machine_design_15_august_2013.pdf
TRANSCRIPT
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HYDRAULICFLUID
Moving Toward Eco-friendly
p|37
machinedesign.com
AUGUST 15, 2013
THE IMPORTANCE OF
CUSTOM PARTS p. 20
A SMARTER WAY
TO SPECIFY
COMPOSITES p. 44
SIZING MOTORS FOR
LINEAR MOTION p. 50
BY ENGINEERS FOR ENGINEERS
A Penton Publication
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YA S K AWA A M E R I C A , I N C .
D R I V E S & M O T I O N D I V I S I O N
1 - 8 0 0 -YA S K AWA YA S K AWA . C O M
Follow us: For More Info:
http://Ez.com/yai513
2013 Yaskawa America Inc.
:+$7
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NEWS
20 ENGINEERS & CUSTOM COMPONENTS: A reader survey
DEPARTMENTS
4 ON MACHINEDESIGN.COM 10 LETTERS 12 WHATS INSIDE
Eco-friendly Hydraulic Shock Absorbers
A Bearing Built for Wind Turbines
33 SENSOR SENSEEncoders for safety
80 PUZZLES, MYTHS, AND CURIOSITIES
PRODUCTS
65 PRODUCT SPOTLIGHTSFluid-Power Cylinders & Valves CAD
68 NEW PRODUCTS77 DATA FILES78 CLASSIFIEDS78 AD INDEX
FEATURES
37 MAKING THE MOVE TO ECO-FRIENDLY HYDRAULIC FLUIDS
Biodegradable hydraulic uids are safer for the environment than petroleum-based uids, but they require special design considerations.
44 HOW TO AVOID OVERENGINEERING COMPOSITE PARTS
Analysis techniques help avoid a tendency for designers to overengineer composite parts.
50 HOW TO PICK MOTORS FOR LINEAR MOTION
The easiest way to design a linear-motion system is to add components one by one. Then, step-by-step calculations relate input to power dissipated moving a load in a specic amount of time.
60 FORCE SENSORS AND THEIR USES
Force sensors use load cells to weigh objects and prevent machinery from overloading.
COLUMNS
6 EDITORIALEnd-of-life blues
16 COMMENTARYFracking: Its Better Than the Alternatives
34 INTERVIEWThe Changing Role of System Integrators Tom Price
64 GOLDENSE ON R&D-PRODUCT DEVELOPMENT Innovation-enabling Tools and Software for Individuals and Product Pipelines
ON THE COVER: Photo illustration: Tony Vitolo
2 08.15.13 MACHINE DESIGN
ISSN 0024-9114
Printed in U.S.A., Copyright 2013. Penton Media, Inc. All rights reserved. MACHINE DESIGN is published semimonthly except for a single issue in January, February, April, June, July, August, and October by
Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66212.
Paid subscriptions include issues 1-16. Issue No. 17 (OEM Handbook and Supplier Directory) is available at additional cost. Rates: U.S.: one year, $139; two years, $199;. Canada/Mexico: one year, $159; two
years, $239; All other countries: one year, $199; two years, $299. Cost for back issues are U.S. $10.00 per copy plus tax, Canada $15.00 per issue plus tax, and Intl $20.00 per issue. OEM Handbook and
Supplier Directory, $50.00 plus tax. Prepaid subscription: Penton (MACHINE DESIGN), P.O. Box 2100, Skokie IL 60076-7800. Periodicals Postage Paid at Shawnee Mission, KS, and at additional mailing offices.
Can GST #R126431964. Canadian Post Publications Mail Agreement No.40612608. Canada return address: IMEX Global Solutions, P.O. Box 25542, London, Ont., N6C 6B2.
Digital subscription rates: U.S.: one year, $69; two years, $99;. Canada/Mexico: one year, $79; two years, $119; All other countries: one year, $99; two years, $149.
POSTMASTER: Send change of address notice to Customer Service, MACHINE DESIGN, P.O. Box 2100, Skokie, IL 60076-7800.
37
44
50
60
In This IssueAUGUST 15, 2013 | VOLUME 85, ISSUE 10
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FREE WEBCAST
ENHANCING MEDICAL-DEVICE PERFORMANCE VIA METAL INJECTION MOLDING
AUGUST 27, 2013 AT 2:00 P.M. ETThis presentation will acquaint medical-device designers with the metal injection-molding (MIM) manufacturing process and its capabilities. Presented by the Metal Injection Molding Assn., the Webinar will walk viewers through examples and case studies of successful applications of the technology.Get more details and register at http://machinedesign.com/learning-resources/webinars.
ENGINEERING TV
A LOOK AT GOOGLE GLASSGoogles new glasses are shaking up the concept of intercon-nectivity. They let the wearer capture images and shoot videos, search for info, and translate foreign languages all hands-free. Electronic Design Editor Bill Wong talks to app devel-oper and CEO of Pepperdeck.com and Glass Tesla about the underlying technology. View the episode at www.engineer-ingtv.com/video/A-Look-at-Google-Glass.
ACCESS HARDWARESouthco has a new Web site (www.southco.com) in eight lan-guages on its access hardware, including latches, hinges, handles, and locks. Users can find product info and compliance certifi-cates, download CAD files and catalogs, and request samples.
HEATER CATALOGWatlows new Heating Solutions catalog covers electric industrial heaters, sensors, and controllers. Content includes product specs and drawings, and a selection matrix that helps users match heater type and application. Get a copy in various formats at www.watlow.com.
TEST & MEASUREMENTAgilent Technologies Faculty Spotlight Web site features uni-versities throughout the world using the companys electronic test and measurement instrumentation in unique applications, new curriculum, research, and novel projects. Find it at www.agilent.com/find/facultyspotlight.
TYPES OF PRESSURETurck has released a new white paper, Types of Pressure: When and Why Are They Used? It explain how good mea-surement practices are essential in industrial and process automa-tion, but there are different ways to interpret measurements. The white paper discusses different types of measurements, when and why they are used, and highlights how they suit various applica-tions. Download a copy at www.askturck.com.
BEARING SELECTORThe Kaydon Bearings Web site, www.kaydonbearings.com, now has an interactive bearing selector. Users search by details such as bore size, OD, and width and results include applicable products and 2D and 3D drawing downloads. Results can be refined using Kaydons engineering software, which analyzes loads and calculates basic life and safe operating speeds.
EDITORS WEB PICKS
on
join us online
4 08.15.13 MACHINE DESIGN
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A bad choice could cost you thousands!
Look Familiar?When hot weather causes the electronics inside
a control cabinet to fail, there is a panic to get
the machinery up and running again. Th e
operator might choose to simply open the
panel door and aim a fan at the circuit boards.
In reality, the fan ends up blowing a lot of
hot, humid, dirty air at the electronics and the
cooling e ect is minimal. If the machinery
starts functioning again, the likelihood of
repeated failure is great since the environment
is still hot (and threatens permanent damage
to the circuit boards). Worse yet, that open
panel door is an OSHA violation that presents
a shock hazard to personnel.
The Real Solution!Stop electronic downtime with an EXAIR
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Jeff Hauck, Lasercraft Inc. Cincinnati OH
It took us three days to get a replacement computer cabinet and we didnt
want to risk another heat failure. Fans werent an option since they would
just blow around a lot of hot air. Freon-type air conditioners like those on
some of our other machines were a constant maintenance project of their
own. We purchased EXAIRs Model 4330 NEMA 12 Cabinet Cooler
System since it was easy to install and requires no maintenance. @exair
The only compressed air powered cooler that is CE compliant!
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NEMA 4 and 4XCabinet Coolers
NEMA 4 and 4X Cabinet Coolers for large heat loads up to 5,600 Btu/hr. Th ey are ideal for PLCs and modular controls.
Enclosure remains dust-tight, oil-tight and splash resistant
Suitable for wet locations where coolant spray or hose down can occur
Type 316 Stainless Steel Cabinet Coolers
Type 316 Stainless Steel Cabinet Coolers for NEMA 4X applications are available for heat loads up to 5,600 Btu/hr.
Resists harsh environments not suitable for Type 303/304
Ideal for food and chemical processing, pharmaceutical, foundries, heat treating and other corrosive environments
Mini NEMA 12, 4, and 4X Cabinet Coolers
Th e mini NEMA 12, 4 and 4X Cabinet Coolers for small heat loads upto 550 Btu/hr. are ideal for control panels, relayboxes, laser housings,and electronic scales.
Measures 5" (127mm) high
Mounts top, side or bottom
Enclosure remains dust-tight and oil-tight
High TemperatureCabinet Coolers
High Temperature CabinetCoolers for NEMA 12, 4 and 4X applications are available for heat loads in many capacities up to 5,600 Btu/hr.
Suitable for ambients up to 200F (93C)
Ideal for mounting near ovens, furnaces, and other hot locations
Non-Hazardous PurgeCabinet Coolers
NHP Cabinet Coolers keep a slight positive pressure on the enclosure to keep dirt from entering through small holes or conduits. For use in non-hazardous locations.
Uses only 1 SCFM inpurge mode
For heat loads up to 5,600 Btu/hr.
NEMA 12, 4 and 4X
NEMA 12Cabinet Coolers
Th e NEMA 12 Cabinet Coolers for large heat loads up to 5,600 Btu/hr. are ideal for PLCs, line control cabinets, CCTV cameras, modular control centers, etc.
Measures 8" (203mm) high
Mounts top, side or bottom
Enclosure remains dust-tightand oil-tight
Cabinet CoolerSIZING GUIDE
www.exair.com/45/m_szg.htm
Allow us toSize It Up
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Editorial
LELAND TESCHLER | Editor
ed occasionally find someones garbage dumped on the side
of the road back when I was growing up. That was illegal,
so wed call the cops about it. Theyd happily come out and
sort through the stuff because invariably, the dumpers were
stupid enough to leave their junk mail, complete with an address, in the discarded
trash. The scofflaws would then get a visit from a state trooper who would hand
them a citation and a stiff fine.
I bring this up because there is an intensifying debate about who should be respon-
sible for the disposal of packaging. Economists are starting to think that a system that
gives that responsibility to manufacturers makes more sense than foisting the prob-
lem off on cities and states. They argue that such a scheme would bring some sanity to
the idea of which materials are worth recycling and which are just garbage.
One problem with the existing state of affairs is that both landfills and recycling
programs are subsidized, so it is almost impossible to figure out the real economics
of either disposal method. For example, landfill space is priced below the full eco-
nomic cost of landfilling partly to discourage the kind of illegal dumping I saw as a
kid. Recycling programs typically get priced so their promoters can claim putting
plastic bottles in colored recycling bins is cheaper than throwing them in a landfill.
But its hard to really know the truth of that statement when the price of both landfill
space and recycling programs are distorted.
One economist who has studied these price distortions is Duke University profes-
sor Michael C. Munger. He points out that because it is almost impossible to know the
real price of landfills and recycling efforts, many of the arguments for recycling have
taken a religious tone: Putting garbage in a landfill is no longer expensive; its evil.
This sort of attitude can lead to zany outcomes. Munger recounts an incident
during a North Carolina drought a few years ago when Duke switched to disposable
paper dishes, napkins, and utensils in its food-service operations. The idea was to
save water, which had become more expensive than the landfill space occupied by
low-quality, hard-to-recycle eating supplies. It would have been irresponsible, in
terms of the opportunity cost of the resources, to continue to use water as if it were
plentiful, he says.
But that didnt matter to a lot of students and faculty at Duke. Munger says stu-
dents and faculty both complained that is was wrong to dispose of waste in a landfill.
He says he asked at least 20 people why landfilling the stuff was wrong but could
never get an answer. They just knew that is was, he says.
That takes us back to the concept of making end-of-life issues the problem of
manufacturers. Such a mandate would be an extra headache for designers of prod-
ucts and packaging, who would be forced into figuring out the end-of-life econom-
ics of the materials they used. But it would make discussions about garbage less
theological.
End-of-life
blues
08.15.13 MACHINE DESIGN6
-
The engineers choice
The round thing has to go into the rectangular thing.
These space-saving centrifugal module packages include our new RadiCal impeller design for the best aerodynamic efciency and acoustics. The square packages range in size from 6.5 (165mm) to 11.8 (300mm) with performance up to 940 CFM or 3 static pressure. Modules are plug and play, can be mounted in any orientation and are completely maintenance-free. Available with PSC motors or energy efcient Green-Tech EC motors in 2-speed or fully speed controllable versions. For more information, visit info.ebmpapst.us/RadiCal.
-
EDITORIAL
EDITOR IN CHIEF: LELAND TESCHLER [email protected] EDITOR: KENNETH J. KORANE [email protected] EDITORS: ELISABETH EITEL [email protected] J. MRAZ [email protected] EDITOR: LINDSEY FRICK [email protected] PRODUCTION MANAGER: DENISE GRECO [email protected] DIRECTOR: RANDALL L. RUBENKING [email protected]
INDUSTRY COVERAGE:
AUTOMOTIVE, PACKAGING, MEDICAL STEPHEN J. MRAZCAD/CAM, MANUFACTURING ELISABETH EITEL, LINDSEY FRICKFASTENING & JOINING, MATERIALS LINDSEY FRICKFLUID POWER KENNETH J. KORANEMECHANICAL ELISABETH EITEL, LINDSEY FRICK, KENNETH J. KORANE
ART DEPARTMENT
CREATIVE DIRECTOR: DIMITRIOS BASTAS [email protected] DESIGN DIRECTOR: ANTHONY VITOLO [email protected]
PRODUCTION
GROUP PRODUCTION DIRECTOR: CAREY SWEETEN [email protected] COORDINATOR: COURTNEY DENISON [email protected]
AUDIENCE MARKETING
AUDIENCE MARKETING MANAGER: BRENDA ROODE [email protected] DEVELOPEMENT MANAGER: DEBBIE BRADY [email protected]
ONLINE
ONLINE SALES & MARKETING MANAGER: VIRGINIA GOULDING [email protected] SERVICES COORDINATOR: JOANN MARTIN [email protected]
SALES & MARKETING
BRAND DIRECTOR: PAUL MILNAMOW T|312.840.8462 [email protected]
REGIONAL SALES REPRESENTATIVES
AZ, CA, ID, OR, NV, UT, WA, BRITISH COLUMBIA: PAUL MILNAMOW, [email protected] T|312.840.8462 F|913.514.3957AL, AR, FL, GA, KS, LA, NM, MS, MO, OK, TX: FRANNY SINGLETON [email protected] T|678.947.8563 F|913.514.6884CO, IA, S. IN, KY MN MT, NE, ND, S. OH, SD, TN, WI, WV, WY: PAUL MILNAMOW [email protected] T|312.840.8462 F|913.514.3957IL: MELINDA HURLEY [email protected] T|847.784.9825 F|913.514.6625N. IN, N. OH, MI, NY, PA, Ontario: BILL RODMAN [email protected] T|216.931.9636 F|913.514.6841DE, DC, MD, NJ, NC, SC, VA: BRANDY BISSELL [email protected] T|919.773.1875 F|913.514.6357CT, ME, NH, MA, RI, VT, QUEBEC: LIZ STOTT, [email protected] T|857.636.9737 F|913.514.6914
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International Sales Director: MIKE HANCOCK, [email protected] T|011.44.1372.824284 F|011.44.1372.824322UNITED KINGDOM, SCANDINAVIA, FRANCE, SPAIN, PORTUGAL: STUART PAYNE [email protected] T|+44 0)1932 564999 F|+44 0)1932 564998Belgium, Netherlands, Luxemburg: RODRIC LEERLING [email protected] T|011.31.229.841882 M|31.683.232625Germany, Austria, and Switzerland: CHRISTIAN HOELSCHER, [email protected] T|011.49.89.95002778 F|011.49.89.95002779Italy: CESARE CASIRAGHI Casiraghi Pubblicit Estera T|011.390.31.261407 F|011.390.31.261380Tokyo, Japan: YOSHINORI IKEDA Pacific Business, Inc. T|011.81.03.3661.6138 F|011.81.03.3661.6139
DESIGN ENGINEERING & SOURCING GROUP
VICE PRESIDENT & MARKET LEADER: BILL BAUMANNGROUP DIRECTOR OF EDITORIAL CONTENT: NANCY FRIEDRICHGROUP DIRECTOR OF OPERATIONS: CHRISTINA CAVANOGROUP DIRECTOR OF MARKETING: JANE COOPERRESEARCH MANAGER: JULIE RITCHIEMARKETING & EVENTS SPECIALIST: ADRIAN PIAZZAMARKETING COMMUNICATIONS SPECIALIST: CYNTHIA RODRIGUEZ
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AUGUST | 2013
08.15.13 MACHINE DESIGN
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888-439-6264www.clippard.com
Cincinnati, OH 45239
888-439-6264
miniature
pneumatic and
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stainless steel c y l inders shutt le valves push-quick f i t t ings
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stem valves hose modular valves 10 and 15 mm valves pneumatic c i rcuits
tubing brass valves pressure sensors f low controls pressure gauges
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WILL THEY STEP FORWARD?
One of the biggest problems I found
with the new generation of automation
engineers and techs is their lack of ini-
tiative (Seven Ways Older Automation
Experts Can Help the Industry,by John
Rinaldi, Jun. 3). Although many of us
have decades of experience under our
belt, we leave an industry that still relies
on old technology. New engineers have
a hard time incorporating or adapting
the old with the new.
New engineers just dont have the
drive and rely too much on comput-
ers instead of good old creativity or
problem-solving ability. If, or when, we
arrive at a major change in technology,
there will be an explosion of technol-
ogy that should surpass anything we
have available at the moment. The
entire manufacturing sector will have
to change and those who dont will be
left behind.
Thats when our young engineers will
have an opportunity to shine and prove
they can accomplish far better advance-
ments than those on whos foundation
they stood before they started to climb
the ladder.
Joaquin Cardena
EPA COMES CLEAN
The miles-per-gallon of any particular
vehicle is an extraordinarily difficult
parameter to measure because there
are so many variables. Brooks Lyman
(Letters, May 23) listed several, but
there are more, including air tempera-
ture and wind speed, even altitude.
I drove an 85 Chevy Sprint (Suzuki
Swift) for 10 years and consistently
got 50 mpg with a daily 72-mile com-
mute (round trip). The engine was a
three-cylinder, four-stroke one-liter
design. And I was no slouch speed-
wise. Tires lasted 75,000 miles, brakes
85,000. At 110,000 miles I gave it to a
friend who was ecstatic and said that
the government should buy them for
poorer folks to reduce air pollution.
Where are they now?
Robert H. Russell
Just finished reading the letters regard-
ing mileage and the EPA. I drive a
1999 Corvette with a 350-hp engine,
aftermarket exhaust, K&N air filter, and
six-speed transmission. The cars EPA
numbers were about 19/26 mpg on the
sticker. Funny thing about EPA num-
bers is that they are usually not correct.
Also, most people believe you should
have a small car with a small engine to
get good numbers.
On the round trips between our home
in Connecticut and our vacation home
in Florida, my average mileage, while
driving as fast as traffic allows (around
80mph most of the time with plenty of
jack-rabbit starts), is about 30mpg. This
is both the calculated number and that
shown on the cars trip computer. I put
in 87octane gas (with 10% ethylene)
unless it is really hot. Then I buy 89 or
93. Most people with similar Corvettes
get about the same mileage or more with
conservative driving.
What is the magic? How about
good aero design, low weight, and
high horsepower and torque taking
advantage of good overdrive ratios?
At 72mph, my engine turns at about
1,500rpm, which is exactly twice the
engines idle speed.
Lets figure out how to do the same
on some of the boring high-mileage
econoboxes many people feel they
need to drive to get fuel economy.
Imagine how much could be accom-
plished without ethanol. And how
about some of the very economical
European diesel engines?
Robert Bubello
Believe it or not, the EPA must be
listening to the public for once. A
recent check at http://www.fuelecon-
omy.gov shows that some newer ve-
hicles now have fuel-economy ratings
based upon standard gasoline and on
E85. The vehicle I was interested in
suffers a 25% reduction in economy
when E85 is used instead of gasoline.
I guess Ill be looking even more
closely at getting one of the new crop
of diesel-powered vehicles because
the mileage should definitely be bet-
ter and the fuel cost is generally less
than 10% higher. As for the up-front
diesel powerplant cost, I can recoup
that at resale.
Duane Levine
ROOM FOR A CREW?
Looking at the crew module specs for
NASAs Orion capsule (NASAs Orion
Goes International, Apr. 11), it says
the return payload is only 220 lb. Is
this a one-man capsule?
Howard Chin
No, NASA does not include crew
weight,or that of the fuel and breath-
ing gasses among other things, in the
payload weight.
Letters
NEW ENGINE AND
GAS MILEAGE
One reader noticed the difference
between new and older engineers
and hopes the newer ones are up
to the challenge when they become
the ones in charge. Other readers are
troubled that the EPA doesnt account for
E85 gas in mileage ratings.
LETTERS TO THE EDITOR:
Please include your name, address, and day-
time phone number. Letters may be edited for
brevity and to focus on essential points.
Mail: Letters, MACHINE DESIGN, 1300 E. 9th St.,
Cleveland, OH 44114-1503, Fax: 216-621-8469
E-mail, Editorial: [email protected]
10 08.15.13 MACHINE DESIGN
-
Whats Inside
Eco-friendly Hydraulic
Shock AbsorbersTHE ECO SERIES of hydraulic shock absorbers from ITT Enidine Inc., Orchard Park,
N.Y. (www.enidine.com), can handle a wide range of forces and moving masses,
absorbing maximum energy within a compact envelope. The shock absorbers use
materials and fluids that are considered safe for the environment. For example, the
device, along with all the coatings, comply with RoHS. The hydraulic oil it uses is
biodegradable. And even the packaging materials used for shipping the shock
absorbers can be recycled.
The shocks, which all come with a jam nut, are available in adjustable and
nonadjustable versions, and have an Enicote II finish which protects against
corrosion and is rated at 350 hr of saltwater protection. The nonadjustable
shocks are also tamperproof. Threaded cylinders give users flexibility in
mounting the shocks and also increases the surface area for better heat
dissipation. The devices can also mount into pressure chambers.
The shocks have strokes that range from 0.25 to 1.0 in. and can
withstand 25 to 930 in.-lb/cycle, or 55,000 to 682,000 in.-lb/hr.
The devices weigh from 0.5 to 10.5 oz and handle reaction forces
from 200 to 1,250 lb. They operate in temperatures from 15 to
180F, but this can be extended with optional fluids and seals
to 30 to 210F. There are also food-grade versions of the
ECO shock absorbers.
Edited by Stephen J. Mraz
Cylinder
Check
ring
Piston
head
Orifices
Oil
Shock
tube
Coil
spring
Foam
accumulator
BearingPiston rod
Hydraulic Power Pack KA
More power from less energy
Machine tools with built-in
Your machine tools will be extremely
cost-effective with HAWEs efficient
and reliable hydraulic solutions.
Find out more at www.haweusa.com.
efficiency
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>> Accelerate your productivity at ni.com/embedded-platform
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The combination of NI LabVIEW system design software and recon gurable I/O
(RIO) hardware helps small design teams with varied expertise develop demanding
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LabVIEW system design software offers ultimate exibility through FPGA programming, simpli es code reuse, and helps you program the way you thinkgraphically.
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askTURCK.com
2013 TURCK
Types of pressure:when and why arethey used?
Whats Inside
A Bearing Built for
Wind Turbines
THE NAUTILUS BEARING from SKF USA Inc.,
Landsdale, Pa. (www.skf.com/us), is a double-row
tapered bearing set that is compact and used in
wind turbines to carry all rotor loads, forces, and
moments. Up to now, most large turbines used
two bearing sets to handle axial and radial loads
separately. Using only one bearing means only
rotor torque gets transmitted to the drivetrain and
that weight and cost are reduced. The two rows of
tapered bearings are arranged back to back and lock
the unit axially, so it delivers high levels of stiffness.
The bearing is also more compact than the
two bearings traditionally used. This makes for a
smaller, lighter, and less-costly nacelle. And the
large number of rolling elements makes for extreme
precision between raceways, so the unit can
carry high loads. The Nautilus bearing is, in fact,
designed for multimegawatt turbines and those
turbines can be directly driven or have gearboxes,
have outer or inner-ring rotation, and be mounted
on shafts or bolted onto the surrounding structure.
The bearing uses an Ecopur polyurethane seal
that is held in place by built-in carriers. The seal can be replaced
on top of the turbine, simplifying maintenance. Seals and grease
help prevent corrosion, a constant threat for offshore turbines.
The bearing comes standard with a bolted outer ring. A
bolted inner ring is optional, which lets the bearing be attached
to the rotor hub and the mainframe. This eliminates any
effects of excessive tolerances between the bearing and the
surrounding structure, including the shaft, housing, and lock
ring. It also reduces variations in preload during operation.
Edited by Stephen J. Mraz
Pregreased
bearing
eliminates
contamination
Bolted inner
ring for
safety and
reliability
Corrosion protection in vulnerable areas
High-friction
coating
minimizes
movement
between mating
components
Single-pocket, segmented
PEEK cage increases load-
carrying capability.
Combined seals
and carriers
reduce risks of
contamination
and reduces
weight and costs
-
Schaefer, with our INA and FAG brands, has set a standard that is unrivaled throughout the industry by offering innovative products and unmatched sup-port services that can dramatically improve the performance and reliability of pumps used in wastewater, dewatering and petrochemical applications.
Heres why this is no idle boast:
Innovative ProductsSchaefers latest generation of double-row angular contact bearings in X-life quality generate less friction, put less stress on lubricants and en-able lower operating temperatures. Thanks to higher ball quality, improved raceway surfaces and more precise dimensional and running tolerances, the bearings internal friction is signicantly reduced. As a result, higher speeds or longer bearing operating life can be achieved. So reliability goes up, and energy consumption goes down.
Groundbreaking TechnologyX-life is Schaefers designation for premium products from our INA and FAG brands that offer engineers completely new design perspectives. Thanks to supernished raceway surfaces that ensure smooth, uniform running characteristics, maximum load-carrying capacity and superior rigidity, the operating life of X-life bearings is considerably longer than standard bearings under identical operating conditions. Alternatively, higher loads can now be applied while maintaining the same rating life values.
Unmatched Engineering SupportThe industrys most comprehensive suite of calculation software, BEARINX is Schaefers cutting-edge program for performing rolling bearing and linear guidance system calculations. One of our latest modules, BEARINX- online Easy Friction enables customers - free-of-charge - to calculate all of the friction forces at the discrete points of the contact surfaces inside the bearing.
When it comes to bearings for your pumps, dont just go with the ow. Go with Schaefer.
Superior-quality products. Comprehensive reliable solutions.
Need more details? Please contact us at [email protected]
www.schaefer.us
2013
-
Commentary
STEPHEN J. MRAZ
Fracking:
Its Better Than
the Alternatives
Hydraulic fracturing, a method of getting more
natural gas out of shale formations, has been a
major boon for the U. S. and the rest of the world.
It lets the U. S. get 40% of its gas from shale, a
once little-regarded resource. It has pushed the price of natural
gas from $13/ft3 in 2008 to under $4/ft3 today. This translates
into annual savings of $1,000 in heating and electricity costs per
household, with most of these savings going to those who arent
rich. And fracking means fewer U.S. dollars go overseas.
Like any industrial process including steel making, egg farming, and solar power and wind turbines frack-ing can lead to problems if done improperly or negligently. But no responsible person advocates letting companies act negligently or illegally. In fact, gas companies want to make fracking safe for both humans and the environment. These firms are also working with local, state, and federal govern-ments to establish meaningful guidelines and legislation. At the same time, local governments want the taxes, landown-ers want the royalties, consumers want the lower energy prices, and everyone wants a clean planet.
In fact, the EPA has been looking at fracking and has found few problems. One issue it investigated was methane supposedly leaking into water supplies due to fracking. An EPA study found that so-called contaminated wells con-tained levels of methane typical in the area and below levels that the federal government considers a threat to health. Then in 2011, the head of the EPA testified to Congress that she was not aware of any proven case where the fracking process itself affected water In no case have we made a de-finitive determination that the fracking process has caused chemicals to enter groundwater.
So deciding between fracking or the environment looks like a false choice. We can have both. Fracking has already produced enough natural gas to send U. S. coal-generated electricity from 48 to 37% of U. S. needs in only four years. It has also convinced utilities not to build about 150 new coal-fired plants. Many are planning natural-gas burning plants instead. These new plants will release none of the soot,
mercury, arsenic, or lead that come from coal-burning gen-erators and half the CO2. Meanwhile natural gas from frack-ing has been partly responsible for the U. S. cutting its CO2 emissions by 800 million tons since 2007, a better cleanup act than all those countries that signed onto the Kyoto Protocols.
Coal isnt the only energy soured that has problems. As John Hanger, a former secretary of the Pennsylvania Dept. of Environmental Protection, said in a recent article (http://www.guardian.co.uk/commentisfree/2013/jul/08/shale-gas-
fracking-good-for-environment) for The Guardian:Virtually all of our energy choices have big safety and
environmental risks or significant weaknesses. There is no perfect or excellent energy source that has no environmen-tal impact, is low cost, and operates continuously. Indeed, especially in terms of the environment, our energy choices today are mostly ugly.
Nuclear energy, for example, leaves us with hazardous wastes which we cant figure out how to dispose of. And most U. S. residents have a fear, perhaps irrational, of radio-activity. (I wonder how many citizens know they get dosed with relatively high levels of radiation every time they fly.)
Oil can be dangerous to transport, difficult to clean up after spills, and burning it releases lots of CO2, along with other toxic substances and soot.
Hydroelectric dams disrupt river life and tick off the Sierra Club. Corn-based ethanol distorts the corn markets, leaving some people hungry, and has been known to harm engines and fuel systems. Wind and solar power will take a long time to scale up to where they provide more than 5% of our power. Plus, neither can generate a single watt if its too windy or not windy enough at night. And if we did build enough solar panels and wind turbines, whos to say all those non-reflective surfaces and impediments to the wind wont affect weather patterns and climate?
Fracking and the burning of natural gas might not be perfect, but they sure seem to be better than the alternatives. Lets work to make it safer and more affordable with prudent and fairly enforced safety and environmental regulations.
16 08.15.13 MACHINE DESIGN
-
Sense-ability.
Newark element14 makes it easy to nd all of your sensors and transducers fast. newark.com
-
Smart Machines
control strategies and complex control algorithms. The trend is to integrate monitoring and control into one hardware system. This approach can have economic advantages and may boost the performance of the automation equipment as well. Finally, machine builders often rely on an additional system that is added to the
machine controller and performs the monitoring task independent from the machine control system. The two systems generally communicate via standard industrial I/O lines.
HOW ARE SMART
MACHINES DEFINED?
Smart machines usually are built around distributed control archi-tectures that dedicate one electric motor to controlling each axis. This is in contrast to using cams, gear trains, and other mechanical linkages to power individual axes from one central motor. Machine builders need to adopt a software-centric approach to deal with the resulting complexity, usually through software development tools that provide both simulation and deployment capabilities. They let machine designers simulate dynamic systems, design controllers, and deploy control systems to the hardware that will actually run the system. These development systems generally include an analysis palette in the time and frequency domains. Control programs that use adaptive and model-based
and programming tools that let designers use one software design tool for multiple tasks as a means of handling increased system complexity.
WHAT COMPONENTS TYPICALLY
GO INTO A SMART MACHINE?
Smart machines are aware of processes through use of a compre-hensive network of sensors. These sensors collect information about machine conditions and the status of ongoing processes. The resulting measurements are typically used to let the controller monitor the condition and performance of the machine. The sensor network is extensive enough to let the controller gather enough
information to decide whether to initiate maintenance or even automati-cally apply different control settings to the system.
Smart machines also require a high-performance net-work of embedded systems to imple-ment advanced
WHAT IS A SMART MACHINE?
Smart machines today are generally those that must be able to operate somewhat autonomously and must be able to adapt to changing condi-tions. For the most part, they handle tasks that are not solely repetitive. Smart machines must also be able to avoid and correct process errors and learn from those situations to avoid difficulties in the future. Smart machines also typically provide information to a higher level control system that facilitates smarter operations in general.
HOW HAS THE SMART
MACHINE CONCEPT CHANGED
MACHINE DESIGN?
Traditional computer-controlled machines combined a machine controller, a local HMI such as an operator terminal, and connectivity to a plant automation network. In contrast, smart machines tend to have modular architectures that make use of off-the-shelf systems such as robots to speed development. They also integrate additional embedded control and monitoring systems to distribute processing. Consequently, there has been a shift toward software-centric design approaches
Sponsored by National Instruments
FREQUENTLY ASKED QUESTIONS
-
A D V E R T I S E M E N T
control strategies typically can be deployed straight from simulations.
WHY IS THE SMART MACHINE
CONCEPT IMPORTANT FOR
MOTION CONTROL?
Decentralized control works with the trend away from using a central motor to power individual axes through gears trains, cams, and other mechanical linkages. Now individual motors typically power specific axes and are synchronized in software. This approach reduces the cost and weight of the machine and makes the mechanical system more flexible. The resulting machines can also be modular and more easily expanded.
There is also a trend toward more axes and much more complex motion profiles and control algorithms. Mechanical systems that deviate from the classical XYZ axis setup require complex control algorithms to trans-form the movement of the end effector into the movement of individual joints. Machine designers tend to need access to low-level motor control algorithms to implement the commands necessary to realize these sorts of movements. Ditto for implementing adaptive control algorithms. Only a few machine builders feel comfortable custom-izing low-level motor control routines without the help of their tool providers.
HOW DO FPGAS FIT INTO SMART
MACHINE DESIGN?
FPGAs are the primary enabling technology for parallel control. The reason is FPGAs execute multiple tasks simultaneously. They are highly reli-able because they implement control schemes using only hardware logic. There is no overhead of an operating system or interactions with multiple software routines to worry about.
FPGAs once were used only by engi-neers with a high level understanding of hardware circuit design who could program FPGAs in VHDL (VHSIC hardware description language). This is no longer the case as now, software tools can convert block diagrams of control schemes into plans for programming FPGA circuitry.
Software packages are now avail-able which give access to control functions through high-level program-ming interfaces but if necessary, let the builder get at machine-level code to customize lower level IP, often through changes in an FPGA.
The Control Design Guide for Next-Generation Machines explains the challenges machine builders face today and demonstrates proven methods and solutions to get ahead of the competition. Experience the impact graphical system design and customizable off-the-shelf hardware has on the design process and business success.
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-
More than $1,000
27%
Less than $1,000
18%
Less than $500
14%
Less than $200
17%
Less than $50
14%
7%
Less than $20
Less than $5
2%
Never
17%
Once every
two years 7%
Once a year
17%
Every six months
28%
Once every
two months
31%
0 10 20 30 40
43% Lower prices
32% Easier ordering process
46% Faster delivery times
42% Better technical help in conguring custom components
37% A guarantee on quality, price, and delivery times
20 08.15.13 MACHINE DESIGN
ENGINEERS &
CUSTOM COMPONENTS
A reader survey
Companies that want to sell more custom parts should
work on lowering prices, speeding delivery, making
ordering more simple, and then guaranteeing it all.
WHAT FACTORS WOULD MAKE YOU
MORE LIKELY TO SPECIFY CUSTOM
COMPONENTS?
HOW OFTEN DO YOU USE CUSTOM
COMPONENTS IN YOUR DESIGNS?
Custom parts can range from specialty wash-
ers to oversized tires for limited-production
off-road equipment, and prices vary accord-
ingly. Our survey shows that prices do indeed
vary widely when it comes to the custom parts
engineers specify for their designs, with the
median being about $500.
HOW MUCH DOES YOUR COMPANY
SPEND ON EACH CUSTOM
COMPONENT(AVERAGE)?
Machine Design surveyed some of its readers to
better understand how engineers use custom
components. Results show 85% of engineers rely on cus-
tom parts, which have a median price of about $500. And
while many designers specify low-cost custom items like
fasteners, switches, and connectors, others spec in cus-
tom motor and power supplies, as well as structural parts
and machined subassemblies.
Stephen Mraz, [email protected]
A vast majority of
designers (85%)
rely on custom
parts, and over half
(59%) use them in
designs at least
every six months.
-
So much more
difcult than
specifying
standard parts
that we never
order custom
parts 1%
Much more difcult
than specifying
standard parts
31%
Only slightly
more difcult
than specifying
standard parts
57%
As easy as
specifying
standard parts
11%
To save
manufacturing
time 7%
To get a lower
price 4%
To get the right
material 5%To get the
right combination
of features
69%
To get the
exact size
needed
15%
5%
Half the time
Most of the time
86%
Always
8%
Location
does not
matter
14%
Foreign
suppliers
>1%
Suppliers
in the
same country
22%
Suppliers in
the same
general
region
31%
Local suppliers
32%
0% 10% 20% 30% 40% 50%
51% Machined subassemblies
40% Structural components
39% Fasteners
26% Motors
19% Switches/electrical connectors
34% Molded parts
18% 3D printed parts
17% Power supplies
12% HMI/control panels
10% Software
A month
longer than for
standard
components
34%
A week
longer than
for standard
components
50%
Same as
for standard
components
15%
GO TO MACHINEDESIGN.COM 21
WHAT DO YOU
CONSIDER A
REASONABLE DELIVERY
TIME FOR CUSTOM
COMPONENTS?
Engineers want their cus-
tom parts delivered in only
a week longer than what it
takes to get a standard part.
A more-lenient third will give
companies a month.
Closer is better when it
comes to companies sup-
plying custom parts. But a
small slice of the engineer-
ing population says they
prefer to use foreign suppli-
ers for their custom parts.
Over two-thirds of the engineering
respondents say that getting the
right combination of features is the
main reason they order and use
custom components. Price, materi-
als, and saving manufacturing time
each motivate about 5% of engi-
neers to seek out custom parts.
WHAT IS THE PRIMARY
REASON YOU SPECIFY
CUSTOM COMPONENTS?
WHEN IT COMES TO
CUSTOM COMPONENTS, WE
PREFER TO WORK WITH:
Engineers usually
get what they ask for
when they order cus-
tom parts, according
to our survey. But
5% say they arent
getting what they
ordered.
HOW OFTEN ARE YOU
SATISFIED WITH CUSTOM
COMPONENTS?
Although most engineers seem to have little
problem ordering custom parts, almost a
third say suppliers make it much more dif-
ficult to get custom parts than standard ver-
sions. But only a small minority (1%) say that
ordering custom parts is so onerous they
dont do it anymore.
HOW DIFFICULT
IS IT TO
PROPERLY
SPECIFY
CUSTOM
COMPONENTS?
Engineers ask suppliers to customize a range of parts,
even software. But machined subassemblies are the most
commonly ordered customized component, cited by over
half the responding engineers. And although 3D printing
is a relatively new technology, almost one in five engi-
neers are using it in their designs.
WHAT TYPE OF CUSTOM
COMPONENTS DO YOU
SPECIFY MOST OFTEN?
-
POWER DISTRIBUTIONENCLOSURES CLIMATE CONTROL
Thousands of enclosures
Hundreds of options
Designed and delivered in 10 days
Manager for North America.
Were able to make a
complete range of seals,
including rotary seals for
grease and oil, V-rings for
exclusion, static O-rings,
and alternative designs
with better performance,
explains Uncapher. Other
types include hydraulic
seals such as wipers, rod and
piston seals, guide rings, and replacements for gland pack-
ings, as well as buffer seals and antiextrusion rings, he says.
Seals are made from a wide variety of stock materials,
including rubber elastomers, polyurethanes, thermo-
plastics, and specialty materials like SKFs ECOPUR, a
thermoplastic polyurethane (TPU) with unusually high
abrasive resistance, low compression
set, and excellent strength. Also avail-
able are materials complying with a
broad range of industry standards and
regulations, such as FDA guidelines.
Proprietary materials can also be formu-
lated for specific applications.
A key to custom capabilities and rapid
turnaround, according to company
officials, is SKFs Seal Jet machine. This
CNC-controlled production system uses
proprietary software and special cutting
SKFs seal machining
centers can quickly cut
standard and custom
seals from a wide range
of stock materials.
CNC-controlled Seal Jet machines pro-
duce custom seals using proprietary
software and cutting tools specifically
developed for machining polymers.
CUSTOM SEALS ON DEMAND
CUSTOMIZED MACHINED SEALS can be invaluable for engi-
neers and maintenance technicians. Getting a made-to-
order seal in a day or two can keep a project on track
when prototyping new designs. And custom seals can
minimize downtime and lost production when a critical
component fails.
But engineers cant rely on just any machine shop with
a lathe to craft quality seals. For one, seals are precision
components that demand tight dimensional tolerances
to work properly. Making them requires an expertise in
machining elastomers and plastics which, on a machine
tool, behave quite differently from metals. And most
fabricators dont stock the proper material. In a seal, the
right materials are critical for fluid compatibility, shear
strength, abrasion resistance, and a host of other reasons.
SKF USA Inc., Lansdale, Pa., can quickly cut seals from
stock materials to exact customer specifications. The
company can reportedly manufacture
seals and related components up to
157 in. in diameter. And larger seals
are possible using a welding technique
that allows on-site fitting and still pro-
vides the performance of a continuous
machined or molded seal.
The company catalogs several hun-
dred standard profiles, but can produce
virtually any kind of rotating, recip-
rocating, or static seal for most any
conceivable application, says Bryan
Uncapher, SKF Business Development
News
Custom seals continued on page 26
-
SOFTWARE & SERVICESIT INFRASTRUCTURE
www.rittal.us
SOFTWARE ANALYSIS YIELDS METRIC FOR IMPROVING PRODUCT DEVELOPMENT
SOFTWARE NORMALLY
USED to assess the
degree to which
products are assem-
bly friendly is now
used to measure
whether or not new
designs are really
improvements over
the models they
replace.
The software, a
tool called Design
for Assembly from
Boothroyd Dewhurst Inc., Wakefield, R. I., is ordi-
narily used to simplify product designs by showing
designers where to eliminate unnecessary parts,
thereby simplifying assembly and lowering labor
costs. But new-product development engineers at
Motorola Solutions Holtsville, N. Y., design center
used a calculation from the software called the DFA
index as a key measure of overall product design.
The index is simply an ideal assembly time divid-
ed by the actual assembly time. An ideal assembly is
one having a theoretical minimum number of parts
as determined by the DFA software.
Motorola engineers divided the company product
portfolio into product families whose members were
closely related by their technology. Engineers then
figured a DFA index calculation for every product,
computed averages for each product family, and ran
the same calculation for competing products.
The resulting metrics served as a yardstick for gaug-
ing best-in-class design goals and a way to quantify
whether designs were improving. Motorola personnel
say DFA data gets compiled monthly and is presented
to senior management. A product with a DFA index
below target gets attention at all levels.
Products in Motorola Solutions portfolio, which includes hand-
held radios and handheld barcode scanners, are analyzed for
ease-of-assembly factors using Boothroyd Dewhurst Design
for Assembly software.
RESOURCES:
Boothroyd Dewhurst Inc., www.dfma.com/
Motorola Solutions Inc., www.motorolasolutions.com/
-
Innovation distinguishes between
a leader and a follower.
- Steve Jobs
As the leading manufacturer of OEM pumps
and compressors, our innovation in design and
technology has helped our customers create
new innovative products and become leaders
in their marketplace.
For more information on
how Thomas innovation
can help you lead
your industry, go to
gd-thomas.com.
Improving Lives through InnovationTM
-
Improving Lives through InnovationTM
907Z SERIES
BLDC COMPRESSOR
An Illustration
in Innovation
Efficient, durable and
lightweight, the oil-less
907Z Series brushless DC
diaphragm pump is designed
for fuel cell applications.
Lightweight (5.5 lbs/2.49 kg)
Die-cast aluminum parts forstrength and durability
Efficient, low-vibration design
Long-life 24V brushless DC motor
Maximum continuous pressure to 25 psi/1.72 bar, maximum vacuum to 21.2 inHg/717 mbar
For more information on the
innovative 907Z Series, go to
gd-thomas.com.
GO TO MACHINEDESIGN.COM 25
News
VSDs POWER WRAPPING MACHINES, ECONOMIZE ON CABINET REAL ESTATE
SAFE TORQUE-OFF FEATURES in variable-speed motor drives let wrapping machines use
simpler controls and smaller electrical cabinets.
Automatic stretch wrapper machines from Orion Packaging Systems, Alexandria,
Minn., use ACS355 model variable-speed drives from ABB, Cary, N. C. Each machine hosts
at least three drives. One rotates either a turntable holding a pallet full of material, or the
wrapper mechanics around a stationary pallet. Another moves the lift carriage containing
the film-delivery system up and down as it dispenses film. A third drive runs the multistretch
mechanism that actually stretches and pays out the film as the pallet turns. Many Orion auto-
matic-stretch wrappers also incorporate conveyors run by three additional ACS355 drives.
Safe torque-off is a built in and certified function that prevents unexpected start-ups. It
essentially keeps a drive from delivering random rotational energy to motors. This reduces
the need for separate safety components such as a safety contactor to disconnect the
drive and lets machinery start up quickly after a safety stop. It also enables machine
builders to fulfill the requirements of Machinery Directive 2006/42/EC.
For example, drives not equipped with torque-off functions must completely shut down
in the event of an E-stop. But torque-off-equipped drives recover more quickly after an
E-stop because they do not completely power down.
ACS355 drives are also bookshelf mountable, meaning they can mount in the panel
side by side. This helps maintain the system UL rating and does not delimit the drives abil-
ity to dissipate heat.
The variance in load on the motors can be significant
because of factors such as the wide range of pallet
weights that the turntable must rotate. In their most core
function, drives sense the amount of each load and gen-
erate enough motor torque and speed to handle it.
ABB variable-speed drives
power either ABB or Baldor
motors on automatic wrap-
ping machines that handle
package wrapping mechanics
(inset), a film-delivery lift car-
riage, and the turntable hold-
ing pallets of material, as well
as the conveying system on
some models. Safe torque-off
features simplify the associ-
ated electrical safety system.
RESOURCES:
ABB, www.abb.us
Orion Packaging Systems,
www.orionpackaging.com
-
26 08.15.13 MACHINE DESIGN
News
tools developed for machining different polymers, espe-
cially polyurethanes.
All machined seals, whether standard or custom, are
manufactured on demand with no tooling costs. Produc-
tion quantities range from a single piece to lots of several
thousand. Larger quantities can be produced using mold-
ing processes. Normal lead time is 4 to 5 days, but rush
orders for seals up to 24-in. OD can be shipped the same
or next day, depending on the time the order is received,
says Uncapher.
A range of customers take advantage of customized
machined seals from SKF, he notes.
These include:
OEMs and end users that face
performance issues with standard
seals, and need to upgrade the
materials or design.
Users with equipment that suffers
a critical breakdown when stan-
dard seals are not readily available
because they are made overseas, or
the machine is outdated and spare
parts are no longer sold.
Equipment-repair specialists who,
instead of replacing worn shafts or
damaged housings, opt to change
the seal dimensions to fit.
OEMs and end users looking to
boost machine output through high-
er speeds and pressures, but need
engineering and testing assistance
to develop new seal designs that
ensure durability and safety.
In the latter case, SKF engineers
will work with customers to develop
seals tailored to an applications
specific needs. We have proprietary
design and manufacturing software,
which helps engineers develop a seal
based on the application housing and
shaft designs, says Uncapher.
SKF operates more than 200
seal machining centers worldwide,
including in Cleveland and Houston,
Edmonton and Scarborough in Can-
ada, and Monterrey, Mexico. To find
a location, visit www.skf.com/ca/en/
our-company/skf-locations-global/
index.html.
RESOURCES:
Additional information on SKF machined
seals is available at www.skf.com/
us/products/seals/industrial-seals/
machined-seals/index.html.
Custom seals continued from page 22
-
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Pancake Cylinders outperform their rivals.Rugged construction provides unequalled strength, rigidity, and piston rod support maintaining perpendicularity and concentricity for locating, mounting and making attachments to the rod. Heavy wall prevents damage to the bore from external impacts. Magnetic position sensors fea-ture surge suppression, polarity protection, LED indicators and extremely fast switching speeds.
stainless steel shafting.
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Pancake II style has the same rugged components as the original Pancake. Plus. . . Stainless steel tie bolts
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28 08.15.13 MACHINE DESIGN
News
RESOURCES:
Bodine Electric Co.,
www.bodine-electric.com
SOME CUSTOM MOTOR work can be relatively inexpensive, but
not all of it. It is easy to change the number of winding turns.
Changing the lamination stacks is a different story, says Terry
Auchstetter, business development manager for Bodine Elec-
tric Co. in Northfield, Ill. And it is simple to change mechanical
features like bolt patterns if they stay within the envelope of
the existing bracket casting. Of course, if you need an 8-in.-
diameter bolt circle when the casting has only a 6-in. diameter,
obviously youll need a new casting.
Auchstetter is speaking from experience: Some 70% of the
fractional-horsepower motors Bodine
makes are customized in some fashion.
Other things to keep in mind if the need
arises for a custom electric motor: A
stock product is off the shelf and the lead
time is a day. A lot of engineers dont
understand that when you get into custom
work, the price is higher and the lead time
goes into weeks, Auchstetter says.
Most of the customization requests
Bodine sees are in operating voltages,
mounting configurations, the addition of
accessories, and wiring. Its becoming
more common to use motors in remote
locations to handle jobs such as tracking
the sun with solar cells. Motors that work
from the 12-V supplies used in those
arrays are a special order for us, says
Auchstetter.
Special mounting configurations are
another frequent source of customiza-
tion. It is often easier to mate with a
gearbox or pump by modifying the motor
mounting holes rather than by adding an
adapter, he explains. Similarly, it may be
advantageous to add encoders, brakes,
terminal blocks, or other ancillary com-
ponents when the motor is manufactured
rather than later on when it is installed.
Motor wiring gets modified a lot as well.
Medical equipment often has its own
standards for EMI and related factors, so
wiring for motors in that area often need
extra shielding and ferrite beads, says
Auchstetter. Other wiring specials may
include special connectors, differing wire
lengths, and custom-configured wiring
harnesses.
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30 08.15.13 MACHINE DESIGN
News
GEARMAKERS SAY THEY often see unrealistic expectations when
inexperienced engineers get into specifying custom work. A
lot of engineers have never worked in industry so they have no
idea how long it takes to manufacture parts that are intricate or
technically difficult. A lot of purchasing personnel have the same
problem because they have never taken the time to understand
the capabilities of their suppliers, says Fred Young, CEO of cus-
tom gearmaker Forest City Gear in Roscoe, Ill. Among other
things, Forest City frequently custom-fab-
ricates gears with finishes having super-
high AGMA quality tolerances.
Tolerancing is another bugaboo. When
people have gear problems, they often
think tightening-up tolerances will solve it,
Young says. Use of tighter tolerances is
frequently a crutch for engineers who lack
the experience to understand how a mech-
anism actually works and what aspects are
really critical to the build of the part.
Young maintains tolerancing often
gets wrongly blamed for a variety of gear
problems. We sometimes get gears with
noise issues that were made by another
vendor. The first question to ask is
whether the part really was manufactured
poorly or whether it was just a problem
with the design, he says. Most shops
cant check their parts adequately or
monitor the tolerance of gears. They may
not be able to tell whether the gear was
manufactured properly, whether it was
designed to the appropriate tolerance, or
whether the engineer just didnt design
the tooth correctly.
Many such difficulties can be chalked
up to lack of experience. There are a lot
of young engineers who dont have the
years of experience you need to sniff out
gear problems, Young says. And a lot of
manufacturers wont spend money to do
R&D on their parts to detect problems in
advance. Or their designers are afraid to
admit they dont have enough knowledge
to design something and take a pot shot
at it. They end up taking a lot longer to
design a part that is a lot more expensive
than it would be otherwise.
UNREALISTIC EXPECTATIONS FOR CUSTOM GEARS
RESOURCES:
Forest City Gear, www.forestcitygear.com
-
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A safety encoder detects when the machine
stops, and lets the operator in right away.
Unlike traditional setups, encoder-based
safety controls can also detect overspeeds
and if the machi ne is turning in the wrong
direction.
Sensor Sense
tem speed. When a worker needs to get
close and triggers the request-to-enter
signal, the controls slow the machine. As
soon as the encoder detects that poten-
tially hazardous motion has stopped, the
gate opens.
In some cases, encoder-based safety
eliminates the need to remove power
from the drive: The safety encoders con-
tinuously track machine motion and
trigger safety shutdowns if a faulty drive
tries to start the machine while a person
is near.
Safety encoders even mit igate
machine runaways caused by drive fail-
ures if the drive is programmed with
bad limits, if the range of movement is
incorrectly set, or if there are bad refer-
ences in the motion program.
Runaways are dangerous to
operators. They also necessitate
costly repairs when they cause
crashes. Safety encoders can
detect overspeeds before a machine
goes out of control; then the controls
initiate a machine shutdown.
One caveat: Machine-safety sys-
tems must incorporate redundancies.
Conventional safety devices such as
e-stops, for example, have redundant
contacts. In contrast, encoder-based
safety uses redundancies programmed
into a speed-monitoring module. Here,
programmed-in logic activates safe-
guards in response to encoder pulse
counts that represent overspeeds and
stops. Some setups verify the direction
of rotation useful in applications that
can only turn safely one way. Here, if the
encoder detects the machine is spinning
the wrong way (as the result of a drive
failure or PLC programming error) the
controller will shut the machine down.
HELGE HORNIS at Pepperl+Fuchs (www.
pepperl-fuchs.us) provided information for
this column.
Edited by Elisabeth Eitel
FACTORIES USUALLY PUT safety fences
around sorters, fillers, and other rotating
machines that pose a danger to workers.
Gates in fences let operators and mainte-
nance personnel into a machines work-
space only when its safe. Typically, the
worker hits a button that sends a request-
to-enter signal to a timer. The timer
counts down a preset wait period to give
the machine time to come to a halt
even if it was not running at its fastest
when the worker requested access. For
added security the
machines drive power
is disengaged. Then
the gate opens.
Encoders for safety
While effective, timer-based safety is
inefficient because it results in unneces-
sarily long wait periods and safety mar-
gins to 50%. For example, if a machine
coasts a stop in 30 sec (as its assumed
a faulted system lacks the means to
actively brake) the added safety margin
results in a 45-sec wait period even
if the machine was running slowly and
can still brake. This increases machine
downtime and tempts frustrated opera-
tors to bypass the safety devices.
An alternative for rotating machines
is to base safety controls on safety-rated
encoders. Here, the encoder tracks sys-
GO TO MACHINEDESIGN.COM
-
Interview
TOM PRICE | PRESIDENT
Price Engineering Hartland, Wis.
System integrators are playing an increasingly
important role in engineering fluid-power sys-
tems for next-generation manufacturing and
automation equipment. We recently gained some
perspective on the trend from Tom Price of Price Engineering.
What are some factors affecting the fluid-power industry?
First, theres an automation and manufacturing renaissance
taking root in the U. S. Its only recently weve woken up and
realized America cant be a world leader just servicing goods
made elsewhere. We need to actually make things in this
country. Fluid-power technology can play a significant role.
Second, theres been widespread integration of high-
tech components into hydraulics and pneumatics. A lot
of the electronics we now use has migrated from such
industries as automotive and truck things like hardened
PLCs, remote I/O, and joysticks linked via CAN networks
with robust connectors.
As a result, we now have products such as highly efficient ser-
vomotor-driven pumps for machine tools and injection-molding
equipment, and smart mobile hydraulics that help cut fuel con-
sumption and emissions. Now blend that with other technologies
like GPS, cloud and Web-based services, and telematics. This all
leads to many more-advanced automation opportunities.
Next-generation technology will help tell users when a
pump, hose, or machine is ready to fail. However, as equipment
gets more complex and capable, managing that complexity
through easy-to-use human interfaces with the machine will
be very important.
Are todays engineers up to the task?
Yes. That being said, the way systems are engineered is
changing. Traditionally, major manufacturers were vertically
integrated, with in-house engineering experts in areas like
hydraulics. But challenging economics have taken a toll. Weve
had a couple recessions and consolidation in many industries,
creating bigger, public companies keenly focused on the bot-
tom line. When times are tough, they downsize and lose expe-
rienced and talented people. And when times improve, they
tend not to bring them back.
So here we are teetering on the brink of a rebirth of American
manufacturing, and OEMs no longer have the skill sets necessary
to create the next generation of automation in plants or on prod-
ucts. This is where todays high-tech integrators are stepping up.
The Changing Role of
System Integrators
Whats the role of the integrator?
Many integrators have strong legacies in fluid power. Theyre
often privately held with long resumes of automation expertise.
Over the years they have acquired a lot of knowledge often
the hard way and are resilient and they stick around. Price
Engineering, for example, has been in business for 60 years. We
have skills that can be difficult to find in todays OEMs.
These types of companies are also willing to innovate.
Theyre generally small-to-midsize regional companies that
got better by partnering with smaller and experimental OEMs,
or they recognized opportunities that differentiated themselves
from the pack. Theyre dedicated, hardworking, and a bit crazy.
Being privately held affords them the opportunity to do things
public companies would never consider.
Theyve developed a strong set of competencies, niches,
and differentiators with core teams of engineers and software
designers. Around the country, you can find highly skilled inte-
grators with expertise in virtually any kind of market.
What challenges do integrators face?
As industry and technology evolve, there are numerous chal-
lenges. First, in the fluid-power industry weve had some bad
habits. For instance, we would give away the engineering to
sell products. We have to make sure we sell our value.
To fill the ranks of our engineering teams, we have to recruit
from new sources, create training programs within our organi-
zations, and develop educational partnerships. We need to get
more involved in programs like FIRST, where future engineers
are learning about fluid power and automation.
We also face some significant technology challenges. The
traditional methods of engineering are changing. We need to
acquire skills in areas like CFD, mathematical modeling, and
simulation, and embrace concurrent engineering to complete
projects faster.
Finally, projects are getting larger and more complex, involv-
ing multiple engineering disciplines. That demands better
project management skills and perhaps new tools, processes,
people, and strategies in how we become professional engi-
neering-services entities.
Across the country, companies are emerging that have mas-
tered the integration of fluid power with other technologies for
advanced power transmission and motion control. OEMs are
just beginning to realize the value integrators provide.
34 08.15.13 MACHINE DESIGN
-
High Speed Optocouplers in Industrial
Communication Networks
Introduction
The ACSL-7210 is a dual-channel bi-directional 25 MBd high speed digital optocoupler optimized for full duplex industrial communication applications for example PROFIBUS fi eldbus and Serial Peripheral Interface (SPI). The ACSL-7210 utilizes Avagos proprietary IC and patented packaging technologies to achieve 3,750 VRMS signal isolation in a low profi le SO-8 package while supporting high speed full-duplex data communications with data rates of maximum 40ns propagation delay.
Figure 1: ACSL-7210 block diagram.
Patented Packaging and Stacked LED Technologies
Avagos patented packaging process of stacking LED die directly on a silicon IC substrate enables higher integration in monolithic IC packaging and low profi le. Figure 2 shows a cross-sectional view of one of the two channels in ACSL-7210. Input logic signal controls the CMOS LED driver buff er IC, which supplies current to the LED. The
photodetector IC comes with two transparent layers: SiO2 passivation or insulation, and light-transmissive polyimide on top. The LED attaches to the photodetector IC with a transparent connecting layer. Standard die attach process is used to make all the placements.
Unlike conventional standard LED that emits lights on the same side as the metal contacts, Avago develops the back emission LED that emits light from the reverse side of the LED. This allows LED to stack on top of the detector IC.
Figure 3: Standard LED vs Back Emission LED.
This patented packaging technology provides the advantage of high integration, with ACSL-7210 being a dual-channel bi-directional optocoupler utilize for PROFIBUS isolated data communication applications. Another advantage is low profi le package (See Figure 4). ACSL-7210 can be mounted on the back-side of the PCB board to maximize the use of board space.
Figure 4. Profi le packages comparison.
Industrial Communication Networks
Fieldbus (or fi eld bus) refers to a family of industrial computer network protocols used for real-time distributed control of instruments. As shown in Figure 5, an automated industrial system such as a manufacturing
The Avago Advantage
Technical Notes
Your Imagination, Our Innovation
Sense Illuminate Connect
ACSL-7210
VOA
GShield
1VDD1
GND1 4
VDD2
ND 2
VOB
VI A
VIB 3
2
8
5
6
7
Data InData Out
Data OutData In
Photodetector IC Dielectric
LED
LED Driver Buffer IC
Input
Leadframe
LED
Light-Transmissive
PolymideTransparent
Connecting Layer
To LED Driver
Buffer IC
Photodiode ICSiO2
Passivation
Insulation
Ouput
Leadframe
Passivation
Passivation
Active Layer
P Metal Pad
Standard LED
Back Emission LED
P Metal Pad
Epi & Substrate
Epi & Substrate
N Metal Pad
N Metal Pad
Active Layer
Double Mold
~2.5 mm
Stacked LED
~1.6 mm
Dielectric
Placement
~3.2 mm
Planar
~2.5 mm
Figure 2: Cross-sectional view of one channel in ACSL-7210.
-
assembly line usually needs an organized hierarchy of controller systems to function. From the top hierarchy is a Human Machine Interface (HMI) where an operator can operate the industrial system. This is typically linked to a middle layer of programmable logic controllers (PLCs) by a non-time-critical communications system such as Ethernet. At the bottom of the control hierarchy is the fi eldbus that links the PLCs to the assembly line components, such as sensors, actuators, electric motors, switches, and valves. In such industrial environment, high voltages, magnetic fi elds and noise are commonly present. High reliability is also critical to avoid production downtime and ensure data transmission accuracy. Using optocouplers such as ACSL-7210 address to these isolation needs.
Figure 5: Hierarchy of controllers and instruments in automated industrial system.
Figure 6 shows the typical application diagram for 25MBd bi-directional ACSL-7210 and 10MBd ultra low power ACPL-M61L providing isolation in PROFIBUS (RS485) communication. ACSL-7210 isolates the transmitting and receiving data channels while ACPL-M61L isolates the transmit enable signal.
Summary
With its patented packaging and stacked LED technologies, dual-channel bi-directional 25MBd ACSL-7210 optocoupler meets the high switching speed and small package size requirements from industrial communication networks, for example PROFIBUS applications in noisy industrial environments.
Reference
1. ACSL-7210 product page
www.avagotech.com/pages/en/optocouplers_plastic/plastic_
digital_optocoupler/high_speed_cmos_logic_gate/acsl-7210/
2. ACSL-7210 product brief
www.avagotech.com/docs/AV02-4094EN
3. White Paper Fieldbus Applications with Optocouplers
www.avagotech.com/docs/AV02-3090EN
Figure 6: Isolated PROFIBUS (RS485) communication using ACSL-7210 and ACPL-M61L.
Contact us for your design needs at: www.avagotech.com/highspeed
Avago, Avago Technologies, the A logo are trademarks of Avago Technologies in the United States and other countries. All other trademarks are the property of their respective companies.Data subject to change. Copyright 2013 Avago Technolog