Machine Design 15 August 2013 PDF

HYDRAULIC
FLUID
Moving Toward Eco-friendly
p|37
machinedesign.com
AUGUST 15, 2013
THE IMPORTANCE OF
CUSTOM PARTS p. 20
A SMARTER WAY
TO SPECIFY
COMPOSITES p. 44
SIZING MOTORS FOR
LINEAR MOTION p. 50
BY ENGI NEERS FOR ENGI NEERS
AFenton
Fublication
YAS KAWA AMERI CA, I NC.
DRI VES & MOT I ON DI VI S I ON
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products have a meantime-between-failure rate (MTBF) of up to 28 years. That means your
engineers can spec Yaskawa and never have to worry. Just program, plug and play.
Get what you want, every time. Call Yaskawa.
NEWS
20 ENGINEERS &
CUSTOM COMPONENTS:
A reader survey
DEPARTMENTS
4 ON MACHINEDESIGN.COM
10 LETTERS
12 WHATS INSIDE
Eco-friendly Hydraulic
Shock Absorbers
A Bearing Built for
Wind Turbines
33 SENSOR SENSE
Encoders for safety
80 PUZZLES, MYTHS,
AND CURIOSITIES
PRODUCTS
65 PRODUCT SPOTLIGHTS
Fluid-Power Cylinders & Valves
CAD
68 NEW PRODUCTS
77 DATA FILES
78 CLASSIFIEDS
78 AD INDEX
FEATURES
37 MAKING THE MOVE TO ECO-FRIENDLY HYDRAULIC FLUIDS
Biodegradable hydraulic uids are safer for the environment than petroleum-
based uids, but they require special design considerations.
44 HOW TO AVOID OVERENGINEERING COMPOSITE PARTS
Analysis techniques help avoid a tendency for
designers to overengineer composite parts.
50 HOW TO PICK MOTORS FOR LINEAR MOTION
The easiest way to design a linear-motion system is to add components
one by one. Then, step-by-step calculations relate input to power
dissipated moving a load in a specic amount of time.
60 FORCE SENSORS AND THEIR USES
Force sensors use load cells to weigh objects and
prevent machinery from overloading.
COLUMNS
6 EDITORIAL
End-of-life blues
16 COMMENTARY
Fracking: Its Better Than the
Alternatives
34 INTERVIEW
The Changing Role of System
Integrators Tom Price
64 GOLDENSE ON R&D-
PRODUCT DEVELOPMENT
Innovation-enabling Tools and
Software for Individuals
and Product Pipelines
ON THE COVER: Photo illustration: Tony Vitolo
2 08.15.13 MACHINE DESIGN
ISSN 0024-9114
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~~
o
In This Issue
AUGUST 15,

2013
|
VOLUME 85, ISSUE 10
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AUGUST 27, 2013 AT 2:00 P.M. ET
This presentation will acquaint medical-device designers with
the metal injection-molding (MIM) manufacturing process and
its capabilities. Presented by the Metal Injection Molding
Assn., the Webinar will walk viewers through examples and
case studies of successful applications of the technology.
Get more details and register at http://machinedesign.com/
learning-resources/webinars.
ENGINEERING TV
A LOOK AT
GOOGLE GLASS
Googles new glasses are shaking up the concept of intercon-
nectivity. They let the wearer capture images and shoot videos,
search for info, and translate foreign languages all hands-
free. Electronic Design Editor Bill Wong talks to app devel-
oper and CEO of Pepperdeck.com and Glass Tesla about the
underlying technology. View the episode at www.engineer-
ingtv.com/video/A-Look-at-Google-Glass.
ACCESS HARDWARE
Southco has a new Web site (www.southco.com) in eight lan-
guages on its access hardware, including latches, hinges, handles,
and locks. Users can fnd product info and compliance certif-
cates, download CAD fles and catalogs, and request samples.
HEATER CATALOG
Watlows new Heating Solutions catalog covers electric
industrial heaters, sensors, and controllers. Content includes
product specs and drawings, and a selection matrix that helps
users match heater type and application. Get a copy in various
formats at www.watlow.com.
TEST & MEASUREMENT
Agilent Technologies Faculty Spotlight Web site features uni-
versities throughout the world using the companys electronic
test and measurement instrumentation in unique applications,
new curriculum, research, and novel projects. Find it at www.
agilent.com/fnd/facultyspotlight.
TYPES OF PRESSURE
Turck has released a new white paper, Types of Pressure:
When and Why Are They Used? It explain how good mea-
surement practices are essential
in industrial and process automa-
tion, but there are different ways
to interpret measurements. The
white paper discusses different
types of measurements, when and
why they are used, and highlights
how they suit various applica-
tions. Download a copy at www.
askturck.com.
BEARING SELECTOR
The Kaydon Bearings Web site, www.kaydonbearings.com,
now has an interactive bearing selector. Users search by details
such as bore size, OD, and width and results include applicable
products and 2D and 3D drawing downloads. Results can be
refned using Kaydons engineering software, which analyzes
loads and calculates basic life and safe operating speeds.
EDITORS WEB PICKS
on
join us online
A bad choice could cost you thousands!
Look Familiar?
When hot weather causes the electronics inside
a control cabinet to fail, there is a panic to get
the machinery up and running again. Te
operator might choose to simply open the
panel door and aim a fan at the circuit boards.
In reality, the fan ends up blowing a lot of
hot, humid, dirty air at the electronics and the
cooling eect is minimal. If the machinery
starts functioning again, the likelihood of
repeated failure is great since the environment
is still hot (and threatens permanent damage
to the circuit boards). Worse yet, that open
panel door is an OSHA violation that presents
a shock hazard to personnel.
The Real Solution!
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Jef Hauck, Lasercraft Inc. Cincinnati OH
It took us three days to get a replacement computer cabinet and we didnt
want to risk another heat failure. Fans werent an option since they would
just blow around a lot of hot air. Freon-type air conditioners like those on
some of our other machines were a constant maintenance project of their
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Type 316 Stainless Steel
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Type 316 Stainless Steel
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Mini NEMA 12, 4, and
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Te mini NEMA 12, 4
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for small heat loads up
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Measures 5" (127mm) high
Mounts top, side or bottom
Enclosure remains dust-
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High Temperature
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High Temperature Cabinet
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Suitable for ambients up to
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Ideal for mounting near
ovens, furnaces, and other
hot locations
Non-Hazardous Purge
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NHP Cabinet Coolers keep
a slight positive pressure on
the enclosure to keep dirt
from entering through small
holes or conduits. For use in
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Uses only 1 SCFM in
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For heat loads up to 5,600
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NEMA 12, 4 and 4X
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Enclosure remains dust-tight
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SIZING GUIDE
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Editorial
LELAND TESCHLER
|
Editor
leeteschler@penton.com-
ed occasionally find someones garbage dumped on the side
of the road back when I was growing up. That was illegal,
so wed call the cops about it. Theyd happily come out and
sort through the stuff because invariably, the dumpers were
stupid enough to leave their junk mail, complete with an address, in the discarded
trash. The scofflaws would then get a visit from a state trooper who would hand
them a citation and a stiff fine.
I bring this up because there is an intensifying debate about who should be respon-
sible for the disposal of packaging. Economists are starting to think that a system that
gives that responsibility to manufacturers makes more sense than foisting the prob-
lem off on cities and states. They argue that such a scheme would bring some sanity to
the idea of which materials are worth recycling and which are just garbage.
One problem with the existing state of affairs is that both landfills and recycling
programs are subsidized, so it is almost impossible to figure out the real economics
of either disposal method. For example, landfill space is priced below the full eco-
nomic cost of landfilling partly to discourage the kind of illegal dumping I saw as a
kid. Recycling programs typically get priced so their promoters can claim putting
plastic bottles in colored recycling bins is cheaper than throwing them in a landfill.
But its hard to really know the truth of that statement when the price of both landfill
space and recycling programs are distorted.
One economist who has studied these price distortions is Duke University profes-
sor Michael C. Munger. He points out that because it is almost impossible to know the
real price of landfills and recycling efforts, many of the arguments for recycling have
taken a religious tone: Putting garbage in a landfill is no longer expensive; its evil.
This sort of attitude can lead to zany outcomes. Munger recounts an incident
during a North Carolina drought a few years ago when Duke switched to disposable
paper dishes, napkins, and utensils in its food-service operations. The idea was to
save water, which had become more expensive than the landfill space occupied by
low-quality, hard-to-recycle eating supplies. It would have been irresponsible, in
terms of the opportunity cost of the resources, to continue to use water as if it were
plentiful, he says.
But that didnt matter to a lot of students and faculty at Duke. Munger says stu-
dents and faculty both complained that is was wrong to dispose of waste in a landfill.
He says he asked at least 20 people why landfilling the stuff was wrong but could
never get an answer. They just knew that is was, he says.
That takes us back to the concept of making end-of-life issues the problem of
manufacturers. Such a mandate would be an extra headache for designers of prod-
ucts and packaging, who would be forced into figuring out the end-of-life econom-
ics of the materials they used. But it would make discussions about garbage less
theological.
End-of-life
blues
08.15.13 MACHINE DESIGN 6
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free. Available with PSC motors or energy efcient Green-Tech EC motors
in 2-speed or fully speed controllable versions. For more information,
visit info.ebmpapst.us/RadiCal.
EDITORIAL
EDITOR IN CHIEF: LELAND TESCHLER leland.teschler@penton.com
MANAGING EDITOR: KENNETH J. KORANE ken.korane@penton.com
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STEPHEN J. MRAZ stephen.mraz@penton.com
ASSOCIATE EDITOR: LINDSEY FRICK lindsey.frick@penton.com
EDITORIAL PRODUCTION MANAGER: DENISE GRECO denise.greco@penton.com
ART DIRECTOR: RANDALL L. RUBENKING randall.rubenking@penton.com
INDUSTRY COVERAGE:
AUTOMOTIVE, PACKAGING, MEDICAL STEPHEN J. MRAZ
CAD/CAM, MANUFACTURING ELISABETH EITEL, LINDSEY FRICK
FASTENING & JOINING, MATERIALS LINDSEY FRICK
FLUID POWER KENNETH J. KORANE
MECHANICAL ELISABETH EITEL, LINDSEY FRICK, KENNETH J. KORANE
ART DEPARTMENT
CREATIVE DIRECTOR: DIMITRIOS BASTAS dimitrios.bastas@penton.com
GROUP DESIGN DIRECTOR: ANTHONY VITOLO tony.vitolo@penton.com
PRODUCTION
GROUP PRODUCTION DIRECTOR: CAREY SWEETEN carey.sweeten@penton.com
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AUGUST
|
2013
08.15.13 MACHINE DESIGN
888-439-6264
www.clippard.com
Cincinnati, OH 45239
888-439-6264
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WILL THEY STEP FORWARD?
One of the biggest problems I found
with the new generation of automation
engineers and techs is their lack of ini-
tiative (Seven Ways Older Automation
Experts Can Help the Industry,by John
Rinaldi, Jun. 3). Although many of us
have decades of experience under our
belt, we leave an industry that still relies
on old technology. New engineers have
a hard time incorporating or adapting
the old with the new.
New engineers just dont have the
drive and rely too much on comput-
ers instead of good old creativity or
problem-solving ability. If, or when, we
arrive at a major change in technology,
there will be an explosion of technol-
ogy that should surpass anything we
have available at the moment. The
entire manufacturing sector will have
to change and those who dont will be
left behind.
Thats when our young engineers will
have an opportunity to shine and prove
they can accomplish far better advance-
ments than those on whos foundation
they stood before they started to climb
the ladder.
Joaquin Cardena
EPA COMES CLEAN
The miles-per-gallon of any particular
vehicle is an extraordinarily difficult
parameter to measure because there
are so many variables. Brooks Lyman
(Letters, May 23) listed several, but
there are more, including air tempera-
ture and wind speed, even altitude.
I drove an 85 Chevy Sprint (Suzuki
Swift) for 10 years and consistently
got 50 mpg with a daily 72-mile com-
mute (round trip). The engine was a
three-cylinder, four-stroke one-liter
design. And I was no slouch speed-
wise. Tires lasted 75,000 miles, brakes
85,000. At 110,000 miles I gave it to a
friend who was ecstatic and said that
the government should buy them for
poorer folks to reduce air pollution.
Where are they now?
Robert H. Russell
Just finished reading the letters regard-
ing mileage and the EPA. I drive a
1999 Corvette with a 350-hp engine,
aftermarket exhaust, K&N air filter, and
six-speed transmission. The cars EPA
numbers were about 19/26 mpg on the
sticker. Funny thing about EPA num-
bers is that they are usually not correct.
Also, most people believe you should
have a small car with a small engine to
get good numbers.
On the round trips between our home
in Connecticut and our vacation home
in Florida, my average mileage, while
driving as fast as traffic allows (around
80mph most of the time with plenty of
jack-rabbit starts), is about 30mpg. This
is both the calculated number and that
shown on the cars trip computer. I put
in 87octane gas (with 10% ethylene)
unless it is really hot. Then I buy 89 or
93. Most people with similar Corvettes
get about the same mileage or more with
conservative driving.
What is the magic? How about
good aero design, low weight, and
high horsepower and torque taking
advantage of good overdrive ratios?
At 72mph, my engine turns at about
1,500rpm, which is exactly twice the
engines idle speed.
Lets figure out how to do the same
on some of the boring high-mileage
econoboxes many people feel they
need to drive to get fuel economy.
Imagine how much could be accom-
plished without ethanol. And how
about some of the very economical
European diesel engines?
Robert Bubello
Believe it or not, the EPA must be
listening to the public for once. A
recent check at http://www.fuelecon-
omy.gov shows that some newer ve-
hicles now have fuel-economy ratings
based upon standard gasoline and on
E85. The vehicle I was interested in
suffers a 25% reduction in economy
when E85 is used instead of gasoline.
I guess Ill be looking even more
closely at getting one of the new crop
of diesel-powered vehicles because
the mileage should definitely be bet-
ter and the fuel cost is generally less
than 10% higher. As for the up-front
diesel powerplant cost, I can recoup
that at resale.
Duane Levine
ROOM FOR A CREW?
Looking at the crew module specs for
NASAs Orion capsule (NASAs Orion
Goes International, Apr. 11), it says
the return payload is only 220 lb. Is
this a one-man capsule?
Howard Chin
No, NASA does not include crew
weight,or that of the fuel and breath-
ing gasses among other things, in the
payload weight.
Letters
NEW ENGINE AND
GAS MILEAGE
One reader noticed the difference
between new and older engineers
and hopes the newer ones are up
to the challenge when they become
the ones in charge. Other readers are
troubled that the EPA doesnt account for
E85 gas in mileage ratings.
LETTERS TO THE EDITOR:
Please include your name, address, and day-
time phone number. Letters may be edited for
brevity and to focus on essential points.
Mail: Letters, MACHINE DESIGN, 1300 E. 9th St.,
Cleveland, OH 44114-1503, Fax: 216-621-8469
E-mail, Editorial: mdeditor@penton.com
Whats Inside
Eco-friendly Hydraulic
Shock Absorbers
THE ECO SERIES of hydraulic shock absorbers from ITT Enidine Inc., Orchard Park,
N.Y. (www.enidine.com), can handle a wide range of forces and moving masses,
absorbing maximum energy within a compact envelope. The shock absorbers use
materials and fluids that are considered safe for the environment. For example, the
device, along with all the coatings, comply with RoHS. The hydraulic oil it uses is
biodegradable. And even the packaging materials used for shipping the shock
absorbers can be recycled.
The shocks, which all come with a jam nut, are available in adjustable and
nonadjustable versions, and have an Enicote II finish which protects against
corrosion and is rated at 350 hr of saltwater protection. The nonadjustable
shocks are also tamperproof. Threaded cylinders give users flexibility in
mounting the shocks and also increases the surface area for better heat
dissipation. The devices can also mount into pressure chambers.
The shocks have strokes that range from 0.25 to 1.0 in. and can
withstand 25 to 930 in.-lb/cycle, or 55,000 to 682,000 in.-lb/hr.
The devices weigh from 0.5 to 10.5 oz and handle reaction forces
from 200 to 1,250 lb. They operate in temperatures from 15 to
180F, but this can be extended with optional fluids and seals
to 30 to 210F. There are also food-grade versions of the
ECO shock absorbers.
Edited by Stephen J. Mraz
Cylinder
Check
ring
Piston
head
Orifices
Oil
Shock
tube
Coil
spring
Foam
accumulator
Bearing
Piston rod
Hydraulic Power Pack KA
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Other product and company names listed are trademarks or trade names of their respective companies. 12118
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The combination of NI LabVIEW system design software and recongurable I/O
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askTURCK.com
2013 TURCK
Types of pressure:
when and why are
they used?
Whats Inside
A Bearing Built for
Wind Turbines
THE NAUTILUS BEARING from SKF USA Inc.,
Landsdale, Pa. (www.skf.com/us), is a double-row
tapered bearing set that is compact and used in
wind turbines to carry all rotor loads, forces, and
moments. Up to now, most large turbines used
two bearing sets to handle axial and radial loads
separately. Using only one bearing means only
rotor torque gets transmitted to the drivetrain and
that weight and cost are reduced. The two rows of
tapered bearings are arranged back to back and lock
the unit axially, so it delivers high levels of stiffness.
The bearing is also more compact than the
two bearings traditionally used. This makes for a
smaller, lighter, and less-costly nacelle. And the
large number of rolling elements makes for extreme
precision between raceways, so the unit can
carry high loads. The Nautilus bearing is, in fact,
designed for multimegawatt turbines and those
turbines can be directly driven or have gearboxes,
have outer or inner-ring rotation, and be mounted
on shafts or bolted onto the surrounding structure.
The bearing uses an Ecopur polyurethane seal
that is held in place by built-in carriers. The seal can be replaced
on top of the turbine, simplifying maintenance. Seals and grease
help prevent corrosion, a constant threat for offshore turbines.
The bearing comes standard with a bolted outer ring. A
bolted inner ring is optional, which lets the bearing be attached
to the rotor hub and the mainframe. This eliminates any
effects of excessive tolerances between the bearing and the
surrounding structure, including the shaft, housing, and lock
ring. It also reduces variations in preload during operation.
Edited by Stephen J. Mraz
Pregreased
bearing
eliminates
contamination
Bolted inner
ring for
safety and
reliability
Corrosion protection in vulnerable areas
High-friction
coating
minimizes
movement
between mating
components
Single-pocket, segmented
PEEK cage increases load-
carrying capability.
Combined seals
and carriers
reduce risks of
contamination
and reduces
weight and costs
Schaefer, with our INA and FAG brands, has set a standard that is unrivaled
throughout the industry by offering innovative products and unmatched sup-
port services that can dramatically improve the performance and reliability
of pumps used in wastewater, dewatering and petrochemical applications.
Heres why this is no idle boast:
Innovative Products
Schaefers latest generation of double-row angular contact bearings in
X-life
quality generate less friction, put less stress on lubricants and en-
able lower operating temperatures. Thanks to higher ball quality, improved
raceway surfaces and more precise dimensional and running tolerances, the
bearings internal friction is signicantly reduced. As a result, higher speeds
or longer bearing operating life can be achieved. So reliability goes up, and
energy consumption goes down.
Groundbreaking Technology
X-life is Schaefers designation for premium products from our INA and FAG
brands that offer engineers completely new design perspectives. Thanks
to supernished raceway surfaces that ensure smooth, uniform running
characteristics, maximum load-carrying capacity and superior rigidity, the
operating life of X-life bearings is considerably longer than standard bearings
under identical operating conditions. Alternatively, higher loads can now be
applied while maintaining the same rating life values.
Unmatched Engineering Support
The industrys most comprehensive suite of calculation software, BEARINX

is Schaefers cutting-edge program for performing rolling bearing and
linear guidance system calculations. One of our latest modules, BEARINX-
online Easy Friction enables customers - free-of-charge - to calculate all of the
friction forces at the discrete points of the contact surfaces inside the bearing.
When it comes to bearings for your pumps, dont just go with the ow.
Go with Schaefer.
Superior-quality products.
Comprehensive reliable solutions.
Need more details?
Please contact us at ads.ind@schaefer.com
www.schaefer.us
2013
Commentary
STEPHEN J. MRAZ
steve.mraz@penton.com
Fracking:
Its Better Than
the Alternatives
H
ydraulic fracturing, a method of getting more
natural gas out of shale formations, has been a
major boon for the U. S. and the rest of the world.
It lets the U. S. get 40% of its gas from shale, a
once little-regarded resource. It has pushed the price of natural
gas from $13/ft
3
in 2008 to under $4/ft
3
today. This translates
into annual savings of $1,000 in heating and electricity costs per
household, with most of these savings going to those who arent
rich. And fracking means fewer U.S. dollars go overseas.
Like any industrial process including steel making,
egg farming, and solar power and wind turbines frack-
ing can lead to problems if done improperly or negligently.
But no responsible person advocates letting companies act
negligently or illegally. In fact, gas companies want to make
fracking safe for both humans and the environment. These
firms are also working with local, state, and federal govern-
ments to establish meaningful guidelines and legislation. At
the same time, local governments want the taxes, landown-
ers want the royalties, consumers want the lower energy
prices, and everyone wants a clean planet.
In fact, the EPA has been looking at fracking and has
found few problems. One issue it investigated was methane
supposedly leaking into water supplies due to fracking. An
EPA study found that so-called contaminated wells con-
tained levels of methane typical in the area and below levels
that the federal government considers a threat to health.
Then in 2011, the head of the EPA testified to Congress that
she was not aware of any proven case where the fracking
process itself affected water In no case have we made a de-
finitive determination that the fracking process has caused
chemicals to enter groundwater.
So deciding between fracking or the environment looks
like a false choice. We can have both. Fracking has already
produced enough natural gas to send U. S. coal-generated
electricity from 48 to 37% of U. S. needs in only four years.
It has also convinced utilities not to build about 150 new
coal-fired plants. Many are planning natural-gas burning
plants instead. These new plants will release none of the soot,
mercury, arsenic, or lead that come from coal-burning gen-
erators and half the CO
2
. Meanwhile natural gas from frack-
ing has been partly responsible for the U. S. cutting its CO
2

emissions by 800 million tons since 2007, a better cleanup act
than all those countries that signed onto the Kyoto Protocols.
Coal isnt the only energy soured that has problems. As
John Hanger, a former secretary of the Pennsylvania Dept.
of Environmental Protection, said in a recent article (http://
www.guardian.co.uk/commentisfree/2013/jul/08/shale-gas-
fracking-good-for-environment) for The Guardian:
Virtually all of our energy choices have big safety and
environmental risks or significant weaknesses. There is no
perfect or excellent energy source that has no environmen-
tal impact, is low cost, and operates continuously. Indeed,
especially in terms of the environment, our energy choices
today are mostly ugly.
Nuclear energy, for example, leaves us with hazardous
wastes which we cant figure out how to dispose of. And
most U. S. residents have a fear, perhaps irrational, of radio-
activity. (I wonder how many citizens know they get dosed
with relatively high levels of radiation every time they fly.)
Oil can be dangerous to transport, difficult to clean up
after spills, and burning it releases lots of CO
2
, along with
other toxic substances and soot.
Hydroelectric dams disrupt river life and tick off the
Sierra Club. Corn-based ethanol distorts the corn markets,
leaving some people hungry, and has been known to harm
engines and fuel systems. Wind and solar power will take a
long time to scale up to where they provide more than 5% of
our power. Plus, neither can generate a single watt if its too
windy or not windy enough at night. And if we did build
enough solar panels and wind turbines, whos to say all those
non-reflective surfaces and impediments to the wind wont
affect weather patterns and climate?
Fracking and the burning of natural gas might not be
perfect, but they sure seem to be better than the alternatives.
Lets work to make it safer and more affordable with prudent
and fairly enforced safety and environmental regulations.
Sense-ability.
Newark element14 makes it easy to nd all of your sensors and transducers fast. newark.com
Smart Machines
control strategies
and complex control
algorithms. The trend is
to integrate monitoring
and control into one
hardware system. This
approach can have
economic advantages
and may boost the
performance of the
automation equipment
as well. Finally, machine
builders often rely on
an additional system
that is added to the
machine controller and performs the
monitoring task independent from
the machine control system. The
two systems generally communicate
via standard industrial I/O lines.
HOW ARE SMART
MACHINES DEFINED?
Smart machines usually are built
around distributed control archi-
tectures that dedicate one electric
motor to controlling each axis.
This is in contrast to using cams,
gear trains, and other mechanical
linkages to power individual axes
from one central motor. Machine
builders need to adopt a software-
centric approach to deal with
the resulting complexity, usually
through software development
tools that provide both simulation
and deployment capabilities. They
let machine designers simulate
dynamic systems, design controllers,
and deploy control systems to the
hardware that will actually run the
system. These development systems
generally include an analysis
palette in the time and frequency
domains. Control programs that
use adaptive and model-based
and programming tools that let
designers use one software design
tool for multiple tasks as a means of
handling increased system complexity.
WHAT COMPONENTS TYPICALLY
GO INTO A SMART MACHINE?
Smart machines are aware of
processes through use of a compre-
hensive network of sensors. These
sensors collect information about
machine conditions and the status
of ongoing processes. The resulting
measurements are typically used to let
the controller monitor the condition
and performance of the machine. The
sensor network is extensive enough
to let the controller gather enough
information to
decide whether to
initiate maintenance
or even automati-
cally apply different
control settings
to the system.
Smart machines
also require a high-
performance net-
work of embedded
systems to imple-
ment advanced
WHAT IS A SMART MACHINE?
Smart machines today are generally
those that must be able to operate
somewhat autonomously and must
be able to adapt to changing condi-
tions. For the most part, they handle
tasks that are not solely repetitive.
Smart machines must also be able
to avoid and correct process errors
and learn from those situations
to avoid difficulties in the future.
Smart machines also typically
provide information to a higher level
control system that facilitates
smarter operations in general.
HOW HAS THE SMART
MACHINE CONCEPT CHANGED
MACHINE DESIGN?
Traditional computer-controlled
machines combined a machine
controller, a local HMI such as an
operator terminal, and connectivity
to a plant automation network. In
contrast, smart machines tend to
have modular architectures that make
use of off-the-shelf systems such as
robots to speed development. They
also integrate additional embedded
control and monitoring systems to
distribute processing. Consequently,
there has been a shift toward
software-centric design approaches
Sponsored by National Instruments
FREQUENTLY ASKED QUESTIONS
A D V E R T I S E M E N T
control strategies typically can be
deployed straight from simulations.
WHY IS THE SMART MACHINE
CONCEPT IMPORTANT FOR
MOTION CONTROL?
Decentralized control works with
the trend away from using a central
motor to power individual axes
through gears trains, cams, and other
mechanical linkages. Now individual
motors typically power specific axes
and are synchronized in software.
This approach reduces the cost and
weight of the machine and makes
the mechanical system more flexible.
The resulting machines can also be
modular and more easily expanded.
There is also a trend toward more
axes and much more complex motion
profiles and control algorithms.
Mechanical systems that deviate from
the classical XYZ axis setup require
complex control algorithms to trans-
form the movement of the end effector
into the movement of individual joints.
Machine designers tend to need access
to low-level motor control algorithms
to implement the commands necessary
to realize these sorts of movements.
Ditto for implementing adaptive
control algorithms. Only a few machine
builders feel comfortable custom-
izing low-level motor control routines
without the help of their tool providers.
HOW DO FPGAS FIT INTO SMART
MACHINE DESIGN?
FPGAs are the primary enabling
technology for parallel control. The
reason is FPGAs execute multiple tasks
simultaneously. They are highly reli-
able because they implement control
schemes using only hardware logic.
There is no overhead of an operating
system or interactions with multiple
software routines to worry about.
FPGAs once were used only by engi-
neers with a high level understanding
of hardware circuit design who could
program FPGAs in VHDL (VHSIC
hardware description language).
This is no longer the case as now,
software tools can convert block
diagrams of control schemes into
plans for programming FPGA circuitry.
Software packages are now avail-
able which give access to control
functions through high-level program-
ming interfaces but if necessary,
let the builder get at machine-level
code to customize lower level IP,
often through changes in an FPGA.
The Control Design Guide for
Next-Generation Machines
explains the challenges machine
builders face today and
demonstrates proven methods
and solutions to get ahead of
the competition. Experience the
impact graphical system design
and customizable off-the-shelf
hardware has on the design
process and business success.
Download the guide at
QLFRPFRQWUROGHVLJQJXLGH
National Instruments
Control Design Guide
for
Next-Generation
Machines
More than $1,000
27%
Less than $1,000
18%
Less than $500
14%
Less than $200
17%
Less than $50
14%
7%
Less than $20
Less than $5
2%
Never
17%
Once every
two years 7%
Once a year
17%
Every six months
28%
Once every
two months
31%
0 10 20 30 40
43% Lower prices
32% Easier ordering process
46% Faster delivery times
42% Better technical help in conguring custom components
37% A guarantee on quality, price, and delivery times
ENGINEERS &
CUSTOM COMPONENTS
A reader survey
Companies that want to sell more custom parts should
work on lowering prices, speeding delivery, making
ordering more simple, and then guaranteeing it all.
WHAT FACTORS WOULD MAKE YOU
MORE LIKELY TO SPECIFY CUSTOM
COMPONENTS?
HOW OFTEN DO YOU USE CUSTOM
COMPONENTS IN YOUR DESIGNS?
Custom parts can range from specialty wash-
ers to oversized tires for limited-production
off-road equipment, and prices vary accord-
ingly. Our survey shows that prices do indeed
vary widely when it comes to the custom parts
engineers specify for their designs, with the
median being about $500.
HOW MUCH DOES YOUR COMPANY
SPEND ON EACH CUSTOM
COMPONENT(AVERAGE)?
M
achine Design surveyed some of its readers to
better understand how engineers use custom
components. Results show 85% of engineers rely on cus-
tom parts, which have a median price of about $500. And
while many designers specify low-cost custom items like
fasteners, switches, and connectors, others spec in cus-
tom motor and power supplies, as well as structural parts
and machined subassemblies.
Stephen Mraz, stephen.mraz@penton.com
A vast majority of
designers (85%)
rely on custom
parts, and over half
(59%) use them in
designs at least
every six months.
So much more
difcult than
specifying
standard parts
that we never
order custom
parts 1%
Much more difcult
than specifying
standard parts
31%
Only slightly
more difcult
than specifying
standard parts
57%
As easy as
specifying
standard parts
11%
To save
manufacturing
time 7%
To get a lower
price 4%
To get the right
material 5%
To get the
right combination
of features
69%
To get the
exact size
needed
15%
5%
Half the time
Most of the time
86%
Always
8%
Location
does not
matter
14%
Foreign
suppliers
>1%
Suppliers
in the
same country
22%
Suppliers in
the same
general
region
31%
Local suppliers
32%
0% 10% 20% 30% 40% 50%
51% Machined subassemblies
40% Structural components
39% Fasteners
26% Motors
19% Switches/electrical connectors
34% Molded parts
18% 3D printed parts
17% Power supplies
12% HMI/control panels
10% Software
A month
longer than for
standard
components
34%
A week
longer than
for standard
components
50%
Same as
for standard
components
15%
GO TO MACHINEDESIGN.COM 21
WHAT DO YOU
CONSIDER A
REASONABLE DELIVERY
TIME FOR CUSTOM
COMPONENTS?
Engineers want their cus-
tom parts delivered in only
a week longer than what it
takes to get a standard part.
A more-lenient third will give
companies a month.
Closer is better when it
comes to companies sup-
plying custom parts. But a
small slice of the engineer-
ing population says they
prefer to use foreign suppli-
ers for their custom parts.
Over two-thirds of the engineering
respondents say that getting the
right combination of features is the
main reason they order and use
custom components. Price, materi-
als, and saving manufacturing time
each motivate about 5% of engi-
neers to seek out custom parts.
WHAT IS THE PRIMARY
REASON YOU SPECIFY
CUSTOM COMPONENTS?
WHEN IT COMES TO
CUSTOM COMPONENTS, WE
PREFER TO WORK WITH:
Engineers usually
get what they ask for
when they order cus-
tom parts, according
to our survey. But
5% say they arent
getting what they
ordered.
HOW OFTEN ARE YOU
SATISFIED WITH CUSTOM
COMPONENTS?
Although most engineers seem to have little
problem ordering custom parts, almost a
third say suppliers make it much more dif-
ficult to get custom parts than standard ver-
sions. But only a small minority (1%) say that
ordering custom parts is so onerous they
dont do it anymore.
HOW DIFFICULT
IS IT TO
PROPERLY
SPECIFY
CUSTOM
COMPONENTS?
Engineers ask suppliers to customize a range of parts,
even software. But machined subassemblies are the most
commonly ordered customized component, cited by over
half the responding engineers. And although 3D printing
is a relatively new technology, almost one in five engi-
neers are using it in their designs.
WHAT TYPE OF CUSTOM
COMPONENTS DO YOU
SPECIFY MOST OFTEN?
POWER DISTRIBUTION ENCLOSURES CLIMATE CONTROL
Thousands of enclosures
Hundreds of options
Designed and delivered in 10 days
Manager for North America.
Were able to make a
complete range of seals,
including rotary seals for
grease and oil, V-rings for
exclusion, static O-rings,
and alternative designs
with better performance,
explains Uncapher. Other
types include hydraulic
seals such as wipers, rod and
piston seals, guide rings, and replacements for gland pack-
ings, as well as buffer seals and antiextrusion rings, he says.
Seals are made from a wide variety of stock materials,
including rubber elastomers, polyurethanes, thermo-
plastics, and specialty materials like SKFs ECOPUR, a
thermoplastic polyurethane (TPU) with unusually high
abrasive resistance, low compression
set, and excellent strength. Also avail-
able are materials complying with a
broad range of industry standards and
regulations, such as FDA guidelines.
Proprietary materials can also be formu-
lated for specific applications.
A key to custom capabilities and rapid
turnaround, according to company
officials, is SKFs Seal Jet machine. This
CNC-controlled production system uses
proprietary software and special cutting
SKFs seal machining
centers can quickly cut
standard and custom
seals from a wide range
of stock materials.
CNC-controlled Seal Jet machines pro-
duce custom seals using proprietary
software and cutting tools specifically
developed for machining polymers.
CUSTOM SEALS ON DEMAND
CUSTOMIZED MACHINED SEALS can be invaluable for engi-
neers and maintenance technicians. Getting a made-to-
order seal in a day or two can keep a project on track
when prototyping new designs. And custom seals can
minimize downtime and lost production when a critical
component fails.
But engineers cant rely on just any machine shop with
a lathe to craft quality seals. For one, seals are precision
components that demand tight dimensional tolerances
to work properly. Making them requires an expertise in
machining elastomers and plastics which, on a machine
tool, behave quite differently from metals. And most
fabricators dont stock the proper material. In a seal, the
right materials are critical for fluid compatibility, shear
strength, abrasion resistance, and a host of other reasons.
SKF USA Inc., Lansdale, Pa., can quickly cut seals from
stock materials to exact customer specifications. The
company can reportedly manufacture
seals and related components up to
157 in. in diameter. And larger seals
are possible using a welding technique
that allows on-site fitting and still pro-
vides the performance of a continuous
machined or molded seal.
The company catalogs several hun-
dred standard profiles, but can produce
virtually any kind of rotating, recip-
rocating, or static seal for most any
conceivable application, says Bryan
Uncapher, SKF Business Development
News
Custom seals continued on page 26
SOFTWARE & SERVICES IT INFRASTRUCTURE
www.rittal.us
SOFTWARE ANALYSIS YIELDS METRIC FOR
IMPROVING PRODUCT DEVELOPMENT
SOFTWARE NORMALLY
USED to assess the
degree to which
products are assem-
bly friendly is now
used to measure
whether or not new
designs are really
improvements over
the models they
replace.
The software, a
tool called Design
for Assembly from
Boothroyd Dewhurst Inc., Wakefield, R. I., is ordi-
narily used to simplify product designs by showing
designers where to eliminate unnecessary parts,
thereby simplifying assembly and lowering labor
costs. But new-product development engineers at
Motorola Solutions Holtsville, N. Y., design center
used a calculation from the software called the DFA
index as a key measure of overall product design.
The index is simply an ideal assembly time divid-
ed by the actual assembly time. An ideal assembly is
one having a theoretical minimum number of parts
as determined by the DFA software.
Motorola engineers divided the company product
portfolio into product families whose members were
closely related by their technology. Engineers then
figured a DFA index calculation for every product,
computed averages for each product family, and ran
the same calculation for competing products.
The resulting metrics served as a yardstick for gaug-
ing best-in-class design goals and a way to quantify
whether designs were improving. Motorola personnel
say DFA data gets compiled monthly and is presented
to senior management. A product with a DFA index
below target gets attention at all levels.
Products in Motorola Solutions portfolio, which includes hand-
held radios and handheld barcode scanners, are analyzed for
ease-of-assembly factors using Boothroyd Dewhurst Design
for Assembly software.
RESOURCES:
Boothroyd Dewhurst Inc., www.dfma.com/
Motorola Solutions Inc., www.motorolasolutions.com/
Innovation distinguishes between
a leader and a follower.
- Steve Jobs
As the leading manufacturer of OEM pumps
and compressors, our innovation in design and
technology has helped our customers create
new innovative products and become leaders
in their marketplace.
For more information on
how Thomas innovation
can help you lead
your industry, go to
gd-thomas.com.
Improving Lives through Innovation
TM
Improving Lives through Innovation
TM
907Z SERIES
BLDC COMPRESSOR
An Illustration
in Innovation
Efficient, durable and
lightweight, the oil-less
907Z Series brushless DC
diaphragm pump is designed
for fuel cell applications.
Lightweight (5.5 lbs/2.49 kg)
Die-cast aluminum parts for
strength and durability
Efficient, low-vibration design
Long-life 24V brushless
DC motor
Maximum continuous pressure
to 25 psi/1.72 bar, maximum
vacuum to 21.2 inHg/717 mbar
For more information on the
innovative 907Z Series, go to
gd-thomas.com.
News
VSDs POWER WRAPPING MACHINES,
ECONOMIZE ON CABINET REAL ESTATE

SAFE TORQUE-OFF FEATURES in variable-speed motor drives let wrapping machines use
simpler controls and smaller electrical cabinets.
Automatic stretch wrapper machines from Orion Packaging Systems, Alexandria,
Minn., use ACS355 model variable-speed drives from ABB, Cary, N. C. Each machine hosts
at least three drives. One rotates either a turntable holding a pallet full of material, or the
wrapper mechanics around a stationary pallet. Another moves the lift carriage containing
the film-delivery system up and down as it dispenses film. A third drive runs the multistretch
mechanism that actually stretches and pays out the film as the pallet turns. Many Orion auto-
matic-stretch wrappers also incorporate conveyors run by three additional ACS355 drives.
Safe torque-off is a built in and certified function that prevents unexpected start-ups. It
essentially keeps a drive from delivering random rotational energy to motors. This reduces
the need for separate safety components such as a safety contactor to disconnect the
drive and lets machinery start up quickly after a safety stop. It also enables machine
builders to fulfill the requirements of Machinery Directive 2006/42/EC.
For example, drives not equipped with torque-off functions must completely shut down
in the event of an E-stop. But torque-off-equipped drives recover more quickly after an
E-stop because they do not completely power down.
ACS355 drives are also bookshelf mountable, meaning they can mount in the panel
side by side. This helps maintain the system UL rating and does not delimit the drives abil-
ity to dissipate heat.
The variance in load on the motors can be significant
because of factors such as the wide range of pallet
weights that the turntable must rotate. In their most core
function, drives sense the amount of each load and gen-
erate enough motor torque and speed to handle it.
ABB variable-speed drives
power either ABB or Baldor
motors on automatic wrap-
ping machines that handle
package wrapping mechanics
(inset), a film-delivery lift car-
riage, and the turntable hold-
ing pallets of material, as well
as the conveying system on
some models. Safe torque-off
features simplify the associ-
ated electrical safety system.
RESOURCES:
ABB, www.abb.us
Orion Packaging Systems,
www.orionpackaging.com
News
tools developed for machining different polymers, espe-
cially polyurethanes.
All machined seals, whether standard or custom, are
manufactured on demand with no tooling costs. Produc-
tion quantities range from a single piece to lots of several
thousand. Larger quantities can be produced using mold-
ing processes. Normal lead time is 4 to 5 days, but rush
orders for seals up to 24-in. OD can be shipped the same
or next day, depending on the time the order is received,
says Uncapher.
A range of customers take advantage of customized
machined seals from SKF, he notes.
These include:
OEMs and end users that face
performance issues with standard
seals, and need to upgrade the
materials or design.
Users with equipment that suffers
a critical breakdown when stan-
dard seals are not readily available
because they are made overseas, or
the machine is outdated and spare
parts are no longer sold.
Equipment-repair specialists who,
instead of replacing worn shafts or
damaged housings, opt to change
the seal dimensions to fit.
OEMs and end users looking to
boost machine output through high-
er speeds and pressures, but need
engineering and testing assistance
to develop new seal designs that
ensure durability and safety.
In the latter case, SKF engineers
will work with customers to develop
seals tailored to an applications
specific needs. We have proprietary
design and manufacturing software,
which helps engineers develop a seal
based on the application housing and
shaft designs, says Uncapher.
SKF operates more than 200
seal machining centers worldwide,
including in Cleveland and Houston,
Edmonton and Scarborough in Can-
ada, and Monterrey, Mexico. To find
a location, visit www.skf.com/ca/en/
our-company/skf-locations-global/
index.html.
RESOURCES:
Additional information on SKF machined
seals is available at www.skf.com/
us/products/seals/industrial-seals/
machined-seals/index.html.
Custom seals continued from page 22
FABCO-AIR solves problems. Let us help!
www. f a bc o- a i r. c om
www.fabco-air.com (352) 373-3578
Pancake
Cylinders outperform their rivals.

Rugged construction provides unequalled strength, rigidity, and piston rod support maintaining
perpendicularity and concentricity for locating, mounting and making attachments to the rod.
Heavy wall prevents damage to the bore from external impacts. Magnetic position sensors fea-
ture surge suppression, polarity protection, LED indicators and extremely fast switching speeds.
stainless steel shafting.
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Self lubricated, the rod bearing has a
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News
RESOURCES:
Bodine Electric Co.,
www.bodine-electric.com
SOME CUSTOM MOTOR work can be relatively inexpensive, but
not all of it. It is easy to change the number of winding turns.
Changing the lamination stacks is a different story, says Terry
Auchstetter, business development manager for Bodine Elec-
tric Co. in Northfield, Ill. And it is simple to change mechanical
features like bolt patterns if they stay within the envelope of
the existing bracket casting. Of course, if you need an 8-in.-
diameter bolt circle when the casting has only a 6-in. diameter,
obviously youll need a new casting.
Auchstetter is speaking from experience: Some 70% of the
fractional-horsepower motors Bodine
makes are customized in some fashion.
Other things to keep in mind if the need
arises for a custom electric motor: A
stock product is off the shelf and the lead
time is a day. A lot of engineers dont
understand that when you get into custom
work, the price is higher and the lead time
goes into weeks, Auchstetter says.
Most of the customization requests
Bodine sees are in operating voltages,
mounting configurations, the addition of
accessories, and wiring. Its becoming
more common to use motors in remote
locations to handle jobs such as tracking
the sun with solar cells. Motors that work
from the 12-V supplies used in those
arrays are a special order for us, says
Auchstetter.
Special mounting configurations are
another frequent source of customiza-
tion. It is often easier to mate with a
gearbox or pump by modifying the motor
mounting holes rather than by adding an
adapter, he explains. Similarly, it may be
advantageous to add encoders, brakes,
terminal blocks, or other ancillary com-
ponents when the motor is manufactured
rather than later on when it is installed.
Motor wiring gets modified a lot as well.
Medical equipment often has its own
standards for EMI and related factors, so
wiring for motors in that area often need
extra shielding and ferrite beads, says
Auchstetter. Other wiring specials may
include special connectors, differing wire
lengths, and custom-configured wiring
harnesses.
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News
GEARMAKERS SAY THEY often see unrealistic expectations when
inexperienced engineers get into specifying custom work. A
lot of engineers have never worked in industry so they have no
idea how long it takes to manufacture parts that are intricate or
technically difficult. A lot of purchasing personnel have the same
problem because they have never taken the time to understand
the capabilities of their suppliers, says Fred Young, CEO of cus-
tom gearmaker Forest City Gear in Roscoe, Ill. Among other
things, Forest City frequently custom-fab-
ricates gears with finishes having super-
high AGMA quality tolerances.
Tolerancing is another bugaboo. When
people have gear problems, they often
think tightening-up tolerances will solve it,
Young says. Use of tighter tolerances is
frequently a crutch for engineers who lack
the experience to understand how a mech-
anism actually works and what aspects are
really critical to the build of the part.
Young maintains tolerancing often
gets wrongly blamed for a variety of gear
problems. We sometimes get gears with
noise issues that were made by another
vendor. The first question to ask is
whether the part really was manufactured
poorly or whether it was just a problem
with the design, he says. Most shops
cant check their parts adequately or
monitor the tolerance of gears. They may
not be able to tell whether the gear was
manufactured properly, whether it was
designed to the appropriate tolerance, or
whether the engineer just didnt design
the tooth correctly.
Many such difficulties can be chalked
up to lack of experience. There are a lot
of young engineers who dont have the
years of experience you need to sniff out
gear problems, Young says. And a lot of
manufacturers wont spend money to do
R&D on their parts to detect problems in
advance. Or their designers are afraid to
admit they dont have enough knowledge
to design something and take a pot shot
at it. They end up taking a lot longer to
design a part that is a lot more expensive
than it would be otherwise.
UNREALISTIC EXPECTATIONS FOR CUSTOM GEARS
RESOURCES:
Forest City Gear, www.forestcitygear.com
Engineered to improve performance.
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when selecting the best proximity
sensor for abusive environments,
the decision has always carried
a difcult tradeoff - durability vs
sensing distance. The 1cc% stainless
steel X-series Pile 0river is the rst
sensor to deliver both.
Row durable! Impact
withstandability is zcX beyond
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Row far! Sensing ranges exceed
industry standards by up to z.X.
So what does this 1-z combination
mean to you!
N Fewer sensor-target impacts
N Increased machine uptime
N keduced maintenance and
troubleshooting
N Fewer re|ects and increased quality
N Lower spare parts inventory
5)& "#*-*5: 50 8*5)45"/%
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A safety encoder detects when the machine
stops, and lets the operator in right away.
Unlike traditional setups, encoder-based
safety controls can also detect overspeeds
and if the machi ne is turning in the wrong
direction.
Sensor Sense
tem speed. When a worker needs to get
close and triggers the request-to-enter
signal, the controls slow the machine. As
soon as the encoder detects that poten-
tially hazardous motion has stopped, the
gate opens.
In some cases, encoder-based safety
eliminates the need to remove power
from the drive: The safety encoders con-
tinuously track machine motion and
trigger safety shutdowns if a faulty drive
tries to start the machine while a person
is near.
Saf et y encoders even mi t i gat e
machine runaways caused by drive fail-
ures if the drive is programmed with
bad limits, if the range of movement is
incorrectly set, or if there are bad refer-
ences in the motion program.
Runaways are dangerous to
operators. They also necessitate
costly repairs when they cause
crashes. Safety encoders can
detect overspeeds before a machine
goes out of control; then the controls
initiate a machine shutdown.
One caveat: Machine-safety sys-
tems must incorporate redundancies.
Conventional safety devices such as
e-stops, for example, have redundant
contacts. In contrast, encoder-based
safety uses redundancies programmed
into a speed-monitoring module. Here,
programmed-in logic activates safe-
guards in response to encoder pulse
counts that represent overspeeds and
stops. Some setups verify the direction
of rotation useful in applications that
can only turn safely one way. Here, if the
encoder detects the machine is spinning
the wrong way (as the result of a drive
failure or PLC programming error) the
controller will shut the machine down.
HELGE HORNIS at Pepperl+Fuchs (www.
pepperl-fuchs.us) provided information for
this column.
Edited by Elisabeth Eitel
FACTORIES USUALLY PUT safety fences
around sorters, fillers, and other rotating
machines that pose a danger to workers.
Gates in fences let operators and mainte-
nance personnel into a machines work-
space only when its safe. Typically, the
worker hits a button that sends a request-
to-enter signal to a timer. The timer
counts down a preset wait period to give
the machine time to come to a halt
even if it was not running at its fastest
when the worker requested access. For
added security the
machines drive power
is disengaged. Then
the gate opens.
Encoders for safety
While effective, timer-based safety is
inefficient because it results in unneces-
sarily long wait periods and safety mar-
gins to 50%. For example, if a machine
coasts a stop in 30 sec (as its assumed
a faulted system lacks the means to
actively brake) the added safety margin
results in a 45-sec wait period even
if the machine was running slowly and
can still brake. This increases machine
downtime and tempts frustrated opera-
tors to bypass the safety devices.
An alternative for rotating machines
is to base safety controls on safety-rated
encoders. Here, the encoder tracks sys-
GO TO MACHINEDESIGN.COM
Interview
TOM PRICE
|
PRESIDENT
Price Engineering
Hartland, Wis.
S
ystem integrators are playing an increasingly
important role in engineering fluid-power sys-
tems for next-generation manufacturing and
automation equipment. We recently gained some
perspective on the trend from Tom Price of Price Engineering.
What are some factors affecting the fluid-power industry?
First, theres an automation and manufacturing renaissance
taking root in the U. S. Its only recently weve woken up and
realized America cant be a world leader just servicing goods
made elsewhere. We need to actually make things in this
country. Fluid-power technology can play a significant role.
Second, theres been widespread integration of high-
tech components into hydraulics and pneumatics. A lot
of the electronics we now use has migrated from such
industries as automotive and truck things like hardened
PLCs, remote I/O, and joysticks linked via CAN networks
with robust connectors.
As a result, we now have products such as highly efficient ser-
vomotor-driven pumps for machine tools and injection-molding
equipment, and smart mobile hydraulics that help cut fuel con-
sumption and emissions. Now blend that with other technologies
like GPS, cloud and Web-based services, and telematics. This all
leads to many more-advanced automation opportunities.
Next-generation technology will help tell users when a
pump, hose, or machine is ready to fail. However, as equipment
gets more complex and capable, managing that complexity
through easy-to-use human interfaces with the machine will
be very important.
Are todays engineers up to the task?
Yes. That being said, the way systems are engineered is
changing. Traditionally, major manufacturers were vertically
integrated, with in-house engineering experts in areas like
hydraulics. But challenging economics have taken a toll. Weve
had a couple recessions and consolidation in many industries,
creating bigger, public companies keenly focused on the bot-
tom line. When times are tough, they downsize and lose expe-
rienced and talented people. And when times improve, they
tend not to bring them back.
So here we are teetering on the brink of a rebirth of American
manufacturing, and OEMs no longer have the skill sets necessary
to create the next generation of automation in plants or on prod-
ucts. This is where todays high-tech integrators are stepping up.
The Changing Role of
System Integrators
Whats the role of the integrator?
Many integrators have strong legacies in fluid power. Theyre
often privately held with long resumes of automation expertise.
Over the years they have acquired a lot of knowledge often
the hard way and are resilient and they stick around. Price
Engineering, for example, has been in business for 60 years. We
have skills that can be difficult to find in todays OEMs.
These types of companies are also willing to innovate.
Theyre generally small-to-midsize regional companies that
got better by partnering with smaller and experimental OEMs,
or they recognized opportunities that differentiated themselves
from the pack. Theyre dedicated, hardworking, and a bit crazy.
Being privately held affords them the opportunity to do things
public companies would never consider.
Theyve developed a strong set of competencies, niches,
and differentiators with core teams of engineers and software
designers. Around the country, you can find highly skilled inte-
grators with expertise in virtually any kind of market.
What challenges do integrators face?
As industry and technology evolve, there are numerous chal-
lenges. First, in the fluid-power industry weve had some bad
habits. For instance, we would give away the engineering to
sell products. We have to make sure we sell our value.
To fill the ranks of our engineering teams, we have to recruit
from new sources, create training programs within our organi-
zations, and develop educational partnerships. We need to get
more involved in programs like FIRST, where future engineers
are learning about fluid power and automation.
We also face some significant technology challenges. The
traditional methods of engineering are changing. We need to
acquire skills in areas like CFD, mathematical modeling, and
simulation, and embrace concurrent engineering to complete
projects faster.
Finally, projects are getting larger and more complex, involv-
ing multiple engineering disciplines. That demands better
project management skills and perhaps new tools, processes,
people, and strategies in how we become professional engi-
neering-services entities.
Across the country, companies are emerging that have mas-
tered the integration of fluid power with other technologies for
advanced power transmission and motion control. OEMs are
just beginning to realize the value integrators provide.
High Speed Optocouplers in Industrial
Communication Networks
Introduction
The ACSL-7210 is a dual-channel bi-directional 25 MBd high speed
digital optocoupler optimized for full duplex industrial communication
applications for example PROFIBUS feldbus and Serial Peripheral
Interface (SPI). The ACSL-7210 utilizes Avagos proprietary IC and
patented packaging technologies to achieve 3,750 VRMS signal
isolation in a low profle SO-8 package while supporting high speed
full-duplex data communications with data rates of maximum 40ns
propagation delay.
Figure 1: ACSL-7210 block diagram.
Patented Packaging and Stacked LED Technologies
Avagos patented packaging process of stacking LED die directly on
a silicon IC substrate enables higher integration in monolithic IC
packaging and low profle. Figure 2 shows a cross-sectional view of
one of the two channels in ACSL-7210. Input logic signal controls
the CMOS LED driver bufer IC, which supplies current to the LED. The
photodetector IC comes with two transparent layers: SiO2 passivation
or insulation, and light-transmissive polyimide on top. The LED
attaches to the photodetector IC with a transparent connecting layer.
Standard die attach process is used to make all the placements.
Unlike conventional standard LED that emits lights on the same side as
the metal contacts, Avago develops the back emission LED that emits
light from the reverse side of the LED. This allows LED to stack on top
of the detector IC.
Figure 3: Standard LED vs Back Emission LED.
This patented packaging technology provides the advantage of high
integration, with ACSL-7210 being a dual-channel bi-directional
optocoupler utilize for PROFIBUS isolated data communication
applications. Another advantage is low profle package (See Figure
4). ACSL-7210 can be mounted on the back-side of the PCB board to
maximize the use of board space.
Figure 4. Profle packages comparison.
Industrial Communication Networks
Fieldbus (or feld bus) refers to a family of industrial computer network
protocols used for real-time distributed control of instruments. As shown
in Figure 5, an automated industrial system such as a manufacturing
The Avago Advantage
Technical Notes
Your Imagination, Our Innovation
Sense Illuminate Connect
ACSL-7210
VOA
G
Shield
1 VDD1
GND1
4
VDD2
ND2
VOB
VI A
VIB 3
2
8
5
6
7
Data In Data Out
Data Out Data In
Photodetector IC Dielectric
LED
LED Driver Bufer IC
Input
Leadframe
LED
Light-Transmissive
Polymide
Transparent
Connecting Layer
To LED Driver
Bufer IC
Photodiode IC
SiO2
Passivation
Insulation
Ouput
Leadframe
Passivation
Passivation
Active Layer
P Metal Pad
Standard LED
Back Emission LED
P Metal Pad
Epi & Substrate
Epi & Substrate
N Metal Pad
N Metal Pad
Active Layer
Double Mold
~2.5 mm
Stacked LED
~1.6 mm
Dielectric
Placement
~3.2 mm
Planar
~2.5 mm
Figure 2: Cross-sectional view of one channel in ACSL-7210.
assembly line usually needs an organized hierarchy of controller
systems to function. From the top hierarchy is a Human Machine
Interface (HMI) where an operator can operate the industrial
system. This is typically linked to a middle layer of programmable
logic controllers (PLCs) by a non-time-critical communications
system such as Ethernet. At the bottom of the control hierarchy is
the feldbus that links the PLCs to the assembly line components,
such as sensors, actuators, electric motors, switches, and valves. In
such industrial environment, high voltages, magnetic felds and
noise are commonly present. High reliability is also critical to avoid
production downtime and ensure data transmission accuracy. Using
optocouplers such as ACSL-7210 address to these isolation needs.
Figure 5: Hierarchy of controllers and instruments in automated
industrial system.
Figure 6 shows the typical application diagram for 25MBd bi-
directional ACSL-7210 and 10MBd ultra low power ACPL-M61L
providing isolation in PROFIBUS (RS485) communication. ACSL-
7210 isolates the transmitting and receiving data channels while
ACPL-M61L isolates the transmit enable signal.
Summary
With its patented packaging and stacked LED technologies, dual-
channel bi-directional 25MBd ACSL-7210 optocoupler meets
the high switching speed and small package size requirements
from industrial communication networks, for example PROFIBUS
applications in noisy industrial environments.
Reference
1. ACSL-7210 product page
www.avagotech.com/pages/en/optocouplers_plastic/plastic_
digital_optocoupler/high_speed_cmos_logic_gate/acsl-7210/
2. ACSL-7210 product brief
www.avagotech.com/docs/AV02-4094EN
3. White Paper Fieldbus Applications with Optocouplers
www.avagotech.com/docs/AV02-3090EN
Figure 6: Isolated PROFIBUS (RS485) communication using ACSL-7210 and ACPL-M61L.
Contact us for your design needs at: www.avagotech.com/highspeed
Avago, Avago Technologies, the A logo are trademarks of Avago Technologies in the United States and other countries.
All other trademarks are the property of their respective companies.
Data subject to change. Copyright 2013 Avago Technologies
The Avago Advantage Technical Notes
Ethernet
FIELDBUS FIELDBUS
Internet
Isolation
Isolation
Rx
Tx
Tx Enable
Tx Enable
RS485
Fieldbus
Network
(Twisted Cable)
ACSL-7210
ACPL-M61L
Rx
Tx
VDD1
VDD1
VDD1
AN
RO VCC
B
A
RE_
DE
DI
VDD
VO
VDD2
VIA VOA
VIB VOB
GND1 GND2
GND GND CA
VDD2
VDD2
VDD2
C4
100n
R1
R2
510
U1
U2
U3
1
1
1
2
3
4 5
6
7
8
6
5
4 3
2
3
4 5
6
7
8
Off-highway Industry Focus
THELMA MAROUGY
|
Lubricant Specialist
Power and Control Div., Eaton Hydraulics
Eden Prairie, Minn.
Making the Move to
Eco-friendly
Hydraulic Fluids
G
overnments around the world have enact-
ed regulations aimed at protecting the
environment, and they usually carry
significant fines and remediation costs
for violators. Thats become increasingly important to
designers and users of hydraulically powered equip-
ment, especially when operating in wetlands and
other environmentally sensitive areas.
While hydraulic hose and connectors perform
better than ever, they still have the potential to leak
or rupture and spill fluid. Fluid suppliers have
responded by introducing eco-friendly biodegrad-
able and nontoxic fluids based on
a variety of chemistries. Unfortu-
nately, none of these fluids is a direct
replacement for petroleum-based
hydraulic fluid.
Heres a look at commonly avail-
able bio fluids, and some engineer-
ing considerations when making
the switch.
BIODEGRADABLE FLUIDS
Four basic types of environmen-
tally friendly hydraulic fluids are
commonly used. Each is derived
from different base stocks and is best
applied to a specific range of applica-
tions and operating conditions. And
because they have different chemis-
tries, interactions with seal materials
and other system components vary
from fluid to fluid. Engineers must account for these interac-
tions when weighing whether or not one will be a suitable
replacement for petroleum-based fluids in a specific hydrau-
lic system.
HETG fluids (hydraulic environmental triglyceride) are
water insoluble triglycerides derived from vegetable or ani-
mal oils with soybean, sunflower, and rapeseed (Canola)
being the most common sources. They frequently contain
soluble thickeners to increase their natural viscosity,
which is approximately 35 mm
2
/sec at 40C.
Triglycerides are long-chain fatty acids combined
with alcohol in the form of glycerin. Natural triglycer-
ides have excellent lubricity but
poor thermal and hydrolytic sta-
bility. They also oxidize rapidly.
Additives, chemical modifica-
tion, and even genetic modifi-
cation of the seeds used to pro-
duce the base stock can improve
hydrolytic stability and oxida-
tion resistance.
HETG f l ui ds of f er many
advantages. For one, they are
highly biodegradable and non-
Mobile equipment operating in
environmentally sensitive areas
increasingly relies on biodegrad-
able hydraulic fluids. While not
harmless, they are less toxic than
petroleum-based fluids and cause
less damage in the event of a spill.
Biodegradable hydraulic fluids are safer for the environment,
but they require special design considerations.
Simple Cne-Piece Construction
No C-rins or Threads
Slips into a Drilled Hole
Press to Lock and Seal
Pre-tested for ubble-Tiht Leakae
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S
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2 Pettipau Road
Westbrook, CT 06498 USA
Tel: 860-399-6281
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2 Pettipau Road
Tel: 860-399-6281
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toxic. They offer excellent lubricity and anticorrosion prop-
erties. And because they are made from natural, renewable
resources, they are readily available. In addition, they have a
high viscosity index and high flash point.
But HETG fluids also have drawbacks. High-temperature
operation can cause quick aging, rapid oxidation, and extreme
thickening and gumming. In addition, they are susceptible to
water contamination, which causes hydrolysis and increases
total acid number (TAN). They tend to thicken and gel at low
temperature, which hurts machine performance. And because
they are miscible with mineral oil, this can lower biodegrad-
ability in circuits that arent properly flushed. Finally, they are
double the cost of mineral oils.
HEES fluids (hydraulic environmental ester synthetic) are
water-insoluble synthetic esters derived from either petroleum
or vegetable (typically rapeseed) oil feedstocks. Petroleum-
sourced HEES fluids combine an organic acid and alcohol,
whereas vegetable sourced fluids combine a fatty acid and
alcohol.
HEES fluids are available as unsaturated, partially saturated,
and fully saturated products. Of these, fully saturated versions
generally offer the best performance and command the high-
est price.
HEES fluids offer long service life due to high thermal and
oxidative stability and good fluidity at low temperatures. They
are also available in a broad viscosity range (ISO VG 32/46/68).
However, they have more disadvantages than advantages. For
example, theyre expensive and, like HETG fluids, require spe-
cial system-design requirements. They also hydrolyze in the
presence of water. And like HETG, because they are miscible
with mineral oil, this can hurt biodegradability.
HEPG fluids (hydraulic environmental poly glycol) are
water-soluble polyalkylene glycols (PAG), polymers made
from reacting alkylene-oxide monomers such as ethylene
oxide, propylene glycol, or propylene oxide with glycol. Those
with 50 to 100% ethylene oxide are water soluble, while those
with 100% propylene oxide are water insoluble. Both types are
inherently fire resistant.
The biodegradability of HEPG fluids depends on the ratio
of propylene to ethylene oxides. The higher the molecular
weight, the lower the biodegradability of the fluid. HEPG
fluids come in a broad viscosity range and have an operating
temperature range of 20 to 80C. In addition, water-soluble
polyglycols can be used as anhydrous lubricants.
However, they require special system designs. For instance,
they are incompatible with polyurethane seals, and pumps and
motors may need to be derated when used with HEPG fluids.
HEPR fluids (hydraulic environmental polyalphaolefin
and related) are water-insoluble polyalphaolefins (PAO) and
related hydrocarbon-based fluids. These synthetic hydrocar-
bons are made by polymerizing alpha olefins to produce PAO.
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Tel: 860-399-6281
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Only low viscosity polyalphaolefins are considered environ-
mentally friendly.
A key advantage of HEPR fluids is that they offer excellent
oxidation stability and good corrosion protection. They also
have good lubricity and aging characteristics, and a long ser-
vice life. They offer good viscosity performance over a wide
temperature range: pour point is 20 to 40C and operating
temperature range is 30 to 100C. However, like most green
fluids, they can be costly and are incompatible with many seal
and gasket materials.
DESIGN CONSIDERATIONS
Seal compatibility. Traditional nitrile seals will have shorter
lives when used with many environmentally friendly hydrau-
lic fluids. In general, fluorocarbon seals give the best results.
HEPG fluids may require special seal materials formulated
specifically to work with these more aggressive products. The
same is true for back-up rings, gaskets, and other components
used in the system.
In any case, consult the fluid supplier, equipment manu-
facturer, and seal supplier before converting any system to an
environmentally friendly fluid. Fluid suppliers generally test
their fluids with different seal materials per ISO, ASTM, or
other specifications.
Hydraulic hose. As with seals, talk to your hose supplier
before switching to a biodegradable fluid. Many major sup-
pliers have done extensive testing with these fluids and can
recommend a hose compatible with a specific fluid, as some
fluids may require specialty hoses.
The same advice holds for other components containing
rubber or elastomers, such as bladder accumulators. The
material must be tested with the specific biodegradable fluid
before using it in a hydraulic system.
Component performance. Biodegradable fluids come in
many different formulations, and they differ in many regards
from standard mineral-oil-based hydraulic fluids. That, in
turn, may affect the performance of components such as
pumps. For example, most environmentally friendly fluids
have a higher specific gravity than traditional petroleum based
fluids. This may require adjusting pump-inlet conditions, say
with overhead reservoirs to ensure positive inlet pressure,
maintain adequate suction, and avoid cavitation.
Bio fluids also differ from standard petroleum-based
hydraulic fluids in terms of properties like oxidation stabil-
ity, hydrological stability, water compatibility, filterability,
and so on, and this can require special design and mainte-
nance considerations.
Experts recommend testing the fluid with say, a specific
pump. Use standard rating procedures to establish how that
pump and fluid work together. Some fluids permit use at
full rating, given proper system design, while others must be
DEFINING BIODEGRADABLE
AND NONTOXIC
BIODEGRADATION IS THE process of chemical
breakdown or transformation of a substance by
organisms or enzymes. Two common measures
of degradation are complete (ultimate degrada-
tion), in which the only end products are carbon
dioxide, water, and any indigestible inorganic
elements; and incomplete degradation (primary
degradation) measured by the reduction of hydro-
carbons in the original substance. The relevant
test standards are OECD 301 or ASTM D5864
for ultimate degradation and CEC-L-33-A-93 for
primary degradation.
Two other commonly used terms are readily
and inherently biodegradable. A readily biode-
gradable fluid undergoes primary degradation
greater than 80% within 21 days or ultimate
degradation greater than 60% within 28 days.
Inherently biodegradable fluids break down
slowly over time, usually measured in years, and
cause substantial damage to the environment.
Eco-toxicity is a measure of the concentration
required to kill various organisms over a short
period of time ranging from 24 to 96hr. The
fluid toxicity is described by a loading rate in parts
per million (ppm) of fluid that has a 50% effect, or
causes 50% mortality of the organisms after the
stated time.
The important thing to remember is that
both biodegradability and nontoxicity are rela-
tive terms. Environmental friendliness does not
mean the fluid is totally harmless to the environ-
ment and living things, only that it is less harmful
than something else. Environmentally friendly
or green fluids, like any hydraulic fluid, must be
disposed of carefully and responsibly.
derated. But, in general, engineers must take special care when designing a system
to run on specialty fluids such as bio fluids.
Water contamination. Some bio fluids, particularly HEES and HETG types, are
susceptible to water contamination, which degrades fluid properties. They read-
ily absorb water and, if water remains in the fluid, will hydrolyze the bio fluid. In
essence, the fluid will break down and lose lubricity, and acidity will increase. Its
essential to closely monitor water content and acid levels in vegetable based and
synthetic bio fluids.
To limit water contamination, use water-absorbent breathers on the reservoir. So
when fluid level drops and outside air enters the reservoir, any moisture is captured.
Temperature extremes. Some bio fluids face problems at extremely low and high
temperatures. For instance, vegetable-
based fluids usually should not be used
below rated temperature limits, as they
tend to crystallize at low temperatures
much faster than other fluids. Like-
wise, vegetable-based fluids tend to
oxidize at high temperatures, which
shortens fluid life. This is especially
true in mobile equipment, where it
is not unusual for hydraulic fluids to
reach 180 to 200F. Synthetic bio flu-
ids, on the other hand, handle a wider
temperature range, depending on the
degree of saturation.
A rough rule of thumb is to maintain
a 160F upper limit with vegetable-
based fluids (good for most industrial
hydraulic applications). Synthetics
(HEES) are suitable to around 180F
depending on the type of ester and
degree of saturation.
Filtration and maintenance. Stan-
dard fi lter el ements are compat-
ible with bio fluids. And filtration
requirements are generally the same
for petroleum based and environmen-
tally friendly fluids in terms of particle
sizes. Filter change intervals may be
different, however, particularly with
HETG fluids that may have shorter
service lives and a tendency to produce
varnish and other contaminants. Size
filters generously.
And keep in mind that all hydraulic
fluids, not just biodegradable fluids,
must be maintained in good condition.
Additives may degrade depending on
the fluid condition. Operating a fluid
at too high a temperature shortens its
life; and the presence of contaminants
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it is often advisable to perform multiple
flushes to ensure the system is perfectly
clean before adding environmentally
friendly fluid.
Note, especially, that engine oil addi-
tives are not compatible with environ-
mentally friendly fluids. Equipment
that has operated with engine oil as a
hydraulic fluid requires an exception-
ally thorough cleaning before environ-
mentally friendly fluid is installed.
ADDITIONAL
RECOMMENDATIONS
Engineers and equipment users must
keep in mind that environmentally
friendly hydraulic fluids are no substi-
tute for regular maintenance and good
operating practices. Preventing leaks is
much more cost effective than remedia-
tion when it comes to the environmental
impact of any operation.
Spills of environmentally friendly
fluids are still reportable incidents, but
many environmental regulatory agen-
cies treat them differently from petro-
leum-based fluid spills. Because the
fluids are less toxic and more biodegrad-
able, cleanup and reclamation costs may
be lower. For example, the affected soil
often does not have to be dug up and
autoclaved, as is the case in most petro-
leum-based spills. And operations are
frequently allowed to continue during
the cleanup.
Eco fluids offer a less-toxic alternative
to petroleum-based fluids that are more
easily assimilated by the environment
when properly disposed of, and cause
less damage should they spill. The price
for these benefits is often measured in
higher initial cost, potentially shorter
service life, lower efficiency, and addi-
tional maintenance requirements.
in excellent condition, and monitor it frequently to ensure it
performs as intended in the hydraulic circuit.
System flushing. Although traditional petroleum-based
fluids will mix readily with environmentally friendly fluids,
this should be avoided because petroleum contamination
nullifies the biodegradability and toxicity benefits of the
green product. Thorough system flushing is necessary, and
such as water and particulates can promote oxidation and also
shorten the life of the fluid. No fluid is maintenance-free.
While actual life depends on the duty cycle and countless
other factors, properly formulated and maintained fluid thats
not exposed to extreme temperatures and contamination will
give good life in a wide range of applications. Perhaps the
most important system consideration is to maintain the fluid
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GALIL MOTION CONTROLLERS
Materials/CAD/CAM/CAE
PRABHAKAR VALLURY, PH.D.
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Director of Business Development
e-Xstream Engineering, Fort Smith, Ark.
ROGER ASSAKER, PH.D.
|
Chief Material Strategist
MSC Software, Fort Smith, Ark.
How to Avoid
Overengineering
Composite Parts
Composite-part designs
are likely to work better if
they are simulated first.
C
omposites, or fiber-rein-
forced pl astics (FRPs),
give engineers a palette of
options for replacing con-
ventional low-carbon steel with lighter,
more-efficient material. At the same
time, these combinations of epoxy res-
ins and carbon or glass fibers create
special properties which make it dif-
ficult to calculate performance. Never-
theless, engineers can design optimal
FRP parts by simulating the materials
anisotropic properties, understanding
how processes affect fiber direction,
and using predictive analysis.
Engineers regularly overdesign FRP
parts to avoid failure, adding weight and
cost that defeats the rationale for design-
ing with new materials. Sure, the design
wont fail, but it also may not be eco-
nomically competitive. A major cause of
FRP overdesign is a lack of knowledge
about FRP properties. There is a tenden-
cy to treat FRPs like metals with isotro-
pic (same direction) properties instead
of understanding their anisotropic (dif-
Isotropic analysis of a
composite oil pan reveals
a maximum deflection of
4.1 mm and two potential
failure points.
ISOTROPIC
VERSUS
ANISOTROPIC
SIMULATION
Isotropic d
max
= 4.1 mm
Anisotropic d
max
= 3.1 mm
DIFFERENCES BETWEEN ISOTROPIC
AND ANISOTROPIC SIMULATION
AND ACTUAL MEASUREMENT
Measurement
10 mm/min 80C
FEA isotropic
10 mm/min 80C
FEA anisotropic
10 mm/min 80C
Displacement
F
o
r
c
e

(
N
)
ferent directions) nature. In
many cases, an FRP parts
anisotropic behavior can
enable better performance
than engineers could antici-
pate if they assumed metal-
lic isotropic properties.
Unlike the stiffness of met-
al parts, which is consistent
throughout their geometries,
the stiffness of FRP parts can
vary in different areas. That
variation comes from two
factors: production processes,
and the alignment of carbon
fibers in FRP epoxy resin
matrices. The two factors are
related because production
processes determine the posi-
tion of carbon fibers.
To illustrate this relation,
assume a homogenous plas-
LINEAR AND NONLINEAR SIMULATION OF LOCAL LOAD
F
o
r
c
e

(
N
)
Deection (mm)
Test averaged
Material linear
isotropic
35
30
25
20
15
10
5
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Material linear
isotropic 0.6 red.
Material nonlinear
isotropic
Material nonlinear
anisotropic
Isotropic analysis of a composite
part shows more than 80% variation
from actual physical measurement.
Nonlinear anisotropic analysis of a composite sunroof bearing close-
ly follows the averaged results from physical testing. Engineers felt
the linear isotropic analysis was too conservative, so they multiplied
the line by 0.6. Even so, the results of the nonlinear anisotropic analy-
sis better reflect physical measurement.
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Tsubaki cubed.

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2011 U.S. Tsubaki Power Transmission LLC , . All Rights Reserved.
on an FRP injection mold needs more
design consideration than on a mold for
a homogenous metal or plastic part. If a
mold for the homogenous part has two
gates directly opposite one another, the
two material flows meet and disperse to
the corners of the mold without affect-
ing the materials properties.
On the other hand, if two epoxy-resin
flows meet in the mold, carbon fibers
displace from their intended location
and change alignment. To correct the
win over the plastic part and will per-
form better in crash applications.
But it can be tough to realize that
stiffness because engineers need assur-
ances that the fibers will align properly.
Production process can affect the align-
ment. For example, the gate location
tic part is subjected to a 1,000-lb load.
It deflects 10 mm on its long end and
5mm on its short end. If carbon fibers
are placed along its upper surface, the
FRP part deflects 3 mm on its long end
and 0.25 mm on its short end. There-
fore, the FRP parts stiffness properties
MODELING ANISOTROPIC
PROPERTIES
THE ENERGY-MANAGEMENT COMPANY
Schneider Electric in France and FRP
supplier DuPont, Wilmington, Del., rede-
signed a bracket in FRP. The companies
used predictive analysis to modify and
optimize the FRP bracket design. Engi-
neers analyzed the design in two materials
to determine the breaking-point stiffness
based on the fiber orientation. One of the
materials was made of 20% glass-fiber-
reinforced polymer and the other was 50%
glass-fiber-reinforced polymer.
Production-process models were
then imported into a nonlinear, multiscale
material and modeling platform. The
designs were analyzed using isotropic
and anisotropic material properties.
The isotropic analysis varied 85% for
the 20% material and 120% for the 50%
material. The anisotropic testing produced
a curve that differed from the physical
measurements by only 5% for the 20%
material and 2.5% for the 50% material.
Clearly, the anisotropic results pro-
duced a smaller variation between
simulated and actual results. This helped
the companies find an optimal design.
If the companies relied on the isotropic
analysis alone, the variation between the
simulated and actual results would be
too large and unpredictable for engineers
to design with the maximum possible
precision. Instead, they would overdesign
to avoid failure.
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the performance of a part is called pre-
dictive analysis.
PREDICTIVE ANALYSIS OVER
BENCHMARKING
Anisotropic analysis is a major com-
ponent of predictive analysis. Most types
almost identical to the physical test-
ing. When results are close, models can
go from computer to production with-
out multiple rounds of physical pro-
totyping. Use of computational analy-
sis modeling and simulation methods
early in the design process to predict
problem, engineers can adjust the rate
of injection or the temperature of the
epoxies. But if that doesnt work, they
must change the gate positions so the
flows intersect in a way that keep the
fibers aligned.
To avoid trial-and-error testing, engi-
neers need to simulate both the FRP
injection-molding process and the part
performance with anisotropic proper-
ties in mind. Yet, most of the FEA and
simulation tools in use today treat FRPs
as isotropic materials. The resulting
simulation can yield less-than-accurate
results.
TESTING EXAMPLES
The accompanying figure labeled
Isotropic versus anisotropic simula-
tion gives proof to this theory. The red
arrows indicate isotropic analysis of two
potential failure points on a composite
oil pan. Anisotropic analysis reveals the
part does not deflect excessively at those
points. An engineer relying on the iso-
tropic analysis would likely add more
mass to guard against failure which will
not occur.
Another example of isotropic versus
anisotropic simulation is visible in the
chart labeled Differences between isotro-
pic and anisotropic simulation and actual
measurement. The blue line is an FEA
comparison curve and represents the
actual physical measurement of a com-
posite prototype. The variance in results
between the isotropic analysis and the
physical measurement is more than
80%. The anisotropic analysis curve
closely resembles the physical testing.
The same pattern emerges on the
chart called Linear and nonlinear simu-
lation of local load. The chart shows the
testing of a sunroof bearing under a
local load with the bottom sides of the
part fixed. It compares the accuracy of
nonlinear anisotropic simulation with
linear and nonlinear isotropic simu-
lation. The dotted line represents the
averaged results from physical testing.
The anisotropic, nonlinear analysis is
s %NGINEERING %XPERTISE
s #!. 4ECHNOLOGY
s &AST $ 0ROTOTYPING
s 1UALITY 4ESTING
s -ANUFACTURING
s ,%$ ,IGHTING
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Copyright 2013 OTTO Engineering, Inc. OTTO and the OTTO Expect Excellence logo are registered trademarks of
OTTO Engineering, Inc. All rights reserved. 2013-29
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then make a physical part and compare it
to the initial FEA. Correlations are made
to the FEA model until it represents the
final product behavior. The benchmark
provides data for the remainder of the
project and future projects. This method
works for metals, but because the shape
and fiber alignment in each FRP part
gives varying stiffness, benchmarking
can prove to be unreliable for deciding
mass and geometry.
Predictive analysis can reduce time
to production. However, a fast produc-
tion process that yields erratic quality
can be self-defeating. To use predictive
analysis successfully, engineers need to
understand three things: the individual
properties of the fiber and the matrix,
the composition of the overall materials,
and how manufacturing processes influ-
ence them.
The three elements can be under-
stood with the help of FEA and simula-
tion tools. Specific tools that are helpful
include smart material data models and
fiber orientation maps. Smart in this
context means employing material data
sets that, given any fiber alignment, can
tell you the exact stress-frame response.
The fiber orientation information
comes from process simulation software
that depicts the group of fibers in the
epoxy resin matrix that emerges from
the production process.
These tools let engineers see the stress
frame response for each section of the
design. They can use that knowledge to
reduce mass where possible and increase
it where needed.
Edited by Lindsey Frick,
lindsey.frick@penton.com,
@MaterialShout
does not depict its anisotropic proper-
ties. In addition, current FEA and simu-
lation software products benchmark the
results, which is a comparative process,
rather than create a predictive process.
Benchmarking takes place when engi-
neers run an FEA analysis of a design and
of analysis software incorporate some
level of anisotropic material behavior to
help engineers approximate FRP behav-
ior. For example, FRPs are represented
as black aluminum a kind of place-
holder that accurately depicts FRP part
geometry. However, this placeholder
RESOURCES:
Digimat Software, http://www.e-
xstream.com/en/digimat-software/;
http://www.e-xstream.com/event.html/
DIGIMATUM09/Proceedings/digima-
tum09_ticona_why_anisotropic_simula-
tions_are_necessary.pdf
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Sensing and Control Technology Guide
DAN MONTONE
|
Director of Business Development
Pittman Motors, Div. of Ametek Precision Motion Control
Harleysville, Pa.
LINEAR SYSTEMS DRIVE everything from
inexpensive seat movers in passenger
vehicles to precision laser cutters and CNC
machines. All move loads through a linear
distance in a specific amount of time.
One approach for designing a linear sys-
tem is to list basic requirements, add com-
ponents one by one, and define every force
interaction along the way.
DEFINE THE PROBLEM
To begin a linear design, determine the
mass of what moves and how fast it goes
from A to B. We work in SI units, as they
eliminate multiple conversion constants
and can always convert back into English
units. For example, assume were choosing
a motor for a simple linear-rail mechanism that moves a load:
Load's mass = 9 kg
Mass orientation: Vertical
A-to-B move distance and time = 200 mm in 1.0 sec
Dwell time = 0.5 sec
Move profile =
1
/3-
1
/3-
1
/3 trapezoidcontrolled acceleration
and deceleration
Rotary-to-linear conversion = TFE-coated leadscrew
8mm and 275-mm long
Load support: Linear ball rail and TFE-coated guide rails
with a friction coefficient = 0.01
Overall size: Limited to the smallest volume possible
Drive architecture: Must be simple, as this is a cost-sensi-
tive application
Drive control: Four-quadrant operation with encoder
feedback
Drive power supply = 32 Vdc, 3.5 A
rms
, 5.0 A
peak
maxi-
mum output
Worst-case ambient temperature = 30C
The easiest way to design a linear-motion system is to add
components one by one. Then, step-by-step calculations relate
input to power dissipated moving a load in a specific amount of time.
The second and third steps of the approach outlined here are to
choose the motor type and size.
Motors for
Because force = ma (where a = acceleration due to gravity =
9.81 m/sec
2
), the 9-kg mass lifted against gravity requires a
force of 88 N.
1. How much power is needed to move the load in the
required time?
Calculating minimum power output to translate the load
provides a starting point for specifying the rest of the sys-
tem's components. For our example, this is the average power
needed to lift the 9 kg from A to B in 1 sec.
P
F S
t
88 N 0.2 m
1.0 sec
17.64 W
where P = power, W; F = force, N; S = linear distance, m; and t
= time, sec.
HOW TO PICK
Note that power calculated here is less than peak power (or
instantaneous power during the move profile) to accelerate
and decelerate. Likewise, power calculated here doesnt fac-
tor in extra power to overcome system losses such as friction.
Well calculate the motor-shaft power for that in a later step.
PICK THE MOTOR
2. What motor technology is best for this application?
As outlined in our original parameters, the final design must
be inexpensive and have simple drive architecture. Stepper
motors satisfy both of these requirements. However, mini-
mizing this machines overall volume is also important, so a
stepper isnt recommended: The 17.64-W minimum power
requirement at the load (not including system losses and
instantaneous peak power) would necessitate a large stepper.
A brushless motor solves the problem of design footprint, but
adds cost and complicates the drive architecture.
The third option a dc-brush gearmotor with an in-line
planetary gearhead provides a small footprint, simplified
drive, and relatively low cost. Adding a leadscrew for rotary-
to-linear conversion keeps gearmotor output speed at around
Linear Motion
1,000 rpm, which reduces generated heat at the leadscrew and
nut-thread interface.
GEARMOTOR OUTPUT
3. Whats the velocity, reflected inertia, and reflected load
at the gearmotor output shaft (acting as the leadscrew
input)?
Step one: Calculate the peak linear velocity of the application
with its
1
/3-
1
/3-
1
/3 motion profile:
v
pk

3S
2t
30.2 m
21 sec
0.3 m/sec
where v
pk
= peak linear velocity, m/sec.
Step two: Calculate the minimum pitch needed to keep the
leadscrew speed at about 1,000 rpm:
p
min

v
pk
60
Maximum screw rpm
0.3 m/sec 60
1,000
18 mm
where p
min
= minimum leadscrew pitch, m.
For one typical product, the closest pitch in an 8-mm screw
diameter is 20.32 mm.
Step three: Calculate the peak shaft speed of the leadscrew
(in rad/sec) for a linear velocity of 0.3 m/sec:
Peak leadscrew speed =
v
pk
60
p
=
0.3 m/sec 60
0.02032 m
886 rpm 900 rpm
pk

9002
60
94.2 rad/sec
The leadscrew we select is TFE coated, 275-mm long, 8 mm
in diameter with a 20.32-mm pitch, and paired with a free-
wheeling nut. Assume the leadscrew efficiency,
s
, is 86% and
its inertia, J
s
, is 38.8 10
-7
kg-m
2
.
Step four: Determine the total reflected inertia, J
T
, back
from the load to the leadscrew shaft:
SIZING: JUST THE BEGINNING
THIS ARTICLE EXPLAINS how to size a motor for a relatively simple
single-axis linear-motion application. What dont we cover here?
Sizing motors for complex designs. The motor-sizing principles
we outline are applicable to X-Y tables and multiaxis pick-and-
place machines. However, every axis in these designs requires
independent analysis of load demands.
Choosing a safety factor so the machine lasts for its intended life.
A designs number of useful cycles depends on motor size, as
well as the machines mechanical elements including the gearbox
and leadscrew assembly.
Accounting for positioning accuracy, resolution, repeatability,
maximum roll, pitch, and yaw. Only linear-motion systems that
account for these fully meet application requirements.
initial linear velocity, m/sec; t
f
= final time, sec; t
i
= initial time,
sec; and = angular acceleration, rad/sec
2
.
4. What is the RMS torque T
rms
required at the gearmotor
shaft (acting as the leadscrew input)?
T
rms

t
1
T
1
2
t
2
T
2
2
t
3
T
3
2
t
1
t
2
t
3
t
dwell
The
1
/3-
1
/3-
1
/3 motion profile over 1 sec means that 0.3582 Nm is
applied for 0.333 sec, then 0.3309 Nm is applied for 0.333 sec,
then 0.3582 Nm for the remaining 0.333 sec.
T
rms

0.3330.3582
2
0.3330.3309
2
0.333(0.3582
2
)
0.3330.3330.3330.5
0.1219
1.5
0.2851
The RMS torque requirement predicts the gearmotors ther-
mal rise. The motor is thermally overloaded if the RMS torque
falls outside the safe or continuous-operating area of the dc-
motor curve.
DEFINE TOTAL POWER
5. What are the first-approximation power requirements to
drive the leadscrew shaft?
P
pk
T
a
pk
0.3582 Nm94.2 rad/sec = 33.74 W
P
avg

m g S
t
9 kg 9.8 m/sec
2
0.2 m
1.0 sec
0.86 20.47 W
6. What are the final load parameters at the leadscrew input
shaft (acting as the gearmotor output shaft)?
T
rms
= 0.2851 Nm; T
g
= 0.3309 Nm; T
a
= 0.3582 Nm;
pk
=
900 rpm = 94.2 rad/sec; P
pk
= 33.74 W; and P
avg
= 20.47 W.
J
s
38.810
7
kg-m
2
J
L
m
p
2
2
9 kg
0.02032 m
2
2
9.4210
5
kg-m
2
J
T
J
s
J
L
38.810
7
kg-m
2
9.4210
5
kg-m
2
9.8110
5
kg-m
2
where J
L
= reflected load inertia, kg-m
2
; m = mass, kg; and p =
leadscrew pitch, m.
Step five: Determine the shaft torque needed to accelerate
the load inertia T
a
:
T
a
T
J
T
f
T
g
T
J
J
T
a
T
f

cosmg p
2
s
T
g

sinmg p
2
s
a
v
f
v
i
t
f
t
i
0.3 m/sec 0 m/sec

0.333 sec 0 sec
0.901 m/sec
2

a2
p
0.901 m/sec
2
2
0.02032 m
278.6 rad/sec
2

T
a
J
T
a
cosmg p
2
s
sinmg p
2
s
9.8110
5
kg-m
2
278.6 rad/sec
2
+
cos909 kg 9.8 m/sec
2
0.010.02032 m
20.86
sin909 kg 9.8 m/sec

2
0.02032
20.86
0.027300.3309 0.3582 Nm
T
a
0.3582 Nm
T
f
0 Nm
T
g
0.3309 Nm
T
d
T
a
0.3582 N
where T
J
= torque required to overcome load inertia, Nm;
T
f
= torque required to overcome friction, Nm; T
g
= torque
required to overcome gravity, Nm; a = linear acceleration,
m/sec
2
; = load orientation, with horizontal = 0 and vertical
= 90; m = mass, kg; g = gravitational constant = 9.8 m/sec
2
;
p = leadscrew pitch, m; v
f
= final linear velocity, m/sec; v
i
=
POWER CONVERSION
Power supply Drive
= Watts out
Watts in
(V
in
) (I
in
)
Watts in
(V
in
) (I
in
)
Watts in
(V
in
) (I
in
)
T
= Watts to
leadscrew
shaft
Gearmotor
Load
F S
t
Electrical power converts to mechanical power. Equations describ-
ing each conversion provide the framework for specifying each part.
Begin at the load and work through the power-conversion elements
back to the motor and then to the motor drives power supply.
tinuous torque I
C
= 2.36 A; continuous output power P
C
= 37
W; torque constant K
T
= 0.042 Nm/A; voltage constant K
E
=
0.042V/rad/sec; terminal resistance = 1.85 ; N
L
current I
0
=
0.180 A; N
L
speed n
0
= 5,230 rpm; peak current I
pk
= 13 A; peak
torque T
pk
= 0.5422 Nm; and thermal resistance R
th
= 11C/W;
motor insulation = Class F (to withstand up to 155C).
At first glance, this motor seems to meet our application load
requirements while providing a bit of a safety factor: Its con-
tinuous output power is 37 W using a reference voltage of 24 V.
Remember that our initial application parameters indicate
we have a 32-Vdc drive power supply available. Therefore,
choosing a 24-Vdc motor winding makes for some voltage
headroom about 33%. This allows the drive to sup-
ply an additional voltage "boost" during intermittent
peak-power events. A lower-voltage motor winding
would also work, but would require more current from
the drive for a given load. A 24-V motor winding allows
for higher speeds while minimizing load current.
Now use the motor data above and the load param-
eters at the leadscrew shaft to choose an appropri-
ate gearbox. For this application, an in-line planetary
gearmotor is most suitable. After confirming that such
a planetary gearbox is compatible with the motor we
The gearmotor applies torque to the leadscrew
shaft. First it must transmit peak acceleration
torque to accelerate the mass against gravity
and get the leadscrew to its steady-state speed of
886 rpm (rounded to 900 rpm.) The gearmotor
must then supply enough steady-state torque to
move the mass against gravity at constant veloc-
ity. Finally, during deceleration the gearmotor
must supply a negative torque to stop the load in
a controlled manner. All this occurs in the 1.0sec
before the motor stops and dwells for 0.5sec.
After this dwell, the gearmotor reverses and
moves along the same motion profile to bring the
load back to the starting point.
CHOOSE GEARS
7. What motor-gearbox combination (gearmo-
tor) meets the load parameters?
Several gearmotor options will work. The best
choice depends on the designs total footprint,
audible noise limits, and price, which we wont
cover here. The maximum torque capabil-
ity of the gearbox must exceed the peak torque
required by the application; otherwise, the gear-
box will be damaged.
RMS torque required at our designs leadscrew
input shaft is 0.2851 Nm. Average and peak pow-
ers required at the leadscrew shaft are 20.47 W
and 33.74 W. Here, a 21-W motor wont meet the load require-
ments because it wont have the extra power to overcome
system losses. (Remember that leadscrew shaft power comes
from the motor through a gearbox, so the motor must supply
enough power to overcome gearbox efficiency losses.) The
motor must also have extra power if the design needs a built-
in safety factor.
A good first pick is a relatively small-diameter brush-type
dc motor with a rated (continuous) output power of 37 W.
Assume:
Winding voltage V = 24 V; continuous torque T
c
= 0.0812Nm;
speed at continuous torque n
CT
= 4,370 rpm; current at con-
Strengths Weaknesses
D
c
-
s
t
e
p
p
e
r

m
o
t
o
r
Open-loop positioning no encoder
required
No position correction if load exceeds output
torque
Simple pulse-and-direction signal needed
for rotation
Low power density torque drops off dramatically
at higher speeds
High torque density at low speeds Motor draws continuous current, even at standstill
Motor can be in a stall position without
overheating
Noticeable cogging at low speeds (can be
improved with a microstepping drive)
Lowest-cost solution Ringing (resonance) at low speeds
D
c
-
b
r
u
s
h

s
e
r
v
o
m
o
t
o
r
Linear speed-torque curve (unlike
steppers)
Draws high current during overload (same as
brushless motors)
Low-cost drive electronics (consisting of
four power-switching devices)
Encoder needed for closed-loop positioning (same
as brushless motors)
Many different configurations available Limited in speed due to mechanical commutation
Very smooth operation possible at low
speeds
Brush wear
High power density flatter torque at
higher speeds (compared with a stepper)
High thermal resistance (because copper is in the
armature circuit)
D
c
-
b
r
u
s
h
l
e
s
s

s
e
r
v
o
m
o
t
o
r
Highest speeds possible (faster than
stepper and brush-dc motors)
Highest cost of the three motor technologies
Linear speed/torque curve (compared with
a stepper)
Draws high current during overload (same as
brush motors)
Electronic commutation (no mechanical
brushes)
Encoder needed for closed-loop positioning (same
as brush motors)
Low thermal resistance (copper is in the
stator circuit)
Higher drive complexity and cost Six power-
switching devices
High power density flatter torque at
higher speeds (compared with a stepper)
Rotor-position sensors required for electronic
commutation
Brush, brushless, and stepper motors come in many shapes and sizes. Design parameters
dictate which motor is most suitable. Each requires design trade-offs.
EXAMPLE MOTION PROFILE
V
e
l
o
c
i
t
y
A
c
c
e
l
e
r
a
t
e
Time t
1
t
2
t
3
t
dwell
Constant
velocity
D
e
c
e
l
e
r
a
t
e
1.0 sec
1.5 sec
0.5 sec
www.masterbond.com
Hockensock, NJ O7O1 USl - -1.2O1.3/3.8?83 - noinnoslerbond.con
in a new york
minute
in a new york
minute
ONE PART ADHESIVE MASTERSIL 711
- kes|sts ap tr /11|
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- \||rat|rr ar1 s|rrk res|start
- N|]| flet|||l|t
ONE PART ADHESIVE MASTERSIL 711
- kes|sts ap tr /11|
- Selfleel|r]
- \||rat|rr ar1 s|rrk res|start
- N|]| flet|||l|t
Silicone Elastomer
Cures In Minutes
Silicone Elastomer
Cures In Minutes
eration, Nm; T
rms
= RMS torque required over the total duty
cycle, Nm; T
rms(motor)
= RMS torque required at the motor
shaft, Nm;
pk
= Peak angular velocity, rad/sec.
Our chosen 24-Vdc motor is rated for a continuous output
torque of 0.0812 Nm and a continuous current of 2.36 A. The
RMS torque requirement of the application is 0.0634 Nm. As
a first approximation, this motor-gearbox pairing safely meets
the RMS torque requirements. Note the continuous rated
power output of the motor is 37 W and the peak (intermit-
tent) power required for the motion profile is 37.5 W. But this
motor is still sufficient because the application's RMS torque
requirement is still within the motor's safe operating limits.
SPEC THE DRIVE
8. Can the drive and power supply meet the requirements
of the load?
First, calculate the required peak current:
I
pk

T
a(motor)
K
T
I
00
0.0796 Nm
0.042 Nm/A
0.180 A
= 2.075 A
where I
pk
= peak current, A, and K
T
= torque constant, Nm/A.
Then calculate the required RMS current:
I
rms

T
rms(motor)
K
T
I
0
0.0634 Nm
0.042 Nm/A
0.180 A
=1.690 A
where I
rms
= RMS current, A; then calculate the minimum bus
voltage required for P
pk
:
V
Bus(min)
(I
pk
R
m
)(
pk
K
E
)
2.075 A 1.85 + 471 rad/sec 0.042 V/rad/sec
= 3.839 + 19.782 V
= 23.621 V 24 V
where V
Bus
= drive bus voltage (dc), V and R
m
= motor termi-
nal resistance, . Based on these calculations, the drive and
power supply should meet the dynamic load requirements of
the motion profile. Drive power-supply input is 32 V and
maximum dc bus voltage is roughly 30 V, leaving plenty of
margin above the minimum bus-voltage requirement of 24V.
Maximum current of the drive and power supply also meet the
application's RMS current and peak current demands.
A comparison of the performance plots at 24 and 30 V tells a
more complex story. Our application's load points are the same
on both plots. However, a 24-V condition may or may not deliv-
er the required maximum velocity of 4,500 rpm as points for
both acceleration torque T
a(motor)
and RMS torque T
rms(motor)

picked, we use a few quick calculations to determine that a
5:1 reducer can safely output a maximum torque of 2.47 Nm.
That easily exceeds the applications 0.3582-Nm peak-torque
requirements.
Assume our 5:1 planetary gearbox has a published effi-
ciency of 0.90. At the motor output shaft (reducer input) it
requires:
T
gearbox (input)

T
gearbox(output)
N
g
P
pk(motor)
T
a(motor)
pk(motor)
T
a
@gearbox output (leadscrew input) = 0.3582 Nm
T
a(motor)
@ motor output (gearbox input) = 0.0796 Nm
T
rms
@gearbox output (leadscrew input) = 0.2851 Nm
T
rms(motor)
@ motor output (gearbox input) = 0.0634 Nm
pk(motor)
@ gearbox output (leadscrew input) = 900 rpm = 94.2 rad/sec
pk(motor)
@ motor output (gearbox input) = 4,500 rpm = 471 rad/sec
P
pk(motor)
@ motor output (gearbox input) = 37.5 W @ motor shaft
where N = gear ratio;
g
= gearbox efficiency; P
pk
= peak pow-
er, W; T
a(motor)
= torque required at motor shaft during accel-
MOTOR PERFORMANCE AT 24-V REFERENCE
Continuous torque region function of motor capability 8
7
6
5
4
3
2
1
0
S
p
e
e
d

(
r
p
m

x

1
,
0
0
0
)
24 Vdc
T
rms
(motor) = 0.0634 Nm
T
a
(motor) = 0.0796 Nm
0.100 0.200 0.300 0.400 0.500 0.600
Torque (Nm)
peak
= 471 rad/sec = 4,500 rpm
The motor we picked performs under a 24-V reference voltage as
shown. Within limits, voltage into the motor can be slightly increased
to ensure the peak velocity is maintained under load conditions.
MOTOR PERFORMANCE AT 30-V REFERENCE
Continuous torque region function of motor capability
8
7
6
5
4
3
2
1
0
S
p
e
e
d

(
r
p
m

x

1
,
0
0
0
)
30 Vdc
T
rms
(motor) = 0.0634 Nm
T
a
(motor) = 0.0796 Nm
0.100 0.200 0.300 0.400 0.500 0.600
Torque (Nm)
peak
= 471 rad/sec = 4,500 rpm
Maximum torque (Power supply/drive limitation)
This is the same motor operated using a 30-V bus voltage.
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profile is altered total move distance, acceleration and
deceleration rates, dwell time, and so on the equivalent
motor load (both peak and RMS) also changes. Repeat the
analysis using the revised motion-profile parameters to verify
the motor remains within safe temperature limits.
DESIGN CAVEAT
Note that the approach outlined here is a first-approxima-
tion analysis. All systems should be tested using actual load
conditions. Steady-state temperature should be determined
using thermocouples in several locations on the motor. Cur-
rent into the motor and voltage across the motor should also
be measured and recorded.
Motors operate differently under elevated temperature; motor
resistance, torque constant, and voltage constant all change under
actual operating conditions. This spurs corresponding changes in
peak current, RMS current, and bus voltage requirements. There-
fore, always contact the motor's manufacturer for advice and test
all systems under real-life operating conditions.
Edited by Elisabeth Eitel, eeitel@penton.com
fall close to the 24-V load line. In fact, our calculations indicate
we need a minimum bus voltage of 24 V to meet the applica-
tion's peak requirements. A 24-V bus voltage may initially
work, but there's no safety factor so any mechanical wear in
the system over time could cause speed to fall below 4,500-rpm.
In contrast, 30-V bus voltage from the drive provides plenty of
safety margin to help deliver peak velocities of 4,500 rpm.
Consider the plot of the motor under a 30-V reference and
notice how T
a(motor)
and T
rms(motor)
both lie within the shaded
region on the plot. T
rms(motor)
must remain below the continu-
ous torque rating of 0.0812 Nm. However, in many applications
T
a(motor)
moves outside the continuous-torque region. This is
perfectly acceptable because acceleration torque is factored into
the RMS torque. Here it's just a coincidence that both T
a(motor)
and T
rms(motor)
fall within the plot's shaded area. The point to
remember is that its absolutely necessary for RMS torque to
fall within the shaded region of the curve: Otherwise, thermal
overloading results.
CHECK FOR HEAT
The prime mover the dc gearmotor must be sized to
meet dynamic load conditions encountered throughout the
motion profile. (This contrasts sharply with sizing a motor for
continuous operation at an unchanging load point.) What com-
plicates the issue are incremental positioning applications that
make frequent starts and stops with duty cycles that make the
motor work harder during periods of controlled acceleration
and deceleration. The main concern in these situations is that
the motor remains below the maximum temperature rating.
Calculations based on RMS torque and current estimate the
motor's overall temperature and temperature rise for a given
motion profile:
r

R
th
I
rms
2
R
m
1(R
th
I
rms
2
R
m
0.00392/ C)
m

r

a
where
m
= motor temperature, C;
a
= ambient tempera-
ture, C; and
r
= temperature rise, C.
9. What is the motor's (estimated) worst-case temperature
under load at an ambient temperature of 30C?
r

R
th
I
rms
2
R
m
1(R
th
I
rms
2
R
m
0.00392/ C)
11C/W1.690 A
2
1.85
1(11C/W1.690 A
2
1.85 0.00392/C)
75.26C 76C
where R
m
= motor terminal resistance, and R
th
= thermal
resistance, C/W. With a 76C rise based on the RMS load and
a worst-case ambient temperature of 30C, the motor stabiliz-
es at about 106C. A Class-F rated (155C) motor allows a
safety margin of 49C. However, if any portion of the motion
MOTOR TYPE AND SIZE
NO MOTOR TYPE is best for all applications but there's usually one
particularly suitable motor for each design. For most incremental-
motion applications the choices are stepper, brush-dc, or brush-
less-dc motor. Some complex designs use linear motors to directly
drive the load and eliminate intermediate leadscrews, ball screws,
gearboxes, pulleys, and other mechanical power converters. These
direct-drive motors maximize accuracy, repeatability, and position-
ing resolution but are more costly and complex than designs based
on rotary motors. Plus, machines based on rotary motors satisfy
most linear-motion requirements.
All motors (ac and dc) use the interaction of magnetic fields to
generate output torque, but dc-stepper, brush, and brushless ser-
vomotors use a dc power supply. For linear-motion applications, a
fixed source of dc cant be applied directly to the motor windings;
electronics must control the winding current (related to output
torque) and voltage (related to output speed).
After determining which motor type is best, choose a frame
size with enough torque, speed, and power to accelerate the load
quickly enough to satisfy design requirements. The motor must also
generate enough torque to overcome the effects of friction (in the
designs mechanical transmission) plus gravity without overheating.
RESOURCES:
Leadscrew calculations in this article are based on values from
a Kerk screw chart, www.haydonkerk.com
Motor calculations are based on values for a Pittman 9237
motor and G30A gearbox, www.pittman-motors.com
Switches are only the beginning.
When its time to source components for your next project, dont just pick and
choose. Think Nason. The same experts you already trust for custom-engineered
switches are also hard at work perfecting precision-manufactured cylinders,
compact transducers and more. Were ready to customize a solution for any
challenge so you can be sure youve got the right part for the job.
800.229.4955
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SWITCHES
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Linear Position
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Miniature and Sealed Versions
Perfect for machine control, R&D and testing,
including servo valves; actuators; hydraulic cylinders;
robotics; structural monitoring; medical devices; et al.
800/828-3964 www.lvdtsensor.net
Free 76-page catalog... Also includes Gaging, Angular
Displacement & Velocity Transducers
DEL WILLIAMS

Massload Technologies Inc.
Saskatchewan, Canada
Force sensors
and their uses
FORCE SENSORS WEIGH freight on
manufacturing and transportation
equipment. They also monitor loads
on machines subject to stringent safety
standards such as mine lifts, con-
struction cranes, industrial tanks, grain
silos, and locomotives to ensure
equipment isnt overloaded.
At the core of force sensors are load
cells, transducers that convert force
into measurable electrical outputs.
There are hydraulic, pneumatic, piezo-
electric, and capacitive load cells. How-
ever, strain-gage-based load cells are
most common. These have fine wires
(to 0.02 mm in diameter) made of
steel, aluminum, or beryllium-copper
alloy. The wire adheres to a thin paper
or plastic base in one continuous zig-
zag that magnifies the effect of mate-
rial changes in the wire in response to
external loads. Leads at the beginning
lifting, pulling, and winching applications on cranes
and wire tensioners on safety cages used in mines.
Standard tension links measure 25,000 to 100,000lb,
though custom versions can measure more.
Load pins: These substitute for structural pins any-
where theres a need to know shear force. Typically,
a beam is machined to be almost completely hollow
(like a pipe) save for one segment with a solid cross
section. Sensing elements mount on this remaining
wall of material (also called a web). The pipelike body
of the load pin withstands bending stresses while the
solid cross section withstands vertical and horizon-
This scale uses a double-ended shear beam to measure static and running cable tension.
The cable feeds through the roller set to transmit force to the shear beam. Then a digital
readout converts output into weight readings.
and end of the zigzagging wave connect to circuits.
Often, four strain-gage sensing elements are bonded to a machined
housing in a Wheatstone-bridge arrangement. When subject to force,
this array develops strain that changes the wires resistance and that
triggers a change in electrical output.
FORCE-SENSOR TYPES
The most-common force sensors based on strain gages are load
pins, shear beams, and tension links.
Tension links: Tension links, also called a tension cells, consist of
two steel padeyes and a center body housing the load cell. They mea-
sure the force in cables, chains, and pulleys, and are most common in
Force sensors use load cells
to weigh objects and prevent
machinery from overloading.
tersunk bolts to secure the sensor to the machine, especially
if the heads are at risk of being sheared off by nearby equip-
ment during operation.
Also support the force sensors correctly. Unsupported ends
of single-ended shear beams should be unobstructed. Double-
ended shear beams should not be installed under tension or
forced into spaces that degrade weighing accuracy. Where shear
beams are used in tandem (on large cattle or truck scales, for
example) scribe lines make it easier to level the beams to the same
elevation. Loading-direction arrows printed on load sensors also
help installers, particularly with symmetrical and sealed load pins
(which make it difficult to know which way to mount them in a
piece of equipment).
OUTPUT AND DISPLAY
Usually the sensor-to-readout signal type
is only important to the machine builder,
not end users. Many load cells send signals
through hard-wired connections. These
generally transmit industry-standard mil-
livolt/volt signals because most weight
indicators can handle this signal type. Else-
where, load cells transmit output signals
wirelessly. Wireless interfaces can connect
nearly any load cell to nearly any display.
Two other options for nonstandard weight
indicators are 4-to-20-mA and 0-to-10-V
interfaces.
Stand-alone readouts just show the
weight measured. In contrast, portable
PCs collect load-cell measurements and
store and share that data locally or over
the Internet. Full industrial controls take
tal shear stresses. The webs strain
gages measure these shear stresses.
Standard capacities exceed 20,000lb, though
custom pins go higher.
Shear beams: Just like load pins, these measure shear stress.
Single-ended shear beams cantilevered sensors to which
load is applied at the free end weigh loads in blenders, hop-
pers, and floor scales. Double-ended shear beams sensors
supported at both ends and the load is applied at the middle
weigh tanks and items on large-capacity platforms. Both
single and double-ended shear beams operate like load pins
in that they incorporate a solid web in an otherwise-hollow
beam. Strain gages mounted on the
web measure load via shear stresses.
Standard shear beams detect loads to
40,000lb in 20 to 40-lb increments.
INSTALLATION REQUIREMENTS
Tension links, load pins, and shear
beams are rugged but must be pre-
cisely instal led. Their load cel ls
deflect predictably only when prop-
erly aligned to the applied load and
surrounding machinery. Otherwise,
skewed loading and moments cause
incorrect readings, and oversup-
ported load cells yield less than their
expected outputs.
For accurate readings from shear
beams and load pins, use the brackets
and pins that come with them. Where
applicable, carefully choose fasteners.
For example, a design may need coun-
Truck weighers are a common force-sensor
application. One way for vendors to validate the
output of load cells subject to real-world condi-
tions is with digital photos of the test setup.
Tension links are used in wired and wire-
less crane scales. For the latter, a bat-
tery-powered transmitter on the load
cell communicates with the readout
device.
Knows Where
to Turn
Sensors for Extreme Applications
800-350-2727
|
www.beisensors.com
Whether exposed to dirt, moisture,
extreme temperatures, shock, or
vibration, BEI Sensor products
have stood the test of time.
Their robust design and rugged
construction ensure accurate
and reliable operationday
after day, year after yearin
the toughest environments.
Learn more about how we
can help with your extreme
applications.
ized to fit existing systems typically to
enhance machine safety or performance.
When specifying a custom force sen-
sor, carefully review its CAD and FEA
models and the stress patterns they pre-
dict. Sometimes software presentations of
a load cell are misleading: For example, a
stress concentration that looks artificially
high in one area may mask a stress pattern
in another area. A mistake as simple as
modeling with the wrong support con-
straints can inflate load-pin results. If test-
ing doesnt catch the error, components
may not perform at their stated capacity.
Also look for documentation of a
force sensors initial calibration. Refer-
ence cells in test devices must be trace-
able as outlined by National Institute
of Standards and Technology (NIST)
standards. Some suppliers comply with
the Verified Conformity Assessment
Program (VCAP), a National Confer-
ence on Weights and Measures track
that certifies designs in North Amer-
ica. If VCAP applies, get the auditors
report. When warranted, some vendors
also verify results with those from third-
party engineering firms. Complex or
mission-critical applications require
such quality assurance most often.
Edited by Elisabeth Eitel, eeitel@penton.com
it further and spur machine responses based on collected
load-cell data.
CUSTOM-DESIGN TIPS
Off-the-shelf load cells and tension links go into machines
when their integration is planned early in design. However,
many load cells, load pins, and tension links are retrofits custom-
RESOURCES:
Massload Technologies Inc., massload.com
Verified Conformity Assessment
Program, nqa-usa.com
Load pins, also called lifting pins or force-
sensing clevis pins, measure shear force in
shackles, crane sheaves, and lifts. Plates
keep pins aligned to prevent side loads that
botch readings.
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Kentucky Exposition Center
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Held October 3rd in conjunction with the International
Construction & Utility Equipment Expo
Goldense on R&D-Product Development
BRADFORD L. GOLDENSE
|
President
Goldense Group Inc. (GGI)
Needham, Mass.
decade and will continue to grow for at least another decade.
Researchers are mapping the brain, developing artificial
intelligence, simulating combinational molecular chemistry,
engaging in crowdcasting and crowdsourcing using the Inter-
net and a host of other activities that are leading to improved
abilities to innovate across industries. The tools and enabling
technology available to folks sitting at their desks, and to
groups and teams chartered with bringing improved products
to market, are getting better every day.
Right now, we know enough about innovation to talk about
early market results. We cannot yet determine what the best
long-run tools will be to achieve it consistently. But there are
already 300 of these tools available that are being kick-tested
by companies today. Some are gaining traction. Offerings span
self-help, group-help, and sharing and structuring knowledge.
Some products actually increase the available domain knowl-
edge in brainstorming sessions and enable companies to better
innovate themselves out of specific problems.
It is prudent to not tout specific tools. After all, it is not
possible to review every companys offering, software, or
service. But it goes without saying that Microsofts Office is
the number one tool used for innovation. Another tool, the
USPTO Web site, is regularly used by half of the companies.
Next are Wiki sites with 40% of companies using them. Triz
has penetrated about 20%. And around 15% of companies use
different brain and mind-mapping tools that let you create,
place, link, and annotate just about any thought that pops
up in brainstorming and problem-solving sessions. Tried-
and-true techniques like Lead User Analysis, Six Hats, the KJ
Method, and Creative Whack Pack, which have been used by
companies for over 30 years, are regularly used by 10 to 15% of
companies. Even if we ignore MS Office, just about all workers
and managers should be running into one or more of these
innovation-enabling tools at their companies.
Innovation-enabling Tools and
Software for Individuals
and Product Pipelines
estern corporations have been try-
ing to harness innovation since the
mid-1990s when leading companies
realized the world was becoming
a global marketplace and began changing their competitive
posture to compete in that new arena. By the late-1990s, key
articles and books focusing on accelerating technologies and
more-innovative products into the new marketplace started
appearing. Those types of publications steadily increased
through the mid-2000s.
Then in 2004, Business Week and Boston Consulting
Group, recognizing that leading companies had been building
their innovation acumen for several years, teamed up to rank
the worlds most-innovative companies. Everything was now
in place for a widespread western-industry movement towards
repeatable innovation to maintain competitive position in the
now global economy.
The demand for ways to innovate was steadily increas-
ing and everything from Disruptive Innovation to Value
Engineering gathered disciples. About two years later in
2006 about the time it usually takes for savvy companies
to develop and sell tools to help slow adapters catch up with
their competitors numerous innovation-enabling products
targeted at these thirsty corporations began to appear. There
was now an emerging industry to service the latest corporate
movement, the belief that innovation was crucial to success.
Industry progress on improving speed to market in 1990s,
and innovation in the early 2000s, put in place the final cogs
that had been eluding yet another source of competition the
Makers and what is now called the Makers Movement.
(Machine Design, June 13, 2013) These Makers were quick-
er to market; CAD/CAM was available as shrink-wrapped
software for home use, and rapid prototyping was nearly
everywhere and inexpensive. Now Makers even have manu-
facturing capacity, thanks to 3D printing and manufacturing
companies for hire eager for their business. Between talented
individuals, small companies on ones home turf, and global
competitors coming out of nowhere, just about all established
corporations clearly had to improve their ability to systemi-
cally innovate.
The study of innovation has been growing steadily for a
BRADFORD L. GOLDENSE, NPDP, CMfgE, CPIM, CCP, presi-
dent of Goldense Group Inc. (GGI) (www.goldensegroupinc.
com), has advised over 300 manufacturing companies on four
continents in product management, R&D, engineering, product
development, and metrics. GGI is a consulting, market research,
and executive education firm founded in 1986.
Lockout valves
THE COMPANY is expanding its line of pneumatic lockout
valves. The Standard LV Series now includes compact and
high-ow versions. Lockouts are installed in pneumatic drop
legs or individual pneumatic control lines and are used during
maintenance of pneumatically operated equipment to help
protect maintenance personnel by preventing a machine
from engaging while it is being worked on.
The LV Series features port sizes from
3
/8 to 1 in.
and the compact version features and
3
/8-
in. sizes. The high-ow LV Series features 1
and 2-in. port sizes and is suited for higher
ow applications. All versions operate in
40 to 175F (4.4 to 79.4C). The compact
version handles 15 to 145-psi inlet pressures,
while both the standard and high-ow versions
handle 15 to 300-psi inlet pressures. All versions
are in-line or surface mountable.
The new EZ Series meets the same standards
as the LV Series but with the added feature of a
soft start when opened. Upon opening, an adjust-
able needle valve controls pressure buildup rate. The valves
feature
3
/8 to 1-in. port sizes and handle 30 to 150-psi inlet
pressures.
The new LVSS Series consists of corrosion-resistant stainless-
steel versions of the LV Series.
An important new option for all of the valves is a visual indica-
tor that veries energy isolation by popping-up when the valve is
open and air is owing.
PARKER HANNIFIN CORP., PNEUMATIC DIV., 8676 E. M89, Box
901, Richland, MI 49083, (269) 629-5000, www.parker.com/pneu/
lockout
Pneumatic cylinder switches
THE NITRA line now includes
nine styles of position switches for
pneumatic cylinders, including round,
dovetail, T-slot, square, and D-shaped.
Also available are additional dovetail
accessories to accommodate larger
dovetail slots. The solid-state electronic
switches come in normally open
three-wire dc pnp and npn congu-
rations, and can be purchased with
an M8 wiring connector or 3-m inte-
gral cable with wire leads. Mounting
bands with adapters for round body
cylinders come in
1
/8 to 4-in. sizes.
AUTOMATIONDIRECT, 3505 Hutchinson Rd.,
Cummings, GA 30040, (800) 633-0405, www.
automationdirect.com/cylinder-switches
Spotlight_
FLUID-POWER
CYLINDERS & VALVES
Toggle and stem valves
THE HV-HTV toggle and stem Series valves are available in three
and four-way congurations. The valves feature #10-32 inlet and
outlet ports, and 15 scfm @ 100-psig ow. They are available as
toggle or stem actuated and cartridge styles are also available.
The HV-3 Series is a fully ported three-way valve that can be
used to choose between two separate pressures or uids going
to a single output. Being fully ported, the inverse will work as well
using the valve as a diverter sending a uid to two separate out-
puts. It may also be used as a normally closed or normally open
three-way valve. The HV-4 Series is a four-way valve that vents its
exhaust ports to atmosphere and is suitable for powering simple cylinder applications.
CLIPPARD INSTRUMENTS LABORATORY INC., 7390 Colerain Ave., Cincinnati, OH 45239,
(877) 245-6247, www.clippard.com
Highest power density, smallest footprint, most durable.

Unrivaled power, performance and compactness comes from our T-LAM
stator design and rugged roller screw technology.
Compare and learn more at www.exlarcorp.com
Patented actuators from
Exlar utilize planetary roller
screws to outperform ball
screw actuators in life, load,
speed and acceleration.
Actuator
Motor
Amplifer
Controller
Linear or Rotary Actuator
Solutions Available
electric actuator solution
Save time and development costs.
Eliminate complex engineering and achieve signicant savings with our
low-maintenance Tritex II motion solutions. These include an integrated controller,
amplier, motor and robust roller screw actuator, all in one efcient, sealed package.
Or try our totally-integrated
Reverse engineering, inspection, design, and
modeling software
THE 2014 release of its new, comprehensive reverse en-
gineering, inspection, design, and 3D modeling software
reinvents the engineers desktop by providing accurate and
comprehensive precision engineering capabilities.
The release includes updates to Geomagic Design X
(formerly Rapidform XOR), Geomagic Design Direct (formerly
Geomagic Spark), Geomagic Verify (formerly Rapidform
XOV), Geomagic Control (formerly Geomagic Qualify), and
Geomagic Freeform software as well as the availability of
new Dynamics and Simulation tools for Geomagic Design.
Dynamics for Geomagic Design is a kinematics and dynamics simulation tool that builds and
tests functional virtual prototypes of designs on the computer and simulates the designs full-motion
behavior. This includes complex motion types such as conveyor belts, pulleys, ropes, and bushings.
Simulate for Geomagic Design adds the power of nite-element analysis with stress, strain, deec-
tion, vibration, buckling, and heat-transfer analyses. Users perform FEA on parts by dening the
boundary conditions manually, or using the integration with Dynamics for Geomagic Design to
automatically transfer the boundary conditions from a motion analysis, including dynamic contact,
into the FEA simulation.
3D SYSTEMS, 430 Davis Dr., Suite 300, Morrisville, NC 27560, (919) 474-0135, www.3dsystems.com
Spotlight_
CAD
Encoder testing
software
NEW ADJUSTMENT
and testing software
(ATS) Version 2.8 pro-
vides an easy-to-use
platform to diagnose
encoder faults and
evaluate encoder
output signals. The sig-
nals can be evaluat-
ed on a bench work-
station or while the
encoder is connected
to a machines control
without the need of
an oscilloscope.
Sine commutation
of servomotor encod-
Simulate for Geomagic Design
Dynamics for Geomagic Design
08.15.13 MACHINE DESIGN 66
BEGIN WITH THE SOLUTION.
hydraforce.com
Lincolnshire, IL, USA 847-793-2300 Birmingham, UK 44 121 333 1800 Changzhou, China 86 519 6988 1200
Designed to save valuable engineering
time, HydraForce now offers INTEGR8
a unique series of innovative engineered
hydraulic control solutions. These solutions
take the guesswork out for the most common hydraulic functions by
providing engineered circuits featuring optimal valve combinations.
Each solution is engineered for maximum system efficiency and
is backed by our 5-year warranty. Start saving time today by
downloading a free copy of i-Design 4 featuring the built-in
INTEGR8 library. Visit www.hydraforce.com/INTEGR8.
GET A HEAD
START.
to work on modules simultaneously and load them to the hardware separately,
shortening development time and making it easier to integrate external develop-
ers into the process and reuse parts of the system that have already been tested.
A SmartEdit feature generates context-related suggestions from function
libraries and existing program sections. Visualization templates also accelerate
user interface design.
B&R INDUSTRIAL AUTOMATION CORP., 1250 Northmeadow Pkwy., Suite 100,
Roswell, GA 30076, (770) 772 - 0400, www.br-automation.com
Smart engineering software
AUTOMATION STUDIO 4 software
keeps quality high,
engineering costs low,
and time to market short.
A System Designer tool
congures hardware easily and with
fewer errors with its visual editor and
lifelike representations of hardware
components. The tools automated
plausibility check congures basic
parameter settings and offers highly
effective functions for reusing entire
parts of a system.
A bidirectional EPLAN Electric P8 inter-
face lets users integrate ECAD projects
with hardware congurations designed
in Automation Studio, reducing the
amount of work required and eliminat-
ing one possible error source that arises
from having two sets of master data. Ap-
plications are generated automatically
from simulation data to test develop-
ment results at an early stage.
Full project-modularity support
makes it possible to split a project
into a series of autonomous modules,
allowing a software-engineering team
ers is also possible. For quick and
efcient mounting of an incre-
mental encoder, a PWT mode lets
users evaluate signal amplitude
and reference-mark signal. While
mounting the LIP 200 and LIC
4000, the output signals can be
electronically compensated for
the highest quality signal for sub-
sequent electronics.
HEIDENHAIN CORP.,
333 E. State Pkwy., Schaumburg,
IL 60173, (847) 490-1191,
www.heidenhain.us
Contrinex Inc.
Old Saybrook, CT 06475
Toll free: (866) 289-2899
Fax: (860) 388-3574
E-mail: info_us@contrinex.com
www.contrinex.com
Contrinex Series 700 the worId's toughest
inductive proximity sensors
ExceptionaIIy rugged and impervious
Housings machined from a single piece of stainless steel
Mechanically and chemically very rugged and resistant to operating
pressures of up to 850 psi.
Condet
technology provides long operating distances of 3 mm

(embeddable) and 6 mm (non-embeddable) on steel and aluminum
ldeal for applications where harsh liquids are present and
contact with machine parts, sparks, or hot shavings is possible
Handheld 3D scanner
THE HANDHELD Artec Spider is a 3D scanner
capable of scanning sharp edges and small
objects with extraordinary resolution and
accuracy. Named because of its many eyes,
the Spider has higher accuracy, resolution, and
the ability to digitize the most complex, industrial
parts such as molds, PCBs, coins, and engravings.
Features of the scanner include high resolution (up
to 0.15 mm) and high accuracy (0.03 to 0.05 mm); no markers or manual
alignment required during postprocessing; the scans have texture; scans
sharp edges and intricate details of the object; when used with the Artec
battery, working time is extended; and the device provides real-time scan-
ning and fusion.
ARTEC3D, AN ARTEC GROUP CO., 125 University Ave., Palo
Alto, CA 94301, (650) 325-2200, www.artec3d.com
Heavy-duty HEPA Vac
THE HEAVY Duty HEPA Vac attaches to
a 55-gallon open-top drum, turning it
into a HEPA-quality, industrial vacuum
cleaner. It lters contaminants to HEPA
requirements in dusty environments
that require frequent cleaning.
Extremely quiet at 82 dBA, the vacs
prelter stops larger particles, while the
HEPA lter handles the smaller ones. All
lters are tested for minimum 99.97%
ltration at the 0.3-micron level.
The system includes the Heavy Duty Dry Vac, lever-lock drum lid, shutoff
valve, prelter, HEPA lter, 10-ft (3-m) static-resistant hose, hose hanger, -NPT
quick-connects coupling, 20-ft (6-m) compressed-air hose, pressure gage, and
aluminum chip wand (drum not included).
EXAIR CORP., 11510 Goldcoast Dr., Cincinnati, OH 45249, (800) 903-9247, www.
exair.com/hepa.htm
Programmable electric
actuator
THE S-TRACK line of linear actua-
tors now offers a programmable
model. Operators can set and re-
set end-of-travel positions as well
as two intermediate stops. Feed-
back range automatically adjusts
to new end position settings.
The actuator turns power off
to the motor automatically when
the internal end limits are
reached. An integral MP150 Metri-
Pack 8-pin molded connector
allows several standard input and
output features to monitor the
operation of the actuator, includ-
ing motor thermal and current
overload protection.
Feature include a <56-dB noise
level, 700-lb maximum dynamic
and static load rating, 0.25ips
(1-in. no-load) speed rating, and
a 16-in. maximum stroke length
with end-of-stroke limits.
WARNER LINEAR, 6593 Revlon Dr.,
Plant #1, Belvidere, IL 61008, (800)
825-6544, www.warnerlinear.com
Products
Eliminate
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Most materials available in sleeve
and flange designs, in inch and
metric sizes.
iglide
plastic bearings can replace

bronze, metal-backed and custom
injection-molded bearings in
almost any application. Low-wear,
economical, dry-running, and best
of all predictable. There are over 30
various iglide
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igus.com/iglide
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East Providence, RI 02914 800-521-2747
Plastics for longer life
High-speed ink sintering

THE SINTERON 5000 system
is designed for high-speed
sintering of silver inks in printed
electronics production lines. It
uses the companys patented
pulsed-light technology to
deliver high-energy bursts of
pulsed light for sintering silver
nano-inks at up to 100fpm.
The system can be scaled in
the eld to support as many
as 10 pulsed lamps.
XENON CORP., 37 Upton Dr.,
Wilmington, MA 01887, (978)
661-9033, www.xenoncorp.
com
Pneumatic assembly
tools
PNEUMATIC ASSEMBLY tools
are available in hand or
bench models. They are used
to make plumbing as-
semblies; splice wire
rope and cable;
crimp electri-
cal components;
swage mechani-
cal fasteners; stake,
punch, pierce and flare; seal,
emboss and notch; and
clamp and hold assemblies.
FABCO-AIR INC., 3716 NE
49th Ave., Gainesville, FL
32609, (352) 373-3578, www.
fabco-air.com
Dual-range rotating
torque sensors
THE DYNO LaborSaver
Series of dual-range
rotating torque
sensors features
a 5:1 ratio
capacity of 0
to full scale.
The new Series
allows for dual-
measurement capa-
bilities and extended
capacities to accommodate
most testing requirements as a
single unit, reducing downtime.
Six base models are avail-
able with the high-bridge Dyno
LaborSaver in standard ranges
from 100 to 500,000 lb-in. The
low-range bridge version offers
capacities from 0 to
1
/5 full scale
of the higher range. Units feature
high accuracy on both distinct
bridges. Voltage outputs are either
simultaneous for both bridges or select-
able to suit requirements. High torsional
stiffness and low rotating inertia allow for
high-frequency response.
SENSORDATA TECHNOLOGIES, 50207 Hayes
Rd., Shelby Township, MI 48315, (586)
739-4254, www. sensordata.com
s
RAPID DELIVERY
s
ONLINE DESIGN
s
LIVE SUPPORT
Visit www.rollonnews.com
for technical papers and
application help or call
1.877.976.5566
75D
61CD
Dont let misalignment slow
you down. Compact Rail
self-aligns in three axes.
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YOURE PROBABLY STILL USING
Products
Solenoid interlock
THE AZM300 Series solenoid locking
keyed interlock switch features an ex-
ternal cross-shaped cam that allows
it to accept an actuator from any of
three sides. This provides mounting ex-
ibility for either left or right-hinged doors,
or sliding guards. The solenoid lock-
ing force of 1,000 N keeps the guard
door securely locked until dangerous
conditions, which may exist even after
removal of power, are removed.
The interlocks radio frequency
identication (RFID) sensor detects
the actuator and indicates a closed
guard, which limits wear on compo-
nents, tolerates misalignment, and
offers the option of individual coding.
The AZM300 features the diagnostic
advantages of electronic safety sen-
sors. With continuous internal function
tests and monitoring of the safety
outputs, the AZM300 can be wired in
series without detriment to the safety
levels. The sensors diagnostic LEDs
indicate various errors, misalignment,
and door open/closed signaling.
The AZM300 also offers adjustable
latching, providing a holding force
of 5 or 11 lb. A dampener pad lets
the switch be used as a door stop
for small to medium-sized guard
doors. Lockout/tagout is achieved by
placing padlocks through the key of
the actuator, preventing the guard
to close.
SCHMERSAL INC., 660 White Plains Rd.,
Suite 160, Tarrytown, NY 10591, (914)
347-4775, www.schmersalusa.com
Concentric reducer
THE NEW Dodge Maxum
XTR concentric
reducer, pack-
aged in a rug-
ged ductile-iron
housing, fea-
tures a sealing
system, long-life
bearings, and
is interchange-
able with in-
dustry-preferred
dimensions.
The reducer offers more
torque rating per case size than its
counterparts.
The units standard tandem seal
system features HNBR oil seals pro-
tected by an excluder lip auxiliary
seal on all shafts. The seals provide
high-temperature protection and
minimize shaft wear, while keeping
out contaminants.
Longer life
tapered and/or
spherical roller
bearings are used
throughout the
reducer to provide
a minimum unad-
justed L-10 life.
The reducer
comes in nine
case sizes, with
torque ratings from
29,500 to 579,000lb-in.
Available accessories
include internal high-capacity
backstops, shaft-driven fans, and
scoop motor bracket package or
top motor mounts.
BALDOR ELECTRIC CO., 5711 R.S.
Boreham Jr. St., Fort Smith, AR 72901,
(479) 646-4711, www.baldor.com
Clobal manufacturer of process control
and factory automatlon solutlons
For more lnformatlon:
Ca||: 1-800-Ce-feste
1-800-463-3786
www.feste.cem{us{hand|ing
Leading Manufacturer
ef Autematien
Preducts & 5e|utiens
wlth a comprehenslve llne
of automatlon components,
custom components and
complete electromechanlcal
and pneumatlc motlon
controlled multl-axls systems...
Festo can support your
most complex automatlon
requlrements!
3
$
7
(
1
7
(
'
t O ~ 1.O MFa (O ~ 145 FS)
ressure ranqe
t Fressure unit Pn dislay
t FPur ressure unit
cPnversiPns. MFa, kql/
cm
2
, bar, FS
t Accurate readPut and
wide viewinq anqle
t Relaceable CR2O82
battery last u tP 8 years
t FG5 dust and slash
rPPl enclPsure
t ac00m UZe
t 8acL IIhU
t 1/4w PSU [8815, /15 &
8811)
Digital Pressure Gauge
Email: sales@adsens.net
www.adsens.net
18310 Bedford Cir., Industry, CA 91744-5971 USA
TEL: 626-854-2773 FAX: 626-854-8183
NEW AVAILABLE OPTION:
Digital CNC
THE TNC 620 control now
offers features and software
options that let users custom-
ize the CNC.
New functions include a
DXF converter that lets users
open DXF les directly on
the TNC to extract contours,
point patterns, or machining
positions. The control also
comes with an HSCI inter-
face which permits greater distance
between components, high noise
immunity, and simplied troubleshoot-
ing and installation.
When programming away from
the machine, the TNC 620 automati-
cally takes machine geometry into
account, tilting the working plane,
and conducting cylinder surface
machining, 3D tool compensation,
and fast execution through short
block processing times, allowing it to
handle complex operations.
The control also dynamically
calculates and adapts to conditions
through the use of new functions
like crosstalk compensation, load-
adaptive control, and active chatter
control.
HEIDENHAIN CORP., 333 E. State
Pkwy., Schaumburg, IL 60173, (877)
887-6431, www.heidenhain.us
Products
:(9( 387 21
$ )(: 3281'6
The Dorner 2200 Series increases
weight capacity to 200 pounds
65% capacity increase
Low profle fts into tight spaces
Cogged tooth belt prevents slipping
Widths: 1.75" to 24"; Lengths: 1.5' to 30'
Quick shipment Call 800.397.8664 or visit www.dorner.com
Visit us at
Booth #3845
Sept. 23-25, 2013
Las Vegas, NV
Polyurethane hoses
THE 83FR DuraGard nonconductive, weld-spatter-resistant polyure-
thane hose is suited for robotic-assembly applications. Ultralite
superbraid poly-
urethane air hose
is 29% lighter than
equivalent thermo-
plastic air hoses
and 63% lighter
than rubber. The
compact hoses
offer an extremely
tight bend radius
without reducing
the flow of media
traveling through
the core tube.
The polyurethane hoses come with permanent fittings or con-
venient push-on fittings. The UltraLite hose uses a strain relief that
lets the hose bend freely without kinking at the fitting. Standard
sizes range from to -in. ID.
PARKER HANNIFIN CORP., PARFLEX DIV., 4700 Lone Star Blvd., Fort
Worth, TX 76106, (817) 984-0135, www.parker.com
ExtremeIy robust Sensors
for angIe / incIination /
position measurement
PRAS5V
WB85
PCST25
PCFP25
PTAM27 / PTDM27
PTAM2 / PTDM2
x Measurement range
0 ... 236.2 in.
x AnaIog, 4...20mA, SSI,
CANopen, J1939
x Protection cIass IP64
/ IP67
x 360 angIe sensor
x AnaIog, incrementaI,
SSI, CANopen, J1939
x With 0.39 in. shaft
/ IP69K
POSITAPE

Tape Extension
Position Sensors
POSIROT

Magnetic AngIe Sensors
POSICHRON

Magnetostrictive
Position Sensors
x Measurement range
0 ... 216.5 in.
CANopen, J1939
/ IP69K
x 1/2 axes, 180, 60
x AnaIog output,
CANopen, J1939
POSITILT

IncIinometers
POSICHRON

Magnetostrictive
Position Sensors
x Measurement range
0 ... 216.5 in.
CANopen, J1939
/ IP69K
x 1/2 axes, 180, 60
x In MEMS technoIogy
x AnaIog output,
CANopen, J1939
/ IP69K
POSITILT

IncIinometers
R
ASM Sensors, Inc.
www.asmsensors.com
info@asmsensors.com
TeI. 1-888-ASM-USA-1
Farmington Hills, MI 48335
tel: 800-521-3320 / fax: 248-476-2470
e-mail: shocks@acecontrols.com
www.acecontrols.com
EASY STEPS
TO CUSTOMIZED
GAS SPRINGS
Gas Springs are
universally used
for lifting assist
and lowering applications
such as, lids, hoods,
panels, doors and machine
guards. They remove the need for
muscle power.
BENEFITS
Push & Pull type designs
Precision Steel Tube
Stainless Steel models available
Maintenance Free
Long Service life
Easy mounting
Call ACE to get
the right Gas Spring...
800-521-3320
We do all the
calculations...
at no cost to you.

Custom made...
to your requirements.
Fast delivery.
From our doorstep
to yours.
1
2
3
4
Products
Ball bearings for low-friction movement
THE A 755Y... Series of ABEC 3 ball bearings are
suitable for applications requiring low-friction
movement. The bearings support axial and radial
loads with minimal play.
Available in inch and metric sizes, the bearings
come in plain and anged styles and can be
single or double shielded. Standard options for
lubrication include oil and both military and commercial-grade grease. Static
and dynamic load ratings go up to 1,030 lbf and 1,620 lbf, respectively.
STOCK DRIVE PRODUCTS/STERLING INSTRUMENT, 2101 Jericho Turnpike, Box
5416, New Hyde Park, NY 11042, (800) 819-8900, http://www.sdp-si.com/prod-
uct-announcements/ABEC-3-Ball-Bearings.htm
Continuous-use liquid
diaphragm pump
THE MAINTENANCE-FREE NF2.35 liquid micro
diaphragm pump delivers a ow rate of 100 ml/min
at 235-psig continuously. The pump lets OEM engineers use instrument tubing
with increasingly smaller inner diameters, thereby reducing reagent usage.
Powered by a brushless BLDC motor, this oil-free pump draws only 10 W at
full load, is self-priming, can run dry, and mounts in any direction. The units
head is constructed of PEEK, which provides broad chemical resistance. The
diaphragm and valves are available in EPDM and FFKM, allowing use with
most neutral and aggressive liquids and gases.
Uses include fuel cells, cleaning and disinfection devices, needle cleaning
in medical devices, liquid spraying and atomizing devices, degassing equip-
ment, chemical injection, water treatment, pressure and leak tightness control
devices.
KNF NEUBERGER INC., Two Black Forest Rd., Trenton, NJ 08691, (609) 890-8600,
www.knfusa.com/pdfs/nf2-35.pdf; www.KNFusa.com/oemliquidmicro.htm
Stainless-steel pneumatic ttings
THE NITRA line of pneumatic
products now includes 316
stainless-steel ttings that stand
up to harsh chemicals and
washdowns, and can withstand
pressures up to 290 psi and
temperatures to 390. The push-
to-connect male ttings, in NPT
inch and BSPT sizes, feature 303
stainless-steel gripping collets with
internal Viton O-ring. The ttings
can be used with polyurethane,
nylon, and PTFE tubing. Available ttings include straight unions, straight reduc-
ers, male straight and bulkhead ttings.
AUTOMATIONDIRECT, 3505 Hutchinson Rd., Cumming, GA 30040, (800) 633-0405,
www.automationdirect.com/pneumatic-ttings
www.diequa.com
630-980-1133
6HH RXU FRPSOHWH
SURGXFW OLQH
DieQua offers
more gearboxes
plus application experience to help
select the best one for your needs
s 175 hF CaaciTy
s MoTori/ed or AdaTers
s RihT Anle or nline
s ShalT MounT Besins
s MulTiSTae RaTios
s Modular Besin
Helical Gearmotors
s 7 si/es, 2811Omm CB
s FreTlree ConnecTion
s .EMA or EC AdaTers
s Coulin nuT
s Aluminum housins
s 2Side worm SuorT
Worm Reducers
s Frecision or Economy
s nline or RihT Anle
s 4O155mm Frames
s Low Backlash
s 1 and 2 STae RaTios
s LubricaTed lor Lile
Planetary Gearheads
s 8 Backlash Levels
s ShalTs or hollow Bores
s Sinle or Bual 0uTuTs
s 11 si/es, 252OOmm CB
s CaaciTy. 1O7OOO .m
s 2O,OOO hour RaTins
Servo Worm Gearheads
s O Si/es
s 125O hF CaaciTy
s Low Backlash 0Tion
s RaTios lrom 1.1 To O.1
s 0uTuT ShalT 0Tions
s Machined housins
Spiral Bevel Gearboxes
s Add0n 0Tions
s Modiled Bimensions
s hih Seed AlicaTions
s Secial EnvironmenTs
s Secial BuTy .eeds
s CusTom Besins
Special Designs
Single Lock Valves
The industry proven Kepsel Cartridge
combined with a rugged pilot section pro-
duces the leak tight Lock Valve. Free flow
from valve port to cylinder port. Reverse
flow checked until the pilot is engaged. The
Flexible Seal Seat design assures drift
free holding. Easy field maintenance.
Sizes to 40 GPM.
For details visit: www.kepner.com
Diodes protect against ESD and lightning-induced surges
THE SRDA3.3 Series TVS diodes combines low-capacitance steering diodes
with a Zener diode to protect against electrostatic discharge (ESD) and high
surges. The devices provide 40% greater protection without per-
formance degradation than comparable products and 50%
lower loading capacitance 10pF (maximum).
Features and benets include surge protection lightning,
IEC61000-4-5, 35 A (8/20sec), peak pulse power, 600W (8/20sec); 5- dy-
namic resistance; low capacitance of 8 pF (typical) /10 pF (maximum) from
I/O to GND; enhanced ESD capabilities ESD, IEC61000-4-2, 30-kV contact,
30-kV air, and very-low clamping voltages for sensitive chipsets.
LITTELFUSE INC., 8755 W. Higgins Rd., Chicago, IL 60631, (773) 628-1000, www.
littelfuse.com
Variable-speed dc control
THE OMDC-125 Series variable-speed dc control controls
the speed of PM, shunt wound, and universal motors. The
CE-compliant control features dual voltage (120/240 Vac
or 24/36 Vac), adjustable horsepower settings, a 50:1
speed range with 1% speed regulation, and a speed
potentiometer kit that includes leads, dial, and knob.
OMEGA ENGINEERING INC., One Omega Dr., Stamford,
CT 06907, (800) 826-6342, www.omega.com
Call 1-888-323-8751
info@wilbrechtledco.com www.wilbrechtledco.com
WILBRECHT LEDCO, INC.
If your application
depends on it
STANDARD AND CUSTOM SWITCHES
Large range of snap action microswitches as well as
limit, security and emergency switches. Temperature
resistant, IP67 or even IP68 protected, with custom
cable solutions to adapt to your specific application.
Sealed cable or M12
connector versions
Large range of actuators
Microswitches
High precision and small
differential movement
Sealed switches up to IP68
Much longer life 50 million
cycles
Limit Switches
11715 Main Street,
Roscoe, IL 61073
815-623-2168
Hunting for
High Quality Gears?
US Navy MH-60S Seahawk helicopters patrolling for mines
out ahead of surface vessels use a powerful and precise
Carriage Stream Tow and Recovery System (CSTRS)
to quickly raise and lower mine-hunting and destruction
equipment. Very high-precision gears from Forest City Gear
help to ensure that the mission goes as planned.
Dont let gear challenges go undetected.
Visit www.forestcitygear.com.
Power supplies
THE PS6R power supplies have a built-in
expansion slot for dc-dc converters, allow-
ing users to add 5 and 12-V outputs with a
simple plug-in module.
The 480-W power supplies are only
85-mm wide. With the addition of a branch
terminal module, users can add outputs
and extra + and slots.
An indicator alarm contact
(npn transistor) closes when
the output voltage has fallen
below 80%. With a steady pow-
er source and a 93% efciency
level, the supplies keep energy
consumption low while
maintaining high-output
power ratings (up to 20A).
IDEC CORP., 1175 Elko
Dr., Sunnyvale, CA. 94089,
(800) 262-4332, www.
idec.com/powersupplies
Captive panel screws
THE PEM types PF50 and PF60
self-clinching captive panel
screws keep hardware parts
count to a minimum by integrat-
ing a captive screw in a spring-
loaded assembly for easy and
efcient handling and installa-
tion. The screws permanently
mount in thin metal assemblies (0.30in./0.8mm), eliminating the
risk of hardware falling out, getting lost, or being misplaced.
Their low-prole design minimizes protrusion on front pan-
els. When tightened, the fastener (depending on size) will
protrude only 0.340in. (8.64mm) from the top of the sheet.
The screws feature a Phillips recess as standard so
they can be tightened or loosened simply using a Phillips
screwdriver. Multiple screw lengths with thread sizes from
#4-40 through -20 and M3 through M6 are available. They
can be engineered with MAThread anticross-threads and
customized with a scratchproof DuraBlack nish.
PENNENGINEERING, 5190 Old Easton Rd., Danboro, PA 18916,
(800) 237-4736, www.pemnet.com
Products
Data File/Literature Advertising
Digital Pressure
Gauge
AP60 digital pressure
gauge is CR2032 battery
powered, offers wide
viewing angle and provides
an accurate readout. They
are rated for pressures up
to 1.0MPa (145 psi) with
user-programmable display pressure units for MPa, kgf/cm
2
,
bar and psi. Suitable for fltered air and non-combustible and
non-corrosive gases; excellent repeatability of +0.2% F.S. +1
digit or better.
Adsens Technology Inc.
City of Industry, CA
New tutorials and podcasts on Learn Web site
What is a PLC plus many more
topics on industrial control prod-
ucts including new videos and
podcasts on AutomationDirects
free self-service learning site.
Visit http://learn.automationdirect.com
to watch these and other tutorials
on a range of industry topics.
Te Brushless DC Servomotor series 2232
& 2250BX4 CSD/CCD is the worlds most
compact drive with an integrated motion
controller. Tis new series combines all the
advantages of the BX4 four pole brushless
technology with a single axis motion con-
troller. High reliability, high torque, compact
slotless design with no cogging torque, and
robust construction without the use of adhesives make this new
series ideal for complex applications such as robotics, automa-
tion, medical and laboratory technology, specialty machinery and
aerospace.
800-807-9166 + www.micromo.com
Worlds Most Compact Drive with Integrated Motion Controller
Smalley Steel Ring Company
New Smalley Engineering
& Parts Catalog
Smalleys new catalog combines
existing Spirolox Retaining Ring
and Smalley Wave Spring selec-
tions with series recently released
from Smalley. Now a single catalog
includes new: Hoopster Rings, Met-
ric Wave Springs, Constant Sec-
tion Rings and more. Over 10,000
standard parts in carbon and stain-
less steel; free samples available.
Specials manufactured with
No-Tooling-Costs from .200-120.
rJOGP!TNBMMFZDPNrXXXTNBMMFZDPNHFUDBUBMPH
Stainless Steel
Tube Fittings
20-page catalog (#74-H) describes
these Mark VIII O-SEAL stainless steel
tube fittings that will not shake loose.
Unique leakproof sealing system al-
lows easy slip-in, slip-out connections
matched to your system. O.D. tube
sizes from 1/4 to 2. Reliable to 6,000 psi for liquids and gases.
Available in steel, bronze, monel, and titanium. Call 888-278-
5449, Web: www.cpvmfg.com
CPV Manufacturing Inc., Philadelphia, PA
WITTENSTEIN - Experience a revolution in linear
technology with the most compact reliable and
robust linear system for your applications.
Learn more at www.wittenstein-us.com
Tubus Bumpers
Ace Controls, Inc. offers TUBUS
Bumpers that outperform rubber,
urethane, and coiled steel shock
absorption materials. These cost
effective bumpers are perfectly
suited for harsh environments, with
excellent resistance to Oil, Grease,
Chemicals, Salt-water, Ultra-violet
Light, and Microorganisms.
Contact ACE Controls for your free
catalog:
ACE Controls Inc.
Farmington Hills, MI
(800) 521-3320 (248) 476-0213
Fax (248) 476-2470
Email: shocks@acecontrols.com
www.acecontrols.com

BEIs Industrial Encoders
for Dummies
Visit www.beisensors.com/dummies
for your free copy today
Motion Control
Its What We Do
1. 800. 377. 6329
. c om
High Performance
Motion Controllers
Backed by
Our Exceptional
Customer Support
Trim-Lok Inc., Buena Park, CA
Vinyl & Rubber Extrusions
Trim-Lok Inc. releases a brand new
FREE Catalog 500 featuring How
to Order steps for the frst time
customer, along with an expanded
line of complete trims and seals.
FREE samples may be requested.
Latest additions include our Flap
Seal, Fire Retardanct Trim, adn
Hatch Seal. Contact us toll fee at
1-888-874-6565, e-mail us at info@
trimlok.com or visit us on-line at
www.trimlok.com
Kapton Insulating Tubing for High Temperature,
High Dielectric Coil Winding & Insulating Parts.
ExIremely high dielecIric sIrengIh - 7,000 VFM.
Sel-ExIinguishing, ame reIardanI, does noI melI.
ExIremely wide IemperaIure usage, rom -2oC Io +400C.
ExIremely sIrong - very high Iear resisIance.
To receive liIeraIure & deIails asI:
Precision Paper Tube

Company
Phone: 847-537-4250
Fax: 847-537-5777
sales@pptube.com
www.pptube.com
More Than 75 Years - The Original
DuFonI Co.
PRODUCTS/SERVICES
THUMBSCREW
THE ORIGINAL
INSTANT
In most cases, advertisements contained
in MACHINE DESIGN employment section indi-
cate that the companies are equal oppor-
tunity employers. The Federal Civil Rights
Act of 1964, and other laws, prohibit dis-
crimination in employment based on race,
color, religion, national origin, sex, or for
any reason other than lack of professional
qualification for the position being offered.
It should be noted that employment adver-
tisements in MACHINE DESIGN are published
for the readers convenience and, in no
way, to the best of our knowledge, promote
unlawful discrimination.
To Advortiso in
5)+016- ,-;1/6;
ClnssiBods Soction,
pnul.nilnnnowponton.con
Ad index Classifieds
Ace Controls . . . . . . . . . . . . . . . . . . . . . . . . 74
Adsens Technology Inc. . . . . . . . . . . . . . . . . 72
Align Production Systems . . . . . . . . . . . . . . . 49
Aluma Cast Inc.. . . . . . . . . . . . . . . . . . . . . . 59
ASM Sensors . . . . . . . . . . . . . . . . . . . . . . . 73
Automationdirect.com . . . . . . . . . . . . . . . . . . 3
Avago Technologies U.S. Inc. . . . . . . . . . 35-36
Baldor . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC
Banner Engineering Co . . . . . . . . . . . . . . . . 29
BEI Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 62
Centricity Corporation . . . . . . . . . . . . . . . . . 70
Clippard Instrument Laboratory, Inc. . . . . . . . . 9
Contrinex Inc . . . . . . . . . . . . . . . . . . . . . . . 68
Dexmet Corporation . . . . . . . . . . . . . . . . . . 57
Diequa. . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Dorner Mfg Corp. . . . . . . . . . . . . . . . . . . . . 73
Dura-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . 57
EBM-Papst . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exair Corporation . . . . . . . . . . . . . . . . . . . . . 5
Exlar Corporation . . . . . . . . . . . . . . . . . . . . 66
Fabco Air, Inc.. . . . . . . . . . . . . . . . . . . . . . . 27
Festo Corporation . . . . . . . . . . . . . . . . . . . . 72
Fluid Line Products. . . . . . . . . . . . . . . . . . . . 40
Forest City Gear . . . . . . . . . . . . . . . . . . . . . 76
Galil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Hawe Hydraulics. . . . . . . . . . . . . . . . . . . . . 12
Helukabel USA Inc. . . . . . . . . . . . . . . . . . . . 71
Hercules Sealing Products . . . . . . . . . . . . . . 71
Hinder Rust . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraforce, Inc. . . . . . . . . . . . . . . . . . . . . . 67
igus, inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Kepner Products . . . . . . . . . . . . . . . . . . . . . 75
Lee Company . . . . . . . . . . . . . . . . . . . . 38-39
Linx Technologies. . . . . . . . . . . . . . . . . . . . . . 6
Lubriplate Lubricants Co. . . . . . . . . . . . . . . . 30
Master Bond, Inc. . . . . . . . . . . . . . . . . . . . . 55
Microprecision . . . . . . . . . . . . . . . . . . . . . . 76
Minnesota Rubber . . . . . . . . . . . . . . . . . . . . 31
Nason Co. . . . . . . . . . . . . . . . . . . . . . . . . . 59
National Instruments Corporation . . . . . . . . . 13
National Instruments Corporation . . . . . . 18-19
Newark . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Nexen Group Inc. . . . . . . . . . . . . . . . . . . . . 49
Novotechnik U.S., Inc. . . . . . . . . . . . . . . . . . 53
Ogura Industrial Corp.. . . . . . . . . . . . . . . . . 49
Ondrives.us . . . . . . . . . . . . . . . . . . . . . . . . 26
Otto Engineering Inc.. . . . . . . . . . . . . . . . . . 48
Pepperl+Fuchs. . . . . . . . . . . . . . . . . . . . 32-33
PITTMAN . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Proto Labs, Inc. . . . . . . . . . . . . . . . . . . . . . IBC
Quality Transmission Components. . . . . . . . . 55
R + W Couplings. . . . . . . . . . . . . . . . . . . . . 47
Rittal Corporation . . . . . . . . . . . . . . . . . 22-23
Rollon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Santest Co Ltd . . . . . . . . . . . . . . . . . . . . . . . 55
Schaeffler Group USA. . . . . . . . . . . . . . . . . 15
Siemens Industry Inc . . . . . . . . . . . . . . . . . . . 1
Smalley Steel Ring Company . . . . . . . . . . . . 28
Spirol International Corporation . . . . . . . . . . . 8
TDK-Lambda Americas Inc . . . . . . . . . . . . . . 41
Thomas Division . . . . . . . . . . . . . . . . . . 24-25
Trans-Tek Inc. . . . . . . . . . . . . . . . . . . . . . . . 59
Trim-Lok Company. . . . . . . . . . . . . . . . . . . . 57
Turck Incorporated. . . . . . . . . . . . . . . . . . . . 14
U.S. Tsubaki Incorporated . . . . . . . . . . . . . . 46
Watlow . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Yaskawa America, Inc. . . . . . . . . . . . . . . . .IFC
While every effort has been made to ensure the
accuracy of this index, the publisher cannot be
held responsible for any errors or omissions.
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Hydraulics & Pneumaticsg.e.
contnct Pnul Milnnnow nt
(312) 840-8462,
Register today at:
DM-Midwest.com
Source code: AB
Leave your ofce behind and join the community of professionals
at Design & Manufacturing Midwest.
Connections like these cannot be made at your desk!
CUT the
CORD
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Industry Peers Thought Leaders Ideas and Inspiration New Technologies
tIncrease your knowledge and your network by
engaging with like-minded peers and industry
thought leaders.
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tCollaborate with world-class suppliers to create
custom solutions that cant be found online.
tEngineer fresh ideas through face-to-face discussions.
September 1012, 2013
McCormick Place Lakeside
Chicago, IL
Including:
Puzzles, myths, and curiosities
LEDs ARE NOT FIT
FOR CONSUMERS
LIGHT-EMITTING DIODES (LEDS) are popping up in more and
more places as companies and individuals try to save
money and reduce energy consumption. But some
people insist there are problems with them. Here are a
few of the myths that have arisen around LEDs:
Myth 1: LEDs will make you go blind.
An article in a recent issue of the Journal of Photo-
chemistry and Photobiology detailed a study in which
the effects of LED light on human retinal cells were
examined and concluded that LEDs can harm human
eyes. The authors of this article came to this conclusion
based on an experiment that exposed human retinal
cells to 5 mW/cm
2
of light from an LED for 12 hr. This
equates to staring at a 100-W-equivalent light bulb from
4 in. away for 12 hr.
Light at that intensity and duration would likely dam-
age anyones retinas and is one reason parents tell kids
not to stare at the sun. And if scientists ever do discover
a real danger from LEDs, future LEDs can be tuned to
emit a spectrum of light similar to that from ordinary
incandescent bulbs.
Myth 2: Blue LEDs are especially dangerous.
Theres a whiff of truth to this one. The human eye
doesnt handle blue light well, especially bright blue
light. It can cause mild and temporary headaches and
nausea. But if exposure is long enough, it could perma-
nently damage the eye. The source of the blue light
LEDs, incandescents, or neons doesnt matter.
Some overly cautious folks point out that many LED
makers use a primary blue LED and phosphor-down-
convert it to get a white LED. They then leap to the
conclusion that down-converted
blue LEDs will damage eyes or
even cause cancer So far, theres no
proofof this.
There is proof, however, that blue LEDs lower mela-
tonin levels, which can weaken a persons immune
system. Medical science does not yet know if an LED-
weakened immune system can lead to cancer.
To be on the safe side, many companies are limiting
or eliminating the use of blue LEDs for common features
such as backlighting TV screens and power buttons on
electronic devices. There are also LED makers using pri-
mary violet LEDs as the basis for white-emitting lamps.
Myth 3: LEDs arent bright enough
and have poor light quality.
This was true at one time, but no more It can be refut-
ed with some technical specs. LEDs have color tem-
peratures ranging from 2,500K (warm white) to 6,500K
(daylight), and Color Rendering Indexes between 75 and
85, with some high-end LEDs topping 90. (Incandescent
bulbs have a CRI of 100 by definition, the highest pos-
sible value. For comparison, low-pressure sodium lights
have a CRI of 44; coated mercury vapors CRI is 49,
triphosphor warm-white fluorescents have a CRI of 73;
and quartz metal-halide lamps rate an 85 CRI.)
Traffic engineers also think LEDs are plenty bright.
They go into traffic signals which must be visible in the
brightest sunlight. Traffic and auto engineers also use
LEDs on vehicle headlight and tail lights, and to illumi-
nate tunnels and other roadways. LEDs are also used to
light up entire buildings and large rooms.
THERE ARE SIX glasses standing upright on a
table. If you invert five of them (turn five over) on
each turn, how many turns will it take to get them
all upside down? Or is it impossible?
E-mail your answer to stephen.mraz@ penton.com,
and put Glasses in the subject line. (Only one guess
per person.) The first person to send in the correct
answer will win something (not a pyramid), along
with the thrill of seeing their name in print as the winner.
TURNING THEM ALL OVER
MYTH:
Real parts. Really fast.
Its easy to work with Proto Labs. Just upload your
3D CAD model and choose the best process for your project:
CNC machining in 13 days or injection molding in 115 days.
Real parts in real materials, in daysnot weeks. And thats the
real story. Call 877.479.3680 or visit www.protolabs.com
Check out
our virtual tour!
Puzzled by resin choices?
Visit www.protolabs.com/parts today
and request your FREE Resin Puzzle
nine of the most common thermoplastics
used in injection molding. Enter code MA13C.
Proto Labs 2013 ISO 9001:2008 Certied ITAR Registered Visa/Mastercard Accepted
Finalize
options,
order.
Machining
begins.
Receive a
ProtoQuote
interactive
quote.
Finalize
quote and
submit P.O.
Receive
order
conrma-
tion with
gate and
ejector
layout.
Approve.
Mold
design
and
milling.
Part
production.
Upload
3D CAD le.
A product development team needs parts
to meet its rapidly approaching deadline.
Receive
FirstQuote
interactive
quote.
How
Many Parts?
110
parts
Parts
ready
for
shipping.
1010,000+
parts
Parts
ready
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From $1495
From $95
2013 Baldor Electric Company
Local Sales & Support
Energy Efficiency
lndustrial Motors & 0rives
Unmatched 0ustomer Service
For decades, ^BB variable speed drives and Baldor
motors have set the standard for quality, reliability and
energy savings. Now, industrial customers in the U.S.
can buy these products and receive expert support
from a single source. 0all 479-646-4711 to locate the
district office nearest you.

Two trusted names. 0ne local source for sales and sup-
port. 0nly from ^BB and Baldor.
EDOGRUFRP

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