June 24, 2010

A Penton Media Publication

Tune in to EngineeringTV.com

SPECIAL ISSUE:
MOTION CONTROL
ROBOTS ROAM
AT FIRST FINALS,
page 42

WHEN
SERVOMOTORS
HEAT UP,
page 50

ADVANCED
MOTION
CONTROL FOR
HYDRAULICS,
page 55

Don’t Stop Here!

Answers to 20 new questions can
be found inside this issue.
www.smartestdesignengineer.com
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RS# 101
RS# 102

FEATURES
34 E-Stop and go: safely
An emergency stop is more
than just another off switch.
Hot and hotter
50 Servomotors producing
bursts of high torque can
heat up more than what their
specifications predict they will.
So design-in a thermal safety
margin.
55 Extreme force,
deft touch
Combining hydraulics and
a PC with the right motion
controller ensures testing
applications measure up.
The June prize is a $250
American Express gift card.
And it doesn’t stop there!
Keep playing and earning
points towards the
$5,000 Grand Prize!
www.smartestdesignengineer.com
2 MACHINE Design.com
VOLUME 82
ISSUE 11
JUNE 24, 2010
MOTION WHAT’S THIS?
When you see a code like this, take
a photo of it with your smart phone
(iPhone 3G-S gives best results) and,
using software from www.neoreader.
com, you will be connected to relevant
content on machinedesign.com
Technology, Team 71, Hammond Inc., used
pneumatics and neon-yellow tubing
from Freelin-Wade, to complement
electronic and mechanical components.
professionalism challenge simultaneously via satellite.
There’s a newly developed game each
year, but a carpeted field roughly the
first in
size of a basketball court and em-
phasis on cooperation among teams,
creativity, professional courtesy, and
safety are usually the norm.
robotics Robot-design challenges go far
beyond creating a vehicle that moves
in response to radio control. These
robots are equipped with sensors
competition and other components professional
engineers would recognize, includ-
ing machine vision that must be pro-
grammed to recognize targets, ac-
celerometers, gyroscopes, optical
and magnetic encoders, and electric
motors that need to be matched to
gearboxes.
Robots must be able to operate
Robots taking over the autonomously for one segment of the
game, and then switch to semiauto-
Georgia Dome in a battle for nomous radio control. In addition,
because organizers randomly assign
world domination? It’s not a three-team alliances that compete to-
gether, teams need to choose whether
summer blockbuster; it’s the their robot should specialize in one
point-scoring task or be multiskilled.
FIRST Robotics Competition Alliances change from match
to match in the initial competition
Championship. stages, but top teams choose others to
join their alliance going into the play-
off rounds. A team with a specialist
robot might look to join with teams
Students hone their skills, rely on teammates, and whose robots round out its skill set.
compete in regional tournaments in hopes of making In this year’s competition (see
it to the national championship and getting noticed “Breakaway ‘bots’”), teams scored
by top colleges. Sounds like a varsity sport, right? points by having robots send balls
That’s exactly the vision Dean Kamen, inventor, entrepreneur, and founder of
FIRST, Manchester, N.H., had for the FIRST Robotics Competition when it
started 19 years ago.
This year’s championship in Atlanta, April 15 to 17, was the culmination of a
bines the excitement of varsity sports with technology.
Students competing in FIRST events can win awards
for design, team spirit, professionalism and maturity, and
overcoming obstacles as well as for scoring the most points
into goals. They could also earn points for getting their ro-
bots to elevate themselves above the playing surface at the
end of the game.
Even for engineers who understand all the mechani-
three-month season for more than 45,000 students from 12 countries. Starting in competitions. Plus, over $12.2 million in college schol- cal, electrical, and control concepts involved, building a
in January, student teams designed and built robots that would compete both
with and against other teams’ robots for top honors.
Kamen founded FIRST, which stands for “For Inspiration and Recognition
of Science and Technology” in 1989 to motivate young people to pursue educa-
arships are available from over 136 sources to students
who participate in FIRST.
Technical teamwork
robot from scratch in six weeks could be a tall order. Do-
ing it with a team of high schoolers creates a “real pressure
cooker,” says Alan Ostrow, who heads Miss Daisy, the team
at Wissahickon High School, Ambler, Pa., that won the
tion and career opportunities in science, technology, engineering, and math, The season kicks off six weeks before regional compe- Chairman’s Award, FIRST’s highest honor, in April.
and build self-confidence, knowledge, and life skills. The FRC program com- titions begin with FRC teams learning about the season’s Some teams rely on adult engineers to design their ro-
42 MACHINE Design.com JUNE 24, 2010 JUNE 24, 2010 MACHINE Design.com 43
Technology, professionalism
42 first in robotics competition
Student participants in the FIRST
Robotics Competition design, build,
and guide robots through tournaments
while gaining confidence with technical
skills, professionalism, and teamwork.
MOTION
Extreme
force, Combining
hydraulics and a
PC with the right
deft motion controller
ensures testing
touch applications
measure up.
The Innkeeper tester exerts Hydraulics is the technology of choice for moving or lifting heavy loads
multidirectional forces on an
automotive wheel while it spins
or exerting precisely controlled forces. But one of the fastest-growing
inside a rotating drum. A PC areas for hydraulics is in materials and structural test equipment.
provides overall control and data With proper controls, hydraulic actuators can apply and hold exact-
acquisition, but a hydraulic motion ing forces on an object. And they can generate varying load cycles that
controller positions actuators and simulate a lifetime of real-world stresses and wear in an accelerated
controls output forces. time span. Aerospace and automotive-equipment manufacturers are
among the early adopters who are reaping the benefits.
WHAT’S THIS?
When you see a code like this, take PCs versus motion controllers
a photo of it with your smart phone Personal computers, with their ability to collect, display, and archive
(iPhone 3G-S gives best results) and, information, have become the de facto standard computing platforms
using software from www.neoreader.
com, you will be connected to relevant
for testing and data acquisition. Besides the fact that PC hardware pro-
content on machinedesign.com vides the highest level of computing performance per dollar invested, a
wide range of readily available software has made it relatively quick and
JUNE 24, 2010 MACHINE Design.com 55
55
Access our Reader Service
Web site to quickly find and
request information on the
products and services found
in the pages of MACHINE DESIGN.
www.machinedesign.com/rsc
JUNE 24, 2010
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RS# 103
 ON THE COVER
An E-Stop switch from
EAO Switch Corp.

DEPARTMENTS READER SERVICES

Letters to the editor: Please

8 EDITORIAL include your name, address,
Layoffs galore, but is it smart business? and daytime phone number.
Letters may be edited for brevity
10 EDITORIAL STAFF and to focus on essential points.
12 LETTERS Mail: Letters, MACHINE DESIGN,
1300 E. 9th St., Cleveland, OH
18 SCANNING FOR IDEAS 44114-1503, Fax: 216-621-8469
Through-hole reflow beefs E-mail, Editorial:
up circuit-board connections mdeditor@penton.com
A seal for all seasons Online forums: To comment
on articles, editorials, and other
22 REPORTER’S NOTEBOOK engineering topics, go to http://
28 LOOKING BACK community.machinedesign.com/
forums/157/ShowForum.aspx and
32 BERKE ON SAFETY log in.
Anticipate those who play chicken with a Questions about articles:
garage door: The design of safeguards Denise Greco, 216-931-9402,
denise.greco@penton.com,
60 WORLD’S SMARTEST DESIGN Fax questions about releases
ENGINEER GAME UPDATE & literature to 913-514-6694
62 FE UPDATE Subscriptions: For a subscription
Designer’s guide to advanced vibration analysis qualification form, see our Web
page at submag.com/sub/mn.
66 PRODUCT SPOTLIGHT Subscription problems or
Cable & cable carriers questions: Contact a customer
service representative at
68 MOTION PRODUCTS 866-505-7173 or e-mail:
76 BUSINESS INDEX machinedesign@halldata.com.
Order a paid subscription:
77 AD INDEX 847-763-9670
78 BUSINESS Circulation:
STAFF machinedesign@halldata.com.
WHAT’S THIS?
When you see a code like this, take Editorial reprints: Contact
79 BACKTALK a photo of it with your smart phone Joel Kirk, 216-931-9324,
(iPhone 3G-S gives best results) and, joel.kirk@penton.com or
using software from www.neoreader.
com, you will be connected to relevant visit pentonreprints.com
content on machinedesign.com List rentals: Marie Briganti,
877-796-6947,
mbriganti@meritdirect.com
4 MACHINE Design.com JUNE 24, 2010
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RS# 104
What’s new online machinedesign.com
FREE WEBCASTS
July 15, 12:00 Noon ET — Using current sensors in motor drives
Learn how to detect motor current and transmit signals from high-voltage motor
phases/rails to the control circuit. Avago Technologies explains how isolation
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effect transducers and current transformers, iso-amps are smaller, more accurate, UPCOMING WEB
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Benefits of modern cabling practices Industrial
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outsourcing cables; and application examples. new videos and podcasts on
Get more info and register at the Webinars section of http://machinedesign.com. AutomationDirect’s free self-
service learning site, http://learn.
automationdirect.com.

New uses for ePTFE The newest podcast is a two-

Engineers might know of expanded
PTFE from its use in highly flexible
electrical cables. An expert from W. L.
Gore discusses some new uses for the
material, from low-friction, long-lasting
tow cables to breathable gloves for
the military. See the episode at http://
engineeringtv.com.
part series of an interview by
industry editor Dan Hebert
with AutomationDirect’s
Communications Product
Manager Christopher Harris,
discussing why and how industrial
communications have evolved
for use in automation, including
serial, Ethernet, and wireless
networks.

Servo gearboxes techedcnc.com. The latest videos are a set of

The new Wittenstein (alpha) Machine-tool product overviews and tutorials
catalog, available at www. components on Data Collection software
wittenstein-us.com, contains Advanced Machine & packages that work with
EDITOR’S WEB PICKS

technical data on servo gearboxes,
rack-and-pinion systems,
servocouplings, and sensor
technology. It also includes
information on energy-efficient and
large hypoid gearboxes.
Introduction to CNC
machining
Techno Inc.’s new Introduction
to CNC Machining curriculum
covers basic manufacturing skills,
fundamentals of CNC machining,
and CAM software. Primarily
intended for
students, it
includes a
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workbook and
CD. Get more
info at www.
Manufacturing’s new Web site AutomationDirect controllers.
(www.ame.com) includes technical These products can connect
data, literature downloads, CAD serially, via modem, over Ethernet,
files, and video on a wealth of or via a Web interface to monitor,
machine-tool components, record, and analyze process data.
including spindle interfaces, Learn which is most appropriate
metalcutting saws, hydraulic/ for your application and the steps
pneumatic rod locks, safety for simple implementation.
equipment, and metrology gages.
Other new videos include a two-
Electromechanical
part series on universal signal
automation blog
conditioners. HMI, drives/motors,
Parker Hannifin’s
motion control, and sensor
Electromechanical Automation
overviews are also available.
Div. has launched a new blog at
www.parkermotion.com/blog.htm.
Visit http://learn.automationdirect.
Hosted by engineers, topics include
com to watch these and other
visualization, controls, drives,
tutorials on a range of industry
motors, gearheads, mechanics, and
topics.
tales from the field. Users can post
comments, too.

6 MACHINE Design.com JUNE 24, 2010

RS# 105
 EDITORIAL

Layoffs galore, but is it

smart business?
Economists tell us that businesses are starting to expand,
but you wouldn’t know that from mass layoff statistics. In
April, for example, the number of mass layoffs — companies cutting at least
50 people — numbered 1,856 as employers shed over 200,000 jobs, according
to the Dept. of Labor. Almost 450 of these employers were manufacturing
companies.
It looks as though mass layoffs will be a fact of life for some time to come.
So it is fair to ask whether companies that adopt this strategy are being short-
sighted or pragmatic. Wayne Cascio, a professor at the University of Colorado,
Denver, has researched this point for much of the last two decades. Working
with colleagues, he looked at companies that were part of the Standard & Poors
500 from 1982 to 2003, sorting them into categories each year based on whether
or not they cut employees and shed assets.
He then looked at what happened one year before a downsizing until two
years after to see whether company financial performance was better or worse
than competitors in the same industry. The results were noteworthy. Companies
that purely downsized — cutting employees and nothing else — never outper-
formed their competitors. The only companies that did well financially were
those that grew their businesses by adding both assets and employees.
“We were looking at downsizing from the standpoint of a management
decision. If you are a manager, you want to know the best strategies for profit-
ability over time,” says Cascio. “We found that investors who bet on downsizers
wouldn’t have done well.”
Cascio has also looked at companies that have restructured or reorganized
themselves to see if there are similar trends. “We found companies sorted them-
selves into two camps. One had the management philosophy of running the
place with the least number of people possible. Another smaller camp adopted a
different approach by figuring out ways of better using the people they had.”
The classic example of a company in the latter camp is Lincoln Electric Co.
which, in the early 1980s, came up with the Leopard program to avoid laying off
employees during a downturn. In it, factory and clerical workers volunteered to
be trained as assistant salespeople. “One of the opportunities they identified was
a market for home-welding equipment through big-box retailers,” says Cascio.
“Lincoln had never thought about that area before. It turned into an $800 mil-
lion a year business that didn’t exist until Leopard teams went out and found it.”
And though big layoffs make headlines, Cascio claims an increasing number
of firms are taking a different approach. “Right after 9-11, we looked at Fortune
Magazine’s list of the best 100 employers to work for. About 80% of those com-
panies had no layoffs the previous year. That was also true for 2008 and 2009,”
he says. “Companies know that people have long memories and that when the
recession is over, they will need to hire again. So a lot of firms now use layoffs as
a last resort rather than as a signal to the market that they run a tight ship.”
— Leland Teschler, Editor

And speaking of SMART . . .

Let me congratulate our May WORLD’S SMARTEST DESIGN ENGINEER
winner, Steven Ho (who goes by chemicalengineer in the game).
Steven’s top score of the month earned him a $250 Amazon Gift
Card. Steven is among the current game players who have answered
a total of 355,894 questions in our eight categories. It’s interesting
to see that All Things Energy and Mechanical Engineering are the two most popular
categories, but Mechanical Engineering and Hydraulics & Pneumatics appear to be
the most-challenging categories.

RS# 106
8 MACHINE Design.com JUNE 24, 2010
RS# 107
 EDITORIAL STAFF

Leland E. Teschler, Editor,

leland.teschler@penton.com

Kenneth J. Korane, Managing Editor,

ken.korane@penton.com

SENIOR EDITORS
Leslie Gordon,
Stephen J. Mraz

AUTOMOTIVE &
NEWS FEATURES
Stephen J. Mraz,
stephen.mraz@penton.com

CAD/CAM
Leslie Gordon,
leslie.gordon@penton.com

ELECTRICAL, ELECTRONICS
Robert J. Repas, Jr.,
robert.repas@penton.com

FASTENING, JOINING
Jessica Shapiro,
jessica.shapiro@penton.com

FLUID POWER
Kenneth J. Korane,
ken.korane@penton.com

Get more out of it by D MANUFACTURING

Leslie Gordon,

getting more into it.

leslie.gordon@penton.com
Kenneth J. Korane,
B ken.korane@penton.com

A MATERIALS
Jessica Shapiro,
C
The new scalable enclosure solution. jessica.shapiro@penton.com
FUSION G7™ is the global enclosure platform E
MECHANICAL
that offers scalable, multi-surface component Kenneth J. Korane,
mounting via a versatile internal grid system. F ken.korane@penton.com
FUSION G7 maximizes configuration flexibility Jessica Shapiro,
G jessica.shapiro@penton.com
while maintaining global IP66 and UL/CSA
A ) Full & half-height side/back panels
Type 4/12 ratings. Includes standard back B ) Front/rear vertical mounting rails
CONTRIBUTING EDITOR
panel and gland plate(s) for easy cable entry C ) Side mounting & DIN rails Victoria Burt, vburt@gmail.com
D ) Wall-mount provisions
configuration. It’s the one enclosure that EDITORIAL PRODUCTION
E ) Easily reversible hinges and door
won’t box you in. hoffmanonline.com F ) Gland plate(s) standard Denise Greco,
G ) Floor-mount plinth base option Editorial Production Manager
Randall L. Rubenking, Art Director
FUSION G7 is available in 30 standard metric sizes ranging from
300 x 300 x 225 mm (11.8” x 11.8” x 8.9”) to 1500 x 900 x 425 mm
(59” x 35.4” x16.7”)

1300 E. 9th St. Cleveland, OH 44114-1503

RS# 108
©2010 Pentair Technical Products
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RS# 109
 LETTERS
Too much positive
feedback
I cannot begin to tell you how
much I agree with your editorial
(“Positive reinforcement run amok,”
April 22).
You could not be more correct
when you say that too many acco-
lades lead to mediocrity. And this
attitude to reward everyone for
everything doesn’t only affect chil-
dren but our society as a whole.
The recipients of these “false”
accolades begin to expect them
even when not deserved. Then,
when they don’t get a reward, their
efforts greatly decrease and pick
up just marginally when the next
“reward event” rolls around.
Our society has become lacka-
daisical because of attitudes like
this. People who only perform mar-
ginally begin to expect to be re-
warded even though not deserved.
This activity depletes the real re-
wards that should go to outstand-
Control theory trumps
political correctness
As any control engineer will explain, a system that
relies only on positive feedback will be unstable. When
an editorial applied the same principle to politically
correct rewards for school children, our readers agreed
wholeheartedly. In fact, no one disagreed, yet.
ing performers. Hence we have so- bonus points pushed me into the
cial programs that hurt everyone. second level of membership and I
I earned one of these bogus got invited to a company banquet.
rewards. I deserved and earned a I did not think anything about it
certain level of membership in a until I read your commentary and
company club honoring produc- now I have mixed feelings about
tion. During December, the last it because, yes — I deserved basic
month of the annual program, membership but did I really earn
management began handing out advanced membership???
bonus points to people who did David Engman
not deserve them. This was an at-
tempt to boost the number of win- It’s ironic that Leland Teschler’s
ners at the base level. The extra editorial about positive reinforce-
The exact automation products you need, faster.



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RS# 110
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 LETTERS

ment appeared in the same issue
with the salary survey. Let me con-
nect the dots. Variations among
engineering salaries are minimal,
regardless of which variable you
consider. We all get “rewarded”
about the same — $70 to 100K,
a range that is even smaller after
taxes. An engineer whose innova-
tion adds millions to a company’s
bottom line probably might get a
3% increase rather than 1%. The
idea of compensation being re-
lated to performance is manage-
ment fiction in most companies.
The reality is that compensation
is fundamentally a matter of sup-
ply and demand, as evidenced by
low or no wage increases even in
companies having excellent profits
in these days of high unemploy-
ment. Of course, outsourcing and
the H1B visa program have con-
tributed to the overly large supply
of technical talent and both keep
compensation artificially low for
engineers. But as Leland observed,
since we all get gold stars, at least
our self-esteem as engineers must
be good.
Mark Miller
Great editorial. I still have a daugh-
ter in school and I see this type of
thing backfiring all the time. I really
think it begins to set them up for
bad experiences as adults. Because
in the real world, nobody’s looking
for reasons to praise you. (Unless
to soften you up before telling you
there will be no raises this year.)
They only seem to care enough
to talk to you when you’ve done
something wrong.
Terry Persun
Lee, your “everybody gets a tro-
phy” editorial is right on. Kids know
what’s happening, and they’re not
buying it. I remember my 4-year-old
girl bringing home a trophy from
school and asking “Daddy, why
did they give me a trophy, I didn’t
win anything?” And my 12-yr-old
son probably has over 50 trophies,
most discarded, except for the two
he keeps over his bed. They date
from when the teams he was on
won championships.
They don’t give you a trophy (or
a raise) at work for a “nice effort,’” or
last place.
Howard Lind
Building better
wind turbines
The article on wind turbines (“Hy-
draulic wind turbines?”, April 22)
was great. But the concepts pre-
sented lead one to wonder why de-
signers don’t replace complex, ex-
pensive hydraulic motors, pumps
and lines with a multiribbed car-
bon-fiber belt. Such technology is
within design parameters, avail-
able, and very efficient.
The article also states, “Hy-

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RS# 112
14 MACHINE Design.com JUNE 24, 2010
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RS# 113 

LETTERS

draulics offer power density un-
matched by any other technol-
ogy...” I think this is basically a
faulty conclusion, and will lead to
faulty constructions.
Albert A. Crookston
I believe that the main advantage
for hydraulics in wind turbines
is that most of the equipment is
on the ground. The main disad-
vantage is the inefficiency of the
hydraulics.
Here is a possible mechanical
solution. Only main drive machin-
ery is in nacelle. Put two low-speed
double-bevel gear cases with a
fixed horizontal crankshaft with
four throws at 90° up in the nacelle.
At ground level, mount a duplicate
shaft with four throws connected
to the drive gear case/generator.
Between the two cranks (in the
tower) place four pretensioned
steel cables with ball-bearing rod
ends at each end.
I believe that this would be an
efficient method of transferring
the power to the ground.
Ken Stewart
Last of the PEs
versus non-PEs
In a recent letter to the editor
(April 22), Mr. Bernell Shoff, PE,
challenged non-PEs claiming to
be just as intelligent as PE holders
to basically pony up and “take a
day and go for the exam and get
licensed.” So as soon as Mr. Shoff,
PE, can tell me how to get around
the good old boy network which
excludes capable engineers from
qualifying to take the exam, I’ll
go “take a day,” school a test, and
proudly display a PE behind my
name.
I’d love to take the PE exam.
I’d destroy it just like I did the EIT
exam 12 years ago as a senior in
an accredited BSME program. Un-
fortunately, I’m not permitted to
take the test because I’m required
to work under a PE for at least five
years before I’m allowed to take
the exam. My first employer had
no PEs working for them. My sec-
ond employer had two PEs, in a
different department, in a dif-
ferent facility; so my experience
working there did not qualify
me to take the PE exam. My cur-
rent employer does have two PEs
working for them, and I intend to
take the PE exam once I’ve been
here for 5 years.
It’s easy to see the value of a pro-
fessional certification based on skill
and capability. It’s reasonable to
require some work history before
the professional certification of
engineers. However, it’s ridiculous
to base qualifications for a profes-
sional certification on a “must be
invited by a member” Rotary Club-
style restriction.
Russ D. Bafford II

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RS# 114

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[ MOTOR TRUTH #2 ]

Can I really save

money by installing
a smaller motor?

The truth? You just might be able to. If you look at

your entire drivetrain, you’ll probably find that if you
replace inefficient components (which can waste
up to 50% of the energy they use), you’ll be able
to install a new, smaller, high-efficiency DR motor
and still get the power output you need.

And, you’ll save energy at the same time, because

your current oversized motors may be wasting
energy to overcome the inefficiencies of your
entire drivetrain.

SEW’s new DR motor series is specifically designed

to work with a total system, including our helical
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RS# 115
 SCANNING FOR IDEAS
Edited by Stephen J. Mraz

Through-hole reflow beefs

up circuit-board connections
Through-hole reflow (THR) is a recently developed ers up to 40% on the cost of connecting components
method of attaching components to printed-circuit to circuit boards.
boards built with solder-reflow processing. In fact, THR One company pioneering this new process is
and surface-mount devices (SMD) can be handled at Wieland Electric GmbH, a German firm with U.S.
the same time and on the same equipment. This could headquarters in Burgaw, N.C. (www.wieland.
make wave soldering obsolete and save manufactur- com). They say THR makes strong connections
to PC boards, letting electrical components
better withstand mechanical loads. THR
has been shown to create bonds much
stronger than those made using surface-
mount technology (SMT). This means
THR components, particularly terminal
blocks and connectors, can withstand
the mechanical forces required
PCBs with Template is during termination and header-
plated through- positioned and-plug-mating processes.
holes Components can be delivered in
trays or tape and reel, so they
are suitable for pick-and-place
automation as well.
Wieland Electric offers
THR connectors in 3.5,
3.81, 5.0, and 5.08-mm
pitches for both two-
piece connectors and
one-piece terminal
Solder paste is Solder paste blocks. MD
applied fills hole RS# 401

Pin pushes
Component is solder paste
mounted through hole

Access
ou
Web s r Reader Ser
and req ite to quickly vice
f
produc uest in. format ind
t
in the p s and service ion on
age s of sf
MACHINE ound
w w w.m DESIGN.
achine
design
.com/rs Reflow Process
c
soldering complete
carried out

18 MACHINE Design.com JUNE 24, 2010

Lighten up.
Specify REALI-SLIM bearings. ®

Here's an easy way to save weight without compromising design standards:

use REALI-SLIM® thin-section bearings. They are lighter than conventional
bearings, and weight savings increase with bore size (because the cross-
section does not change).
REALI-SLIM® bearings come in I. D.'s from 1" to 40" and cross-sections from
3/16" to 1". They are available in materials to suit most applications, including
440C stainless steel for corrosive environments.
Free White Paper calculates
KAYDON bearings, standard and custom, have been saving space and bearing life more accurately:
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browser to www.kaydonbearings.com.

KAYDON® Corporation Bearings Division

1-800-514-3066, Fax 231-759-4102
www.kaydonbearings.com

RS# 116 © KAYDON® Corporation 2010

 SCANNING FOR IDEAS

A seal for all seasons

The LKS High PV seal from Bal Seal Engineering Inc., Foothill Ranch,
Calif. (www.balseal.com), consists of a graphite-reinforced PTFE seal-
ing ring energized with a canted-coil spring coupled with a high-tem-
perature, thermoplastic antiextrusion element and a metal locking
ring. The hardware holds the seal in place and prevents material from
extruding, despite little or no clearance between the seal and rotat-
ing shaft. The components work together to ensure seal wear is at the
lip-contact area, not the hinge point. This gives the seal long life and
improves sealing. And it not only keeps out dirt, debris and water, it
prevents any fluids inside or on the shaft from leaking out.

Metal locking
ring

Canted-coil
spring In lab tests, the seal has with-
stood 500 psi of water pressure
while it turned at 500 rpm for over
PTFE-sealing 10,000 hr. In the field, it has survived
ring over 9,000 hr of 100-psi heavy oil
with sand while the shaft ran at
PEEK 100 rpm. The seal works despite
antiextrusion temperatures anywhere from –70 to
element
450°F on shafts ranging from 0.187
to 30 in. in diameter. MD
RS# 402


  


 

 





  

 
 



  



    

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RS# 118
REPORTER’S NOTEBOOK

Late start for a high-end hybrid

The Karma, a four-door hybrid
sports car from Fisker Auto-
motive, Irvine, Calif., has been
rescheduled to go on sale next
year, which would make it the
first luxury on the market. But
the company has already missed
several deadlines, including the
promise that the car would go
on sale last year. The 5,000-lb car
carries a 22 kW-hr lithium-ion bat-
tery pack that lets the car travel
50 miles in its most economical,
all-electric Stealth Mode. That
should be enough to han-
dle the daily driv-
ing needs of
60% of Americans and Europeans.
Owners can plug their hybrids into
household current to recharge
overnight. When more range is
needed, a 2.2-liter Ecotec four-
cylinder engine from General
Motors kicks in and turns a gener-
ator, letting the car travel another
250 miles. And when the driver
wants performance, a switch to
Sport Drive mode brings a second
electric motor online and boosts
power to a reported 400 hp. This
is enough to take the car from 0
to 60 mph in under 6 sec and give
it a top speed of 125 mph. For
the truly eco-conscious drivers,
an optional full-length solar roof
generates electricity to keep the
car interior cool when the car is
parked. And if the panel is used
to recharge the batteries, it can
add two to three miles per day, if
the sun shines. The car will cost
an estimated $87,000, but buyers
will be eligible for a $7,500 tax
credit, taking the price just below
$80,000. The company says it will
be making 15,000 Karmas an-
nually within two years of
its launch. MD

Fisker Automotive, karma.

fiskerautomotive.com

Meet the phantom MRI patient

Engineers at the National Institute of Standards and Technology
have developed a device for calibrating MRI machines that is trace-
able to standardized values. The phantom patient, nick-
named Phannie, consists of a plastic sphere about
the size of a human head. It is filled with water-
bathed grids containing 100 smaller plastic
spheres filled with various salt concentrations
that react to magnetic fields. Scans of Phan-
nie will let users consistently evaluate image
contrast, resolution, and the accuracy of
distance and volume measurements. Phannie
will also let health-care institutions track perfor-
mance of their MRI machines for comparison with
others. Finally, it will let radiologists make more-
accurate, quantitative measurements of tumors and
National Institute
other disease markers that can be reproduced across of Standards and
different patients, scanners, and clinics, which could cut Technology, www.
medical costs. MD nist.gov

22 MACHINE Design.com JUNE 24, 2010

30 encoders later, carrier belts
stay on track Chicago Electric, www.
chicagoelectric.com
Optical encoders working over a Circle 406
DeviceNet network let a paperboard mill Fraba Inc., www.fraba.com
automate the positioning and tensioning Circle 407
of conveyor belts.
At the Aurora, Ill. mill
operated by Rock-Tenn Co., each of 10, 170-in.-wide wire
mesh carrier belts ferry binder board through a 240°F
dryer. The belts tend to wander toward the side of the
conveyor frame and rub against the frame if they are not
periodically recentered. To automate the positioning and
tensioning of the belts, Chicago Electric, Carol Stream,
Ill., put a Fraba Inc. (Hamilton, N.J.) Optocode (OCD)
DeviceNet encoder and a half-horsepower Marathon
ac motor on each of the 30 axes. The installation was
economical partly because one DeviceNet card handled
all of the high-resolution, absolute encoders. Control
was via Control Techniques’ (Eden Prairie, Minn.) half-
horsepower ac vector drives run from an Allen-Bradley
Control/Logix PLC and a touchscreen.
Using DeviceNet encoders and relatively
inexpensive drives, motors, and a PLC kept Chicago
Electric’s quote at just under $200,000. A more-
typical system with servo or stepper technology and
separate interface cards for each of the 30 encoders
would have cost as much as 50% more.
Each OCD absolute encoder uses an integrated
Opto-ASIC that provides up to 30-bit multiturn resolution and
can withstand the heat near the dryer.
At Aurora, the fully automated closed-
loop system for positioning the belts
replaced a completely manual process.
If a belt slackens, a worker taps a button
on the touch screen to take up the slack.
MD

Visible in this view of the carrier

system are some of the motors
and adjusters in place at the
Rock-Tenn papermill. Each motor
employs a Fraba DeviceNet
encoder for feedback.

n via
f r e e in formatio
b s ite at
t
Requesder Service We
o u r Re a .com/rs
c
esign
a chined
w w w.m

JUNE 24, 2010 MACHINE Design.com 23

 REPORTER’S NOTEBOOK
Chevrolet Equinox
FWD 1LT
Some of the
criticisms lev-
eled against
General
Motors have
been that it
wasn’t focused
on making the high-efficiency cars
Americans wanted to buy and that
it was falling behind in green tech-
nology. The 2010 Chevrolet Equi-
nox is GM’s answer to its detractors.
The Equinox is redesigned for
2010 with a focus on boosting fuel
economy. So the front-wheel-drive
model comes with a 2.4-liter four-
cylinder, direct-injection engine
the EPA estimates burns 22 mpg in
the city and 32 mpg on the high-
way. Adding part-time all-wheel
drive drops the estimates to 20 and
29 mpg, respectively. Drivers can
also opt for a V6 in LT and better
trims.
The four-cylinder’s highway fuel
economy beats that of Equinox’s
competitors, including the Honda
CR-V and Ford Escape, by four or
five points. It also beats the Escape
Hybrid by one point, although the
hybrid does far better in town than
competing models.
But an empty Equinox still
weighs 3,761 to 3,838 lb, depend-
ing on options, so barring anti-
gravity technology, how did they
do it?
Most of the efficiency comes
from the smaller engine and six-
speed automatic transmission.
The transmission defaults to “eco”
mode, which forces it to upshift
RS# 119
earlier and downshift later. The
driver can bypass this mode to get
more low-end power.
That strategy works for most
driving situations, like highway
cruising or tooling around town.
But try to floor it on an on-ramp
to get ahead of a semi, and the
Equinox is all bark and no bite. Eco
mode prevents downshifting, so
the engine emits a high-pitched,
grating scream but doesn’t really
pick up the pace.
Perhaps this is GM’s way of
encouraging consumers to drive
“greener” through negative rein-
forcement. But the company has
included positive reinforcements,
too, like an in-dash driver informa-
tion center that updates your gas
mileage in real time.
Small efficiency gains also
come from electronic power steer-
ing (the engine no longer has to
run hydraulic boosters) and low-
rolling-resistance tires. Although
these are well-accepted strategies
for boosting fuel economy, they
both contributed to the trouble
I had driving the Equinox uphill
in wet snow. The wheels slipped
and could not track straight. At
the same time, the power steering
didn’t provide enough tactile feed-
back, so the steering wheel felt dis-
connected from where the vehicle
was actually headed.
However, once you accept that
GM has stuffed a small sedan’s
engine under the hood and that
you may need better tires, there is
plenty to like about the Equinox.
Engineers at GM weren’t totally fo-
cused on fuel economy; they took
a good look at comfort, too.
The cushy driver and front pas-
senger seats were cherry-picked
from the Cadillac CTS. A full 8 in.
of travel, plus height and lumbar
adjustments, accommodate just
about any size driver. Rear seats are
almost as comfortable, split 60/40,
continued on page 27
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RS# 120
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coatings. These compounds are formulated to the


 



strictest quality control standards and are designed
 
  to maximize reliability and performance. We offer
prompt technical assistance and solve problems.
A & A Mfg. Co., Inc.
(800) 298-2066
(
  
 

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154 Hobart St., Hackensack, NJ 07601
TEL: 201-343-8983  FAX: 201-343-2132
www.gortite.com
www.masterbond.com  main@masterbond.com
RS# 121 RS# 123

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RS# 122
 Head-to-head
Chevy Honda Ford Toyota
Equinox 1lt Cr-V Escape Rav4
Wheelbase (in.) 112.5 103.1 103.1 104.7
Height (in.) 66.3 66.1 67.9 66.3
Cargo Room (ft3) 63.7 72.9 67.2 73.0
mpg (city/hwy) 22/32 21/28 21/28 22/28

continued from page 24 port. The standard AM/FM/CD ste-

and can slide and recline slightly.
However, all the attention paid
to passenger comfort came at
the expense of cargo space. The
Equinox can carry 63.7 ft3 of cargo
with the rear seats folded nearly
flat. This compares to the Escape’s
66.1 ft3 and the CR-V’s 72.9 ft3.
Roof-rack side rails and a 1,500-lb
towing capacity complete the
Equinox’s cargo capabilities.
Our tester came with a vehicle-
interface package comprising
Bluetooth, audio controls on the
leather-wrapped steering wheel,
remote starter controls, and a USB
reo also has an aux jack and comes
with three months of Sirius/XM sat-
ellite radio. Onstar network knows
when your airbag goes off and calls
officials. The service is free the first
year and can be upgraded to add
navigation help.
The front-wheel-drive 1LT
model we drove costs $23,360,
and the interface package added
another $495. Upgrading to AWD
would add $1,750. The $22,615
base LS model doesn’t include
roof racks, tinted windows. body-
colored mirrors, or floor mats.
— Jessica Shapiro

COMPANY NEWS
AWARDS has awarded its 2009
Mouser Electronics Distributor of the Year
Inc., Mansfield, Tex., has Award to Digi-Key
been awarded the Em- Corp., Thief River Falls,
erson Network Power Minn.
Connectivity Solu-
Knovel, New York, has
tion’s 2009 Top Distribu-
been selected as a final-
tor Award. Emerson,
ist in the 2010 Ameri-
St. Louis, is a leader in
can Business Awards
embedded telecom-
in the “New Product
munications and data
or Service of the Year
network infrastructures. – Computer Software”
Mouser is an electronic category. Knovel is a
component distributor, Web-based application
focused on the rapid integrating techni-
introduction of new cal information with
products and technolo- analytical and search
gies to electronic design tools. Over the last year,
engineers. Knovel has added 21
new content partners,
C&K Components, introduced Knovel Math
Newton, Mass., an in- (why.knovel.com/com-
ternational supplier of pany/press/221-knovel-
tact, toggle, rocker, and introduces-knovel-math-
pushbutton switches,
for-ptcr-mathcadr-.
and smart card in- html), fully documented
terconnect devices, and validated Math-
cad worksheets for
engineering calcula-
tions, and launched
My Knovel (http://why.
knovel.com/company/
press/339-knovel-
empowers-engineers-
to-get-personal-with-
my-knovel.html), a
personalized space
where users can save
and organize frequently
used content, titles, and
searches.
A provider of standard
and custom-extruded
and molded sealing
solutions, Lauren
Manufacturing, New
Philadelphia, Ohio, has
been awarded a Strate-
gic Supplier Award by
Precision Gasket Co.
(PGC), Edina, Minn. Lau-
ren supplies PGC with RS# 124
raw and value-added
products. MD

JUNE 24, 2010 MACHINE Design.com 27

 REPORTER’S NOTEBOOK
10 YEARS AGO — 2000
Spark plug doubles as fuel
injector: A new gasoline direct-
injection technology from
Delphi Automotive Systems,
Troy, Mich., and Australia-
based Orbital Engine Corp.
combines a spark plug and
At last, you can get
fuel injector in a single de-
vice. The result is low emission,
direct fuel injection without
costly engine redesign. The
injector uses an air-assisted
direct fuel-injection system with
only one point of access to the
combustion chamber for fuel and
LOOKING BACK
spark. According to Delphi, the
new technology boosts efficiency
with only minor changes to to-
day’s engines.
30 YEARS AGO — 1980
Sealed foam quiets diesel engine:
Acoustical foam with a newly de-
veloped thermal-edge seal is being
used to quiet Cummins Engine’s
NH-Series diesel
engine and gen-
erator sets. Called
Tufcote Acoustical
Foam, it is supplied

Zero Backlash Universal Joints in die-cut parts by

Specialty Compos-
ites Corp., Newark,
N.J., for use on noise
shields around
engine-oil pans.
The material has
a Tedlar facing chemically bonded
to the foam. The edge seal protects
the foam from hot oils, water, and
grease, and allows full noise absorp-
tion properties without degradation.

50 YEARS AGO — 1960

World’s shortest and hottest rail-
road: Traveling along 4 ft of track,
a toy locomotive runs samples
of nickel isotopes in and out of
a nuclear reactor at the Univ. of
Michigan. The track winds through
a “tunnel” in the concrete-block
Choose because you get: shielding and stops at the focal point
+ Zero Backlash with torques to 600 in-lbs
+ Instrumentation quality
+ In single, double or telescoping versions
+ Lubrication: sealed in solid film plus oil suspension
+ 303 stainless body construction
+ Bores from 3/16” to 1”, 5 to 25mm
of a neutron beam. Here, isotope
Call us at 1-888-260-7466 or fax us at 516-867-5656 samples mounted on the locomo-
or Email us at sales@rinomechanical.com tive absorb bombarding neutrons
and give off gamma rays. Samples
See us at www.RinoMechanical.com/ZUJcoupling.htm differ in the number of neutrons
present in their nuclei, and UM re-
searchers are measuring gamma-ray
Mechanical Components Inc. intensities to chart energy levels of
nuclei in each sample. The beam,
216 North Main Street, Freeport, NY 11520 fatal to man, makes the engine only
Phone: (516) 867-5665 Fax: (516) 867-5656 slightly radioactive. MD
RS# 125
 LEESON Offers More...

More Expertise...

More Speed...

More Solutions...

More Coming...

c MH_
LTHPS!SLLZVU'SLLZVUJVT

www.leeson.com

RS# 126
 REPORTER’S NOTEBOOK
ACQUISITION
Thermacore Inc., Lancaster, Pa., a
provider of thermal-management
equipment, has acquired Pitts-
burgh Materials Technology
(PMT), Jefferson Hills, Pa. PMT spe-
cializes in complex metal joining
and the development, fabrication,
RS# 127
30 MACHINE Design.com
testing, and characterization of
high-temperature metallic alloys
and other specialty materials.
Linx Technologies Inc., Merlin,
Oreg., a firm that makes wireless de-
vices, has acquired Apex Wireless
Inc., Boulder, Colo. Apex Wireless
JUNE 24, 2010
COMPANY NEWS
specializes in high-performance
wireless products employing RF
transmitters, receivers, and trans-
ceivers, including frequency hop-
ping and direct sequence radios.
PARTNERSHIP
Fabrico, Kennesaw, Ga., a provider
of design and manufacturing
services for flexible materials, is
partnering with Henkel, Rocky
Hill, Conn., to offer custom, high-
performance Loctite products for
liquid adhesives handling a variety
of applications, including coating,
gasketing, and potting.
ANNIVERSARY
GKS Global Services, Detroit, a me-
trology service provider, is celebrat-
ing 29 years in business by complet-
ing its 20,000th project. The lucky
customer whose job queued up at
#20,000 is a Tier One and Tier Two
supplier of high-quality aluminum
die castings for the automotive in-
dustry from Kentucky. The company
was awarded a $500 discount off its
next scanning order.
NEW FACILITY
Strongarm Designs Inc., Horsham,
Pa., which makes operator inter-
face mountings and systems, has
expanded its manufacturing opera-
tions by adding a 30,000-sq-ft fabri-
cation and production facility.
NAME CHANGE
Motoman Inc., Dayton, Ohio, and
Yaskawa Electric America Inc.,
Waukegan, Ill., will combine to
form Yaskawa America Inc. Mo-
toman will become the Motoman
Robotics Div. of Yaskawa America;
the Yaskawa Electric America Inc.
operations will become the Drives
& Motion Div.
DISTRIBUTION AGREEMENT
Dow Corning Solar Solutions,
Midland, Mich., has signed Ells-
worth Adhesives, Germantown,
Wis., as an authorized distributor
of its silicone materials for the so-
lar industry. Ellsworth Adhesives is
a distributor of adhesive products
and equipment. MD
I T ’ S S H O C K I N G H O W M U C H W E A B S O R B !

ENERGY CONTROL SOLUTIONS

FROM TAYLOR DEVICES
Solving your unique energy control challenges is the hallmark of Taylor Devices. We can adapt our proven energy management technology
to meet the precise requirements of your application. One of every six Taylor employees is an engineer with the expertise to analyze your
problem, establish your needs, and design the most efficient answer. When you need to tailor a unique solution, you need Taylor Devices.

1. Fluid Viscous Dampers /Massive Loads

Taylor Fluid Viscous Dampers are engineered for trouble-free protection of building
and bridge structures subject to seismic, blast or high wind loading.

2. Hydraulic Buffers /Heavy Duty

The highest capacity standard absorbers manufactured. Over 60 sizes are available
in capacities to 60 million in.-lbs. Oversize stainless steel piston rods are non-exposed
for long, zero-maintenance life in adverse environments.
1.
3. Fluidicshoks® Compact Capability
The most compact hydraulic shock absorbers available, in both self-adjusting and
custom-orificed styles. Twenty-six standard sizes are offered with capacities from
3 in.-lbs. to 56,000 in.-lbs. An exclusive non-exposed stainless steel piston rod is
featured on many models. Reset by coil, air or our exclusive liquid spring. 2.
Pure damper styles also available.

4. Shock Isolators
These devices protect sensitive systems from multidirectional seismic or
weapons grade shock. After the shock transient has passed, the isolator
automatically repositions the system. 3.
®
5. Uni-Shok Self-Adjusting
The unique self-adjusting industrial shock absorber for high speed, automated
machinery. Fourteen basic models provide up to 5000 in.-lbs. maximum capacity.
Patented self-adjusting fluidic metering eliminates downtime for adjustment.
Standard features include a stainless steel piston rod, internal coil spring reset,
bronze bearings, silicone fluid, and threaded body for easy mounting. 4.

6. Aerospace and Custom Products

Taylor Devices’ products easily lend themselves to custom applications on
aerospace and related applications. Active and passive Shock Isolation Systems,
Liquid Springs, Machined Springs, Single/Double Acting Dampers, Snubbers,
Linear Accelerators, Elastomeric Products, and other custom components
5.
are available on a design-to-order basis. Turnkey analysis, design, and
manufacturing capability for blast, ground shock, recoil, and MIL-S-901
naval pulses are available.
6.

www.taylordevices.com




  




 









RS# 128

/LQHDU
6KDIW0RWRU
More Ef¿cient than a U-Shaped
The Linear Shaft Motor does not
produce eddy currents, maximizes
usage of all magnetic Àux, and
uses less power while producing
equal force and less heat.
Precision and Speed Simultaneously
If you need a more precise, faster
linear motion system, our Linear
Shaft Motor outperforms traditional
ball-screw systems. Using our
Linear Shaft Motor will eliminate
many of your machining and
maintenance costs.
The Nippon Pulse Advantage
When you choose one of our mo-
tors, you’re doing more than just
buying a quality product. You’re
bene¿tting from the Nippon Pulse
Advantage. To learn more, contact
a sales engineer at 1.540.633.1677.
Also Available from Nippon Pulse
tin-can steppers, hybrid motors,
linear steppers, drivers, controllers,
prototyping, system engineering, and
product/application support
130
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<RXU3DUWQHULQ0RWLRQ&RQWURO
ZZZQLSSRQSXOVHFRP«LQIR#QLSSRQSXOVHFRP
RS# 129
32 MACHINE Design.com
BERKE ON SAFETY
Anticipate those who play
chicken with a garage door:
The design of safeguards
A 10-year-old girl had her leg badly crushed when an automatic garage-door
opener didn’t detect her presence.
A number of years ago it was not uncommon to hear of a person, usually a
child, being seriously injured or killed by a garage door controlled by an auto-
matic opener. In most cases, the person pressed the button inside the garage to
close the garage door, then tried to run through the large opening before the
garage door closed. The door could pin a person who wasn’t quite fast enough to
the ground and injure or kill them.
On older garage doors, resisting torque would tell the motor to reverse and
open the door when it met a preset threshold of resistance. I had this type of
garage-door opener years ago, and I tested it monthly by trying to close it over
a 1-gallon plastic bucket. As I became an empty-nester, I let this test program
slide. Then, I caught my grandson trying to race the door.
I quickly installed a newer opener with an electric eye about 7 inches from
the bottom of the door travel. If the beam of light is broken while the garage
door is descending, the motor reverses and pulls the door back up.
The old resisting-torque safety feature was retained in the new design as
well. The owner’s manual recommended I place a 1-inch-wide piece of wood in
the door’s path and attempt to close the door to test whether the motor would
reverse. However, the manual didn’t indicate how much resistance the opener
needed to reverse the motion. The resistance offered by a 1-inch-thick board is
much different from that of an arm or leg.
A few months after I installed my new door, I investigated the accident in-
volving the 10-year-old girl. The electric eye had been mounted 22 inches above
the floor, and the threshold torque for the older safety system had been raised
so I could not trigger it, even when my portable scale measured 75 pounds of
vertical force.
The offending door guarded the entrance to her apartment-building’s park-
ing garage, and I wondered why the electric eye was set so much further from
the ground than recommended in single-family homes. A local survey of apart-
ment complexes and two commercial sites revealed the thinking: If the electric-
eye system was 7 inches above the floor, it might miss a vehicle in the door’s
path. The door owners had never considered mounting two sets of electric
eyes — one 7 inches high and one 22 inches high — to protect both vehicles and
people, and had opted to save the vehicles.
The owner’s manual for these commercial garage-door openers specifically
discuss the safe force needed to reverse the door, and the door that crushed the
girl’s leg was not within their recommended limits. It appeared the installer
missed or ignored the reversing torque of the opener. He also seemed not to
understand the reason for the electric-eye system.
Manufacturers of garage-door openers should add warning labels to the
units to call installers’ attention to these two safety features and the reasons for
them. In addition, owners manuals should clearly state both the optimal ranges
for torque resistance and electric-eye height and the rationale behind those
ranges.
— Lanny Berke
Lanny Berke is a registered professional engineer and Certified Safety Professional involved
in forensic engineering since 1972. Got a question about safety? You can reach Lanny at
lannyb@comcast.net.
Edited by Jessica Shapiro
JUNE 24, 2010
New ACE Controls GAS SPRING AGS Models provide
controlled motion for lids, hoods, hatches, machine
guards, panels and more. Offered in a wide range of
body sizes, stroke lengths and forces.

· Maintenance Free
· Solid, Long Life Construction
· Push & Pull Type Models
· Fixed Force or Adjustable Models
· Precision Steel Body
· Treated Steel Rod
· Variety of End Fittings
& Mounting Brackets

Aerospace, Defense, Transportation,

RV, Medical, Furniture, Packaging,
Printing Amusement and More

Product
Information
Available Online

)DUPLQJWRQ+LOOV0,
WHO
ID[
HPDLOVKRFNV#DFHFRQWUROVFRP

DFHFRQWUROVFRP
RS# 130
 MOTION
E-Stop
and go:
SAFELY
Emergency-stop switches, generally referred to as E-Stops,
help ensure the safety of people and machinery by deliv-
ering a consistent and predictable fail-safe response. A
wide range of electrical machinery need these specialized
switches to meet workplace safety and established inter-
national and domestic regulatory requirements. E-Stops
differ from simple stop switches that merely turn equip-
ment off in that they offer foolproof equipment shut-
down. This takes place through switch designs that need
a twist, pull, or key to release the electrical contacts so the
machinery can restart.
Fail-safe operation gives the E-Stop command prior-
ity over any sustaining function that keeps equipment
running. Innovative switch designs prevent blocking, a
wanton or accidental obstruction of the actuator with for-
eign objects, and teasing, a momentary actuation without
latching the power circuit open, that may give prema-
ture or unreliable operation. Problems arise when con-
tact blocks and actuators are improperly installed or if
they separate because of vibration or other malfunctions.
These realities have forced switch companies to improve
switch reliability and, thus, safety.
Virtually all industry segments mandate E-Stops for
safe operation. Unfortunately each area also has its own
compliance requirements that designers must know. In
addition, international standards may differ from local
standards and compliance needs.
Simply stated, E-Stops should go on all machinery
except for that in which an emergency-stop function
would not lessen the risk. An E-Stop is only one part of
a comprehensive safety system. Equipment designers
34 MACHINE Design.com JUNE 24, 2010
E-Stops safely
halt equipment
motion as rapidly
as possible.
must also consider safety functions, such as reversal or
limitation of motion, deflection, shielding, braking, and
disconnecting.
Safe emergency stopping
International standards state that emergency-stop
functions must trigger on a single human action using a
manually actuated control device. The stop must remain
operational at all times and be designed in such a way as
to stop the machine without creating additional hazards.
Resetting an E-stopped electrical system means first
releasing the E-Stop that was originally activated. If more
than one E-Stop activated, all must be released
before the machinery can restart. Note that just
resetting E-Stops does not restart the machinery;
this action only permits restarting through nor-
mal procedures appropriate for the machinery
involved.
Ergonomic, electrical, mechanical, and color
requirements for E-Stops are quite specific. Many
E-Stop controls use a distinctive mushroom-head
pushbutton switch although wires, ropes, bars,
handles, or foot pedals are sometimes employed.
The E-Stop must also use direct mechanical ac-
tion with mechanical latching such that when
activated or pushed, it permanently opens the
electrical contacts. To close the electrical contacts
and let the machinery restart, the E-Stop actuator
is manually unlatched with a twist or key release.
Some E-Stop actuators can simply be pulled to
close the electrical contacts. However, the pull approach
 E-Stop switches like these
come in various sizes and
configurations, but all have
similar qualities set by
national and international
regulations such as a positive
latch on actuation, a specific
method of clearing the stop
position to permit restarting
the equipment, and
recommended coloration.

may be less desirable from a safety standpoint than a twist The key to picking the right
or key release that needs more deliberate action by an E-Stop is a thorough un-
operator. derstanding of the machin-
ery and associated control
Picking the right E-Stop system.
One of the first steps in E-Stop selection is in deter- A second and equally
mining where the E-Stop fits within the machine control important step is to deter-
system and whether the particular application needs a mine what international
Category 0 or Category 1-type emergency shutdown. standards, performance
The intended application often determines the place- ratings, and codes apply.
ment, size, electrical specifications, mechanical qualities, Requirements vary by in-
ergonomics, color/legends, and the number of E-Stops. dustry segment, so stan-
dards for E-Stops on trans-
portation vehicles differ
significantly from those on
process machinery or med-
ical equipment and will be
governed by different reg-
ulatory bodies. Regulatory
bodies may also specify
size, color, legend, contact
terminals, and so forth.
It is often useful to con-
struct or consult an existing
E-Stop Series selector chart
that vendors often supply.
For example, EAO Switch
Corp., Milford, Conn.,
provides a chart that allows
E-Stop switches must be easily identified and accessible. easy comparison of key de-
Here the E-Stop is in the upper left of this control panel. sign factors for its multiple
Authored by:
Joseph Torzillo &
Lance Scott
EAO Switch Corp.
Milford, Conn.
Edited by Robert Repas
robert.repas@penton.com
Key points:
t

E-Stops do not merely
turn equipment off, but
offer foolproof equipment
shutdown.
t

Standards and regulations
for E-Stops vary
significantly by industry.
t

E-Stops should stop all
hazardous mechanical
motion, but not shut off
associated equipment.
Resources:
EAO Switch Corp.,
www.eao.com
OSHA: Industrial Robots and
Robot System Safety, www.
osha.gov/dts/osta/otm/otm_iv/
otm_iv_4.html
Article: “Safety Rides the Bus,”
machinedesign.com/article/
safety-rides-the-bus-0123

JUNE 24, 2010 MACHINE Design.com 35

 MOTION

E-Stop Series. The chart simplifies

Emergency Stops versus Stop Switches selection of panel cut-out size, type
International Standards of actuator, type and number of con-
Emergency stop Stop switch tact blocks, connectors, colors, and
General maximum electrical rating to come
Actuators of emergency switching-off devices up with one or more appropriate
shall be colored RED.
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The resetting of the latching means shall be
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36 MACHINE Design.com JUNE 24, 2010

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RS# 131
 MOTION

A machine may need more

than one E-Stop switch
to meet accessibility
requirements. This large
semiconductor production
machine uses three E-Stop
switches: one on the
control panel and one at
each end of the machine.

E-Stops, requiring the lat-

ter be clearly distinguish-
able from EMOs through
the use of color (red), ac-
tuator shape (extended
not mushroom), and
labeling (“Emergency
Stop”). It also specifies
that E-Stops should stop
all hazardous mechanical
motion at the equipment
interface, but not shut off
associated equipment.
Large lifting and mov-
ing devices like gantry
cranes may have a gan-
try-mounted cab which
includes an E-Stop on the
operator console. Smaller
overhead cranes usually
have a wired or wireless
pendant control operated
from ground level that
includes an E-Stop. The
chief regulating body for
these massive devices is
the Occupational Safety
and Health Adminis-
tration. OSHA 29 CFR
1910.179(a)(59) defines
“emergency-stop switch”
as a manually or auto-
matically operated elec-
tric switch to cut off elec-
tric power independent
of the regular operating
controls. Another sec-
tion, 29 CFR 1910.179(a)
(61) def ines “mai n
switch” as a device con-
trolling the entire power
supply to the crane.
Future technology
The pace of change
in E-Stop technology is
steady, not revolutionary.
Finding the right E-Stop
The confusing array of available E-Stops makes it important to understand the design
basics that contribute to high-quality, ergonomic switch design. Quality E-Stops are de-
signed for long life and reliable service. Switch contacts should use hard silver, gold, or
palladium for extended wear. International standard EN IEC 60947 5-5, paragraph 7.3.3
specifies a mechanical life in excess of 6,050 operations. By precision molding all actuators
and contact blocks from high-quality polymeric materials, EAO E-Stops generally exceed
250,000 operations. Extensive research, testing, and quality assurance measures are inte-
gral to the design, engineering, and production of E-Stops.
E-Stops have evolved over the years with a general trend from larger 30.5-mm-diameter
mounting hole sizes to smaller 22.5 and 16-mm sizes. The development of shorter, behind-
panel-depth designs give designers convenient choices. Although each size and config-
uration offers special combinations of electrical and mechanical specifications, there are
important design and safety features shared by most E-Stops such as teaseproof design,
a twist-to-release actuator, and foolproof designs in compliance with international safety
standards and codes. Many are sealed to IP65 oil and watertight standards, conform to
color and legend standards, and often have available enclosures and legend plates.
Robust, heavy-duty construction is the hallmark of the original 30.5-mm switches. Many,
like the EAO Series O4 E-Stops, have stackable contact blocks, optional mushroom and key
release actuators, and mounting options for 30.5 and 22.5-mm panel openings. Typically
rated at up to 10 A, 600 Vac, these switches have silver contacts with available gold over
silver or silver over palladium contacts along with silver-plated screw terminals or quick-
connect terminals.
Modern applications often demand a slimmed down E-Stop with 16-mm mounting.
Innovative products have actuator shapes that prevents blockage from foreign objects, a
black indicator ring visible from long distances, and availability of key release actuators.
The 16-mm Series are typically rated at 5 A, 250 Vac, with a choice of silver or gold contacts,
screw or solder quick-connect terminals, and optional ribbon cable terminals.
Newer electronic applications need E-Stops with shorter behind-panel-depth. EAO’s
Series 84 E-Stop, for example, features a short behind-panel depth of 18-mm maximum, a
single monoblock construction, 22.5-mm mounting, and optional LED illumination that is
visible from the side as well as front of the actuator. This Series is rated at 3 A, 120 Vac and
1.5 A, 240 Vac, has gold contacts, quick-connect/solder printed-circuit-board terminals, and
ribbon-cable terminals.

38 MACHINE Design.com JUNE 24, 2010

RS# 132

When
it matters...
GORE® Electronic Materials
Enhance performance and
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gore.com/emi
RS# 133
EMI GASKETS AND
GROUNDING PADS
MOTION
Applicable standards for E-Stops
The ISO (International Organization for Standardization) and IEC (Internation-
al Electrotechnical Commission) are the two international bodies that govern
E-Stop design standards. National bodies that are members of ISO or IEC partici-
pate in the development of international standards through technical commit-
tees established to deal with particular fields of activity, such as emergency stop
functions for machinery.
DIN EN ISO 13850: 2008 (Safety of machinery
— Emergency stop — Principles of design)
The first edition of ISO 13850 (published in 1996) replaced the EN 418
“Emergency Stop” directive in March 2008. Significant changes in this second
draft mandated the manual resetting of E-Stops, require E-Stops use mechanical
latching, and state that the revision will remain unchanged until 2010.
EN 60204-1: 2005 (Safety of machinery
— Electrical equipment of industrial machines)
This document applies to the application of electrical, electronic, and
programmable electronic equipment and systems to nonportable machines
including groups of machines working together in a coordinated manner. The
standard applies to equipment that operates with nominal supply voltages not
exceeding 1,000 Vac with supply frequencies not exceeding 200 Hz or 1,500 Vdc.
DIN EN ISO 13849-1: 2008 (Safety of machinery
— Safety-related parts of control systems)
This document, which replaces EN 954-1, provides safety requirements and
guidance on the principles for the design and integration of safety-related parts
of control systems (SRP/CS), including the design of software. For these parts of
SRP/CS, it specifies characteristics that include the performance level needed
based on risk assessment for carrying out safety functions. It applies to SRP/
CS, regardless of the type of technology and energy used, whether electrical,
hydraulic, pneumatic, or mechanical, for all kinds of machinery and mandates
independent validation of safety-related control systems. The new standard
officially replaced EN 954-1 on November 30, 2009. Beginning January 2010, ma-
chinery shipped to the European Union must meet the new standard.
The following international standards for low-voltage switchgear and control
gear must also be observed: EN IEC 60947-1: 2004 (Part 1: General rules), EN
IEC 60947-5-1: 2003 (Part 5-1: Control-circuit devices and switching elements
— Electromechanical control-circuit devices) and EN IEC 60947-5-5 Edition
1:1997 consolidated with amendment 1:2005 (Part 5-5: Control-circuit devices
By their nature, these devices must be recognizable, reliable, and rugged. Es-
tablished standards, function, and familiarity dictate a certain beneficial iner-
tia in new E-Stop developments.
Many advances are driven by norm changes for E-Stops, such as DIN EN
ISO 13850:2008 that now requires mechanical latching and manual resetting
of E-Stops. Most research and development is aimed at improving the safety
and reliability of the switches themselves to expand their roles as lockout de-
vices in worker-safety applications.
One area of current interest is making sure that the E-Stop itself will “fail-
safe” should the actuator and contact block separate. The contact block has
normally closed contacts that let power flow to the machinery. Pushing an
E-Stop separates the spring-loaded contacts, and mechanical latching keeps
them open, stopping the machinery. But what happens if the actuator separates
from the contact block or the latching mechanism fails?
 When failure
and switching elements — electrical E-Stop devices with mechanical latching
is not
function.)
New EU requirements for U.S. exporters of machines became effective on an option...
December 29, 2009 when Machine Safety Directive 2006/42/EC (adopted in June
2006) replaced previous Directive 98/37/EC. The new directive acts as an umbrella
for harmonized safety standards and adds a detailed list of 17 safety components
in a new Annex V, including E-Stops. The new directive is designed to make design
standards compatible with modern and future advances in technology.
U.S. Standards for E-Stops fall under a number of different agencies:
Occupational Safety and Health Administration (OSHA) — Standards – 29
CFR (Code of Federal Regulations); OSHA 1910
American National Standards Institute (ANSI) — B11, Electrical and Mechani-
cal Equipment Guidelines
ANSI/NFPA (National Fire Protection Association) — 79, Electrical Standards
for Industrial Machinery
Underwriters Laboratories Inc. (UL) — Category NISD, Emergency-Stop Device
Food and Drug Administration, Department of Health and Human Services,
Subchapter J — Radiological Health: CRF Title 21, Part 1020, Performance Stan-
dards for Ionizing Radiation-Emitting Products
Semiconductor Equipment and Materials International (SEMI) — S2-93,
Safety Guidelines for Semiconductor Manufacturing Equipment; S8-95, Safety
Guidelines for Ergonomics/Human Factors Engineering of Semiconductor
Manufacturing Equipment
Most quality E-Stop switches, including those made by EAO, meet other
compliance and rating bodies such as RoHS and Reach (Registration, evaluation,
and authorization of chemicals), cUL (Canadian UL), TÜV (Technischer Überwa-
chungsverein, a German safety-monitoring agency), SEV (a Swiss designation),
and CE (European-Union) approvals.
Depending on design and application requirements, many E-Stops are listed
as UL category NISD emergency-stop devices. This rating covers two categories
of E-Stop function as defined by the American National Standards Institute
and the National Fire Protection Association in ANSI/NFPA 79, Electrical Stan-
dards for Industrial Machinery:
Stop Category 0 — Immediate removal of power to the machine or mechani-
cal disconnection (declutching) of hazardous elements.
GORE® Wire and Cable
Stop Category 1 — Controlled stop with power available to stop the machine
followed by removal of power once stop is achieved.
The emergency-stop actuator provided in these devices must be a self-
When reliability, durability, and
performance can be compromised
latching type. E-Stops with this rating have been investigated for their fire and
by harsh environments,
electric shock safety in addition to their emergency-stop function.
GORE® Wire and Cables
offer the best solution.
Separation of the contact block from the actuator renders an E-Stop inef-
fective. Current solutions include monoblock or unibody switches with a one-
piece actuator/contact block, as well as switches with fail-safe-contact blocks
that automatically shutdown the machinery if the actuator and contact block gore.com/electronics
separate.
Other advances are application driven. For example, EAO’s Series 84 E-
Stops were developed for handheld enclosures with slim back-of-panel depth RS# 134
as with teach pendants for robots. These versatile E-Stops also go in pendant
controls for lifting and moving machinery. Application requirements have
WIRE AND CABLE
created a wide variety of available optional features and accessories for most
E-Stop products such as illumination, protective rings, enclosures, guards, and
legend plates.
E-Stops will continue to evolve to meet new standards and new applications.
MD
 MOTION

Technology,
professionalism
first in
robotics
competition
Authored by: Robots taking over the
Jessica Shapiro Georgia Dome in a battle for
Associate Editor
jessica.shapiro@penton.com
Key points”:
world domination? It’s not a
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donations of robot parts help defray the Students hone their skills, rely on teammates, and
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UFBN compete in regional tournaments in hopes of making
Resources: it to the national championship and getting noticed
AutomationDirect, www. by top colleges. Sounds like a varsity sport, right?
automationdirect.com That’s exactly the vision Dean Kamen, inventor, entrepreneur, and founder of
FIRST, www.usfirst.org FIRST, Manchester, N.H., had for the FIRST Robotics Competition when it
started 19 years ago.
Freelin-Wade, www.freelin-wade.com
This year’s championship in Atlanta, April 15 to 17, was the culmination of a
igus, www.igus.com three-month season for more than 45,000 students from 12 countries. Starting
Team 341: Miss Daisy
www.team341. in January, student teams designed and built robots that would compete both
com with and against other teams’ robots for top honors.
Kamen founded FIRST, which stands for “For Inspiration and Recognition
of Science and Technology” in 1989 to motivate young people to pursue educa-
tion and career opportunities in science, technology, engineering, and math,
and build self-confidence, knowledge, and life skills. The FRC program com-

42 MACHINE Design.com JUNE 24, 2010


bines the excitement of varsity sports with technology.
Students competing in FIRST events can win awards
for design, team spirit, professionalism and maturity, and
overcoming obstacles as well as for scoring the most points
in competitions. Plus, over $12.2 million in college schol-
arships are available from over 136 sources to students
who participate in FIRST.
Technical teamwork
The season kicks off six weeks before regional compe-
titions begin with FRC teams learning about the season’s
WHAT’S THIS?
When you see a code like this, take
a photo of it with your smart phone
(iPhone 3G-S gives best results) and,
using software from www.neoreader.
com, you will be connected to relevant
content on machinedesign.com
Team 71, Hammond Inc., used
pneumatics and neon-yellow tubing
from Freelin-Wade, to complement
electronic and mechanical components.
challenge simultaneously via satellite.
There’s a newly developed game each
year, but a carpeted field roughly the
size of a basketball court and em-
phasis on cooperation among teams,
creativity, professional courtesy, and
safety are usually the norm.
Robot-design challenges go far
beyond creating a vehicle that moves
in response to radio control. These
robots are equipped with sensors
and other components professional
engineers would recognize, includ-
ing machine vision that must be pro-
grammed to recognize targets, ac-
celerometers, gyroscopes, optical
and magnetic encoders, and electric
motors that need to be matched to
gearboxes.
Robots must be able to operate
autonomously for one segment of the
game, and then switch to semiauto-
nomous radio control. In addition,
because organizers randomly assign
three-team alliances that compete to-
gether, teams need to choose whether
their robot should specialize in one
point-scoring task or be multiskilled.
Alliances change from match
to match in the initial competition
stages, but top teams choose others to
join their alliance going into the play-
off rounds. A team with a specialist
robot might look to join with teams
whose robots round out its skill set.
In this year’s competition (see
“Breakaway ‘bots’”), teams scored
points by having robots send balls
into goals. They could also earn points for getting their ro-
bots to elevate themselves above the playing surface at the
end of the game.
Even for engineers who understand all the mechani-
cal, electrical, and control concepts involved, building a
robot from scratch in six weeks could be a tall order. Do-
ing it with a team of high schoolers creates a “real pressure
cooker,” says Alan Ostrow, who heads Miss Daisy, the team
at Wissahickon High School, Ambler, Pa., that won the
Chairman’s Award, FIRST’s highest honor, in April.
Some teams rely on adult engineers to design their ro-
JUNE 24, 2010 MACHINE Design.com 43
 MOTION

Breakaway Vision Alliance

In this year’s FIRST Robotic Competition Guardrail target wall
(FRC), robot and human players ‘bots system
competed in a game dubbed Breakaway.
In the game, two alliances of three teams
each compete on a 27 × 54-ft field with Blue zone
bumps. Robots, which can’t exceed
Bumps
120 lb when weighed without batteries
or bumpers, start the game able to fit Goal
through the tunnels on the field with Midfield
maximum dimensions of 28 × 38 × 60 in. Tower and
tunnel
Teams earn a point for each soccer ball
collected in their goals, two points for
every robot that suspends itself from a Red zone
tower at the end of the game, and three
points for every robot that suspends itself Gate
from another hanging robot at the end of
the game.
Robots start the game by attempting to Following the autonomous period, In the final 20 sec of the game, the robots
score soccer balls in vision-ready targets human drivers use radio control to attempt to pull themselves up on the
autonomously for 15 sec. The robots may direct robots into scoring goals for towers or other robots to score extra
hold one ball at a time, but may herd or 2 min. One robot for each alliance is points. During this time, robots can
kick multiple balls along the floor. Human permitted to play defense on the two extend to up to 7 ft in diameter and 90 in.
players return scored balls to midfield. goals. in height.

bots and help the students build them. At Wissahickon,
about 95% of game strategy, robot configuration, and ro-
bot assembly are up to student team members. Some 10
adults, half-of them college-age mentors who were previ-
ously on the team, tutor students in CAD and animation
programs, machine-shop skills, Web-site development,
programming, and robot architecture.
Starting small
Even with mentors, teams like Miss Daisy rely on re-
turning students who already have experience with robots
and the tools used to build them. Ostrow says students
who have been designing and building robots through all
four years of high school are as good as their professional
mentors when it comes vetting proposed designs.
Like other varsity sports, FRC, which serves students
in grades 9 through 12, has developed a system that gets
younger players involved early and develops the skills
needed to compete at the highest levels.
The FIRST Lego League (FLL), for fourth through
eighth grades, has kids build robots using Lego Mind-
Storm components to tackle simulations of real-world
technology challenges, like biomedical engineering or en-
vironmental disasters. Students in kindergarten through
third grade build models, research challenges that mirror
those of FLL, and creatively present what they’ve learned
in Junior FLL (JFLL).
Schools that have a strong interest in FRC competi-
tion often promote the formation of FLL and JFLL teams.
One example comes from Georgia’s Forsyth County where
nearly all the elementary schools now have an FLL team
and where the high school offers a robotics-focused tech-
nical degree track.
The Forsyth County program started with a single
FRC team requesting support from local company Auto-
mationDirect (ADC) during the 2006-2007 season. In

RS# 135
44 MACHINE Design.com JUNE 24, 2010
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RS# 136
 MOTION

subsequent seasons, ADC went on

to become a Gold sponsor of FIRST,
supplying over $50,000 of parts each
year. The company also supported
the advocacy of FRC coaches to get
robotics on school curricula.

Kit competition
But implementing robotics cur-
ricula is not cheap. Neither is field-
ing an FRC team. Teams competing
at the highest levels need $45,000 to
$125,000 per season, depending on
whether students pay for their own
travel to tournaments. Smaller teams
get by with less, but the costs are still
high.
An initial registration fee of $5,000
to $6,000 covers participation in one
event and a kit of basic parts. Win- The robot for Team 3138, Dayton, Ohio, defends the goal against shots from
ners of the initial regional competi- Team 67, Milford, Mich. Robots used machine vision and other sensors along
tions spend $4,000 to register for a with radio control from human players to score goals, play defense, and
second regional, and those who con- navigate obstacles on the field.
tinue to the championship pony up
yet another $5,000.
Corporate and institutional sponsorships usually help
defray some of the cost. Some teams, like Miss Daisy, also
run off-season events that raise money and drum up inter-
est in FIRST. The team’s Ramp Riot event draws 36 teams
and over 2,500 spectators to a competition that mirrors
that year’s FRC game, acts as a training event for rookie
team members, and provides opportunities for teams to
learn from each other.
FIRST also helps out with expenses by supplying
teams with a large kit of parts, worth more than the
$5,000 registration fee and donated by companies like
Bishop Wisecarver, Festo, Monnier, Rockwell Auto-
mation, Gates, Bimba, Norgren, Axis, EnerSys, Andy
Robots lift themselves off the playing field at the end of
their match with help from one of the two towers on the
playing field. Robots earned two points for the stunt. The
FRC game changes each year, so student teams face fresh
design challenges each season.
Mark Inc., and Parker. ADC donates limit switches,
terminal blocks, and pushbuttons.
igus, East Providence, R.I., supplies cable carriers, con-
tinuous-flex cables, plastic plain bearings, linear bear-
ings and guides, and spherical bearings through its Young
Wanted: engineering mentors
One thing that’s clear in any conversation with FIRST devo-
tees is the need for more mentors. Depending on the team,
mentors might raise money, arrange group travel, help with ro-
bot design, supervise machine-shop operations, tutor students
on software tools and technical topics, interact with the media,
and act as chaperones.
“One of the things that led me from my engineering career
into teaching and to FIRST was directly helping others,” says Alan
Ostrow, head coach of Miss Daisy, the team from Wissahickon
High School, Ambler, Pa., that won this year’s FIRST Chairman’s
Award. “I love seeing the light bulb go on for the kids I work with.”
Helping kids find their way and get excited about math,
science, and engineering is what has inspired Ostrow through
the 11 years he has worked with Miss Daisy, and his story is not
unique. “People really get hooked” on FIRST, he says.
Engineers interested in mentoring, should contact FIRST
directly. Staff at the nonprofit can connect potential mentors with
local teams who need them.
Starting in 2004, students and mentors for Miss Daisy created a
DVD they call “Team in a Box” that guides rookie mentors through
the phases of a FIRST season, addresses team organization
and activities, and supplies robot-building tips. Support from
AndyMark helps the team get the DVD out to those who request
it. More information is available on Miss Daisy’s Web site, www.
team341.com.

46 MACHINE Design.com JUNE 24, 2010

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a whole,” says Aimesh Hajela, student
vice president of Team 2791. Compe-
RS# 139

3
tition judges recognized the team for
its unique efforts, performance, and
dynamics.
Freelin-Wade, McMinnville,

The Power Oreg., recognized by FIRST as a Sil-

ver supplier, gave each team 50 ft of
transparent, neon-yellow, Fre-Thane
95A polyurethane tubing and a cou-

of
V

BEI Industrial pon for 50% off custom orders. “This

year was a big pneumatics year which
Encoders translated to more teams using tub-
ing in their robots,” says the compa-
V V

BEI Duncan ny’s Ron Miller.

Teams also get hardware, batter-
ies, motors, pneumatic components,
BEI Ideacod actuators, servos, and sensing and
control electronics and accessories.



   
 
 
 A Classmate PC lets teams interface
with robots over radio frequencies,


 
 
 and professional-level software from
  
 

 


 companies like National Instru-
ments, Autodesk, Altium, and PTC

 
helps visualize, design, and program
robots.
FIRST also runs the FIRST Tech
Challenge (FTC), a midlevel robotics
competition for high-school students
that launched in 2005. The robotics
kit and challenge are designed to be
 
   more accessible for teams that can’t
afford the high overhead of FRC. MD
RS# 138
48 MACHINE Design.com JUNE 24, 2010
 ENTER THE INCREDIBLE
!ORLD OF MACHINED SPRINGS
Light years ahead of traditional
springs:
Introducing:
 End attachments
The  More precise performance
 A broad range of spring rates and
spring functionality
 Safety operation
for the  Repeatability–predictability
21st  Integration with entire assembly
 Cost reduction
century  Accommodates spring modes:
compression-extension, torsion,
lateral bending, lateral translation
Free engineering  Torsional springs produce pure
consultation moments. Multiple starts resolve
(cancel) moments
 Easier assembly

The key is integrating

several parts into one
piece.

Before After

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RS# 140
 MOTION
Hot
and
hotter
Motion-system designers frequently
crank pretty hard on servomotors. To get
the highest possible performance, they’ll
often command the servomotor to put out
the maximum peak torque that its maker
allows. However, servomotor electrical
windings can overheat rapidly and even
burn up when this happens. Consequently,
a servomotor needs a hot-spot temperature
safety margin. This margin is defined as the
difference between the winding maximum
allowable hot-spot temperature and its
maximum continuous winding tempera- One of the first steps in selecting a servomotor is to characterize the
ture. Stated mathematically, dynamic motion profile over which the motor must operate.
Tsm = Ths – Tmax
where Tsm = hot-spot temperature safety margin; Ths =
maximum hot-spot temperature; and Tmax = maximum
continuous-winding temperature, all in degrees.
Manufacturers normally publish values for each motor’s
Tmax, along with the corresponding maximum continuous
current and torque output, plus the ambient conditions (drive
electronics, ambient temperature, amount of forced cooling,
heat-sinking method, and so forth). One needn’t worry about
hot spots so long as the motor never exceeds its maximum
continuous current value and ambient conditions don’t devi-
ate from those the manufacturer specifies. However, that’s not
the way a servomotor typically operates. Servomotors more
often are commanded to produce a dynamic motion profile
that contains one or more time intervals during which the
motor must output peak torque exceeding its maximum con-
tinuous value. Hence, the manufacturer also specifies a peak-
torque value for each servomotor. Depending on the motor
WHAT’S THIS?
When you see a code like this, take
a photo of it with your smart phone
(iPhone 3G-S gives best results) and,
using software from www.neoreader.
com, you will be connected to relevant
content on machinedesign.com
50 MACHINE Design.com JUNE 24, 2010
Build in a thermal
safety margin to
handle servomotors
that heat up more
than theoretical
Motor
models predict.
Repetitive motion profile
rpm for a typical machining operation
Repeat
Retract
Rapid Time
advance Thrust Dwell
model, the peak-to-continuous torque ratio typically ranges
between 2:1 and 5:1, though one brand of brush dc servomo-
tor carries a 7.2:1 ratio.
It’s normal for a servomotor to put out peak torque ex-
ceeding its maximum continuous value. But overheating
can be a problem if it stays in this condition for too long.
So during times of peak-torque output, the motor duty
cycle must be less than 100%. The more the peak-torque
value exceeds the maximum continuous value, the lower
the allowable duty cycle.
For over 50 years, servomotors have been characterized
thermally by what’s generally called the two-parameter
thermal model. One generally finds manufacturers pub-
lishing one value for the motor winding-to-ambient ther-
mal resistance, Rth (°C/W), plus the corresponding ther-
mal time constant, τ (seconds). This information permits
calculating the motor’s thermal capacitance, Cth (J/°C),
using the following equation:
Cth τ/Rth
This two-parameter thermal model lets motor manu-
facturers and users size and select the right motor. Many
motor manufacturers have developed sizing programs
employing this model that are publicly available. However,
I have yet to find a single manufacturer willing to size a
 Authored by:
Richard Welch, Jr.
Consulting Engineer
Oakdale, Minn.
Typical motor intermittent welch022@tc.umn.edu
and continuous torque-speed curves Edited by Leland Teschler
One determines leland.teschler@penton.com
the peak torque
and velocity the 24
Intermittent Key points:
motor must output t

5IF
SFMBUJPOTIJQ
CFUXFFO

during the most- Peak-operation point intermittent and continuous torque
is important when evaluating
Torque, lb-in.

demanding time
interval in the servomotor thermal qualities.
Continuous
motion profile and 12 RMS-operation point t

5FNQFSBUVSF
JO
TFSWPNPUPST
SJTFT

enters this peak- much more quickly than predicted
operation point by conventional thermal model,
on the motor’s particularly under high-torque
intermittent and demands.
continuous torque-
speed curves. 500 1,000 1,500 2,000 2,500 References:
Speed, rpm Example brush and brushless
servomotor data sheets with peak,
continuous torque values: http://
competitor’s motor. Hence, motor users generally must size and compare competing www.exlar.com/prod_SLM_ST_curves.
html)
brands themselves to make valid comparisons.
Frequently, the first step in the sizing process is to completely specify the dynamic-mo- http://tinyurl.com/yg6o45z
tion profile, along with specifying the ambient conditions in which the motor will operate. http://tinyurl.com/2w67auy
Next, in combination with the motor’s engineering specifications, one determines http://www.hurst-motors.com/
the peak torque and velocity the motor must exhibit during the most demanding time ntdynamo.html
interval in the motion profile. This information becomes the peak operation point on
http://tinyurl.com/2wvl6n5
the motor’s combined intermittent and continuous torque-speed curves, as shown in
the accompanying figure. http://tinyurl.com/34mn4wx
A necessary requirement is that this peak operation point lies within the boundary More info on motor thermal
of the intermittent torque-speed curve. Otherwise, the motor-drive combination in qualities: R. Welch, Continuous,
question will lack enough torque, velocity, and/or power for the application. %ZOBNJD
BOE
*OUFSNJUUFOU
5IFSNBM

Finally, one calculates the root-mean-square (rms) torque and velocity for the entire Operation in Electric Motors, http://
motion profile from the two-parameter thermal model in combination with the time- www.smma.org/motor_college_
averaged power dissipation technique. This rms-operation point goes onto the com- thermal.htm
QBHF
5VUPSJBM
#PPL

available from welch022@tc.umn.
bined torque-speed curves visible in the accompanying figure. If the rms-operation edu)
point lies outside the boundary of the continuous torque-speed curve, then it is an
absolute certainty the motor will overheat. 4
/PPEMFNBO

#
1BUFM
%VUZ

Conversely, the graph tells us that so long as the rms-operation point lies within the Cycle Characteristics for DC Servo
.PUPST
QBQFS
50%
*&&&
boundary of the continuous torque-speed curve, this particular motor will not over- *"4
$POGFSFODF
0DU



heat and it’s okay to use. However, extensive research has proven this last statement is 1IJMBEFMQIJB
1B
NOT always true. In the real world of servomotors, it’s entirely possible the winding
maximum allowable hot-spot temperature is actually exceeded in direct violation of Underwriters Laboratories,
UL 1446 – Systems of Insulating
UL 1446, despite operating in the safe part of the curve. Designers who depend on the Materials – General, http://tinyurl.
two-parameter thermal model won’t realize this is happening. com/35grzb8
This simple, two-parameter thermal model is still used extensively to calculate dynamic-
winding temperature during all possible modes of servomotor operation. But experimental 3
8FMDI
8IZ
B
5FNQFSBUVSF
4FOTPS

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measurement shows it’s NOT particularly accurate in calculating dynamic-winding tem- From Overheating, MACHINE DESIGN
perature when the motor uses more than its maximum continuous current. A much-more Magazine, February 4, 2010, http://
accurate four-parameter thermal model has been developed to overcome this inaccuracy. tinyurl.com/3776lue
The basic problem with the two-parameter model is it assumes the entire motor, and every
Motor-temperature switch
component in it including the windings, has the same dynamic operating temperature. placement, http://tinyurl.
Actual measurements show this isn’t true. In fact, measurements reveal that within the com/3x4by7u
motor and even within the winding itself there can be temperature differences that the two-
parameter model simply doesn’t account for. Motors spec’d with four-parameter
thermal models, http://www.
Furthermore, there can be as much as a 50°C temperature difference between the micromo.com/uploadpk/2607_SR_
motor winding and its outermost surface area, depending on motor size and operating IE2-16_FTB.pdf, http://www.micromo.
temperature. This difference can’t be ignored. A higher order [i.e., 4, 6, 8,… parameter] com/uploadpk/4490B_4490_BS_MIN.
thermal model allows for temperature gradients in the motor. The winding can have its pdf
own dynamic-operating temperature, thermal resistance, and thermal time constant.
These can differ from those of the rest of the motor. Research has shown the four-

JUNE 24, 2010 MACHINE Design.com 51

 MOTION
parameter thermal model is accurate enough to explain
all the measured temperature data. And it’s rather easy to
obtain the four parameter values for the model.
As shown in the accompanying figure, the winding
temperature calculated by the four-parameter model ini-
tially rises faster than in the two-parameter model. How-
ever, both curves converge at the rated 130°C maximum
continuous-winding temperature. This feature is con-
sistent between these two models with the continuous
power-dissipation rating.
It is useful to compare the calculated temperature rise be-
tween the two-parameter and four-parameter models while
the motor is producing 4× peak torque, corresponding to 16×
power dissipation in the winding. (Torque developed by a
servomotor rises linearly with current, while the power dissi-
pation in its electrical winding rises as current squared, I 2R.)
An accompanying figure depicts the case of 4× peak-
torque output, specified for many servomotors, corre-
sponding to 16× power dissipation. The four-parameter
model shows that the winding temperature rises from its
initial 25°C to its rated 130°C value in only 12 sec. The
two-parameter model takes longer to respond. It predicts
the winding temperature should be less than 55°C at 12
sec. Experiments show this winding temperature is in er-
ror. All in all, a significant temperature error that is clearly
unacceptable accompanies the use of the two-parameter
thermal model in calculating dynamic winding tempera-
ture when peak torque exceeds the 1× value.
Several motor manufacturers proudly claim their ser-
vomotors are recognized under the UL 1004 and/or CSA
22.2/100 standards by Underwriters Laboratories and the
Canadian Standards Authority, respectively. As part of
the UL/CSA recognition process, the insulation system
for the motor’s electrical winding must comply with the
UL 1446 Insulation System Standard. That standard says
the class of the insulation on the winding determines the
winding’s maximum allowable hot-spot temperature. To
Example: Winding heat-up with
1× constant-power dissipation
(40-mm motor)
140
Four-parameter model
120
Temperature, °C
100
Two-parameter model
80
60
40
20
0 2,000
1,000 3,000 4,000
Time, sec
The winding temperature calculated by the four-
parameter model initially rises faster than that of the
two-parameter model. However, both curves converge
at the rated 130°C maximum continuous-winding
temperature.
comply with UL 1446, the winding must have a hot-spot
temperature rating at least equal to the maximum contin-
uous-winding temperature. To ensure the motor complies
with UL 1446 and to make sure the winding can’t possibly
overheat, manufacturers often place a temperature sensor/
switch inside the motor. The sole purpose of this tempera-
ture sensor/switch is to tell the drive when the winding
approaches its maximum allowable hot-spot temperature.
The drive responds by shutting off the power to the motor.
However, there are at least three practical reasons why this
overtemperature protection scenario doesn’t always work.
A point to note is that even the four-parameter model
isn’t perfect. Though it allows the winding to have its own
dynamic operating temperature, it still assumes the entire
winding is at one temperature. Measurements at different
points in the winding show this is not true. Nevertheless,
the four-parameter model is accurate enough to show why
a servomotor must have a hot-spot temperature safety




 
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52 MACHINE Design.com JUNE 24, 2010

 Example: Winding heat-up with
16× power dissipation
(40-mm motor)
160 change the ambient conditions. Conversely, both motor
140 manufacturers and conventional calculations will predict
the motor won’t overheat if the rms-operation point lies
120
Temperature, °C

Four-parameter model within the boundary of the motor’s continuous torque-

100
80
60
40
Two-parameter model
20
0
0 2 4 6
8 10 12 14 16 18 20
Time, sec
With 4× peak torque output — a parameter specified
for many servomotors and corresponding to 16× power
dissipation — the four-parameter model shows the
winding temperature rising to its rated 130°C value in
only 12 sec. The two-parameter model lags way behind.
margin while at peak-torque output.
Most servomotor manufacturers still perform all their
motor-sizing and dynamic-winding-temperature calcu-
lations using the two-parameter thermal model. (I have
found only one that uses the four-parameter model.) Thus
motor users have no choice but to use the two-parameter
model in calculating dynamic-winding temperature un-
less they measure the four parameter values themselves.
These measurements are relatively straightforward.
Sizing the optimum motor for the application begins
with the process of defining the dynamic-motion profile
and the ambient conditions. Next, the designer deter-
mines the candidate motor’s rms-operation point and
notes it on the continuous torque-speed curve. The motor
will certainly overheat if this rms-operation point lies out-
side the boundary of the motor continuous torque-speed
curve. The only way to use the particular motor under in-
vestigation would be to modify the motion profile and/or
speed curve.
However, the four-parameter model predicts the wind-
ing heats more quickly and hits a higher temperature than
the two-parameter model shows. In fact, the motor ex-
ceeds its maximum continuous-temperature value while
at peak torque. Furthermore, the sensor/switch can’t al-
ways react fast enough to prevent this high temperature.
Thus, the electrical-winding insulation must have a
maximum hot-spot temperature value exceeding the
maximum continuous-winding temperature. The greater
the safety margin for the hot-spot temperature, the better
the protection. For example, all Exlar SLM servomotors
have a 130°C maximum continuous-winding tempera-
ture. Their windings insulation system is rated Class H,
which provides a 180°C maximum allowable hot-spot
temperature. This gives a 180 – 130 = 50°C hot-spot safety
margin.
In addition, all SLM servomotors have a 2:1 peak-to-
continuous torque rating. This combined with their hot-
spot safety margin gives excellent thermal protection dur-
ing times of peak-torque output. In contrast, many other
servomotors have a hot-spot safety margin of 15°C or less
(some are zero). It is also common to find peak-to-contin-
uous torque ratios ranging between 3:1 up to 5:1.
Over time, different authors have suggested varying
figures of merit for selecting high-performance servomo-
tors. But from a motor user’s perspective, the single-most
important figure of merit is one that shows how much out-
put to expect from a servomotor for the longest time pe-
riod while remaining compliant with UL 1446. A hot-spot
temperature safety margin provides this kind of feedback.
So far, a 50°C margin is the highest value that I’ve been
able to find. MD

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JUNE 24, 2010 MACHINE Design.com 53
    

    
 



   

   
 


   


   
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RS# 142
 MOTION
Extreme
force,
deft
touch
The Innkeeper tester exerts
multidirectional forces on an
automotive wheel while it spins
inside a rotating drum. A PC
provides overall control and data
acquisition, but a hydraulic motion
controller positions actuators and
controls output forces.
WHAT’S THIS?
When you see a code like this, take
a photo of it with your smart phone
(iPhone 3G-S gives best results) and,
using software from www.neoreader.
com, you will be connected to relevant
content on machinedesign.com
Authored by:
Bill Savela
Delta Computer Systems Inc.
Battle Ground, Wash.
Edited by Kenneth J. Korane
ken.korane@penton.com
Key points:
t

(PPE
FMFDUSPIZESBVMJD
NPUJPO

controllers close control loops an
order of magnitude faster than PCs.
t

"EWBODFE
DPOUSPMMFST
USBOTJUJPO

smoothly from position to force
control, something difficult to do with
general-purpose computers.
Resources:
Delta Computer Systems, www.
deltamotion.com
Emprise Corp., www.emprise-usa.com
Innkeeper LLC, www.innkeeperllc.com
Microsoft, www.microsoft.com
National Instruments, www.ni.com
Combining
hydraulics and a
PC with the right
motion controller
ensures testing
applications
measure up.
Hydraulics is the technology of choice for moving or lifting heavy loads
or exerting precisely controlled forces. But one of the fastest-growing
areas for hydraulics is in materials and structural test equipment.
With proper controls, hydraulic actuators can apply and hold exact-
ing forces on an object. And they can generate varying load cycles that
simulate a lifetime of real-world stresses and wear in an accelerated
time span. Aerospace and automotive-equipment manufacturers are
among the early adopters who are reaping the benefits.
PCs versus motion controllers
Personal computers, with their ability to collect, display, and archive
information, have become the de facto standard computing platforms
for testing and data acquisition. Besides the fact that PC hardware pro-
vides the highest level of computing performance per dollar invested, a
wide range of readily available software has made it relatively quick and
JUNE 24, 2010 MACHINE Design.com 55
 MOTION
The automotive wheel-tester operator screen shows
how LabView software displays data from the Delta
RMC motion controller. RMCLink software enables
direct communication via Ethernet between the
controller and PC.
easy to develop powerful test systems.
Software packages such as LabView from National In-
struments and Visual Basic and Visual C++ from Micro-
soft let test engineers build virtual models of test equip-
ment on screen, collect data from actual tests, display
results in tables, graphs, and charts, and save the informa-
tion locally or transfer it via a network for analysis and
storage elsewhere.
PCs, with their flexibility and intuitive human inter-
faces, are seeing wider use as alternatives to traditional
PLC/HMI systems. But PCs by themselves are not ideal
for high-performance, closed-loop control. The Windows
operating system that is fine for displaying visuals and
processing data cannot guarantee predictable responses to
high-speed sensor feedback. As a result, hydraulic systems
typically require separate closed-loop motion controllers
along with a PC.
Closed-loop electrohydraulic motion controllers con-
nect to sensors such as position, force, and pressure trans-
ducers, and can drive proportional servovalves. The best
controllers close the control loop (that is, receive inputs,
make controlling decisions, and generate control outputs)
in 1 msec or less — typically an order of magnitude faster
than a PC or PLC alone can respond.
Even with slow-moving actuators, it pays to use spe-
cial-purpose electrohydraulic controllers. That’s because
hydraulic motion control typically involves nonlinear re-
lationships between inputs and outputs, so setting up and
tuning control loops is much easier using controllers spe-
cifically designed for the task.
56 MACHINE Design.com JUNE 24, 2010
Advanced controllers can also
transition smoothly from accu-
rately positioning a hydraulic ac-
tuator to controlling the force it ap-
plies — something difficult to do
with general-purpose computers
without jumps or discontinuities
in the motion. Hydraulic motion
controllers use special prepro-
grammed functions to smoothly
vary accelerations and decelera-
tions, ultimately permitting faster
operating speeds while extending
machine life.
The latest electrohydraulic
motion controllers also provide
straightforward interfaces to stan-
dard communications networks.
Most support a range of industrial
fieldbuses, with the most ubiqui-
tous interface being Ethernet. Us-
ing EtherNet/IP, a PC can down-
load motion parameters into the
controller and read the results of motion steps. It’s even
possible for production-control personnel to monitor pro-
cesses remotely via an Internet or intranet connection to
the machine.
Electrohydraulics in action
One example of electrohydraulics used in R&D in-
volves a hydraulic biaxial wheel tester interfaced to a PC
for control and data acquisition. The controls, developed
by Innkeeper LLC of Redford, Mich., command hydraulic
actuators to exert forces along two axes on a spinning au-
tomotive wheel to stress and test its mechanical structure.
An image of the PC screen shows how an intuitive visual
interface, in this case developed using LabView, lets engi-
neers set motion parameters, initiate action, and display
results.
Linear-variable-differential transformers (LVDTs) con-
nected to the cylinders send position information to the
motion controller, while load cells provide data on the
force applied by the hydraulic actuators. In the motion
controller, closed-loop control algorithms process posi-
tion and force inputs as feedback and generate a variable-
voltage control output to drive the proportional valves.
The controller relies on position feedback to properly
orient the wheel in the drum in which it spins, and then
switches to force feedback to ensure hydraulic axes apply
the correct force throughout the test.
Another example involves closed-loop hydraulic con-
trol in a test rig developed by Emprise Corp. of Kennesaw,
Ga. It measures the strength and integrity of ordnance
latches on the U.S. Air Force’s new F-35 Joint Strike Fighter.
A six-axis hydraulic system exerts stresses that mimic
those the latches would experience during high-speed
aircraft maneuvers. A PC handles the HMI and sequences
testing operations, collects data, and communicates with
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 MOTION

the motion controller via Ethernet.

For each load step, application software
reads a load-spectrum file that specifies the
forces required of each actuator. Calculated
setpoints are transmitted from the LabView
program to the controller which, in turn,
actuates a hydraulic servovalve mounted on
each cylinder.
Load cells on the hydraulic actuators
measure forces and provide feedback to both
the NI hardware and controller. Though the
actuators actual displacements are negli-
gible, pressure on the latches ramps up at
approximately 3,000 psi/sec. The controller,
in this case a Delta RMC150, ensures precise
results because its control loops run as fast
Cylinder
as once per millisecond.
Each load step takes about a second, and Load cell
simulating a lifetime of operation requires
more than 1 million load points. Actual
tests last several life cycles. The durability
test generates cyclic fatigue data at all load
Load cell
points, which can be converted into Excel
spreadsheets for analysis and archiving. Cylinder
Selecting EH controllers
Test applications such as these often in-
volve repetitive stress cycles. A controller
that supports direct execution of repetitive
motion operations makes it quick and easy
to set up testing profiles. For example, Delta
Computer Systems’ RMC family of con-
Load cells attached to hydraulic cylinders provide force feedback
trollers can produce precise cyclic motion on Emprise equipment for testing Joint Strike Fighter ordnance
sequences such as trapezoidal profiles, ramp latches. A PC running LabView software connects to a Delta RMC 150
up/down profiles, and sine waves. The con- electrohydraulic motion controller, which can control up to eight motion
trollers can also generate complex, repetitive axes simultaneously.
profiles using spline functions to connect
target points in a motion sequence.
As both the Innkeeper and Emprise examples point Direct connection is via serial bus or Ethernet.
out, another aspect of complex tests is the need to simul- It also helps if the motion-control software includes
taneously coordinate several hydraulic axes. It’s often not full-function example projects (ideally, embedded in free
possible to simulate real-world stresses accurately without software downloads) for many programming languages.
submitting a device under test to 3D motion. Therefore, These ready-to-use examples illustrate concepts such as
test-system designers should select electrohydraulic con- reading positions and plots and issuing commands.
trollers that synchronize the motion of multiple axes. This Tuning wizards in the software are another major time-
can take many different forms, from simply moving sev- saver. They simplify and accelerate motion-axis tuning by
eral axes in lock step, to “gearing” or “camming” functions developing mathematical models of the system. This, in
that express the motion of one axis via a mathematical re- turn, lets test-system designers tune control parameters by
lationship to another axis or an outside stimulus. merely using a visual “point-and-click” interface.
These two examples also demonstrate a key factor Whether you’re more familiar with controls or fluid
that contributes to building good test platforms: The power, there’s no question that combining PCs with hydrau-
ability to work seamlessly with popular data acquisi- lics can result in best-in-class materials testing equipment. As
tion and control software programs hosted on PCs. The the above examples show, PC software can give “personality”
motion controller’s software should give direct access to hydraulics, making it easy to visualize test processes and
to and from Windows-based PCs running data-acquisi- share and archive results. Likewise, hydraulics, together with
tion software. Delta Computer Systems’ RMCLink soft- an electrohydraulic motion controller that connects easily,
ware, for example, lets PC applications read and write controls reliably, and can be tuned to produce precise outputs,
registers in the controller and issue motion commands. gives “muscle” to PC-based test systems. MD

58 MACHINE Design.com JUNE 24, 2010














 



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RS# 144 

 New Questions Just Added
Every two weeks our editors add new questions in our eight
categories of THE WORLD’S SMARTEST DESIGN ENGINEER. Test
and challenge yourself and colleagues in the online game that is
sweeping the industry. Check the scoreboard for current leaders
and check out our partners in the game.

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RS# 125
60 MACHINE Design.com JUNE 24, 2010
SMALL, MIGHTY AND AFFORDABLE I/O CONTROLLERS

THE RIO POCKET PLC—packed with analog and digital

RIO Pocket PLC
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All the Bells and Whistles are Standard:

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View free web tutorials and specs at www.galilmc.com/pocketplc_md or call 800-377-6329 to speak to an Application Engineer

RS# 145
 FE UPDATE
Designer’s guide to advanced vibration analysis
Many readers probably think
“black magic” describes the
math involved in finding the
dynamic response of a struc-
ture from random excitation.
When can you be sure you
have jumped through all the
necessary “hoops and widgets”
to generate a solution? Before
you tackle advanced vibration
analysis, it helps to know how
to estimate resonant or natural
vibration frequencies and plot
animated mode shapes.
Confidence comes from prac-
tice. First solve sample problems
with known solutions you can
work through using hand cal-
culations. In the case of simple
static analysis or resonant-vibra-
tion problems, you can typically
refer to “cookbook” equations in
engineering text books to build
sample FEA models.
Recall that free resonant-
vibration problems necessitate
obtaining the natural frequen-
cies or eigenvalues of deform-
able bodies vibrating about
the position of equilibrium and
the associated mode shapes
or eigenvectors. When damp-
ing is small, resonant-vibration
frequencies are approximately
equal to “free-vibration fre-
quencies.” It can be useful to
determine these frequencies to
help estimate a design’s antici-
pated service life. Also, data from
resonant-vibration analysis can
provide the input for random vi-
bration studies.
Under the hood, the FEA soft-
ware produces a solution output
file that consists of a table con-
taining a certain set number of
resonant-vibration frequencies,
each of which has a correspond-
WHAT’S THIS?
When you see a code like this, take
a photo of it with your smart phone
(iPhone 3G-S gives best results) and,
using software from www.neoreader.
com, you will be connected to relevant
content on machinedesign.com
62 MACHINE Design.com
Sample random- David R. Dearth
m2 President
vibration Applied Analysis & Technology
problem Huntington Beach, Calif.
k2 c2
Resources:
AppliedAT@aol.com or
www.AppliedAnalysisAndTech.com
m1 +y
+x Edited by Leslie Gordon
+z
k1 c1
the structure move rela-
ÿ (t)= f (Ω) tive to others, but the ac-
Base input excitation tual displacement values
Two-degree-of-freedom (2 DOF) are still unknown.
spring mass system with base After you perform
input random-vibration excitation. the resonant-vibration
y2 analysis, the next step is
Next month’s column to estimate how a struc-
will illustrate the
use of the normal
ture responds to dynamic
modes and the Mile’s k 2
( y 2
 y1
) · ·
c1 ( y2 y1) loading from vibration
equation approaches inputs. Dynamic loading
to approximate the y1 is either harmonic or ran-
response caused by dom. Harmonic vibration
a random-vibration subjects the structure to
input on a simple two input loading, gs, at spe-
degree-of-freedom k1 y1 c1 y· 1 cific sinusoidal frequen-
(2 DOF) spring-mass cies; for example, 2-gs
system such as this.
m1 and m2 represent
∑ Fy = m · a base excitation at 115 Hz.
the individual
Free-body diagrams Random vibration, on
concentrated mass the other hand, excites
2
— units are lb-sec /in.; k1 and k2 represent the spring all resonant frequencies
rate or stiffness — units are lb/in.; c1 and c2 represent simultaneously over a
the damping — units are lb-sec/in.; and y1(t) and y2(t) bandwidth range, say 5 to
represent the displacement of each mass, m1 and m2, as a 2,000 Hz. Input excitation
function of time — units are inches. levels are typically de-
fined in terms of power-
ing mode shape. The software spectral density (PSD) curves over
stores the mode shapes and their a range of frequencies.
stresses as a series of “load cases” Some FEA software performs
or “solution sets.” Animation rou- random analysis by essentially
tines found in most FEA software “shaking” the entire model as
display the mode shapes as deflec- though it is fastened at its support
tions at each particular resonant points to a shaker table. Sometime
frequency. this approach is referred to as
Note that because resonant- “base excitation.” To determine the
vibration problems do not account response at explicit points in the
for excitation, the structure with regions other than
magnitudes of the de- support points attached to the
flected shapes at this shaker, it is necessary to use com-
point are for reference prehensive analysis codes such as
only. The information MSC.Nastran.
is valid in the sense The random-analysis software
that it tells you how searches the table of resonant-
much some areas of vibration frequencies for those
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RS# 147 RS# 148

RS# 146
 FE UPDATE

that match the inputs.

When the software finds
free-vibration frequen-
cies that match or closely
match the input frequency,
it computes the response
or amplification caused by
the external excitation.
For harmonic inputs, the
software processes the FEA
model using an external
excitation force at the reso-
nant frequency associated
with the deflected-mode
shape shown on the com-
puter screen. This approach
quantifies the precise mag-
nitude of displacements and
stresses at a particular reso-
nant-vibration frequency to
an external excitation.
Random-vibration analy-
ses define external loading
in terms of PSD inputs (g 2)
as a function of frequency.
The units for the input, g 2/Hz,
cover the bandwidth of inter-
est. The software calculates
an overall root-mean-squared
average, depending on the The image shows sample hand calculation of
level of participation each a free (natural) resonant-vibration problem.
resonant mode plays on the
structure’s response. The solution but it proves logistically
magnitude of the displacements difficult to manage for most soft-
and stresses now take on a realistic ware. The normal modes method
meaning. In fact, both random and suits large, complex, multidegree
harmonic analyses provide results of freedom systems (>100 DOFs)
that correlate closely to those of that are typically analyzed using
physical tests. FEA techniques. This approach
The know-how to perform introduces a transformation of
dynamic-vibration analyses also coordinate approximations to de-
comes from the process of hand couple the differential equations
calculating sample problems. The of motion and make the problem
sample problems should let you easier to solve.
check results against a known the- The Mile’s Equation approach
oretical solution. Keep in mind that involves FEA models of large com-
the hoops and widgets you jump plicated systems that contain an ex-
through to solve even the simplest cessively large number of DOFs. The
FEA models are the same ones you approach is based on statistical anal-
will encounter when solving real yses of induced acceleration spectra
problems using a computer. The with a three-sigma distribution. The
only difference is usually the com- software computes an equivalent
plexity of the geometry. g loading using the PSD criteria
There are generally three ways at the resonant frequency in each
to address dynamic responses to orthogonal direction of interest.
finite-element models (FEMs) from This equivalent g load is sometimes
random excitation. The direct ap- referred to as the random-vibration
proach provides the most exact load factor (RVLF). MD
RS# 149
64 MACHINE Design.com JUNE 24, 2010
RS# 150

RS# 151

RS# 152
 SPOTLIGHT CABLE & CABLE CARRIERS
Chipproof cable carrier
The RX energy tube is nearly 100% chip-
proof and airtight. Debris, such as metal or
wood chips, simply falls off the carrier’s spe-
cially designed, smooth domed outer contour.
The tube is easily opened using a screwdriver to unscrew bolts on the outer radius of each link. A
large interior space holds cables and hoses, which can be separated using vertical separators. A hori-
zontal shelf safely routes cables and hoses, preventing abrasion.
The tube is available with an interior height up to 2.20 in., making it suitable for short, self-support-
ing lengths inside tooling machines. The chipproof carrier is also designed for use in reverse-bending-
radius (RBR) applications. A high-temperature version, made from igumid HT, a high-temperature
material, is available. With this version, even red-hot chips to 1,562°F fall off the tube rather than melt
onto it.
igus Inc., Box 14349, East Providence, RI 02914, (800) 521-2747, www.igus.com RS# 446

Ethernet patch cables Cable-entry system

The straight and crossover Cat5e Ethernet patch cables,
in eight colors and 3 to 50-ft lengths, support up to
1,000 Mbps. The cables are designed to reduce the EMI ef-
fects by use of a single metal foil shield wrapped around
the entire set of four twisted shielded pairs. The RJ45 con-
nectors are also shielded against electrical interference.
The 350-MHz cables exceed all Cat5e TIA/EIA standards,
and reduce
both imped-
ance and struc-
tural return
loss (SRL), com-
pared to stan-
dard 100-MHz
cables.
Automation- Cables can be mounted up to 70% faster
Direct, 3505 with the Skintop Click cable-entry sys-
Hutchinson tem. With the system’s latching design,
Rd., Cumming, there are no threads to cut, locknuts to
GA 30040, screw in place, and installation is pos-
(770) 889-2858, sible without ever opening an enclosure.
www.automa- Simply click the gland in, turn left, turn
tiondirect.com/ right, and the gland is fixed, centered,
ethernet strain relieved to EN 50262, and sealed
RS# 447 to the protection class IP68. No special
mounting tools, additional clamping
WHAT’S THIS? rings, or locknuts are needed.
When you see a code like this, take Lapp USA Inc., 29 Hanover Rd., Florham
a photo of it with your smart phone Park, NJ 07932, (800)774-3539, www.
(iPhone 3G-S gives best results) and,
using software from www.neoreader.
lappusa.com
com, you will be connected to relevant RS# 448
content on machinedesign.com

66 MACHINE Design.com JUNE 24, 2010

 formation via
Request free in ice Web site at
our Reader Serv
desi gn.com/rsc
w w w.machine

Wind-turbine cables
The Resilience Cables, for wind-turbine ap-
plications, are UL and Wind Turbine Tray Cable
(WTTC) approved and NFPA 79 (12.2.2) rated for
constant flex and high performance. The cables
are designed for low-voltage control, data, com-
munication, and exposed-run power applications
in wind-turbine nacelles. They have a torsional
and bend high-flex life, operate
at temperatures as low as –40°C,
are oil resistant (Oil Res I and II),
and FT4 flame rated. Six to 18-awg
cable comes in AWM 300-V, 600-V
and WTTC-rated 1,000-V configu-
rations with options for customiza-
tion.
Northwire Inc., 110 Prospect Way,
Osceola, WI 54020, (800) 468-1516,
www.northwire.com/resilience
RS# 449

Miniature
trunk cable
The Madison Cat 5E Type minia-
ture trunk cable is for the telecom-
munication and data-commu-
nication industries. Available in
shielded or unshielded configura-
tions, the cable eliminates conges-
tion by offering a flexible, easy-to-
route interconnection. The cable’s
reduced diameter improves rout-
ing within, or between, cabinets
Experience Matters
Designing and manufacturing pumps and compressors for original
and frames. Additional benefits equipment manufacturers for over 40 years, Thomas boasts a base
of air moving knowledge and experience few companies in the world
can match. This, coupled with a large internationally grounded
engineering staff, and a global network of manufacturing, sales and
distribution centers, Thomas stands alone in providing innovative
pump and compressor solutions for OEMs worldwide.
For more information, visit gd-thomas.com

include reduced weight, improved

cabinet/frame airflow, and easier
handling and routing. The mul-
tipair cables include a variety of
pair-counts and awg sizes.
Tyco Electronics Corp., 1050
Westlakes Dr., Berwyn, PA 19312,
(610) 893-9800, www.tycoelectron- PUMP AND COMPRESSOR SOLUTIONS FOR OEMS WORLDWIDE
ics.com RS# 450
RS# 153
JUNE 24, 2010 MACHINE Design.com 67
 MOTION PRODUCTS
Guided-motion
air cylinders
A new family of compact guided-
motion air cylinders, with extended
load-carrying capabilities, feature twin
guide shafts for precise, nonrotat-
ing positioning. Additional features
include choice of sleeve or ball bear-
ings; four mounting methods; dowel-
pin holes on mounting surfaces; no
lubrication necessary; and magnetic
pistons are standard; 12 to 63-mm
bores; and strokes to 100 mm. Catalog
#FGM-10.
Fabco-Air Inc., 3716 N.E. 49th Ave.,
Gainesville, FL 32609, (352) 373-3578,
www.fabco-air.com RS# 465


 


RS# 155
68 MACHINE Design.com JUNE 24, 2010
DIN-rail power supply
The DR Series DIN-rail power
supplies provide a dc-power
source for industrial-control
systems (PLCs, stepper drives, sensors,
switches). Designed for use in harsh indus-
trial environments, the CE-marked device
features a universal ac input (85 to 264 Vac), dc-
compatible input (120 to 370 Vdc), short-circuit/
overload/overvoltage/overtemperature protections,
built-in EMI filter, and low ripple noise, as well as an LED power indicator.
Omega Engineering Inc., One Omega Dr., Stamford, CT 06907, (203) 359-
1660, www.omega.com RS# 466
Linear actuators
The Series A linear actuators can be configured for stroke lengths
up to 16 in., for forces up to 500 lb or speeds up to 20 ips. Add
on equipment includes brakes, position-feedback devices, and
mounting hardware. The actuators are suitable for use in satellites,
unmanned vehicles, robotics, factory automation, and power-as-
sisted prosthetic devices.
Ultra Motion LLC, 22355 Route 48, #21, Cutchogue, NY 11935,
(631) 298-9179, www.ultramotion.com
RS # 467
Seal it tight.
Our inflatable seals are pressurized with
air to close the gap between two surfaces.
Pneuma-Seal® is the perfect solution for
sliding , hinged, or large fabricated doors,
or where rapid sealing and unsealing is
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$



for Medical sterilizers
$

for Nuclear power
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tel 800.431.0101
fax 845.855.1139
pneuma-seal.com
RS# 154
 n via
f r e e in formatio
b s ite at
t
Requesder Service We
o u r Re a .com/rs
c
esign
a chined
w w w.m Smart Ethernet drives Safety circuit for servodrives
A new generation of smart drives feature an Ethernet in- A new safety circuit on the ES and RS
terface compatible with the Powerlink motion-control standard. The Mint models of PositionServo drives disables
Lite capability is available on the Micro- output to the motor so the drive cannot
Flex e100 and MotiFlex e100 single and generate torque in
three-phase drive ranges, in power rat- the motor. Called
ings up to 33.5 A. The drives may be used “Safe Standstill,”
to control rotary and linear servomotors, in the event of
linear motors, closed-loop vector motors, a single-fault
and in V/Hz control modes. (single-com-
Mint Lite supports a range of basic ponent) failure,
motion programming requirements in- the ISO 13849-1
cluding performing relative and absolute safety circuit
moves, S-ramp profiles, jog and homing will still function
movements, changing target positions and disable the
on the fly, registration moves, and react- drive.
ing to real-time trigger events. It allows Lenze-AC
stand-alone drives to handle cutting or Tech Corp.,
feeding to length, indexing axes, simple 630 Douglas St.,
pick-and-place motion, and machine Uxbridge, MA
adjustments such as changing guides or 01569, (508)
backstops to reconfigure machinery for 278-9100, www.
new batches. lenze-actech.
Baldor Electric Co., Box 2400, Fort Smith, AR 72901, (479) 646-4711, www. com
baldor.com/products/servodrives/overview.asp RS# 469
RS# 468

RS# 156
JUNE 24, 2010 MACHINE Design.com 69
MOTION PRODUCTS

Flat dc micromotors diameter version offers 3.8 mNm.

Two new brushless flat-dc micromo- The output torque can be increased
tors provide diameters of 15 and up to 30 or 100 mNm with gearmo-
26 mm. The precious-metal commu- tor versions of the new drives.
tated micromotors have nominal volt- Electronic commutation is
ages of 6 or 12 V. The 15-mm-diameter based on three digital Hall sen-
model provides a 0.6-mNm continu- sors. The cog-free motors feature
smooth operation, high efficiency, and long operational life. The gear-
ous output torque, while the 26-mm-
motor versions come with reduction
ratios of 6 to 324:1 (Series 15…B) or 8
to 1257:1 (Series 26…B). The 26-mm
motor has an optional integrated
"--
4&/4034n speed controller.
The micro motors are suitable for
SUPERTEAM portable devices or continuous-duty
operations such as those in laboratory
XXXBMMTFOTPSTDPN and medical-device applications.
MICROMO, 14881 Evergreen Ave.,
Clearwater, FL 33762, (800) 807-9166,
Amplified Very Low Pressure Sensor www.micromo.com
Includes a PCB mountable feature with dual pressure ports. RS# 470
Pressure ranges are available from 1/4 to 30 inch H2O full
scale. Offset voltage errors are significantly reduced by
electrical cross coupling technology.
Stepper-motor
www.allsensors.com/mad/amp.htm linear actuator
The 36-mm G4 37000 Series Canstack
stepper motor linear actuator features
Amplified Mini Low Pressure Sensor optimized stator-tooth geometry,
high-energy neodymium magnets,
Available in pressure ranges of 1, 5, 10, 20, and 30 inch H2O full
scale. Output is available as a calibrated amplified signal with
superior output offset characteristics.
www.allsensors.com/mad/mini.htm

Surface Mount Basic Pressure Sensor

Surface mount basic pressure sensors provide a low-cost solu-
tion in a small footprint. Pressure ranges include 1, 15, 30, and
100 PSI. In addition, an unprecedented 10 inch device is also an oversized output spline, custom-
available with position sensitivity better than 0.03% full scale. engineered plastics, and larger ball
www.allsensors.com/mad/smt.htm bearings for greater rotor support and
high axial loading capability.
The unit’s high linear force-to-size
ratio is suitable for precision linear
Millivolt Low Pressure Sensor
motion in applications such as medi-
Available in pressure ranges of 1, 5, 10, 20, and 30 inch H2O cal equipment, bar-code scanning de-
full scale. Millivolt output is temperature compensated and vices, printing equipment, laboratory
calibrated to zero. www.allsensors.com/mad/mv.htm instrumentation, and mechanisms
requiring high force.
Three configurations are available:
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RS# 471
RS# 157
70 MACHINE Design.com JUNE 24, 2010
Posts and consuming only 375 mA of 25-mm long. Easy mounting is ac-
clamps current. The totally enclosed complished with four “face-mount”
brake mounts to the rear of M5 threaded holes.
New posts
the motor, creating an IP54- Midwest Motion Products, 10761
and clamps
sealed assembly. The brake Ahern Ave. SE, Watertown, MN 55388,
for the auto-
measures just 2.25 × 9.0-in. (952) 955-2626, www.midwestmotion.
mation and
long, and has a keyed output com
motion-con-
shaft of 12-mm diameter × RS# 473
trol industries offer precise, accurate
positioning of mounted devices. The
devices securely mount equipment
such as CCD cameras and photoelec-
tric sensors, used by machine design-
ers and builders of automated assem-
bly, inspection, and testing systems.
Features include 304 stainless-steel
stand posts, which with the help of Components
Without
a strut clamp, can adjust or reposi-
tion for quick changeover. Diameters
range from 10 to 25 mm and overall
length ranges from 100 to 300 mm.
Photoelectric sensor post clamps mount Don’t let your packaging
Compromise
directly to commonly specified pho-
toelectric sensors. The clamps are equipment components
available in 304 stainless steel or 1018 compromise your bottom
carbon steel with either black oxide or
electroless nickel plating. A turning- line.
prevention feature on vertical-tapped With our wide range of
post clamps allows adjustments in
Z direction with a simple turn of the GERWAH® couplings such
knob, while preventing movement
as magnetic couplings,
in a rotary direction. Accompanying
posts (unscaled) are available in 304 metal bellows couplings,
stainless steel and in 1018 carbon
steel with electroless nickel plating. servo-insert couplings,
Misumi USA Inc., 1717 Penny Lane, line shafts, RING-flex®
Suite 200, Schaumburg, IL 60173,
(847) 843-9105, www.misumi-ec.com/ disc couplings and safety
eusaen/mech/ couplings as well as our
RS# 472
product support and engi-
Gearmotor/brake neering expertise, we’ll
The Model No. MMP-D22-376H-24V make sure we keep you
GP52-195 BR-005-IP54 dc gearmotor,
with an integral brake, features high- up and running.

For more information

on GERWAH® products,
call us today at
Partner for Performance
800-245-2580 www.ringfeder.com
efficiency planetary gearing, high-
output torque to size and weight
ratio, and low speed and noise.
The motor accepts any 24 Vdc
source, including battery power, while
RS# 158
JUNE 24, 2010 MACHINE Design.com 71
 MOTION PRODUCTS

Rod-
style
actuator with
maxon compact drive
Motor, sensor and controller in one.
reverse-parallel
motor
The all-in-one electric ICR SmartActuator (pro-
grammable digital drive, servomotor, and actuator) is
a linear rod-style actuator with a reverse-parallel-mounted
motor that delivers up to 720 lb of force for speeds to 5 ips
or 150 lb of thrust at speeds to 23 ips. The ICR is stroke-con-
figurable up to 24 in. The motor mounts on top, instead of
in-line, to reduce overall actuator length. An ICR Plus version
provides programmability, communication options, and
other features.
The unit’s steel-reinforced HTD belt transfers force from
the motor to the actuator. It can be ordered in either 1:1 or
2:1 drive ratios to deliver either high speed or high power.
Also available is a rear-clevis mount option, which lets
the actuator pivot freely on its mounting, replacing exist-
ing pneumatic or hydraulic cylinders typically used in this
mounting configuration.
The SmartActuator ICR operates on either 24 or 48 Vdc
and accepts signals from PLCs, sensors, network communi-
cation, or an existing motion controller.
Tolomatic, 3800 County Rd. 116, Hamel, MN 55340, (800)
maxon compact drive 328-2174, www.tolomatic.com
RS# 474

Three in one. Serial communication system

The Motionnet serial-communication networking system
provides I/O and motor control, CPU emulation,
and message communication, and
reduces wiring. The system
transfers 4 bytes of data in
15.1 μsec using cyclical com-
munication to control both
input and output.
The heart of the system is
a 64-pin QFP G9001A chip that
controls up to 64 local devices.
When it concerns compact drive intelligence, maxon com- The chip consists of 256 bytes of
pact drives are called for: motor, sensor and controller are all RAM for I/O control and 512 bytes
integrated in an aluminum case. Link the drive through the
of RAM for data. It supports a maximum
CANopen network and solve even complex tasks with the
programming tool included, "EPOS Studio", in no time at all. 256 bytes of data communication within local data devices.
The chip’s maximum communication speed is 20 Mbps.
maxon motor is the world’s leading supplier of high-precision
Two local devices connect to the G9001A chip to let users
drives and systems of up to 500 watts power output. Rely connect up to 64 devices to each chip or a combination of
on the quality of the highly specialized solutions which we up to 64 devices to both chips.
develop with and for you. www.maxonmotorusa.com An I/O device features four 8-bit ports/device, contains
a tolerant buffer, and makes use of cyclic transfer. Another
motor-control device controls a single-axis stepper or ser-
vomotor based on instructions from a center device with a
maximum output of 6.5 Mpps.
Nippon Pulse America Inc., 4 Corporate Dr., Radford, VA
24141, (540) 633-1677, www.nipponpulse.com
RS# 475
RS# 159
72 MACHINE Design.com JUNE 24, 2010
Piezomotor steady at rest, with no energy consumption and heat genera-
rotary stage tion. A directly coupled precision optical encoder provides
The M-660 is a new phase-lag-free, backlash-free feedback to the servo controller.
0.6-in. profile, direct- The stage’s compact design minimizes mass and inertia
driven, high-speed for precise bidirectional speed and position control, as well as
rotary stage based on high-speed motion contouring.
the company’s PILine Physik Instrumente LP, 16 Albert St., Auburn, MA 01501,
piezomotor drive (508) 832-3456, www.pi-usa.us RS# 476
technology. The stage
reaches speeds of 720°/sec and resolu-
tion to 40 μrad (8 arcsec). The unit’s self-
locking ceramic drive holds the position

New features for

motion cards
The Prodigy family of motion-control cards
now include user-accessible onboard non-
volatile memory (NVRAM). This lets users
store configuration parameters, program
variables, and other data directly on the
card. Information stored in the nonvolatile Rugged
memory is not lost when power is re-
moved from the card. p
speed and
t
temp p
temperature
sensing
see

Pre-calibrated,
Pre-ccalibrated, pproven
rove solutions
The IM-600 Interconnect Module
install
install ffast
ast aand
nd pperform
perfo
erfo anywhere
speeds development of motion-control When you need rugged and reliable monitoring solutions for your toughest machine
applications by simplifying the connec- environments, go with proven, solid-state temperature transmitters and shaft tachometers
tion of various motion peripherals to from Electro-Sensors.
the Prodigy card. The module connects TT420 Temperature Transmitters:
t
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HP t
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1/8" or 1/4" NPT taps
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Pulse & Direction connector providing NPEFMT
XJUI
PS
XJUIPVU
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t
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Prodigy cards provide high-perfor- t
4JNQMF
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mance board-level motion control and The affordable, easy-to-install monitoring solution for:
support multiple motor types including dc
$POWFZPST
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t
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brush, brushless dc, step, and microstep-
'BOT
t
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ping motors. The units are available in one,
two, three, and four-axis versions. The cards
come with serial, CAN, and Ethernet com- FREE CATALOG &
munications options. APPLICATION ASSISTANCE:
Performance Motion Devices, 55 Old 1-800-328-6170
Bedford Rd., Lincoln, MA 01773, (781) www.electro-sensors.com
674-9860, http://www.pmdcorp.com/ The original machine monitoring experts
motion-control-cards/ RS# 477 ª
&-&$5304&/4034
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RS# 160
JUNE 24, 2010 MACHINE Design.com 73
MOTION PRODUCTS & LIT
Servomotors
The 1FT7 family of high-performance
servomotors provides short machine
cycles through a 30% shorter design
and 4× overload capacity over previ-
ous servos. Vibration-insulated en-
coder mounting lets users exchange
the encoder in the field in less than
RS# 161
74 MACHINE Design.com
5 min, without encoder alignment.
High-resolution encoders, currently
up to 22-bit, make these servos highly
precise.
The servomotors features Drive-
ment. The drive
CLiQ, the company’s electronic name-
reads all that data
plate and digital encoder interface
from the electronic nameplate stored
that simplifies start-up or replace-
in the encoder system, essentially
making them plug-and-play devices.
The drive automatically recognizes
the motor and optimizes the param-
eterization accordingly.
The motors are available in forced
ventilated, water-cooled types, as well
as a high dynamic design, which fea-
tures very low rotor inertia.
Siemens Industry Inc., Drive Tech-
nologies — Motion Control, 390
Kent Ave., Elk Grove Village, IL 60007,
(847) 640-1595, www.usa.siemens.
com/motioncontrol
RS# 478
Motion systems target
defense, aero
The Advanced Motion Systems for
Defense, Aerospace, and National
Security brochure covers commercial
off-the-shelf
(COTS) mo-
tion-control
components
and systems.
The 56-
page color
brochure cov-
ers advanced
single, two,
and three-
axis motion
simulators,
advanced mo-
tion simulator controls, electro-optics
(optronics) test systems, high load-
capacity linear and rotary stages, high
vacuum and clean-room-ready sys-
tems, prototype laser and microwave-
beam steering systems, solar tracking
and telescope systems, and a com-
plete section on high-performance
components that includes rotary and
linear stages and gantries.
Aerotech Inc., 101 Zeta Dr., Pitts-
burgh, PA 15238, (412) 963-7470,
www.aerotech.com/PDFfiles/
CA0410BMil_Aero.pdf RS# 479
JUNE 24, 2010
 Air Supply


*+-+

042
1
'2 
2
2  12

4+,.,!" B(!.,!" 4+,./:$ B(!./:$

555 


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Find all of your pneumatic needs under one roof at Pisco.

Choose from a complete assortment of fittings, controls,
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Competitively priced, immediately available, compact and
lightweight components. Call for more information.

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RS# 165 RS# 162

Free design guide to

fluid power motion control
[www.deltamotion.com/designguide]

by Peter Nachtwey

Get the Second Edition of this

popular, practical 64-page
application design guide.

Sixteen helpful and practical

topics including:
s#LOSED LOOP#ONTROL
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For a free copy go to www.deltamotion.com/designguide

RS# 164 RS# 163

 BUSINESS INDEX
AB Volvo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Advanced Machine & Manufacturing . . . . . 6
All Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Allen-Bradley. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Altech. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Altium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
American Business. . . . . . . . . . . . . . . . . . . . . . 27
American National Standards Institute . . 41
AndyMark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Apex Wireless Inc.. . . . . . . . . . . . . . . . . . . . . . . 30
Autodesk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2LLWP[
:0473,
0DNHPRWLRQFRQWUROGHVLJQHDVLHU2XUUDWFKHW
DUPVFOXWFKHVDQGK\GUDXOLFGHYLFHVJLYH\RX
VLPSOHZHOOHQJLQHHUHGDQGGXUDEOHVROXWLRQV
WRIXQFWLRQVVXFKDVSRVLWLRQLQJIHHGLQJ
RSHQLQJFORVLQJDQGVSHHGUHJXODWLRQ
$QGZHFDQKHOS\RXZLWK\RXUFXVWRP
GHVLJQVDVZHOO
3OHDVHFRQWDFWXVWRGLVFXVV\RXU
DSSOLFDWLRQIRUWKHQDPHRI\RXU
QHDUHVWORFDOGLVWULEXWRURU
IRUDIXOOOLQHFDWDORJ
MAKING TOUGH JOBS EASIER SINCE 1869
ZZZORZHOOFRUSFRPPGFXVWRPHUVHUYLFH#ORZHOOFRUSFRP
RS# 166
76 MACHINE Design.com JUNE 24, 2010
AutomationDirect . . . . . . . . . . . . . . . . 6, 44, 66
Avago Technologies . . . . . . . . . . . . . . . . . . . . . 6
Bal Seal Engineering Inc. . . . . . . . . . . . . . . . . 20
C&K Components. . . . . . . . . . . . . . . . . . . . . . . 27
Chevrolet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chicago Electric . . . . . . . . . . . . . . . . . . . . . . . . 23
Control Techniques . . . . . . . . . . . . . . . . . . . . . 23
Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . 28
Delphi Automotive Systems. . . . . . . . . . . . . 28
Delta Computer Systems Inc.. . . . . . . . . . . . 55
Digi-Key Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Dow Corning Solar Solutions. . . . . . . . . . . . 30
Dynaflo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
EAO Switch Corp. . . . . . . . . . . . . . . . . . . . . . . . 35
Ellsworth Adhesives . . . . . . . . . . . . . . . . . . . . 30
Emerson Network Power Connectivity
Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Emprise Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Ensinger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Exlar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
FIRST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fabrico. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fisker Automotive . . . . . . . . . . . . . . . . . . . . . . 22
Forest City Gear . . . . . . . . . . . . . . . . . . . . . . . . 80
Fraba Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fraba Posital. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Freelin-Wade . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
GKS Global Services . . . . . . . . . . . . . . . . . . . . 30
General Motors . . . . . . . . . . . . . . . . . . . . . .22, 24
Hammond Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 43
Harting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Henkel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hewlett-Packard. . . . . . . . . . . . . . . . . . . . . . . . 80
igus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42, 66
Innkeeper LLC . . . . . . . . . . . . . . . . . . . . . . . . . . 55
KNF Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Knovel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lapp USA Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Lauren Manufacturing . . . . . . . . . . . . . . . . . . 27
Lemo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Linx Technologies Inc.. . . . . . . . . . . . . . . . . . . 30
Marathon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Microsoft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Motoman Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Mouser Electronics Inc. . . . . . . . . . . . . . . . . . 27
National Fire Protection Association . . . . . 41
National Institute of Standards and
Technology . . . . . . . . . . . . . . . . . . . . . . . . . 22
National Instruments . . . . . . . . . . . . . . . .48, 55
Nippon Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Northwire Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Orbital Engine Corp. . . . . . . . . . . . . . . . . . . . . 28
PTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Parker Hannifin, Electromechanical
Automation Div. . . . . . . . . . . . . . . . . . . . . . 6
Pittsburgh Materials Technology . . . . . . . . 30
Precision Gasket Co. . . . . . . . . . . . . . . . . . . . . 27
R+W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Rock-Tenn Co. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Smalley Steel Ring . . . . . . . . . . . . . . . . . . . . . . 80
Specialty Composites Corp. . . . . . . . . . . . . . 28
Strongarm Designs Inc. . . . . . . . . . . . . . . . . . 30
Team 341: Miss Daisy . . . . . . . . . . . . . . . . . . . 42
Techno Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Thermacore Inc. . . . . . . . . . . . . . . . . . . . . . . . . 30
Tyco Electronics Corp.. . . . . . . . . . . . . . . . . . . 67
Underwriters Laboratories . . . . . . . . . . . . . . 51
Univ. of Michigan . . . . . . . . . . . . . . . . . . . . . . . 28
Vacon Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Volvo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Volvo Car Corp. . . . . . . . . . . . . . . . . . . . . . . . . . 79
W. L. Gore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wieland Electric GmbH . . . . . . . . . . . . . . . . . 18
Wittenstein. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Yaskawa America Inc. . . . . . . . . . . . . . . . . . . . 30
Yaskawa Electric America Inc. . . . . . . . . . . . 30
This index includes all significant references to
parent companies mentioned in feature editorial
material within this issue of MACHINE DESIGN. It
doesn’t cite companies listed solely in the Products
and Lit Section. Page numbers listed refer to the
pages where the articles begin.
ADVERTISER INDEX 158 . . . . . Ringfeder Power Transmission 127 . . . . . Smalley Steel Ring Company . . . 30
USA Corp. . . . . . . . . . . . . . . . . . . . . . 71
125 . . . . . Steinmeyer, Inc.. . . . . . . . . . . . . . . . 60
. . . . . . . . . Rino Mechanical Components Inc 28
RS# . . COMPANY . . . . . . . . PAGE 128 . . . . . Taylor Devices Inc. . . . . . . . . . . . . . 31
117 . . . . . Rollon. . . . . . . . . . . . . . . . . . . . . . . . . 20
130 . . . . . ACE Controls, Inc. . . . . . . . . . . . . . . 33 153 . . . . . Thomas Division . . . . . . . . . . . . . . 67
149 . . . . . Rotor Clip Co . . . . . . . . . . . . . . . . . . 64
113 . . . . . Aerotech, Inc.. . . . . . . . . . . . . . . . . . 15 171 . . . . . Trim-Lok Inc. . . . . . . . . . . . . . . . . . . 80
155 . . . . . Santest Co Ltd . . . . . . . . . . . . . . . . . 68
141 . . . . . Airpot Corp/airpel . . . . . . . . . . 52-53 110 . . . . . Turck Incorporated . . . . . . . . . . . . 12
148 . . . . . Seal Master Corporation . . . . . . . 63
168 . . . . . All Motion, Inc. . . . . . . . . . . . . . . . . 78 163 . . . . . Ultra Motion Company. . . . . . . . . 75
151 . . . . . Sepac . . . . . . . . . . . . . . . . . . . . . . . . . 65
157 . . . . . All Sensors . . . . . . . . . . . . . . . . . . . . 70 133 . . . . . W L Gore & Associates. . . . . . . . . . 40
115 . . . . . Sew Eurodrive . . . . . . . . . . . . . . . . . 17
103 . . . . . Automation Direct. . . . . . . . . . . . . . 3 134 . . . . . W L Gore & Associates. . . . . . . . . . 41
152 . . . . . Shenzhen Power Motor Industrial
104 . . . . . B&R Industrial Automation . . . . . . 5 Co., Limited . . . . . . . . . . . . . . . . . . . 65 119 . . . . . World Success International Dev Ltd24
111 . . . . . Banner Engineering Corp . . . . . . 13 142 . . . . . Sierra Instruments Inc. . . . . . . . . . 54 120 . . . . . ZERO-MAX . . . . . . . . . . . . . . . . . . . . 25
138 . . . . . BEI Sensors . . . . . . . . . . . . . . . . . . . . 48
167 . . . . . Belt Technologies, Inc. . . . . . . . . . 77
122 . . . . . Bosch Rexroth . . . . . . . . . . . . . . . . . 26
107 . . . . . Clippard Instrument Laboratory, Inc. 9 STAINLESS STEEL BELTS
164 . . . . . Delta Computer Systems, Inc.. . . . 75
105 . . . . . Digi Key . . . . . . . . . . . . . . . . . . . . . . . . 7
146 . . . . . Dorner Mfg Corp . . . . . . . . . . . . . . 63
106 . . . . . Dynetic Systems . . . . . . . . . . . . . . . 8
Designed For Today’s Technology
160 . . . . . Electro Sensors . . . . . . . . . . . . . . . . 73
139 . . . . . Enfield Technologies. . . . . . . . . . . 48
118 . . . . . Festo Corporation . . . . . . . . . . . . . 21
150 . . . . . Floyd Bell Incorporated . . . . . . . . 65
135 . . . . . FRABA . . . . . . . . . . . . . . . . . . . . . . . . 44
145 . . . . . Galil Motion Control Inc. . . . . . . . 61
121 . . . . . Gortite,Div A&A Mfg Co., Inc. . . . . 26
165 . . . . . Gortrac, Div of A&A Mfg. Co., Inc. . . . 75
102 . . . . . Haydon Kerk Motion Solutions . . . 1
140 . . . . . Helical Products Company, Inc.. . . . 49
144 . . . . . Helukabel Usa Inc. . . . . . . . . . . . . . 59
132 . . . . . Igarashi Motor Sales . . . . . . . . . . . 39 Complete Conveyor Systems
136 . . . . . IKO International Inc . . . . . . . . . . . 45
124 . . . . . Intelligent Motion Systems, Inc. . . . 27
116 . . . . . Kaydon Bearings Division . . . . . . 19
147 . . . . . Kepner Products Company. . . . . 63
131 . . . . . Lapp USA . . . . . . . . . . . . . . . . . . . . . 37
126 . . . . . Leeson Electric Corp . . . . . . . . . . . 29
143 . . . . . Lin Engineering. . . . . . . . . . . . . . . . 57
166 . . . . . Lowell Corp . . . . . . . . . . . . . . . . . . . 76
137 . . . . . Lubrizol Advanced Materials. . . . 47 Automated Assembly Coated Steel Belts
123 . . . . . Master Bond, Inc. . . . . . . . . . . . . . . 26
159 . . . . . Maxon Motor USA . . . . . . . . . . . . . 72 VERSATILE OPTIONAL FEATURES
109 . . . . . Moog Components Group . . . . . 11
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173 . . . . . NB Corp . . . . . . . . . . . . . . . . . . . . . . . BC
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114 . . . . . Nexen Group Inc. . . . . . . . . . . . . . . 16
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129 . . . . . Nippon Pulse America Inc. . . . . . 32
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112 . . . . . Northwire, Inc . . . . . . . . . . . . . . . . . 14
101 . . . . . Omega Engineering Inc . . . . . . . IFC
154 . . . . . Pawling Corporation. . . . . . . . . . . 68
108 . . . . . Pentair Technical Products . . . . . 10
162 . . . . . Pisco USA, Inc. . . . . . . . . . . . . . . . . . 75
170 . . . . . Placid Industries Inc . . . . . . . . . . . 79
156 . . . . . Portescap . . . . . . . . . . . . . . . . . . . . . 69 www.BeltTechnologies.com
172 . . . . . Proto Labs, Inc. . . . . . . . . . . . . . . . IBC 





  


 






161 . . . . . R + W Couplings . . . . . . . . . . . . . . . 74 800-732-2358
169 . . . . . Raco International, L.P. . . . . . . . . . 79 Teflon is a registered trademark of DuPont. ISO 9001 Registered
RS# 167

JUNE 24, 2010 MACHINE Design.com 77

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RS# 168
78 MACHINE Design.com JUNE 24, 2010
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BACKTALK

Museum rolls into

its 15th year
The Volvo Museum, lo- Mobile training center
cated in Arendal Gothen-
burg, Sweden, recently The “Drive Ahead Road Show
celebrated its 15th anni- Tour” hit the road recently to
versary. Over that time, start a whirlwind tour across
the first-class collection the U.S. and Canada. It’s the
of historic Volvo vehicles brainchild of Vacon Inc., Me-
has grown to more than quon, Wis., a manufacturer of
100 cars, trucks, ac drives.
buses, and construc- Housed in a 53-ft, double-
tion vehicles, as well expandable trailer, the center showcases a PC software tool
as marine and air- and 10 different product lines, including NXS Standalone,
craft engines, tech- NXP, NXC, Liquid Cooled, NX Common DC Bus, and the SE2.
nical components, Sales reps will assist customers with hands-on demonstra-
equipment, display tions of four products — the Vacon 10, Vacon 100 HVAC,
material, and any- Vacon NXS, and the Vacon X-Series. The 1,000-sq-ft space
thing else pertinent also holds two HDTV’s that will air interactive presenta-
to Volvo’s operations. tions during training sessions.
The museum is run “It’s an innovative and memorable way to serve and ed-
jointly by AB Volvo ucate our customers and distributors across the U. S. and
and the Volvo Car Canada,” says Tom Doring, Vacon’s president. Go to www.
Corp. MD driveaheadtour.com for more information. MD

RS# 169 RS# 170

JUNE 24, 2010 MACHINE Design.com 79
 BACKTALK
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80 MACHINE Design.com JUNE 24, 2010
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RS# 173