFD Module Microuidics Module Subsurface Flow Module Pipe Flow Module Molecular Flow Module CHEMICAL Chemical Reaction Engineering Module Batteries & Fuel Cells Module Electrodeposition Module Corrosion Module Electrochemistry Module MULTIPURPOSE Optimization Module Material Library Particle Tracing Module INTERFACING LiveLink for MATLAB LiveLink for Excel CAD Import Module ECAD Import Module LiveLink for SolidWorks LiveLink for SpaceClaim LiveLink for Inventor LiveLink for AutoCAD LiveLink for Creo Parametric LiveLink for Pro/ENGINEER LiveLink for Solid Edge File Import for CATIA V5
Copyright 2013 COMSOL. COMSOL, COMSOL Multiphysics, Capture the Concept, COMSOL Desktop, and LiveLink are either registered trademarks or trademarks of COMSOL AB. All other trademarks are the property of their respective owners, and COMSOL AB and its subsidiaries and products are not afliated with, endorsed by, sponsored by, or supported by those trademark owners. For a list of such trademark owners, see http://www.comsol.com/tm
CAE Solu t i ons
Easily review multiple ow results in a single eDrawings le.
personnel need to examine an earlier version for assembly information, and so on. New features like the history tab allow multiple users to see and track recent design changes with the click of a mouse. Enhanced features such as assembly mates, known as common mates in the context menu, offer intelligent choices based on previous usage patterns and apply new options that make sense while performing assemblies. In other developments, Dassault Systmes engineers are developing tools for Solidworks that work with 3D printing needs. With eDrawings, for example, you can view 3D designs and demonstrate how products behave in the real world through an Augmented Reality 3DExperience on any iOS device, such as an iPad or iPhone. Other new tools and enhancements increase productivity across four key areas: design tools, integrated workows, performance increases and enhanced visualization. In Design Tools, three key tools are Advanced Shape Control, Fast Drawing Detailing, and Sheet metal features. For the Advanced Shape Control feature, a new Style Spline function, automatic Sketch Picture scaling and Conic Fillet controls let you create complex surfaces and organic shapes faster, easier and with more precision. Improvements to Faster Drawing Detailing deliver faster and more automated drawing detailing. New sheet metal features enable faster creation of sheet metal geometry and improved data output for manufacturing. You gain improved control over corner treatments, for example, as well as the ability to create
stiffening ribs such as the indented design seen on mounting brackets used to reinforce the weight and force placed on the part. Changes to better integrate workows, reduce the amount of time needed to manage data across features and platforms include: SolidWorks Enterprise PDM Streamlined Workow, which helps manage more data using the new Microsoft Office integration and enhanced Web Client with graphical preview features. SolidWorks Electrical Improved Integration and Performance has been enhanced to deliver better integration with SolidWorks Enterprise PDM and eDrawings to optimize, share and track electrical designs more easily. Now, you can choose to view your designs on other mobile devices, such as Android, with Design Communication and Collaboration. You can price parts faster with less setup, then share cost data more effectively with Streamlined Cost Estimating and Reporting. For example, key product development data for assembly can now be sent to Microsoft Excel allowing for easy sharing with departments such as manufacturing and purchasing. Visualization has been improved with Streamlined Simulation Setup, which automatically leverages engineering data for re-use in simulations, eliminating duplication of effort and improving design collaboration.
And with Enhanced Assembly Performance and Visualization, you can create assemblies faster and easier with the new in-context Quick Mate tool bar and Slot Mate. For assembly in section views, you can include or exclude selected components allowing for a fast creation of more impressive section views. DW
SolidWorks, Dassault Systmes
www.solidworks.com
A Corner Gusset is added across a sheet metal ange. A full preview is available making it easy to visualize on creation.
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DESIGN WORLD
October 2013
Others say theyre FAST...
But do they have the
SCALE to deliver?
Material Selection Demystied

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Proto Labs entire operation is optimized to deliver quick-turn CNC

machined and injection molded parts in as fast as one business day. We manufacture parts every day for thousands of customers, many of whom come to us at the last minute with dozens of designs they need to test ASAP. Since 1999, weve produced tens of thousands of molds, and shipped tens of millions of parts to our customers all over the world. Sure, its our technology that allows us to make your parts faster than anyone else. We back it up with large-scale global manufacturing facilities with hundreds of CNC machines and injection molding presses on three separate continents. Whether your project calls for a few machined parts or thousands of molded parts from 50 different designswe have the scale to meet your needs. Every time!
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a series of autonomous modules. This allows a team of software engineers to work on these modules simultaneously and load them to the hardware separately. Concurrent engineering not only shortens development times, but also makes it easier to integrate external developers into the process and reuse parts of the system that have already been tested. In addition, communication through OPC Unied Architecture ensures compatibility with numerous systems from other manufacturers. Direct support of web technologies facilitates the development of visualization, process control and remote maintenance applications. Object-oriented programming in Automation Studio 4 has become more efficient thanks to the SmartEdit feature that generates context-related suggestions from function libraries and existing program sections. Visualization templates also accelerate user interface design. DW
B&R Industrial Automation Corp.
Automation Studio 4 for smart engineering

Automation Studio 4 is integrated automation software that delivers three important goals: Keeping quality high, engineering costs low and time to market short. With the System Designer tool, hardware can be congured easily and with fewer errors thanks to a visual editor and lifelike representations of hardware components. This design tool includes an automated plausibility check and congures basic parameter settings in addition to offering functions for reusing entire parts of a system. A bidirectional EPLAN Electric P8 interface allows developers to integrate ECAD projects with hardware congurations designed in Automation Studio. This approach reduces the amount of work required and eliminates one possible error source that arises from having two sets of master data. Similar interfaces to simulation software allow applications to be generated automatically from simulation data to test development results at an early stage. Full support for project modularity makes it possible to split each individual project into
www.br-automation.com
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Design world
October 2013
Depiction of Frequency Waves
Ensure tolerance information in a CAD model

CETOL 6s v8.3 software for SolidWorks
can initiate directly from the annotations that already exist within a CAD model generated by the SolidWorks design software, reducing the time required to model the dimension scheme. This new feature also allows f2-way associativity between the SolidWorks CAD annotation and the CETOL model. Changes made to the CAD annotations are propagated to CETOL and changes made within CETOL in the process of a tolerance analysis are written back to SolidWorks, helping to ensure that tolerance information in the CAD model reects the correct information. CETOL 6 Sigma and SOLIDWORKS lets you see the impact that tolerance changes will have on the overall assembly. The technology of these two products enables product development teams to optimize their design and manufacturing goals so they can deliver higher quality and more precisely engineered products. DW
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effectiveness in ways that we previously wouldnt have considered. For example, weve been able to accelerate our production process by making Solid Edge available to one of our machinists for editing designed parts. In addition, we could affordably provide professional CAD software to a short-term intern, or enhance collaboration with our vendors, because now it is more feasible for them to work with the same software that we use during the course of our project. Unlike other subscription models, subscribers to Solid Edge will not be locked-in to an extended usage period, said Karsten Newbury, Senior Vice President and General Manager, Mainstream Engineering Software, Siemens PLM Software. The new monthly subscription option will initially be available in the United States, United Kingdom and Japan. DW
Siemens
Flexible licensing for Solid Edge

Siemens is providing a new option to license Solid Edge CAD
software. In select countries, customers can purchase a monthly subscription to Solid Edge. The monthly subscription license is available from the Solid Edge online store where customers can select from four different versions of the software based on the features that best t their needs. Subscriptions can be purchased on a month-to-month basis. The exibility of this licensing model enables companies to ramp up to meet project demands, or manage cash constrained operating expenses by paying for software licenses only when they are needed. We recently started using the new subscription license model, said Oliver Kuttner, CEO of Edison2, one of a small group of customers provided with early access. The exibility has allowed us to expand our engineering resources while managing cash ow. Additionally, the new model provides opportunities to improve cost
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CAE S olution s
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next phase of The Mbius Project, an initiative to support teaching and learning. This project makes it easy to create rich, interactive mathematical applications, share them with anyone, and grade them to assess understanding. After a four month pilot program, The Mbius Project is now available to the public. The goal of The Mbius Project is to provide new tools to engage students with powerful visual aids, deepen their comprehension of mathematical concepts both in the classroom and during independent learning, and revolutionize assessment by providing a new way for instructors to measure and increase students understanding. During the pilot phase, hundreds of educators joined in to explore the possibilities of this approach to learning and assessment. Mbius Apps created during the pilot phase covered a variety of topics, including integration with Riemann sums, quadratic surfaces, and analysis of loaded beams. The project is supported by several Maplesoft technologies. Maple, the foundational mathematical software product, is used as the authoring environment for creating interactive math applications. Maple T.A. 9.5, the newest release of the online testing and assessment system, contains new technology that enables it to automatically grade the students use of the math applications as part of a test or assignment. MapleNet provides the mathematical power to The Mbius Project web site, where these math apps can be accessed by anyone using only a web browser. Users can also run the applications directly on their own computer by using Maple or the free Maple Player. DW
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angular errors (such as pitch) from the linear axis. These contributory angular errors are then measured separately (using the XL-80 laser and angular optics) and removed from the initial rotary axis results. The end result is a set of data reecting only the errors from the rotary axis itself. The off axis rotary software is provided as an extra cost option for XR20-W and includes a suite of software utilities, part program generators and an electronic format manual. The manual details all the requirements for the mounting set-up and associated custom hardware manufacture. Key to precision machining is the ability to understand the location of the centers of rotations of the rotary axes relative to the machines linear axes. Without accurate data about these pivot points, a machines controller will be unable to reliably control the relative positions of the tool and the component as the rotary axes are moving, leading to inconsistent machining results. The AxiSet Check-up provides accurate and repeatable results using automated probing
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rotary axis calibrator checks the alignment and positioning performance of machine tool rotary axes. The software allows the XR20-W to be used to measure the rotary positioning accuracy of an axis on many congurations of ve axis machine tools, where the calibrator often cannot be mounted on the center of rotation. Combined with the AxiSet Check-Up system, which provides machine users with a fast and accurate health check of rotary axis and pivot points, users have comprehensive tools to identify errors with their rotary axes. The rotary axis calibrator combines with the XL-80 laser interferometer to allow rotary axis positioning performance to be measured with 1 arc sec accuracy. With this off axis test capability, users can test more types of machine tools. The method for off axis measurement works by synchronizing movement of rotary and linear axes so that the XL-80s laser beam is kept aligned throughout the test. Because the linear axis is moving, the measurements made by the XR20-W may include additional
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routines to gather performance data from a reference artifact, and includes simple yet powerful analysis. Alignment and positioning performance checks are carried out rapidly to benchmark and monitor complex machines over time. All tests use existing spindlemounted Renishaw touch probes, with probing routines generated using machinespecic macro software supplied with Check-Up. To ensure the highest accuracy, the use of OMP400 or RMP600 touch probes with patented Rengage strain gauge technology is recommended. Set-up is fast and simple. To perform the test a user quickly locates a supplied calibration sphere within the machine tools working envelope using a magnetic mount. Using the supplied custom macro software,
a touch probe is then programmed to automatically take reference measurements around the sphere. Measurement results from the test are output to a PC and presented in a Microsoft Excel spreadsheet. These include a graphical representation of performance that highlights tracking and centering errors, a function that compares two sets of data from the same machine, a simple pass or fail test against the users pre-dened tolerances, and a Ad # allows 5 TransTek ADT Ad history screen that comparisons of the performance of rotary axes over time. To ensure the optimum analysis of rotary axis performance using Check-Up, it is important that the machines standard three linear axes are also performing within specication. This should be determined and
corrected if necessary using Renishaws XL-80 laser calibration system, and then regularly checked using a Renishaw QC20-W ballbar. Together with the XR20-W rotary axis calibrator and AxiSet Check-up these powerful performance testing products combine to ensure that the highest quality parts can be consistently produced by ve axis machining centers and multi-tasking machines. DW
Renishaw
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S en so r N o tes
Detection in diverse
outdoor applications
Banner Engineering has expanded its line of R-GAGE QT50R radar

sensors, with four new models to reliably detect moving or stationary objects. Designed to meet exible application requirements and weather conditions, the enhanced line of radar sensors is suitable for collision avoidance on mobile equipment, outdoor crane-to-crane proximity detection, high-volume parking and vehicle detection and atbed or box truck detection at loading docks. Operating with Frequency Modulated Continuous Wave (FMCW) radar, the sensors provide accurate object detection of stationary and moving targets by providing distance and speed measurement. The sensors function in Industrial, Scientic and Medical (ISM) telecommunication band, with no special license required. For enhanced protection, R-GAGE sensors feature rugged, IP67-rated housing to withstand harsh environments. According to Jeff Curtis, business development manager, Banner Engineering, With single and dual independent sensing zones, sensing ranges up to 24 m and easy, versatile installation options, R-GAGE radar sensors provide exible performance in virtually any outdoor weather condition.
The expanded line includes: R-GAGE QT50R-AFH Adjustable Field, High-Sensitivity: Higher sensitivity, longer range and adjustable sensing eld to ignore objects beyond the setpoint ensure reliable collision avoidance onboard mobile equipment, such as reach stackers, forklifts and mining vehicles. R-GAGE QT50R-AF2W Adjustable Field, Dual-zone Waveguide: A narrow beam pattern and two independent, adjustable sensing zones enable accurate detection for collision avoidance and outdoor crane-to-crane proximity. R-GAGE QT50R-AFS Adjustable Field, Short Range: High sensitivity, short range and adjustable sensing eld to ignore objects beyond the setpoint provide reliable detection for high-volume car parking and other vehicle detection applications. R-GAGE QT50R-RH Retroreective High Sensitivity: Retrowave reference signal and output recognize weak targets in the foreground or for loss of retroreective target, while ignoring objects in the background beyond the retroective target. The sensor detects stationary targets with poor or no radar reection, including atbed or box trucks at loading docks or overhead sensing of vehicles in exit lanes. DW
Banner Engineering
www.bannerengineering.com
October 2013
DESIGN WORLD
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S e nsor Note s
More sensor assembly solutions
new range of customizable pressure and thermal sensor solutions from Honeywell includes modules with multiple sensors and technologies integrated inside. Heaters, magnetic, Magnetoresistive, infrared, optical, pressure, thermal, and humidity options are all available for customization. Options include custom interfaces, I/O, size and shape,environmental packaging, and total thermal management solutions for fast, easy and affordable design options. The companys technical support system will allow new and updated designs to be brought to market quicker. The ability to design a custom version of an already approved sensor design often means that device developers do not have to re-certify their upgraded products, saving both time and money. It is important to provide customers with exactly what they want, all from a single vendor, said Valerie Rothermel-Nelson, Honeywell senior global product marketing manager. This is part of Honeywells new systematic method of providing integrated and differentiated value added solutions. Our new approach means that we are now providing higher-level assemblies, not just components. A higher-level assembly is a package that provides differentiated and integrated solutions that ultimately give our customers a competitive advantage. It could be combining more than one sensor into higher level packaging, providing custom termination or even providing total thermal management solutions. DW Honeywell
www.honeywell.com
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Design world
October 2013
Eth e r n e t Wor ld
Protect networks from cyber attacks

he convergence of IT and industrial automation networks has increased the awareness of security threats posed by hackers, worms, and viruses. The standard solution has been to use an industrial secure router that protects the control network in conjunction with a variety of switches behind it to complete the communication network. But, this approach sometimes introduced compatibility issues. The EDR-810 is a Gigabit-performance secure router with built-in managed switch. Integration of security and networking functions into a single device saves deployment cost and effort. It also reduces power consumption and panel space. The router is an industrial-grade 8+2G secure device with Firewall/NAT/VPN and managed L2 switching functions, which
allows it to transmit data efficiently while protecting the network and critical devices from cyber attacks. Firewall policies can control network traffic between different trust zones, and Network Address Translation (NAT) shields the internal LAN from unauthorized activity from outside hosts, which is a more secure architecture than just NAT alone. Additionally, the router adds Virtual Private Networking (VPN) to provide secure communication tunnels when accessing a private network from the public Internet. DW
Moxa Americas Inc www.moxa.com
Digital pressure sensors with CANopen

Model DPS pressure sensors are
rugged, all-welded devices for use in harsh environments. The sensors are congurable, so customers can choose from multiple pressure types, accuracy levels, pressure ranges, pressure connections, and electrical terminations to meet specic application needs. Congurations for digital measurements are fully temperature compensated and calibrated for pressure ranges from 10 to 10,000 psi or 1 to 700 bar or 70 to 70000 kPa, with accuracy ranges of 0.25% and 0.1%, and operating and storage temperature ranges from 25 C to 85 C [13 F to 185 F]. Built tough to withstand harsh environments, the Model DPS with CANopen protocol communication allows customers to connect to longer cable distances without sacricing accuracy. The sensors have an all-welded, 300 series stainless-steel and Hastelloy design. DW
Honeywell Sensing and Control sensing.honeywell.com
46
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Eth e r n e t Wo rld
Connect remote devices and mobile equipment

The PremierWave XC HSPA+ (3.5G) device is a
high-speed intelligent gateway and application server for easy mobile and remote device connectivity.The latest addition leverages leading-edge 3.5G cellular/mobile technology, bringing M2M connectivity to devices and equipment previously unable to be connected through wired or Wi-Fi solutions. The PremierWave XC family is for applications in a variety of vertical markets including telematics, industrial automation, healthcare, energy, utilities, and more.The product enables remote access and management of virtually any serial equipment or device through the use of the Lantronix device server application suite and optional custom programming environment.Additionally, it can be deployed in areas that do not have an Ethernet or Wi-Fi infrastructure, or for installations that have such connectivity but rely on cellular for failover backup, ensuring redundancy. HSPA (High Speed Packet Access) represents a family of high-speed 3G and 4G digital data services available to GSM carriers worldwide. The service works with HSPA cellphones as well as laptops and portable devices with HSPA modems. Although based on WCDMA, HSPA is a major enhancement with more channels and different modulation and coding techniques. In addition, HSPA can recover faster from errors than WCDMA.HSPA+, also called I-HSPA and HSPA Evolved, is designated as a 4G technology. DW
Lantronix, Inc. www.lantronix.com
Network management for industrial networks

Version 5.0 of Industrial HiVision builds on the previous releases by adding extensive
customer-driven functions. This network management system meets the specic challenges of conguring and supervising an industrial Ethernet network. HiFusion, a tool provided free with Industrial HiVision v5.0, is a stand-alone application that facilitates the integration of any SNMP-capable device into Industrial HiVision. It includes a wizard to guide users through the creation of the integration les. Industrial HiVision v5.0 is a distributed management system. A network management hierarchy provides master and slave network management stations to ensure that any size network can be supervised. It was designed to be a product that will be used by automation engineers. The project set-up wizard in v5.0 will take you through start-up step-by-step. DW
Belden Inc. www.belden.com
47
SIMPLIFYING
Tom Maccianti President Bell Everman
design
machine
you expect. All too often, engineers think of stages or actuators as just another item on the bill of materials. As long as the motion device nominally meets the desired positioning, force, payload, speed and cost requirements, its good to go. With simple motion requirements, this approach to stage or actuator selection may yield acceptable results. However, machines with complex mechanical motion requirements will benet from an embedded motion design strategy. Rather than a collection of electromechanical components, which may or may not work well together, embedded motion systems function as true plug-and-play machine subsystems. Embedded motion systems are engineered to t within a predened physical space on a machine and tie into the machines motion control system, ready to
with plug-and-play motion subsystems
I
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DESIGN WORLD
f you build machines, you probably work with actuators and positioning stages every day. But do you truly get the best performance or lowest cost of ownership from these motion devices? The answer may not be what
accept commands from a top-level computer interface, control card or PLC. At their simplest, embedded motion systems may consist of little more than a stage or actuator that has been tted with a connector to make the drop-in installation easier. At their most complex, these motion subsystems extend from pin-out to payload. They encompass not only the motion device itself but also everything it carries. Compared to a component-by-component approach to machine movement, embedded motion offers some compelling advantages:
Mechanical Performance. Even when they use the same stage or actuator, embedded motion systems will typically outperform component-built motion systems.
October 2013
Motion Control ||||
ServoBelt linear actuators are one of the motion building blocks used in embedded motion systems.
Embedding mechanical motion subsystems into machines improves performance and reduces cost.
October 2013
DESIGN WORLD
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Motion Control ||||

ServoBelt Rotary stages are typically used for precision positioning applications, but they are also an ideal motion platform for a novel CNC machine.
The reason why comes down to application and assembly expertise. A good embedded motion vendor will have years of experience solving difficult positioning problems and a collection of proven motion building blocks that can be customized for the task at hand. They will have an intimate understanding of how the stage dynamics, the motion control architecture and the operating environment will affect positioning requirements. As for assembly, many machine builders lack the skilled technicians, specialized xtures, laser interferometers and other metrology systems needed to align the most precise multi-axis stageswhich often have axis-to-axis alignment tolerances measured in microns.

Controls Expertise. Embedded motion
systems may or may not ship with motion controls, depending on customer requirements. But a control strategy should always be part of the embedded motion equation. A good embedded motion vendor will have an extensive knowledge of how different motion control platforms and their
kinematic capabilities will interact with the mechanical motion systems. This knowledge can allow us to push the envelope of what is possible in terms of dynamic capabilities, such as acceptable inertia mismatch ratios (see sidebar).
Reliability. When commissioning a new
motion system, some of the most common
Just-InTime Maintenance Early warning device for industrial actuators and other moving parts
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Motion Control ||||
problems occur because individual, seemingly minor components fail to work properlyor fail to work properly with one another. For instance, a single faulty connector or the wrong wire can leave even the best motion stage motionless. Embedded motion avoids this type of failure because they are assembled and tested as a system before integration on the production machine. With motion systems composed of individual components, small failures and incompatibilities can go undetected until the production machine comes together.
Cost Reduction. Embedded motion systems typically cost 25 to 50% less than their component-based counterparts. In part, this savings comes from the ability to reduce part countsfor instance, by designing in brackets, connectors and other components. The cost reduction can skyrocket well above 50% when you factor in all the hidden cost components associated with building and installing a motion system. These include costs related to design engineering, inventory, time-to-market and more (see sidebar). Many types of applications can reap the benets of embedded motion. We have implemented this approach on dozens of semiconductor, wet bench, laser cutting, packaging and lab automation machines. The case studies that follow highlight two applications whose performance and cost requirements would
Rules of thumb for exceeding inertia mismatch

Taking an embedded motion systems approach allows us to drive mechanical systems to the highest levels of dynamic performance. Consider inertia mismatch, for example. A typical rule of thumb is to keep the payload inertia to motor inertia ratio below 20:1. This rule will keep you out of trouble when you use the gain presets available in prepackaged amplier and motor combos. We routinely ignore that rule of thumb and create fully controllable systems with inertia mismatch ratios that are 200:1 or even greater. Our biggest inertia mismatch ratio to date is an unbelievable 4,600:1 on a rotary table, making a precise 90 indexing move with no overshoot. We dont break the 20:1 inertia mismatch rule just because we can. When you push the envelope on inertia mismatch, you can often reduce motor size as well as eliminate cost and complexity from the motion subsystem. Breaking the rules does entail some extra engineering effort compared to using preset gains. You will need to dynamically alter the tuning gains and validate those gains with real-world test data.
October 2013
DESIGN WORLD
51
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Motion Control ||||
have been impossible to meet without an embedded motion solution. One is a linear embedded motion system for a precision semiconductor singulation operation. The other is a rotary motion subsystem we created for a unique type of CNC machine.
Linear Stage For Semiconductor Operation Stacked stages of any kind can suffer from alignment and control issues when you design and build them as a collection of individual axes. If that stacked stage has to meet challenging positioning accuracy or speed requirements, its crucial that stage function as an integrated system. We recently delivered just such a stage for a semiconductor singulation operation. This multi-axis stage required a linear drive system versatile enough to make two very different types of moves. One was a long travel move at 400 mm/sec. The other was a short, high-speed move of 13 mm that must settle to 10 microns in 150 milliseconds. The moving mass seen by the lowest axis in the system was 38 Kg with a bi-directional accuracy goal of 5 microns based on the positioning reference from a 1-micron Renishaw optical linear encoder. The customer rst tried to use an existing XY ballscrew stage design. By a wide margin, it simply failed to make the desired moves and meet the customers throughput requirements. It was possible, in theory, to come up with a ballscrew-based design that would meet the motion requirements. Such a design, however, would require expensive zero-backlash ballscrews and encoders that would exceed the projects cost targets.
The hidden costs of motion systems

Component-built motion systems have a number of hidden costs that can be eliminated by the embedded motion approach, including: Time-to-market costs. Embedded motion systems, which inherently support concurrent engineering, can shave weeks or even months off the development time of a complex machine. Program, production and materials management costs. Embedded motion systems ship as a single billof-materials item, eliminating hundreds of parts to be ordered, inventoried and assembled. Production costs. Precision motion systems require skilled assembly technicians and specialized production equipment that can be difficult to cost justify at less than full utilization. Warranty and failure costs. A good embedded motion vendor will warranty their systems against failure and stand behind their work, which reduces the OEMs risk.
October 2013
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Motion Control ||||
The customer next turned to linear motors. While capable of making the desired moves, linear motors for this application would have been large and expensive due
to the long motor coil needed to meet the applications 300 N continuous force requirements. The length of the coil would have required sweeping changes to the
overall machine design. And the cost of the linear motor would have been more than 50% higher than the customers cost targets. Ultimately, the customer went with an embedded motion system based on our ServoBelt Linear drives and a counterintuitive control strategy that rejected dual-loop control in favor of single-loop control using only the linear encoder. The ServoBelt motion system beat out the more expensive linear motor by providing:
A zero backlash solution. The only way to
achieve the fast index moves in this application was to close the servo loops using the linear encoder, which requires a true backlash-free drive line from motor to payload. ServoBelt has no backlash, which proved essential when tuning a control system that would meet the dynamic requirements.
Inherent damping. ServoBelt inherently offers
excellent mechanical damping, which allows for high tuning gainstypically 4 times the velocity and positional gains which translates into extremely low settling times. Linear motors, by contrast, must simulate this damping in the servo amplier electronics, which inherently reduces the possible positional gain.
A compact, plug-and-play system. The stage
was designed, assembled and delivered as a single unit. We handle the crucial alignment, functional testing and burn in work. Problems are identied on our shop oor, not our customers machine. Designing the stage as an embedded motion system also allowed us to meet predened physical space requirements.
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Rotary motion improves surface nish Three-axis CNC milling machines usually rely on linear motion systems to position the cutting tool. We went down a different path with an embedded CNC platform that we recently developed for the milling of medical ceramics. In place of a traditional three-axis linear motion system, this new desktop-sized machine combines rotary and linear positioning devices. The rotary devices, two of our ServoBelt 100 units, face each other. One of the rotary devices carries a 150,000-rpm air-driven spindle. The other rotary holds the workpiece and can spin it
54
DESiGN WORLD October 2013
180 to allow for two-sided machining. The linear axis, driven by our ServoNut actuator, allows the rotary device with the cutting heads to translate axially relative to the workpiece-holding rotary. All three devices move in sync during machining operations. The linear axis handles the Z-axis positioning, bringing the cutting tool to the face of the workpiece. The two ServoBelts rotate relative to one another, so that that the cutting tool can reach any point on the surface of the workpiece in a volume of 40 x 40 x 40 mm. The rotary design offered important technical advantages. For one, the rotary stages exhibit an extremely high stiffness, which is crucial in order to meet the applications machining tolerances. For another, the rotaries are lubed-for-life, saving maintenance costs and reducing the possibility of contamination. And nally, the rotary stages provided a simple sealing solution that protects the motion components from cutting uid and ying ceramic dust. Both rotary stages extend through simple rotary seals in the wall of the cutting chamber. An XYZ motion system, by contrast, would have required less elegant sealing scenarios, such as bellows and armadillo covers. The coordinated motion on this system required a rethinking of CNC kinematicsin large part because the rotary positioning of the cutting tool and workpiece requires the use of polar coordinates rather than Cartesian. The controller still takes in XYZ G-code commands but converts them to polar coordinates in real time, which is no easy task. So why go through the effort? Rotary motion has an inherent advantage over linear in producing a smooth surface nish on the ceramic parts. The reason boils down to the rumble that even the best linear bearings and ballscrews can exhibit as the balls recirculate in and out of a loaded state between bearing grooves. This ball rumble would have reverberated through the motion system and transferred to the part as periodic variations in surface quality. With their large diameter rotary bearings, ServoBelt Rotary stages inherently avoid the ball rumble problem altogether. This nontraditional CNC machine has all the hallmarks of an ideal embedded motion application. It required:
Both controls and mechanical expertise.
kinematics for polar motion required a systems approach and months of testing. We also had to develop a suite of alignment
techniques and tools to build this new CNC system.
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Marrying the mechanical system with the controls and ampliers that support the complex
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Compact design, easy integration. Space
was at a premium on this desktop-sized CNC machine. ServoBelt Rotarys design, which features a large unobstructed through hole, allowed us to use the available space efficiently. The 100-mm through holes made it easy to bring the air supply right to the spindle, embed a material indexer on the workpiece side and make all the required power connections.
Cost containment. One interesting aspect of this embedded motion system is that it is no more complex than it needs to be. The main functional requirement involved surface nish, not positioning accuracy. The positioning needs are actually quite modest, at least by our standards. So we were able to forego direct reading encoders and run the entire system in open-loop mode. That saved our customer thousands of dollars per machine.
Getting started with embedded motion The jump from component-by-component motion systems to embedded motion systems may seem like a leap of faith. You will, after all, be outsourcing the motion control to a vendor. If you pick the right vendor, though, the outsourcing will pay off with improved performance and reliability. Costs will fall too as motion subsystems arrive at your plant fully-tested, warrantied and ready to drop into your machine. DW
http://dwo.me/19F1Qbb
Bell Evans www.bell-everman.com
Mobi l e Integrati on Powered By
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DESIGN WORLD
October 2013
LOPRO L
DISCOV ER YOUR
LoPro lin tough, c ear actuators a re ost effec tive, low built on Dual ideal for Vee fric de Various c bris-laden condit tion, low profil Motion Techno log es oa io available tings and mater ns, extreme clim olutions in unlim y creating ia . Actuat a ion opt ls available. Sing tes and corrosive ited lengths ions: be le, multilt, chain axis, and environments. , lead sc c rew and ustom gantries ball scr ew.
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speed of light
Light-Curable Materials (LCMs) can offer users benets over other types of materials. Over the last 30 years, advances have been made in material and curing equipment technology and thousands of companies worldwide now use light-curing technology to assemble and protect their parts.
Most light-curable materials cure fully in 1 to 30 seconds. This speed provides dramatic cost reducing benets: Shorter cycle timesLess work-in-progress and shorter lead times. Increased capacityBonding steps that may have been bottlenecks with slower systems are no longer issues. Less floor spaceElimination of ovens, humidity chambers, conveyors and racks. Simple and better automationIndexing time on a line is reduced, inspection can be
58
At the
Materi als
Light-curable materials offer designers a fast solution for bonding parts.
Edited by Paul J. Heney
Editorial Director
completed on-line, and the complexity of fixturing during the curing process is reduced. In addition, even more significant than speed, the one-component nature of lightcurable materials can mean lower capital costs; dispensing systems for one-component materials cost signicantly less than systems for two-component materials. Two-component systems generally have pot lives (the time between when a multiple component system is mixed and when it is dispensed or thrown away) measured in minutes or hours. Two-part systems that cure in less than 30 minutes have pot lives of less than 10 minutes. As a result, two-component systems, especially those with shorter cure times, require frequent purge cycles and often result in clogged mixing elements, regardless of operational precautions. Whats more, material purged from a system that remains uncured is
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M a teri a ls
The UVCS UV light-curing conveyor system in action.
usually classied as hazardous waste. The A and B components of a two-component system are hazardous when not fully cured. Of course, product performance is a critical factor in selecting between different technologies. LCMs offer greater adhesive strength to a wider range of substrates and exhibit a wider range of other physical properties than other comparative technologies.
How they work LCMs use energy provided by UV or visible light to start a curing reaction. In all practical systems, light emitted by a source reacts with a photoinitiator sensitive to UV light or UV and visible light. Different LCMs use photoinitiators sensitive to different ranges of UV and visible light. Thus, its important to match the material being cured with the source of light being used to cure the LCM.
Most light-curable resins used for assembly and thick layer curing, including all LCMs manufactured by Dymax, use a broad
spectrum of UV light with a concentration in the UVA range to achieve cure. Some materials also use visible (blue) light for cure. Factors inuencing the cure speed of LCMs include (in no particular order): Light intensity on the LCM (will vary with thickness) Light wavelength present at LCM Photoinitiator sensitivity to light wavelength LCM resin composition
Curing bulbs (also called lamps) vary in their spectral output. Sometimes, lters modify the spectral output of a curing system. The important thing to remember is that the output of a curing lamp must be matched to the absorption of the photoinitiator in LCMs.
Basic types There are two basic types of LCMs: Acrylates and epoxies. Acrylate systems are a broad range of materials including acrylates, methacrylates, and similar functional groups. Acrylate
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M a teri a ls
Most light-curable materials cure fully in 1 to 30 seconds.
systems react when exposed to UVA light (always) and visible light (in many cases). The materials exhibit a very broad range of properties. Depending on additives, acrylate systems can be produced which are colored (i.e., red, blue, or black), opaque, uorescing (often a requirement for in-line inspection), or thermally conductive. The physical properties of acrylates can be varied more than epoxies. These properties include adhesion, viscosity, durometer, and appearance. Since they can be made to cure with visible light, uorescing and red or blue acrylate formulations are common. Cure speeds with acrylate resins depend on formulation specics, and the intensity and nature of light used to cure them. Practical cure speeds generally range from 0.5 to 15 s. Depth of cure also varies with formula and process specics. Typical cure depths range from 2.5 to 15 mm. Acrylate LCMs can also be made to react with heat or an activator. This is useful when light can not be used to cure the material due to the presence of a shadow. Acrylate LCMs typically can not be cured with moisture or air. Cure options are shown on specic Product Data Sheets.
Surface tack is sometimes observed with acrylate LCMs. This is caused by the interference of atmospheric oxygen with the free radical cure mechanism on the surface of acrylate resins. In most cases, surface tack can be eliminated by altering the curing process (greater light intensity, longer cure time, or a slight adjustment in
Viscosity Illustrations of Everyday Items Viscosity (cP) Item Rheology 1 Water Newtonian 100 Vegetable oil Newtonian 2,500 Maple syrup Newtonian 10,000 Corn syrup Newtonian 25,000 Toothpaste Thixotropic 250,000 Peanut butter Thixotropic
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the wavelength of light used). Some acrylate LCMs will not cure tack-free. Most of these products were designed for applications where the LCM is not exposed to air, i.e., in bonding applications between two substrates. Epoxy systems are sometimes called cationic systems by virtue of the type of photoinitiator employed, as opposed to the chemical make-up of the resin. The range of properties that can be achieved with epoxy LCMs is somewhat narrower than with acrylate LCMs. Nevertheless, epoxy LCMs may be formulated to exhibit a few advantages over some acrylate LCMs. These include tack-free cure (no oxygen inhibition) and superior adhesion to certain substrates. Development of full properties of light curing epoxies often takes longer than for light curing acrylics. Heat is sometimes used to accelerate cationic LCM cure. Cationic LCM cure is impeded by moisture/humidity.
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A 5-step process to choosing the proper LCM

Step 1: Adhesion. In most situations, the rst consideration in choosing any assembly material is adhesion. Whether the application is bonding, coating, encapsulating, sealing or potting, candidate materials must demonstrate adequate adhesion to applicable substrate(s). Substrate selector charts are useful for selecting an initial group of product candidates.
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When choosing material candidates based on adhesion: Determine candidates from substrate or product selector guides. Evaluate the adhesion of candidates using a pick test on the substrates to be bonded. Evaluate LCM adhesion under the real life stresses the part will experience. It may be necessary to over stress the bond area to accelerate candidate testing. All adhesives and coatings are weakest when peel forces are applied. If the part and joint will be subjected to peel forces, material evaluations should be conducted taking into account anticipated forces and use conditions.
Step 2: Rheology. Next, consideration should be given
Standard Pre-Engineered Conveyor Products
to how the light-curable resin will be applied and how the material will flow once it is applied. High viscosity materials resist flow more than low viscosity materials. High thixotropy materials also show greater resistance to ow than low thixotropy materials. High thixotropy materials become thinner when they are sheared. Products that do not thin with shear are referred to as Newtonian. Gels have the properties of high viscosity and high thixotropy. These properties are desirable when negligible material ow after dispensing is required. The table on page 62 lists some common materials, along with their approximate viscosities and rheology.
Step 3: Physical properties. Next, consideration should be given to other desirable physical properties. Normally, these include hardness, elongation, modulus, environmental resistance, appearance, etc. Physical properties are described on individual Product Data Sheets and can vary over a very wide range from one LCM to another. Resistance to real-life stresses is an important criterion for choosing a material. In particular, temperature cycling, maximum operating temperature, solvent resistance, resistance to light (especially sunlight) and moisture are often critical factors in selecting an LCM. Remember that
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Ma te ri a ls
each application is unique and there is no substitute for real-life test results on actual parts subjected to the stress conditions that the parts will see over their expected lifetime.
Step 4: Cure Requirements. The cure requirements of the material should be considered. Most importantly, the question of whether shadow areas are present should be taken into account. If shadow areas are present, there are several options:
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Choose a viscosity and/or dispensing system that keeps the LCM out of shadows, Change the substrates so that they do not block light, Employ a secondary cure mechanism, i.e., heat or activator, or Choose an adhesive system other than one that cures with light.
Step 5: Specications. Industry specications or requirements may be a make-or-break consideration. For example, USP Class VI or ISO 10993 designation for medical grade adhesives, IPC 830 qualification for conformal coatings, or UL94 V-0 designation for consumer electronics may be required. Where these standards apply, information is provided on product selector guides and data sheets. DW
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3 D CA D | | | |
Silent air cooling is a new approach to
thermal management
Jennifer Hand , Contributing Editor
trend towards thin Ultrabooks, though, means that a typical fan unit is now squeezed into a height of less than 10 mm. With a couple of millimeters allowance top and bottom for air gaps and casing, the actual fan blade measures only a few millimeters and that is pushing the limit of effectiveness. Although some of the latest fans can operate in cavities of less than 5 mm, performance is diminished because smaller blades move less air with each revolution and thus must turn faster, creating even more noise. The truth is that engineers have nearly exhausted the potential for improving fan technology, just as the consumer tolerance for noise has fallen even further. As a University of Washington student in 2001, Nels Jewell-Larsen recognized the need for research in this area and began a development program focused on nding a silent replacement for rotary fans. For the past ve years he has been Senior Program
A multi-disciplinary team at Tessera Technologies has leveraged simulation to develop a new concept for cooling the thin and light tablets used for entertainment, clarication, and communication.
Thin and light tablets have become an
essential tool for entertainment, clarication, and communication. Serious data handling, however, calls for the power of a bigger device and when tablet users, accustomed to silent running, turn on a notebook, or an even thinner Ultrabook, the rst thing they notice isnoise. For the best performance from electronic devices, its critical to manage heat. For portable computers, up to now, thermal management has been handled with small mechanical fans. The
Here is a Multiphysics plot of a two stage Silent Air Cooling air mover. Space charge density as a surface map (red color indicates higher space
66 charge density) with space charge ux lines shown by white lines. Air velocity displayed as arrows, with arrow length linearly scaled to velocity.
3 D CA D | | | |
Silent Air Coolings
size compared to a pencil.
Manager heading up a specialist development effort within Tessera Technologies Inc. Recently, Tessera Technologies has launched a new product based on Jewell-Larsens research called Tessera Silent Air Cooling. Silent Air Cooling is not a fan, since it does not use a rotating blade to move air. It uses an electric eld and charged air to create airow, a totally different concept. The technology relies on an electric eld that charges and pushes nitrogen molecules in ambient air; these collide with other molecules in the air, transferring momentum and producing a continuous stream of laminar airow. Operation involves applying a voltage between two electrodes, which generates a very high electric eld near one of them that creates positively charged nitrogen ions. The ions created are pushed towards the second electrode, generating a constant pressure source (see photo below). The electric eld does not change with time, so there are no pressure waves, and therefore, virtually no sound. In addition
to being noise-free, Silent Air Cooling (SAC) ts in a thin cavity of less than 4 mm, since it doesnt need rotating fan blades and doesnt need an air plenum above or below it. Simulation has been at the core of our product development because the team needed to take in account electrostatics, charge generation and transport, uid dynamics and heat transfer. We are in a niche eld and there was no dedicated simulation software for this when we started, so we looked at several offers, commented JewellLarsen. We even considered a custom-made software at one point. We then began using COMSOL Multiphysics because of its in-built exibility. Gustavo Joseph, Head Thermal Engineer, noted, Many software packages can easily simulate the movement of uid or electrostatic forces independently. What is difficult to simulate is the generation of ions,
their transport in an electric eld and the force generated on air molecules resulting in the needed cooling ow. COMSOL Multiphysics allowed us to build all our own equations and couple them into the already available uid dynamics and electrostatics capabilities. Joseph and Jewell-Larsen used the program to design the core engine of the new technology, termed the blower. As the main objective was to maximize pressure and airow for cooling, we simulated different geometry and materials to optimize these parameters. After we designed the key aspects of the blower in Multiphysics we ported that over to a CAD software to design the rest of the system. The end result is a reliable, compact unit that operates at less than 15 dBA, which is below the average threshold for hearing. Additional features include a self-cleaning system and, as there are no bearings, the system is easy to maintain. The target market includes suppliers of portable computer devices. Concluded Jewell-Larsen, We have demonstrated that the technology works in Ultrabooks and our objective is to have this technology in as many devices as possible, with designers free to build form factors that are thinner and thinner. This technology is going to have a positive impact for users. DW
COMSOL www.comsol.com
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Silent Air Cooling uses an electric eld and charged air to create airow. An electric eld charges and pushes nitrogen molecules in ambient air, which collide with other molecules in the air, transferring momentum and producing a continuous stream of laminar airow. 68
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Seeing the Light

T
70
What you need to know about todays energy efficiency lighting standards, the benefits of compliance, and the role of third-party testing labs.
he Energy Policy and Conservation Act of 1975 and its
subsequent amendments established minimum efficiency standards for lighting products. This was the impetus for a host of programs and benchmarks for energy efficiency
Jeff Davis
Engineering Manager, Energy Efficient Lighting Intertek Arlington Hts., Ill.
standards. Overall, the growth and increasing variety of energy-efficient lighting products over the past several decades has led to the development of numerous voluntary certication programs and initiatives designed to measure and reect their performance and efficiency. Today, compliance with any or all of these voluntary programs can be a signicant source of differentiation, revenue, leadership, promotion, and pride for lighting manufacturersfactors which represent compelling reasons for manufacturers to invest time and resources into the pursuit of achieving these voluntary standards.
DeSIGN WORLD October 2013
Image: istockphoto.com
E le c tronic s | |||
U.S. and Canadian markets have seen an increase in green lighting certication programs and initiatives over the years. The opportunity to differentiate ones product has led manufacturers to invest time and resources into the pursuit and achievement of these voluntary program performance measures. While voluntary programs have different objectives and requirements, all involve precise measurement and unique submission requirements to assure compliance by a skilled and accredited third-party tester. Here we take a look at the range of voluntary energy-efficient lighting certication programs and initiatives in the U.S. including the benets that compliance with these initiatives can deliver to lighting manufacturers, as well as how an accredited third-party tester can help ensure compliance with these programs and initiatives.
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Performance Testing for Lighting Products While reputable manufacturers typically participate in mandatory safety testing to enable their products retail sale in recognized establishments, performance testing is not mandatory for installation. Instead, it addresses how a product will perform when used by consumers. Throughout the lighting industry, comprehensive performance testing typically consists of assessments in three different, universally accepted areas; distribution, color, and stress/longevity.
Distribution Testing This type of performance testing measures the
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Color Testing This type of performance testing measures the energy of
light at each wavelength and is used to calculate color temperature. The most accurate means of measuring a lights color is through the use of an Integrating Sphere-Spectrometer system, a specially coated apparatus most commonly available in 1, 2, and 3-meter sizes which collects a lights energy and measures it at all wavelengths. Typically, measurements with such systems include lumen or brightness level; correlated color temperature (CCT) in Kelvins ranging from 2,700 to 6,500 for consumers; color rendering index (CRI), which measures how true a color looks under the subject lighting; and other performance measures such as chromaticity, which is a coordinate mapping of the lights color.
Stress and Longevity Testing One key means of measuring a lights lifespan is by testing it on a specially designed and controlled piece of equipment known as a Life Test Rack. These long racks can provide up to thousands of sockets that measure the longevity and durability of a broad range of lamp types in different orientations (base up, down, or
CLAMP LOAD %
light pattern out of a xture or its total light output at all different angles. For all light sources, the most accurate means of measuring a lights distribution is through the use of a Type-C goniometer, a 30-foothigh piece of equipment used to test most residential and commercial lighting products while enabling xtures to rotate in a horizontal plane to measure their entire light distribution. The Illuminating Engineering Society (IES) standard LM-63 species how the results of a distribution test should be formatted and will typically require a text le showing all lighting values at each angle.
200
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Except as otherwise noted, all marks used are trademarks and/or registered trademarks of Henkel and/or its affiliates in the U.S. and elsewhere. = registered in the U.S. Patent and Trademark Office. 2013 Henkel Corporation. All rights reserved. 11240 (9/13)
Ele ct ro n i c s | | | |
Life test racks, pictured here, are used to test the lifespan of various light models. Different orientations can be tested as well as a range of ambient conditions.
horizontal) and in different ambient conditions. For LEDs, the use of IES standard LM-80 measures the individual chips that make up the lamps or xtures; they are typically burned for 6,000 hours to determine how much their light output degrades at different levels (according to this standard, an LED would fail a stress/longevity test if its light output at 6,000 hours fell below 70% of its initial output). In contrast, a surge generator is a key piece of equipment used in the testing of stress and is typically applied to the testing of compact uorescent and LED lamps as well as ballasts used in linear uorescent lamps. This equipment tests to ensure that lamp samples can withstand a ringwave or combination surge waveform without sparking or failing.
Current Programs and Performance Initiatives Separate from the Department of Energys (DOE) mandated minimum energy efficiency standards, the growth of the energy-efficient lighting market has triggered the development of a number of voluntary energy-efficient lighting certication programs, performance initiatives, and labeling standards.
Compliance with any or all of these can enhance a products eligibility for use in high-efficiency applications and upgrade projects of distinction, as well as qualify for rebate in a number of leading utility incentive programs throughout the country. Following is an overview of some of the industrys most popular voluntary energy-efficient lighting certication programs, performance
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DeSiGN WORLd
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initiatives, and labeling/packaging standards for lighting products in the U.S. and Canada.
Energy-Efficient Lighting Certication Programs

ENERGY STAR This EPA-sponsored certication program covers a
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variety of residential and light-commercial luminaires, lamps, light kits, and retrot kitsparticularly in the uorescent and LED arena (previous standards in the halogen and HID technologies are currently being reviewed)and aims to distinguish higher-efficiency products from standard or lower-performing ones. ENERGY STAR certication requires minimum performance standards in the three critical areas of distribution, color, and longevity/stress and all test data must be submitted through an EPA-recognized certication body. Energy-Efficient Lighting Performance Initiatives DesignLights Consortium (DLC)This voluntary initiative applies only to LED technology and typically covers the products not commonly comprehended by ENERGY STAR, such as high bays, wallpacks, cobra and pulse-style lighting for roadway xtures, decorative LEDs, and LED panels for use in heavier commercial, industrial, or outdoor applications such as warehouses, manufacturing, and roadways. In addition, DLC is a utility based initiative in that it currently feeds some 40 utilities nationwide that base rebate programs around DLC standards. Like ENERGY STAR, DLC certication requires minimum performance standards in the three critical areas of distribution, color, and longevity/stress, but, unlike ENERGY STAR, manufacturers must take responsibility for having their products tested by an accredited body and then must submit testing reports directly to the DLC.
California Energy Commission (CEC) Established in 1974, the California Energy Commission is responsible for planning Californias energy policy and promoting energy efficiency through the development of building and product standards. CEC standards for lamps, controls, luminaires, and other lighting products address efficiency only, not distribution, color, or longevity/stress, though their standards for ballasts and portable luminaires do serve to differentiate them from other voluntary lighting performance initiatives. CEC certication is based on the meeting of stringent product standards which can render some products eligible for utility rebates in California and other states, and which also support California-specic Title 20 and Title 24 building code standards. Like the DLC, manufacturers must take responsibility for having their products tested by an accredited body and must then submit testing reports directly to the CEC. National Resources Canada (NRCan) Addressing lighting product standards throughout Canada, NRCan is largely focused on performance measures related to efficiency and energy-using devices imported into Canada or shipped between provinces and must bear an energy efficiency verication mark. Minimum standards are laid out in CSA Energy Efficiency Standards and the mark must be from an SCC (Standards Council of Canada) approved certication body. Lighting products
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covered under NRCan include ceiling fan lighting, compact uorescent lamps (CFLs), exit signs, uorescent lamp ballasts, general service uorescent and incandescent lamps, torchieres, and traffic signals and pedestrian modules. ENERGY STAR is recognized in Canada, however, and ENERGY STAR testing (if applicable) can replace NRCan testing. Municipal Solid-State Street Lighting Consortium (MSSL)This specialized DOE-sponsored organization offers technical information and experiences related to LED street and area lighting demonstrations and serves as an objective resource for evaluating new products on the market intended for street and area lighting applications. MSSL testing is largely focused on measures of distribution, color, transient, vibration, corrosion protection, and longevity.
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Energy-Efficient Lighting Labeling and Packaging Standards

LED Lighting Facts Label Neither a certication program nor a
standards-setting initiative, the DOE-sponsored LED Lighting Facts Label represents a new labeling standard for all solid state xtures and lamps (bulbs). This label is mandatory for integrated SSL lamps in the ENERGY STAR program but voluntary for other product types. The LED Lighting Facts Label provides information on lights brightness, appearance (warm or cool), efficacy, color accuracy, and wattage. Additional label metrics, which are optional, were added in 2012 to cover lumen maintenance and warranty. The label was designed to provide a uniform and user-friendly way for buyers and utilities to review product specications and make comparisons between products. One of the goals is to help change the traditional metrics from watts to one of lumens, which focuses on light output and not on power consumed.
FTC Label The Federal Trade Commission (FTC) label is mandatory for all solid-state lighting (SSL), uorescent, incandescent, and halogen medium screw base light bulbs only. The new FTC-sponsored Lighting Facts Label has subsequently been designed to help simplify and standardize the information shared on lighting product packaging for consumers. It includes easy-to-understand metrics such as Estimated Yearly Energy Cost, Lumens, Lifetime, Light Appearance (Temperature), and Energy Used to enable more apples-to-apples comparisons between products.
AXIAL FORCE (Kgf)
DIAMETER (mm)
The Critical Role of Third-Party Testing Laboratories Along with mandatory energy efficiency requirements established by the DOE, new voluntary energy-efficient lighting certication programs and performance initiatives run by such organizations as ENERGY STAR, DLC, CEC, NRCan, MSSL, and LED Lighting Facts involve specic standards and submission procedures which can be tedious and precise to administer, but which are critical to a companys success. This is where accredited third-party safety and performance testing organizations can help take the guess-work out of the process of testing and the pursuit and successful achievement of compliance. In todays fast-moving lighting industry, a number of issues can delay or derail a manufacturers efforts to achieve compliance with any or all of
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More Information on E le c t ro n i c s | | | | Lighting Programs and Initiatives

Further details on the Energy Star program, including links to current CFL and LED requirements for ENERGY STAR certication, are available at www.energystar.gov. More information, including current technical requirements on DLC, can be found at www.designlights.org. The CEC website is located at www.energy.ca.gov. Here youll also nd information on CEC testing requirements and performance standards for lighting. For more information on NRCan specications, visit the link
An image showing distribution testing of a light, which measures total light output at different angles.
http://oee.nrcan.gc.ca.
Color testing is used to calculate the color temperature of a light source.
The Municipal Solid-State Street Lighting Consortium (MSSL) web site, which includes current and in-progress standards, is at www.eere.energy. gov/buildings/ssl/standards.html.
these programs or initiatives if undertaking their own rst-party testing procedures. For example, the inability to structure appropriate and consistent, repeatable testing conditions could alter results, while the submission of an incorrect number of samples could make the submission invalid. In addition, technology, particularly in the LED arena, is changing quickly and manufacturers might nd themselves challenged to keep up with the latest products and program requirements. For these reasons and more, accredited third-party (external) safety and performance testing organizations can help. Their possession of and investment in the highest-tech and most precise and capitalintensive testing equipment can ensure
76
consistent testing procedures and accurate results, while their demonstrated expertise in the unique details and current requirements of all industry certication programs and initiatives assures manufacturers of the utmost in quality coverage and representation. Along with the relationships theyve established with all of the industrys key certifying organizations over the years, a third-party testing labs exceptional understanding of and experience with the broad range of products and testing procedures can proactively support a manufacturers compliance while delivering security and peace of mind to both manufacturers and customers alike. DW Intertek www.intertek.com/lighting
To nd out more about the DOE-sponsored LED Lighting Facts and Labels standard, visit www.lightingfacts.com.
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Atomic force
sees more through vibration isolation

Vibration isolation and better scan size enables atomic force microscopy (AFMs) to see more at the nanoscale level.
microscope
Edited by Leslie Langnau Managing Editor
W
78
ith its development in 1986, and subsequent commercial introduction in 1989, the atomic force microscope (AFM) is one of the foremost tools for imaging and measuring materials and cells on the nanoscale. Revealing sample details at the atomic level, with resolution on the order of fractions of a nanometer, the AFM is instrumen-
tal for imaging an array of applications, such as dening surface characterizations, lithography, data storage, and manipulation of atoms and nano-sized structures on a variety of surfaces.
The need for more precise vibration isolation with AFM, though, is becoming critical as resolutions continue to bridge from micro to nano. AFM systems are extremely susceptible to vibrations from the environment. When measuring a very few angstroms or nanometers of displacement, an absolutely stable surface must be established for the instrument. Any vibration coupled into the mechanical structure of the instrument will cause vertical and horizontal noise and bring about a reduction in the ability to measure with the highest resolution.

The vertical axis is the most sensitive for AFMs, but these microscopes are also quite sensitive to vibrations in the X and Y axes. The atomic force microscope uses a sharp tip (probe), with a radius of curvature on the order of nanometers attached to the end of a tiny cantilever used to scan across a sample surface to image its topography and material properties. When the tip is brought into proximity of a sample surface, forces between the tip and the surface lead to a deection of the cantilever. This deection is typically recorded
1
The following images demonstrate the resolution capable when using negative stiffness vibration isolation technology in atomic force microscopes.
1. 2.
This image is a 2.5 m width of buttery wing.
This image is of a 32 m width of buttery wing using the University of California, Santa Barbara AFM.
Here is an image of a 250 m width of buttery wing using University of California, Santa Barbara AFM with negative-stiffness vibration isolation.
using a laser beam that is reected from the top surface of the cantilever to a photosensitive detector. The resultant position change of the cantilever allows characteristics such as mechanical, electrostatic, magnetic, chemical and other forces to be precisely measured by the AFM. These characteristics are displayed in a three-dimensional surface prole of the sample (in the X, Y and Z axes)an advantage that the AFM can provide compared to other microscopy techniques, such as the scanning electron microscope (SEM) which delivers a two-dimensional image of a sample (in the X and Y axes).
Expanding AFM capability and scanning range Since the release of the rst commercial atomic force microscope about 25 years ago, technology advances have improved AFM performance. One of these advances has expanded the AFMs ability to image biological samples in an aqueous buffer and provide a range of physical data for the sample. Another has increased the imaging speed of AFMs. Unlike Scanning Electron Microscopes, which are capable of scanning in near real-time, conventional AFMs, prior to about ve years ago, required between one and 100 minutes
to obtain a high-resolution image. With the introduction of high-speed AFM systems, imaging speeds are three orders of magnitude faster than with previous AFMs. Within the past several years, research into AFM design, conducted by the Paul Hansma Research Group, Department of Physics, at the University of California, Santa Barbara, has demonstrated success with AFM imaging of large-scale samples at nanoscale resolutions while extending the range of the Z-axis.
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To image at the extreme depths necessary in large-scale cracks and deep microcracks the AFM must have a Z-range of at least 200 microns and a cantilever tip long enough to probe the crack. As the vertical movement of the tip is increased, however, it brings into play a greater possibility for vibration. This issue was solved with the incorporation of negative-stiffness vibration isolation.
University of California, Santa Barbara atomic force microscope on its negative-stiffness vibration isolation platform.
Improving on AFM vibration isolation Developed and patented by Minus K Technology, negative-stiffness isolators use a completely mechanical concept in low-frequency vibration isolation while achieving a high level of isolation in multiple directions. In negative-stiffness vibration isolation, vertical-motion isolation is provided by a stiff spring that supports a weight load, combined with a negative-stiffness mechanism. The net vertical stiffness is made very low without
affecting the static load-supporting capability of the spring. Beam-columns connected in series with the vertical-motion isolator provide horizontal-motion isolation. The beamcolumn behaves as a spring combined with the negative-stiffness mechanism. The result is a compact passive isolator capable of very low vertical and horizontal natural frequencies and very high internal structural frequencies. The isolator provides 0.5 Hz* isolation performance vertical, and 0.5 Hz horizontal, using a totally passive mechanical system
no air or electricity required. (*Note that for an isolation system with a 0.5 Hz natural frequency, isolation begins at about 0.7 Hz and improves with increase in the vibration frequency. The natural frequency is more commonly used to describe the system performance.) The key factor for us was the incorporation of a true negative spring constant system, together with the positive spring constant, to achieve an effective and very soft spring constant, said Hansma. This allows the
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negative-stiffness vibration isolation device to have a very low vibrational frequency in the vertical direction, which is critical for atomic force microscopy. Negative-stiffness isolators resonate at 0.5 Hz. At this frequency there is almost no energy present. It would be very unusual to nd a signicant vibration at 0.5 Hz. Vibrations with frequencies above 0.7 Hz (where negative-stiffness isolators begin isolating) are rapidly attenuated with increase in frequency. We like the vibration isolation to be at 0.5 Hz, which we can achieve with the negative-stiffness table, continued Hansma. Not so much because of the vibrations at that frequency, which are minimal, but because 0.5 Hz is 16 more resistant to transmitting vibrations at a building resonance of 10 or 20 Hz, than compared with a resonant frequency of 2 Hz which would be found with air tables. Air tables, as vibration isolation systems, deliver limited isolation vertically and less isolation horizontally. They can make vibration isolation problems worse since they have a resonant frequency that can match that of oor vibrations. Air tables will amplify rather than reduce vibrations in a typical range of 2 to 7 Hz because of the natural frequencies at which air tables resonate. All isolators will amplify at their resonant frequency, and then they will start isolating. With air tables, any vibrations in that resonant frequency range could not only fail to be attenuated, they could be amplied. Transmissibility with negative-stiffness isolators is substantially improved over air systems. Transmissibility is a measure of the vibrations that are transmitted through the isolator relative to the input vibrations. The negative-stiffness isolators, when adjusted to 0.5 Hz, achieve 93% isolation efficiency at 2 Hz; 99% at 5 Hz; and 99.7% at 10 Hz. We did consider active isolation systems for our prototype AFM, as well, explained Hansma. We played around with a number of them. But, considering the weight of our systemit being fairly heavy equipment, up to 70 poundsand with a multitude of complications associated with our prototype AFM set-up, we did not want to add the complication of active feedback, which is inherent in an active vibration isolation system.
Also known as electronic force cancellation, active vibration isolation uses electronics to sense the motion, and then adds forces electronically to effectively cancel out or prevent it. Some active isolation systems can start isolating as low as 0.7 Hz. But active systems have a limited dynamic range that can be exceeded, potentially causing the isolator to go into positive feedback and generate noise. Although active isolation systems typically have low response at resonance, their transmissibility does not roll off as fast as negative-stiffness isolators. Because active system isolators run on electricity, they can be negatively inuenced by problems with the electrical supply available. They also generate heat, which can lead to thermal drift problems in certain applications. Negative-stiffness isolators do not require electricity or compressed air. There are no motors, pumps or chambers, and no maintenance because there is nothing to wear out. They operate purely in a passive mechanical mode.
Make the right connection.

You want capabilities and innovative ideas not just connectors. Colder Products works with you to solve your uid handling challenges, using a variety of exclusive technologies to nd a solution that best meets your needs.
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Extended AFM range Using the labs prototyped combined AFM and RPI techniques, and supported by its passive negativestiffness vibration isolation system, it has been able to achieve scan ranges exceeding one millimeter, an order of magnitude larger in the Z-axis than any commercially available AFM. The AFM/RPI system has also proved capable of exploring the molecular origins of fracture resistance in bone tissues to more than 1 mm2, with acceptable resolution and linearity. DW Minus K Technology, Inc. www.minusk.com Dr. Paul Hansma www.hansamalab.physics.ucsb.edu
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strong connections
Because of enhanced ergonomics, lightweight and affordable designs, newer plastic quick connect tube fittings are finding their way into an increasing number of mission-critical laboratory and industrial applications, replacing traditional metal quick connects.
Making
Riley Phipps
technical and design services manager Value Plastics Inc., a Nordson Co.
T
o meet the stringent requirements for use in medical devices, todays plastic tube connectors must be lightweight, cost-efficient and reliable. Because of their proven use in medical applications, they are now increasingly being integrated
into laboratory instrumentation and industrial equipment, where the need for reliable, critical connections is paramount, and ease of servicing vital to maintain production uptime and throughput. In many industrial and manufacturing processes, and with laboratory and in-plant test and calibration instrumentation, plastic tube connectors are used to convey substances that can ow liquids and gases, slurries, powders and masses of small solids. Manufacturing, packaging and material handling functions in many diverse industries including food and beverage, pharmaceutical, oil and gas, alternative fuels, printing and semiconductor manufacturing have embraced plastic tubing connectors as a viable option to supply
Plastic quick connects provide quick and easy connections and disconnections of tubing for servicing equipment, changing consumables and equipment portability.
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DESIGN WORLD
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* Tadiran LiSOCL2 batteries feature the lowest annual self-discharge rate of any competitive battery, less than 1% per year, enabling these batteries to operate over 40 years depending on device operating usage. However, this is not an expressed or implied warranty, as each application differs in terms of annual energy consumption and/or operating environment.
mission-critical functions such as liquid lling equipment, fuel supplies, and low-pressure pneumatic and hydraulic systems. Plastic connectors are well suited for industrial and laboratory equipment because they are lightweight; offer strong chemical resistance and non-corrosive properties; feature exible composites and congurations; and easily make connections with lower costs compared to traditional metal connectors. Nowhere is this more evident than with plastic quick connect ttings, recognized for their ability to provide quick and easy connections and disconnections of tubing for servicing equipment, changing consumables and equipment portability. The advantages of plastic quick connects Typically only a small percentage of a uid handling system in a laboratory or industrial system is subjected to user interface. These
The latest plastic quick connect designs can be equipped with intuitively simplistic thumb latch and side latch mechanisms to make for easy handling in laboratory and industrial uid management applications.
parts, however, should be well designed to reduce or even eliminate the potential for user fault. The choice of connection type depends on a variety of factors, including the expected frequency of connection/disconnection, servicing and safety needs, as well as user expertise. With so many factors to take into consideration, choosing the right connector can present signicant challenges. When frequent maintenance and servicing is required on a system, quick connects are preferred over general threaded ttings for uid control, and can provide an advantage
to OEMs desiring to improve user interface performance. They incorporate design features that prevent spillage and minimize the potential of accidental misconnections or leakage during maintenance and servicing. Equipment maintenance and repair contribute to overall process downtime. Quick connects help minimize service-related downtime by providing quick and easy access to uid lines that may need to be disconnected during repair and maintenance processes. Key features include built-in shut-off valves that automatically close the line to
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stop the uid ow and prevent leakage while the line is disconnected. Conversely, quick connects can be equipped with open-ow valves that will allow a desired consistent ow, with little ow path impedance, to minimize disturbance to media and allow maximum ow ratesboth critical considerations in a number of applications. Many metal and plastic quick connects, however, are limited by their lack of ergonomics and ease of use, making it difficult for users to understand how to operate and manipulate them. For example, determining how to execute the basic disconnection can sometimes present a signicant challenge, creating safety risks and unnecessary inefficiencies while fumbling with connections. These drawbacks have inhibited quick connect usage by OEM designers, and reduced their effectiveness by frustrating end users and increasing the incidence of spillage and misconnects.
The MQC Series quick connect from Value Plastics provides large, ergonomic buttons that make an audible click on connection, and grips for easy handling, even with gloves.
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Streamlined human interface simplies use The latest advances in plastic quick connects deliver an improved level of human engineering, ease of use and operator intuitiveness. These new quick connectors are equipped
with intuitively simplistic thumb latch and side latch mechanisms, for one hand connection and disconnection, which make for easy handling.
The latest advances in plastic quick connects deliver an improved level of human engineering, ease of use and operator intuitiveness.
Featuring: Highest stroke length (90%) Highest cycle life Customization Repeatability Media compatibility High temperature
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Mechanical Lock Protection. Actual "rod interrupt" lock ensures full load capacity is maintained without slipping. (HYS/PVS) Positive Locking Sensor Control. Senses the lock itself to ensure positive machine control. (HYS/PVS) Strong Compact Design. Integral high load locking mechanism helps engineers save space and reduce system complexity. Standard Porting. Lock operation is internally ported, making the cylinders function as a standard 2-port system. (HYS/PVS) Braking cylinders (KPS) have the brake internal to rod to brake in any position without damaging rod surface and seals.
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Dual Latch Quick Connect Interface One of
the newest and most versatile plastic quick connect solutions available for laboratory
and industrial applications incorporates an intuitive dual latch push-to-connect design, using large, ergonomic buttons that provide an
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audible click on connection, and grips for easy handling, even with gloves. One new version of this efficient dual latch design is the MQC Series made by Value Plastics, a Nordson Co. These male and female connectors are made from nylon and buna-N materials, which are autoclavable, ethylene oxide (EtO) compatible and gamma radiation stable, and capable of a working pressure up to 30 psi. They also provide strong chemical resistance and are great for higher temperature applications. The new dual latch design of quick connect maximizes ease of handling and prevents misconnections.
Thumb Latch Quick Connect Interface
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The latest plastic quick connect thumb latch designs feature ergonomic grips and automatic shut-off valves for better connecting and disconnecting ease and optimum uid control. Maximizing convenience and versatility, one such new design from Value Plastics universally interchanges with other thumb latch plastic connectors, and may be used with PVC, polyurethane, silicone and other types of exible tubing.
These new thumb latch quick connectors
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produced in acetal and polypropylene for a variety of application usesare designed with single barbs capable of increased pull-off resistance when compared to multi-barb styles. Proven to provide a more secure seal and superior tubing retention, this design feature minimizes the prospect of leaks and accidental disconnection. These new features in plastic quick connects enhance operator ease of use, and expand the range of available options for the design of laboratory and industrial equipment by OEM designers.
Side Latch Quick Connect Interface
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Signicantly improving on the intuitive use aspect of quick connects, new plastic side latch designs achieve an almost instinctive ease of use. One Value Plastics design, which is available in nylon and for use in small-bore applications in many uid delivery areas, is particularly intuitive. Users automatically know how to operate the quick connect the minute they pick it up.
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These plastic side latch quick connectors are proving to be easy to use, safe, secure and reliable. Audible clicks on connection, ergonomic shape and design simplicityall aspect of these connectors were engineered to cut down on the likelihood of human error. Quarter Turn Lug Style Interface A popular connector in instrumentation applications, this connector employs a rotating lug style latch mechanism with an audible click, and a visible indication when the pair is fully connected. The interlocking teeth provide an inherently rugged connection, and the rotating collar allows for independent rotation to prevent tube twisting and kinking. The new BPL Series version of the connector line by Value Plastics is signicantly easier to use than current commercially available lug style connectors. Its ergonomic ten-point grip on both halves of the connector and additional gripping area allow for easier opening and closing of the connector, while two wings have been added to the male side to further facilitate connector operation. This connector offers a feature-rich quick connect. An attractive option for OEMs Although plastic quick connects may not be applicable for all plant and laboratory uses high pressure pneumatics and hydraulics where metal is generally required, for exampletheir light weight, design exibility and ergonomics make them suitable candidates for many applications, such as liquid transfer and lling processes, operating and integrating portable instrumentation, and where uid connections between exible equipment are required. Additionally, because of cost considerations using metal quick connects is sometimes prohibitive. Plastic quick connects present a price point signicantly less than metal connectors, enabling OEM designers to more liberally specify their use, incorporating more features and better ergonomics with less cost. DW Value Plastics, Inc., a Nordson Co. www.valueplastics.com
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DesiGN WORLD
October 2013
CREATING SOLUTIONS
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Pro duc t Wo rld

Quick change 5-axis workholding
CL5 consists of three components: a subplate, a riser, and top tooling made up of a vise or xture plate. The subplate transforms a T-slot table into a modular xturing plate, allowing exible and easy clamping and locating of other tooling and xtures. Every plate has built-in clamping and locating for risers, which allows for quick and accurate set-ups. Numerous jaw types and sizes are available to accommodate a wide variety of parts.
Power supply
PS6R power supplies offer a built-in expansion slot that allows use of dc-dc converters, allowing users to add 5 V and 12 V outputs with a simple plugin module. At only 85 mm wide, the 480 W PS6R power supplies take up less space than most 240 W power supplies. An indicator alarm contact (NPN transistor) closes when the output voltage has fallen below 80%. These power supplies suit any industrial or machine application where reliable dc power (even in multiple voltages) is required. With a steady power source and a 93% efficiency level, PS6R power supplies keep energy consumption low while maintaining high-output power ratings (up to 20 A), as well
Carr Lane
www.carrlane.com
Molded lter screen assemblies

Custom designs are possible to lter out contaminants of all kinds, from small particles in transmission and hydraulic uids to heavy brine particles in food processing systems. Wide ranges of screen options are available in many materials for difficult ltration applications allowing use with most uids. Filter assembly orice sizes available range from 0.71 mm to 1.4 mm.
as being parallel-capable for increased power.
IDEC
www.idec.com/usa
Minnesota Rubber and Plastics

www.mnrubber.com
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DESIGN WORLD
October 2013
a giant breakthrough in small readers
Meet the DataMan 50L. The tiny barcode reader that brings big performance to consumer products.
Dont let its size fool you. The DataMan 50L is huge in barcode reading performance. Measuring just 23.5mm x 27mm x 43.5mm and featuring an IP65-rated housing, the DataMan 50L is premium technology designed for 1-D-oriented barcode reading. The DataMan 50L delivers read rates that can surpass 99% through Cognexs proprietary Hotbars image-analysis technology. The new DataMan 50L is a powerful upgrade for applications that use small laser barcode scanner systems. Visit us at www.cognex.com/50L.
Scan to Learn More
Pro duc t Wo rld

Touch screen smu instrument
The new low current (100 nA, 10 nA) and voltage (20 mV) ranges eliminate the need to add separate low-level instruments to a bench top system. Back-panel triax cable connections eliminate the need for expensive cable adaptors, which can degrade low-level measurement performance. The full-color display and large on-screen characters enhance legibility. A simple, icon-based menu structure allows reaching any measurement set-up panel with just a touch. This no-programming instrument control software simplies taking and graphing data in minutes.
Keithley Instruments
www.keithley.com
Temperature/process limit controllers

Omegas iseries is a simple-to-congure limit controller that features universal inputs, high accuracy, 2 relay alarm outputs, totally programmable color displays, builtin excitation, ac or dc powered units, front removable plug connectors, programmable digital lter, high/low limit and remote reset input. CNi-AL can be used to monitor the temperature of a plastics extruder, and with the programmable limit alarm setpoints, the controller can provide a visual display color change and a latching limit alarm output to shut down process if an alarm condition exists.
Entry level micro PLC

The FX3S micro PLC provides full function PLC control. It retains core FX3 Series performance and exibility traits, with built-in high-speed inputs and outputs, available relay outputs, and multiple, built-in communication ports. It also includes expansion options for communications, analog, and temperature control. Communication options are available for RS-232, RS-485, Modbus and Ethernet.
Mitsubishi Electric Automation

www.meau.com
Omega
www.omega.com
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DESIGN WORLD
October 2013
Pro duc t Wo rld

Hazardous location relay module
The electro-mechanical 750-538s switching voltage/current is rated 125 Vac/0.5 A and 30 Vdc/1 A; the maximum permissible limits depend on the actuators location per EN 60079-11. 750-538 Normal Open (NO) contacts are electrically isolated; on-board LEDs indicate relay switching status. To ensure connection reliability within operating temperatures of 0C to +60C, 750-538 employs CAGE CLAMP Spring Pressure Technology. Highly modular digital, analog and specialty modules are available 1-, 2-, 4- or 8-channelsusers only purchase the I/O needed.
Lightweight dc compressor
Designed for air seats, lightduty air suspension and other mobile applications, the Thomas 135 Series DC WOB-L compressor is a compact, lightweight intermittent-duty pump. The compressor is only 1.16 lb (.53 kg) and is 3.6 in. (91.6 mm) high x 1.66 in. (42.2 mm) wide x 4.34 in. (110.3 mm) long. Available in 12 V or 24 V, the 135 Series features an oil-less piston and cylinder, stainless steel and silicone valves and a built-in inlet lter.
Wago
www.wago.us
Encoders for heavy duty environments

Each unit has an electronic label with basic data like part number and technical specication. This way, the encoder is recognized by the system when installed and automatically set up according to its exact conguration. A DRIVE-CLiQ system also minimizes cable requirements. Up to ve units may be connected to a hub for transfer of data over a common cable. Thanks to a high encoder resolution (19 bit single-turn) and very fast cycle time (31,25 s), the digital speed value given by the encoder can be used for accurate speed control in a closed loop.
Thomas
www.gd-thomas.com
Leine & Linde
www.Leinelinde.com
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DeSIGN WORLD
October 2013
SOLUTIONS COME TOGETHER

AND CONNECTIONS ARE MADE
WHERE ALL THE
Register now to get the ultimate up-close look at the future of the uid power, power transmission and motion control industries.
Registration is now open for IFPE 2014 the event that features all of the newest technology, product breakthroughs and leading-edge education. From components, systems, and controls, IFPE is your destination for finding all the solutions and design expertise you need to stay competitive and make your applications cleaner, Co-Located With greener and more efficient all in one place.
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Self-adjusting pneumatic cylinders
The self-adjusting ability ensures optimum-cushioning performance at all times without the need for any manual intervention even for changes in parameters such as friction and pressure, thus reducing wear and vibration. A bumper has been integrated into the DSBC seal for both noise and vibration reduction. Sizes range from 1.25 to 5 in. (32 to 125 millimeters). A range of conguration options are available for the following: Seals, including chemical resistance, low friction or slow speed, scrapers, including those optimized for high dust areas and safety, including rod clamp or mechanical end lock.
Self-contained push button sensor

The Q45 push button models bidirectional communication permits operators to send a digital signal with the push of a button and receive conrmation the signal has been received. The Q45 push button has a line-of-site range of up to 3,000 ft enough to easily cover even very large factories and can run for up to ve years on two AA lithium batteries, or it can be powered by a local 10-30 V power supply.
Festo
www.festo.com
Banner
Weld immune factor 1 sensors

The one-piece stainless steel housing offers a robust operating face for the most demanding applications. Features include 5 mm operating distance (ush), weld slag resistant W51 coating, high switching frequency and a round corner housing. Suited for welding, stamp and die, lightweight construction, conveyor technology, the automotive industry and automated assembly applications.
www.bannerengineering.com
Balluff
www.balluff.com
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DEsIGN WORLD
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Ad Index
Accumold ...........................................................65 All Motion ...........................................................4 Allied Electronics, Inc. ......................................1 American Control Electronics/ Minarik Drives ............................................59 AMETEK Precision Motion Control ..................9 AMETEK Windjammer ......................................15 AST Bearings .....................................................5 Aurora Bearing Company ............................... 41 Automation Direct ........................................... IFC Avnet ..................................................................52 BellowsTech ......................................................86 Bishop-Wisecarver ...........................................57 Bison Gear & Engineering Corp. ................. 6,IBC Bodine Electric Company ................................72 BOKERS, Inc. ....................................................37 The Carlyle Johnson Machine Company .......10 Carr Lane Mfg. Co. .............................................29 CGI, Inc. ..............................................................74 Cicoil ..................................................................55 Clippard Instrument Laboratory, Inc. .............BC COGNEX ..............................................................93 Colder Products Company ...............................81 COMSOL .............................................................33 Del-Tron Precision, Inc. ....................................27 Design2Parts ....................................................95 DIEQUA Corporation ..........................................38 DSM Somos .......................................................61 Dunkermotor, part of AMETEK ........................11 Eagle Stainless Tube & Fabrication Inc. ................................... 46,47 Encoder Products .............................................80 ENERTROLS Inc. ................................................12 Ferrule-Lock ......................................................56 Harmonic Drive LLC ..........................................89 Heidenhain ......................................................67 Helical Products Company, Inc. ......................42 Helukabel ..........................................................44 Henkel Corporation ...............................71,73,75 Henkel Corporation .................. cover/corner ad IFPE 2014...........................................................97 IKO International, Inc........................................85 J.W. Winco, Inc. .................................................56 Keystone Electronics Corp. .............................3 Lee Spring Company ........................................88 LEWCO, Inc. .......................................................63 Lin Engineering ................................................91 Master Bond ......................................................84 Minnesota Rubber & Plastics ..........................77 Moog Components Group ...............................17 National Instruments Corp. .............................19 Panasonic .........................................................7 Patrick Plastics Corp. .......................................40 PBC Linear, A Pacic Bearing Company .........45 PFA Inc. ..............................................................87 PHD Inc. .............................................................50 PITTMAN .............................................................13 Proto Labs, Inc. .................................................35 PTI Design .........................................................69 R+W ....................................................................54 Rotor Clip Company, Inc. ........................... 51,53 SANTEST Co., Ltd. ..............................................84 Sensoray ...........................................................31 Setco ..................................................................64 Smalley Steel Ring Company .................... 24,25 Sorbothane .......................................................37 Suco Technololgies Inc. ...................................86 Tadiran Batteries .............................................83 TDK Lambda ......................................................23 The Timken Company ......................................16 TRANS-TEK Incorporated .................................41 TRIM-LOK, Inc. ...................................................26 Wago ..................................................................90 Whittet-Higgins Company ..............................21 Zero-Max ............................................................2 ZoomRP .............................................................39
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Motion Control Handbook

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Design Worlds Fluid Power and Motion Control Digital Issues Now Live
Designers using motion control and uid power components have a world of information at hand with the new 136-page Motion Control Handbook and the 100-page Fluid Power Handbook. Both books include detailed information on the main components usedhow they operate, the best ways to incowrporate them in your system, and how an engineer should specify them correctly. Also included are industry overviews and thoughts from design leaders on where the technology is going in future years.
Hamilton Caster Launches New Website
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NuSil Technology Presents New Elastomer

NuSil Technology LLC introduces R-2165, the newest robust silicone solution for the protection of electronic components and systems such as sensors, relays, and connectors. R-2165 was inspired by market growth in applications in which silicone is desired due to its excellent ability to perform at elevated temperatures.
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Hamilton Caster announces the launch of cartsandtrailers. com. This all-new website is dedicated to Hamiltons entire line of stock and custom-engineered carts and trailers. The site includes extensive product information and specications to help customers learn about Hamiltons complete line of products.
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October 2013 www.designworldonline.

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