Product Design & Development - June 2015

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JUNE 2015 70TH YEAR, ISSUE 5WWW.PDDNET.COM

Watlow’s new controller, the F4T with Intuition, combines the functionality of multiple devices.See page > 9

LEMO has announced a new watertight connector series, the T Series.See page > 18

COMPONENT, SYSTEM AND APPLICATION SOLUTIONS FOR DESIGN ENGINEERS

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30Intelligent Underwater Robots

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4 JUNE 20154 JUNE 2015

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10 Engineering Answers

Validating Designs on the Living Heart

The Living Heart Project is revolutionizing the development and testing of cardiovascular products, diagnoses, and treatments with 3D modeling and simulation.

16 Motion Control

Improving Product Quality with Custom Bearings

Custom bearings can be sized to an application’s specific needs, improving the assembly process, and boosting product quality.

20 Materials

Glass-Filled Nylon Laser Sintered Parts

Synergeering’s home brew of glass-filled nylon powder material has properties comparable to production material.

26 Brainstorm

Automation What future automation systems should

design engineers know about now in order to stay ahead of the curve?

22Engineering Answers

Intelligent Underwater

RobotsBy providing robots with control over higher-level decision making, engineers and scientists have more time to focus on scientific objectives.

6 At Issue

7 From pddnet.com

8 First Look

14 New Products

29 Marketplace

30 Final Thought

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6 JUNE 2015

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M e l i s s a F a s s b e n d e r , E d i t o r

AtIssueThis month’s Brainstorm asks what

design changes must be made in order for wearables to become

adopted by the general population (Brainstorm page 24). The consensus? Smaller, longer lasting batteries. While I don’t contest these answers, the reason that I don’t wear my FitBit has nothing to do with its size or charging requirements – it was comfortable on

my wrist, water-resistant, and since I charge my phone every night, I had no problem plugging in one more device.

My issue was that the wearble didn’t provide me with any real ben-efit. Although I quickly jumped on the bandwagon, as my dad and sister decided we would compete to see who could get the most steps on any given day (we are a wildly competitive fam-ily), the novelty soon wore off, and I removed my FitBit for good.

What my FitBit did tell me was that I really don’t walk that much some days (so is the life in a cubicle) and I really don’t sleep that soundly at night. But I knew these behaviors already. The wearable just made it difficult to deny. Apparently walking to the coffee machine and back doesn’t force me up and around as much as I had hoped (even though it happens regularly, all day, because of the aforementioned sleep issues and general caffeine addiction).

My other qualm: It didn’t give me any credit for going to yoga but my dad racked up his steps by simply rocking in his La-Z-Boy. Needless to say, my dad still wears his, although he did take a short hiatus from the tech in a period of frustration, as he has less patience with the device’s charging time.

According to a recent report by Pew Research Center, 83 percent of experts say wearable technology will have a “widespread and beneficial effect” on the public by 2025. While I don’t doubt the consensus, I don’t think this “ben-eficial effect” will be the ability to count how many steps we take in a given day.

Recently, I had to wear a Holter monitor, a medical device that continu-

ously recorded my heart's rhythms for 24 hours (don’t worry, I am quite positive any issues stem from my aforementioned coffee consumption). However, I was able to avoid a long stay in a hospital bed because of this technology. Although the technology is not new (Norman J. Holter invented telemetric cardiac monitoring in 1949) it is an example of where wearables have an opportunity to really improve quality of life.

The device let me go along about my day as normal, but it was very uncomfortable and bulky. Simple tape was still used to secure the electrodes to my skin – apparently some instances offer no high-tech solutions.

My issues with consumer wearables persist, and I remain hesitant about the many expert reports that predict our future. Yet any time I find myself feel-ing doubtful about impending technol-ogy, I remember that my grandfather grew up nothing during the Great Depression, and now he can FaceTime with his grandchildren on his new iPhone. That is pretty amazing.

What do you think? Will wearables change our lives for the better? Email me at [email protected].

When WearablesActually Work

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6 May 2015

At the International Plastics Show-case (NPE) in Orlando, FL, the usual excitement surrounded 3D

printing. What may have been more im-pressive was the amount of companies that were actively looking to reshore, and the reports of those working to keep their facilities and workforce in the U.S.

Describing this as an “encouraging sign,” Scott Paul, the Alliance for Amer-

ican Manufacturing (AAM) president, recently shared his thoughts when I spoke with him about the current state of manufacturing.

“Strength of the dollar is a concern for any company with international exposure,” says Paul, adding that the growing concern with the strength of the U.S. dollar has increased as American exports could become less competitive. Evidence validating these concerns has emerged recently as the March trade figures were released by U.S. Census Bureau and the U.S. Bureau of Econom-ic Analysis, through the Department of Commerce. The numbers “showed an explosion in our trade deficit,” adds Paul.

The goods and services deficit was $51.4 billion in March, up $15.5 billion from $35.9 billion in February. Accord-ing to AAM, this is the largest monthly expansion in the trade deficient since December 1996.

Other data is indicating that manufac-turing job growth may be in a slow-down period, and while Paul explains it is not a recession, it is “obviously a concern.” Ultimately, compared to last year’s manufacturing growth, 2015 is not off to an encouraging start – not yet.

“There are still a number of com-panies that are looking seriously at bringing work back to the U.S.” A recent poll by Ipsos reported that eight in 10

Americans would prefer to protect jobs when asked to choose between access to goods and American manufacturing jobs.

Paul was encouraged to see this for himself at NPE, as many attendees visited the AAM booth explaining their decision to manufacture in the U.S. Yet this wouldn’t have been the case seven or eight years ago, he says. “It would have been the opposite point of view

with companies looking to close down production in American.”

The factors encouraging this shift towards “Made in America” include, the ability to control inventory, quality, and shipping costs, in addition to mitigating political risks.

Other factors encouraging a shift toward American manufacturing is the ongoing wage pressure in lower-cost areas in Asia. Paul explains that as wag-es rise, cost calculations are different, adding that energy costs are becoming relatively low for U.S. manufacturers as well.

Paul’s last observation pertains more specifically to commodity manufactur-ing, as he explains, “There seems to be some global overcapacity that’s driven by over production in China as the economy is slowing there.” This creates some challenge for U.S. manufacturers.

In the face of these challenges, many are still moving work overseas; however Paul still remains optimistic, as fewer companies are making this decision, and more are beginning to realize the benefits of “Made in America.”

What are your thoughts? Is optimism warranted? Or do the concerns outweigh the encouraging signs? Email me at [email protected].

AtIssuewww.pddnet.com

M e l i s s a F a s s b e n d e r , E d i t o r

The Weak Dollar, Wage War & Why ‘Made in America’ is Still Better

5

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From pddnet.com

Integrated Circuit First ProposedOn May 7, 1952, Geoffrey Dummer’s concept of theintegrated circuit was first proposed in a research paper.

An integrated circuit from an EPROM memorymicrochip shows the memory blocks, the supportingcircuitry, and the tiny silver wires which connect theintegrated circuit die to the legs of the packaging.

Image credit: Zephyris, Wikipedia Commons

Bill Nye Answers Solar Sail QuestionsThe craft,colorfullynamed theLightSail, uses32 squaremeter sails– which willeventually bepacked into a30 centimeter CubeSat – to reflect photons.

Image credit: Josh Spradling/The Planetary Society

Engineering Newswire:Flying Car Crash Lands in Test Flight

AeroMobil took to the roads and to the skies with itsflying car prototype, AeroMobil 3.0. However, duringthe test flight, the inventor and test pilot, StefanKlein, had to activate the ballistic parachute systemafter encountering what is being described as an “unexpected situation.”

Image credit: AeroMobil

www.pddnet.com 7

Portable BeerDispenserThis invention is “easy to use,convenient, compact, energyefficient, labor efficient,cost-effective, fast, safe,neat, electricity-independent,self-contained, [and]portable.” And, it’sfor beer.

“Simplicity is the essence of brilliance. Mydad, an industrial engineer who designed largefactories, paper mills, and other process plantswas always fond of saying, ‘Any idiot can makeit complicated.'" − Old Fart, PD&D commenter

Hybrid Car Batteries Live On atYellowstone ParkAt the Lamar Buffalo Ranch field campus in YellowstoneNational Park, solar panels generate renewable electricitystored within 208 used Toyota Camry Hybrid battery packs.

Image credit: Toyota

PD1506 07 From PDD indd 7 5/26/2015 1:21:08 PM

8 JUNE 2015

FirstLook

8 May 2015

Shielded Power InductorsCoilcraft's (Cary, IL) new MLC75xx Series of shielded, high-cur-rent power inductors have soft saturation characteristics that make them suitable for VRM/VRD designs and other applications with occasional overcurrent require-ments. Features include:• Isat ratings up to 59.2 A.• A DC resistance down to 1.2 m.• A measurement of 7.0 x 7.5 mm.• A max height of 4.2 mm.

Why Would I specify?• The MLC75xx Series inductors are constructed of

proprietary materials that are not subject to thermal aging issues associated with other iron powder core inductors.

• Coilcraft offers the series in 7 inductance values ranging from 0.10 to 2.17 µH.

• The inductors feature RoHS compliant tin-silver (96.5/3.5) over copper terminations and offer a maxi-mum reflow temperature of 260°C.

www.coilcraft.com

Silicon Carbide XY Air-Bearing StageAerotech (Pittsburgh, PA) has developed the PlanarHDX, a commer-cially available planar air-bearing platform for semiconductor manufac-turing and test and inspection. Features include:• Directional gain sched-

uling.• Iterative learning

control.• Harmonic can-

cellation.• An ETM

(enhanced throughput module) option.

• Passive or active iso-lation systems.

• Speeds to 1.5 m/s.• Accelerations to 5 g.

Why Would I Specify?• The PlanarHDX structural elements were designed using an

advanced silicon carbide ceramic with a specific stiffness (elastic modulus/density) 5 times higher than aluminum and a coefficient of thermal expansion approximately 5 times lower.

• Using proven air-on-air preloading in critical bearing elements improves turnaround and settling times over vacuum-preloaded designs.

• A proprietary reaction-mass design reduces stage-induced forces in the step-axis that are transferred to the isolation system or custom-er’s structure. By minimizing the dynamic forces, move-and-settle time is reduced and process throughput is increased.

www.aerotech.com

Reverse Displacement MotorDanfoss (Ames, IA) has expanded on its Reverse Displacement Motor (RDM). The open circuit piston motor offers reverse circuit functionality without external valves offering a hydraulic system solution for mobile equipment applications. Features include:• A 12 or 24 V integrated proportional shifting valve.• A speed sensor option.• Increased displacements.

Why Would I Specify?• The RDM enables customers to achieve up to 10% power savings, a 15% average

reduction in total system cost, and reduced system complexity.• The reverse functionality of the RDM enables the fan to purge trapped dirt and debris, restoring cooling efficiency. Additionally, the

fan drive packages can be tuned to meet the cooling requirements of Tier 4 equipment applications.• The simplified design of the RDM eliminates the external valves and pressure supply required in typical reversing solutions and elimi-

nates the cost and pressure losses associated with them.www.powersolutions.danfoss.com

Two-Axis Gear-Drive GimbalAerotech (Pittsburgh, PA) has announced AMG-GR gear-driven motorized gimbals. Features include:• An economical, high-accuracy, 2-axis gimbal design.• Front surface reflecting and centered cell options.• A direct encoder option for increased accuracy/repeatability.• Circular (100 to 300 mm) and custom cells.

Why Would I Specify?• The AMG-GR is available in a variety of standard travel

ranges in both azimuth and elevation to fit any application, accommodating customized travels.

• The modular design permits each gimbal mirror cell to be modified or replaced with different shaped cells to accommodate sensors or other asymmetrically shaped payloads.

• The AMG-GR can be outfitted with brushless servo or stepper motors, and a full range of matching drives and controls are available for a complete single-source solution.

www.aerotech.com

Long Range UltraSonic Sensors PIL (Germany) has announced its new P43 ultrasonic sensors to measure distances. Applications include object recognition for agriculture and fluid levels, distance measuring for trucks and loading ramps, level sensing in dusty conditions, parking lot detection/barrier monitoring as well as a variety of other industrial and manufacturing applications. Features include:• A range from 250 to 6,000 mm. • A standard analog 0-10 V / 4-20 mA output.• 2 integrated internal LED’s for echo justification.

Why Would I Specify?• M12, M18, and M30 dimensions are available –

with or without thread or cubic housing. • The sensor provides a small sound cone shape,

and analog internal sensors, and there is no need for digital translation and no loss of accuracy.

• In addition to these fixed settings, the P43 series can be programmed via Teach-In for various other custom settings.

www.pil.de

Diaphragm PumpThomas by Gardner Denver (Sheboygan, WI) has announced the Thomas 1610. The diaphragm pump combines precise and consistent performance with low sound levels. Features include:• A volume flow rate of up to

8.0 l/min.• A vacuum of up to 90%.• A pressure of up to 2.0 bar.

Why Would I Specify?• The Thomas 1610 features a 30% faster evacuation

time than the industry standard. • When running under full load, the pump operates with

a low sound level that remains stable over the entire performance range.

• The pump features a plug and play design of connectors according to customer specifications.

www.thomas1610.com

Large Diameter Pneumatic CylindersFesto (Hauppauge, NY) has introduced the DSBG line of ISO 15552 large diameter tie rod cylinders in 160, 200, 250, and 320 mm sizes. The DSBG cylinders are quieter, cost less, and are more durable than the cylinders they replace. Features include:• An operating temperature range of up to 150°C.• Applicability in harsh environments.• A rating for 2,700/4,200 lbs. (12,000/18.8 kN) force

(DSBG-160/200).

Why Would I Specify?• DSBG cylinders come standard with an elastomer bumper or

an adjustable air cushion for noise reduction and, with the air cushion, higher energy absorption than the previous line.

• The higher load bearing capacity of the DSBG improves protection against overpressure and ensures easier handling and operating efficiency.

• Stud bolts are available for vertical or horizontal mounting in demanding environments, such as mining and water/wastewater.

www.festo.com/us

www.pddnet.com 9

From the CoverHard Contact Surface,Straight Beam PhasedArray ProbesGE Measurement & Control(Germany) has introduced theMB.FPA16 and B.FPA16 ultrasonic probes,the world’s first straight beam phased array probesto feature hard face, direct contact surfaces instead of non-abrasive protective membranes. Typical applications include fast,accurate, and comprehensive inspection of billets, welds, andforgings in a range of industrial sectors. Features include:• Frequencies of 2 MHz and 4 MHz.• The ability to inspect workpieces up to 100 mm thick.• An ergonomic and robust housing• A low-profile, fingertip design with a height of 14 mm.

Why Would I Specify?• By matching a low impedance composite transducer material

with a high impedance hard face protection, there is no needfor surface protection or delay lines which can cause recurringinterface echoes, reducing the inspection range, and affectingthe probability of detection of small defects.

• The phased array operation of the probe eliminates the need forwedges, which further increases the probes’ sensitivity, especiallyfor near-surface defects, and reduces inspection times.

• The new probes are each available at frequencies of 2 MHz and4 MHz. B.FPA16 probes have a longitudinal steering wave rangeof ±35°, and MB.FPA16 probes a steering range of ±45°, whichprovides comprehensive sector scan coverage without the needfor wedges.

www.ge-mcs.com

DIN Process Controllerwith Touch-ScreenWatlow (St. Louis, MO) has announced its newF4T with INTUITION temperature process controller.Watlow’s new controller combines the functionality ofmultiple devices, including temperature PID, over/undertemperature limit, power switching, math, logic, timers,and counters, into one integrated system. Featuresinclude:• A 4.3”, capacitive color touch panel with high

resolution and graphical user interface.• Agency certifications, such as UL, FM, CE, RoHS,

W.E.E.E., and NEMA 4X/IP65.• Communications options, including Ethernet Modbus

TCP and SCPI and EIA 232/485 Modbus RTU.

Why Would I Specify?• The F4T controller offers robust algorithms for

temperature, cascade, altitude, humidity, andcompressor functions, which lowers ownership costs,eliminates the need for separate discrete components,reduces complexity, and simplifies ordering andinstallation.

• The touch panel and graphical user interface providesintuitive navigation and screen personalization, whichallows channels, alarms, inputs, and outputs to beprogrammed with user-defined specifications.

• The F4T features Watlow’s new COMPOSERgraphical configuration PC software that connectswith the controller via Ethernet. COMPOSER speedsup and simplifies commissioning and archives anddocuments controller setup.

www.watlow.com

High-Load HexapodsPI (Physik Instrumente) (Auburn, MA) has announced theH-845, a new series of preconfigured high-load hexapods. Thisnewest addition extends PI’s catalog to 50 standard hexapodscovering a variety of applications, from palm-sized units for micro-manufacturing to high-speed motion simulators and vacuum andUHV compatible units. Features include:• 6 axis motion with virtual pivot point (XYZ, pitch, roll, yaw).• The ability to handle up to 1 metric ton.• An actuator resolution <50 nm.• A velocity to 20 mm/s.• A repeatability to ±2 μm.• A positioning range up to 220 mm (linear) 60° (rotations).

Why Would I Specify?• The H-845 series features 6 degrees of

freedom, no moving cables, and a large clearaperture – advantages of the parallel-kinematicdesign – resulting in fast solution implementationadaptable to various needs.

• Each hexapod comes with the C-887 highperformance vector motion controller, whichpowers the 6 hexapod axes and 2 additionalmotorized single axes.

• All position values can be commanded simply asCartesian coordinates and the center of rotationcan be changed on the fly with a software command.

www.pi-usa.us

10 JUNE 2015

MED

ICAL

“Through decades of research and practice, there is a wealth of scientific knowledge, technology, and expertise,” explains Steve Levine, chief strategy officer and director of the Living Heart Project for Dassault Systèmes. “But this knowledge has been fragmented across thousands of different groups.”

Seeking to unite these groups, the Living Heart Project is a collaborative initiative with the mission to translate this knowledge into tools and services to address CVD. The initiative joins bioengineering professionals and various experts with regulatory groups who hope to revolutionize the development and testing of cardiovascular products,

diagnoses, and treatments through the use of 3D modeling and simulation.

“The human heart is actually an incredibly sophisticated machine, that in many ways is more complex than any man-made machine,” explains Levine. “We are just beginning to

understand the interdependency of all of the elements in the heart to allow us to bring together knowledge gained from different groups into a single model that replicates the full range of behavior under a variety of conditions.”

Bringing together knowledge that has been independently validated, but never used in unison, was the project’s biggest challenge. To do this, the team used a crowdsourcing model developed specifically for the project.

“Our model allows for each relationship to be uniquely shaped to fit with the constraints of the contributor, protecting the aspects that they choose and allowing us to share the collective outcome to everyone’s benefit,” says Levine. “The results are published in reviewed journals so the crowd is even further enhanced to include the entirety of the scientific community.”

3D Heart SimulatorThe current heart simulator is based on detailed 3D

model geometry derived from actual patient scans. To convert the raw geometry into a living model, the team had to define the tissue’s electrical and mechanical properties, including physical elements, such as the muscle’s dynamically changing fiber orientation.

“Once defined, we simply stimulate the sinus node [the system that controls the heart rate] as nature would.The electrical pulse is conducted through the heart in the appropriate pathways, which leads to a mechanical response,” such as a heartbeat, explains Levine. This required a tightly coupled multiphysics simulation environment, which was developed over decades to support manufacturing applications.

Cardiovascular disease (CVD) is the leading cause of death worldwide. The

disease costs the U.S. more than $300 billion each year, and this number continues to grow.

By Melissa Fassbender, Editor

Above and top right: The Living Heart Project’s human heart simulator is demonstrated in The CAVE, a 3D immersive environment that displays images on the walls and floor at Dassault Systèmes’ U.S. headquarters in Waltham, MA. Users wear a special headset to experience 3D viewing and navigate the environment with a joystick-like device. (All image credit: Dassault Systèmes)

Validating Designson the Living Heart

www.pddnet.com 11

“We have been fine tuning the parameters of the model to replicate the actual motion and response of a normal, healthy human heart,” says Levine. “We see this as becoming the first baseline model by which other models can be referenced and devices can be tested.” Future versions will expand the behavior range and amount of disease conditions that can be modeled.

The model could also be used for something as simple as patient education, as understanding what the problem is and how it’s going to be treated has proven to make a big difference in a patient’s outcome.

Most importantly, Levine says, “It is a step function above what’s available today for being able to validate new products in the human environment without actually using a human – which is much more convenient.”

Yet, the model’s uses are virtually endless. “A lot of creative people will come up with new ideas with how to use the model,” says Levine. The simplest way to use it, is for rapidly evaluating product design.

“[Engineers] can try radical new designs that could be breakthroughs that they couldn’t possibly do before,” adds Levine.

Personalized Medicine“For centuries, [the medical] field has been driven as

predominantly observational, relying primarily of use of animals or humans to understand the performance of new devices or pharmaceuticals, supplemented by bench research which was typically disconnected from the end use environment,” says Levine.

Today, technologies such as 3D printing, simulation, and augmented reality have advanced what is possible in the medical industry. Additive manufacturing, specifically, is poised to be a breakthrough technology in the field, and is an apt partner to support a 3D heart simulator.

“Instead of cranking out small, medium, or large options... You can come up with product families that can be tuned to an individual patient and then eventually printed as needed,” says Levine.

Doctors may also 3D print models of a patient’s heart to aid them in pre-surgical planning.

“It’s personalized in the sense that you want to select the right device for that patient,” adds Levine. While this is done to some extent today, “it can be better,” he adds.

The team is also beginning talks with pharmaceutical companies about being able to help them understand why certain patients respond to treatment while others don’t. “If they can understand the correlation between which treatment affects the disease, they can adjust it to what’s appropriate,” explains Levine.

With multiple end-users, with various backgrounds, the team also had to balance the model’s computational efficiency with scientific rigor, to develop a tool that is both practical to use and accurate. “Once again the structure of the project has allowed us to get direct guidance from those who will be the end users of the model, so we do not have to guess,” says Levine.

Working for Good DataThe biggest engineering challenge in developing the heart

simulator was fine tuning the model. “Because of the active nature of the heart, it is virtually impossible to perform testing of the material properties in the use environment,” explains Levine. Therefore, the team had to take indirect measures, modifying them based on a range of observed properties, which in themselves were a challenge to obtain.

“Getting good data is difficult, because the industry has never systematically collected good data,” says Levine. “Unlike manufactured products made from commercial materials, the detailed properties of the tissues and muscles of the heart defy the typical approach to testing.”

Other industries, such as aerospace or automotive, have been driven to develop simulation technology by the direct economic benefits it offers. Reducing time-to-market and prototyping costs fueled innovation.

“In medicine, while the socio-economic benefits of accurate simulations of the heart or brain would be profound, it if far less

direct and typically spans multiple steps in a supply chain,” says Levine. “We recognized a need for an organization to take the leadership role in coordinating this, and it had to be a commercial venture to be sure the final hurdle will be overcome, that being a direct vehicle to bring the technology to market.”

But the interest and the need is there, and the work is more than warranted. The team has already been approached by proximal groups who want to adapt the model for other organs, such as the brain and lungs. “Part of the hope when I started the project is that we could really crystalize the function around something core like the heart, and provide a template for the community,” says Levine.

Recently, Levine led a group through Dassault’s 3D immersive cave at the company’s headquarters in Waltham, MA. After walking through The Cave, and using the holographic heart tablet, one participant said, “I just realized that one day my kids are going to look and say, ‘Can you believe we used to perform surgeries without simulating what we were going to do first?’”

In that moment, it became clear to Levine that the way surgeons operate today is pretty crude compared to the technology that is available.

“I think we are on the threshold of finally crossing that bridge where people realize you can do this,” he adds. “It’s just a matter of committing to it.”

12 June 2015

NG

NG

ONE PARTNER FOR EVERY PART

S TR ATA S Y SD I R E C T. C O M

1- 8 8 8 -311-1017

[email protected]

A F UL L S U I T E OF T R A D I T ION A L

& A D D I T I V E M A N U F A C T U R I N G

TECHNOLOGIES

From 3D printed prototyping to full-scale production, Stratasys Direct Manufacturing empowers designers and

engineers with solutions at every stage of the design and development process. Discover our industry-leading

machine capacity and full suite of traditional and advanced manufacturing services to manufacture your products

better, faster and more affordably. To learn how Stratasys combined the widest breadth of technology and experience

from the industry’s top service pioneers, visit S T R A T A S Y S D I R E C T . C O M

7374_SB_TECH_SPRD_H1_PRODUCT_DESIGN_DEVELOPMENT_0615.indd 1 5/7/15 12:07 PM

www.pddnet.com 13

NG

NG

ONE PARTNER FOR EVERY PART

S TR ATA S Y SD I R E C T. C O M

1- 8 8 8 -311-1017

[email protected]

A F UL L S U I T E OF T R A D I T ION A L

& A D D I T I V E M A N U F A C T U R I N G

TECHNOLOGIES

From 3D printed prototyping to full-scale production, Stratasys Direct Manufacturing empowers designers and

engineers with solutions at every stage of the design and development process. Discover our industry-leading

machine capacity and full suite of traditional and advanced manufacturing services to manufacture your products

better, faster and more affordably. To learn how Stratasys combined the widest breadth of technology and experience

from the industry’s top service pioneers, visit S T R A T A S Y S D I R E C T . C O M

7374_SB_TECH_SPRD_H1_PRODUCT_DESIGN_DEVELOPMENT_0615.indd 1 5/7/15 12:07 PM

14 JUNE 2015

FAST

ENIN

G &

ASSE

MBL

Y

14 JUNE 2015

Self-Clinching FastenersNew patented microPEM TackPin Type T4 self-clinching fasteners have been introduced by PennEngineering (Danboro, PA) for installation into stainless steel or higher-strength aluminum alloy sheets. This latest addition to the microPEM family of fasteners enables sheet-to-sheet attachment for a range of applications in compact electronic assemblies wherever disassembly will not be required. Features include:� An interference fit to minimize hole tolerance issues.� A tapered tip to assist in location.� A low-profile head to save space.www.pemnet.com

Enclosures with Glass PanelsOKW’s (Bridgeville, PA) multifunction INTERFACE-TERMINAL enclosures are now suitable for touchscreen applications. The cases can be ordered with a high quality glass panel fitted in the top to protect the touchscreen underneath. Features include:� A design for use with Version II base sections. � Clear RoHS- and REACH-compliant safety glass with an

anti-reflective coating and high scratch-resistance. � 3 sizes: S for 5.7, 6.4, and 6.5” screens; M for 7, 7.5, 8,

8.4, and 8.5” screens; and L for 8.4, 9, and 10.4” screens. � Assemblies that include the glass panel, mounting frame,

and adhesive foil.www.okwenclosures.com

Self-Lubricating Rod End Bearings J.W. Winco (New Berlin, WI) now offers WN 648 Self-Lubricating Rod End Bearings, in inch sizes. The RoHS-compliant rod end bearings are suitable for high load, low speed applications with hanging angles, requiring linear, rotational, or oscillatory motions. They are offered in both tapped and threaded stem versions. Features include:� Rod end bearing construction with zinc-plated low

carbon steel, with right or left hand threads.� Ball socket construction with low carbon, zinc-plated

steel, case hardened. � An external ring made of a special oil impregnated

bronze material.www.jwwinco.com

Self-LubricatingSelf-Lubricating Rod End BearingsJ.W. Winco (New Berlin, WI) now offers WN 648 Self-

14 JUNE 2015

www.okwenclosures.com

� An interference fit to minimize� A tapered tip to assist in� A low-profile head to savewww.pemnet.com

space.

www.pddnet.com 15

We love a good challenge.If you need a fl uid handling component for whatever reason, no matter how extreme, talk to The Lee Company. We’ve been solving complex fl uid control problems in all kinds of industries for more than 60 years. Our extensive family of precision fl uid control products offers unsurpassed

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We’re not just talking about off-the-shelf solutions, either. A Lee engineer will be happy to discuss your application, and develop a custom design if needed. From managing nanoliter droplets to creating fully integrated fl uidic systems, we’re unsurpassed in breadth and experience to deliver the precise, reliable performance you require.

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16 JUNE 2015

MOT

ION

CONT

ROL

Unfortunately, there are some instances in which adesigner is unable to definitively answer one or more ofthese questions. This dilemma results in the decision toselect a standard bearing – a safe and quick choice. Inmany instances, the standard bearing will work well andyields an appropriate outcome. In others, it results in abearing that is more expensive than necessary.

A standard bearing almost always exceeds the functionalneeds that the application requires, as they are designedto operate in a range of products and are necessarilymanufactured to carry heavy loads and run at high speedsand tight tolerances. The result is a bearing that is over-specified and costly.

A cost-effective alternative to an over specified standardbearing is a custom bearing. Custom bearings can be sizedto an application’s specific needs, which improves theassembly process and boosts product quality.

The following are six considerations to take into accountwhen specifying a bearing to meet a project’s cost andperformance requirements.

1. Select the Bearing TypeThe type of bearing needed is defined by the direction

of the load in the application. Thrust bearings support axialloads; radial bearings support radial loads; and angularcontact bearings support loads that are a combination ofradial and axial.

2. Define the Loads & SpeedsCustom bearings can be designed to carry loads from

ounces to tons and accommodate lower or higher speeds,depending on the application. The next step in creatinga custom bearing is defining these factors as closely asis practical. The combination of load and speed helpsdetermine the most appropriate style of bearing.

The uncertainty of load and speed in the applicationis often the factor that prompts the product designer todefault to a standard bearing. However, the safety factorthat is inherently built into a standard bearing often hasexpensive consequences that impact product design.

Custom bearings can be properly sized to fit the actualdemands of the application. Dependent on load and speedof the application, bearings can be designed with the rightnumber of rolling elements or by using races that have uniquediameters or widths. That means a housing or mount can bedesigned for a bearing that is smaller and less expensive. Itcan also mean that an adapter does not need to be added tofit a shaft or spindle to a standard bearing bore.

3. Consider the Operating EnvironmentEnvironmental conditions must be addressed to ensure

proper product operation. A standard bearing can failprematurely or might require extraordinary protection tofunction reliably for the life of the application.

• Corrosion – Will the bearing be exposed to salt water,sunlight, or chemicals that might quickly destroy astandard bearing? Choosing an appropriate materialsuch as stainless steel or an engineered plastic resincan mitigate the corrosive effects.

• Temperature – Will the bearing experience extremetemperatures or temperature changes during operation?Selecting materials that do not change dimensionally ordeteriorate in extreme conditions is critical.

The bearing selection procedureis a step-by-step process ofanswering a series of questions:

1. What type of bearing is needed?2. What are the loads and speeds of the

application?3. What is the operating environment?

Improving Product Quality withCustom Bearings

By Mark Bos, Vice President, National Bearings Company

www.pddnet.com 17

• Contamination – Will the bearing need to be protected from contamination or can it be designed to resist fouling? Dust, body fluids, and abrasive materials can destroy or compromise even the toughest standard bearings. Selecting the appropriate lubricants or designing bearings that do not require lubrication can dramatically improve bearing performance

4. Can the Bearing Do More than Just Rotate?Selecting a standard bearing requires the product

design to submit to the constraints of the bearing and limits design freedom. Opportunities to optimize the other components in a design are sacrificed for the sake of fitting the bearing into the design. A custom bearing can do more for a product than merely rotate – it can set a design free to do more.• More Compact – Standard bearings often contain

components that are not necessary to product functionality. A custom bearing can be simplified to eliminate unnecessary components. A product might only need a thrust retainer rather than a complete thrust bearing, or a roller bearing might not need an inner race.

• More Features – Only a custom bearing can be designed to incorporate additional features that can simplify assembly or improve functionality. A threaded mounting stud could eliminate a component in an assembly. A ratchet and pawl feature can create a bearing that turns in only one direction, produces an audible click to indicate position, and reduces the overall size of the product.

• More Quality – A custom bearing can improve the way components work together from the outset. An adjustable threaded mount can be used to eliminate misalignment due to variation of other components.

5. Improve Assembly ProductivityA subassembly that includes a custom bearing and

other components that work together in a product can dramatically improve assembly productivity. In some cases, components like bolts and adapters can be eliminated. In other instances, a subassembly that is ready to install in an assembly cell can improve throughput, reduce the number of parts inventoried, and help consolidate the supply chain.

Developing a custom packaging solution that presents bearings to assembly personnel ready to install, in the right quantities, and properly sized for the assembly area, can improve productivity and reduce the number of times that products are ferried from inventory to assembly cell and back again. Reusable and recyclable packaging can also be developed to reduce costs and waste.

6. Post-Production StrategiesOpportunities to improve the bearing specification

process don’t stop at the product level. Inventory management assistance is another way in which the process can be streamlined to the manufacturer’s benefit.

Radial LoadAxial Load

BEARING BASICS & BEYONDBEARING TYPE

LOADS & SPEEDS

OPERATING ENVIRONMENT

CORROSION

TEMPERATURE

CONTAMINATION

MORE THAN ROTATE?

IMPROVE ASSEMBLY PRODUCTIVITY

POST-PRODUCTION STRATEGIESPOST-PRODUCTION6

IMPROVE5

4

OPERATING3

2

1

Radial Load

Axial Load

Thrust Bearing

Roller Bearing

Washer

Roller

Needle Bearing

Thrust Bearing

Radial Bearing

Angular Contact Bearing

More Compact

More Features

Quality

Subassemblies

Custom Packaging

Post-production Strategies

(All image credit: National Bearings Company)

18 JUNE 2015

ELEC

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18 JUNE 2015

Qspeed 150 V DiodesPower Integrations (San Jose, CA) has announced a new family of Qspeed 150 V diodes. Features include:� Availability from 10 to 40 A in

common-cathode configuration. � Target applications in DC/DC

converters and output rectifiers for hard switching or soft switching.

� Immediate availability in DPAK, D2PAK, and TO-220 packages.

www.power.com

Indicators for Material Handling ApplicationsAPEM (Vista, CA) has announced its new Q series indicators, suitable for material handling applications and any panel mount configuration, including industrial control panels, automation and medical equipment, vehicles, and marine instrument panels. Features include:� Availability in red, green, yellow, blue, and white.� Availability with bicolor, tricolor, and flashing LEDs.� Solder lug/quick-connect terminals, wire terminations, and

200 mm elongated wires.� Availability in 7 different package sizes, 3 bezel styles, and

3 bezel finishes.� Available custom engraving and illumination. � Direct connection to 12 VDC, 12 VAC/DC, 24 VDC, 24

VAC/DC, 110 VAC, and 220 VAC.� Viewing angle ranges

from 70° to 100°.� A life expectancy of 100,000 hours.� An operating temperature range from -40° to +85°C.www.apem.com

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Watertight Connector LEMO (Rohnert Park, CA) has announced a new watertight connector series, the T Series. The T Series Connector offers a new design for the defense and security market, test and measurement, medical, and any other application that requires a watertight connection. Features include:� LEMO Push-Pull technology. � 2- to 32- contact configurations. � An outershell available in a black-chrome or

plated brass finish.� IP68 water protection. www.lemo.com

JUNE 2015

� IP68 water protection. www.lemo.com

From the Cover

www.pddnet.com 19

20 JUNE 2015

MAT

ERIA

LS

The company started off with one SLS machine; however, they have acquired a number of machines over the years. Today, Synergeering is one of the world’s only suppliers in the industry for large frame, glass-filled nylon laser sintered parts. The company’s laser sintering process builds parts without secondary support material, allowing users to build more complex geometries.

Part ProductionParts are produced using duel CO2 lasers that sinter

cross sections of parts in 0.15 mm layers using a unique material called RapidNylon. The material is a blend of glass-filled nylon that mimics a 30 percent glass-filled nylon 6 production material. The parts can even survive in temperatures up to 150°C.

“Our customers can use our parts as if they were injection molded,” explains Lindsay Lewis, Synergeering Group. “That way they can use their designs in real-life, harsh environments.” In fact, RapidNylon is resistant to alkalines, hydrocarbonates, and many fuels and solvents.

According to Lewis, two of Synergeering’s three SLS machines have the largest build chambers in the world, allowing parts to be built in one piece up to 28 x 15 x 23”. “We can build larger parts in less portions, or if [the parts] get larger than that, we can build them in portions and bond them together,” says Lewis.

RapidNylon Synergeering’s home brew of glass-filled nylon powder

material has properties comparable to production material and can even serve as a replacement for aluminum. It’s 1.25 g/cc density and 45 MPa tensile strength allow for the production of parts with increased rigidity.

Due to the material’s strength and resilience to harsh chemicals, the company no longer caters just to the automotive industry. “We accommodate many industries that need parts that can withstand high temperatures and harsh environments, like deep sea testing,” says Lewis. “We’ve produced aftermarket, military, marine, and consumer products parts – whether it be vacuum cleaners, underwater robots, or mop buckets.”

Synergeering also offers an infiltration process that allows for parts to withstand over 9 Bar of pressure. “Our post-process allows parts to be airtight and impervious to many harsh chemicals,” explains Lewis. “This includes fluids, oil, coolants, brake fluids, and low saturations of chlorine.”

Due to the post infiltration process, the glass-filled material’s porosity is sealed, making it resistant to air, water, and stains. The process is why the company specializes in producing fully functional intake manifolds and other under-hood components. The manifolds can even be run on vehicles and dynos over many days of testing, and they remain fully functional in pressures well over 100 PSI.

“What we specialize in is so far removed from other types of technologies,” says Lewis. “We’re able to better mimic products that engineers would have in final production.”

Rapid prototyping is a method of producing 3D parts without the use of molds

or tooling. The process is geared toward engineers and manufacturers who need a low quantity of parts in a short amount of time. In 2001, Synergeering Group sought to bring this technology to the automotive industry by opening up a facility to perform selective laser sintering (SLS) in Farmington Hills, Michigan.

Glass-Filled Nylon Laser Sintered Parts By Kaylie Duffy, Associate Editor

The RapidNylon material is a mix of glass-filled nylon material that mimics a 30 percent glass-filled nylon 6 production

material. (Image credit: Synergeering Group)

www.pddnet.com 21

The f irst name in 4K..From compelling visualization to immersive entertainment to powerful data display, the benefts of Sony® 4K projection

(4096 x 2160) are profound. We were the world’s frst with 4K and have the largest installed base of commercial 4K

projectors. Exclusive SXRD® technology delivers stunning contrast, color accuracy, consistency and uniformity. Now we’re

pushing even farther ahead with ultra-short throw laser light source models that open the door to new applications.

So the real choice isn’t which brand of 4K. It’s which Sony.

Schedule a demonstration at sony.com/4Kprojectors.

© 2015 Sony Electronics Inc. All rights reserved. Reproduction in whole or in part without written permission is prohibited. Features and specifcations are subject to change without notice. Sony, SXRD and the Sony logo are trademarks of Sony.

22 JUNE 2015

WIR

ELES

S

Most autonomous vehicles are commanded by a low-level sequence of instructions, such as a series of way points that guide the vehicle in a straight line. These sequences leave little latitude to compensate for failures, except to return to the surface and call for help.

Autonomous Mars rovers, spacecraft, and air vehicles are commanded in a similar manner; however, writing such a sequence is time consuming and error prone. Scientists spend most of their time writing these scripts, or low-level commands, leaving them little time to think about the actual scientific objectives.

In order to give autonomous underwater vehicles (AUVs) more cognitive capabilities, engineers at the Massachusetts Institute of Technology (MIT) have developed a new programming approach that allows humans to identify high-level goals, while the vehicle performs the decision making to best accomplish them.

In March, the team traveled to the western coast of Australia to test the autonomous mission-planning system. For three weeks, the MIT engineers, along with researchers from Woods Hole Oceanographic Institution, the Australian Center for Field Robotics, and the University of Rhode Island, tested several classes of AUVs and their aptitude to work as a team to map the ocean surroundings.

“Our cruise demonstrated that a large number of autonomous vehicles can be used at the same time to perform much more effective monitoring of the environment,” explains Brian Williams, aeronautics and astronautics professor at MIT, and principle developer of the mission-planning system.

COGNITIVE REASONINGWhile on the research cruise, Williams and his team

were able to demonstrate that their AUV, a Slocum Glider, could be commanded in terms of goals. These goals include telling the glider areas to explore, areas to avoid, the scientific value of the different explorations, and deadlines on when to perform the explorations.

The glider was then able to select which areas to explore, and which to skip, as well as to perform the explorations to meet all deadlines; and which paths to

Intelligent underwater robots have increasingly been deployed as vital tools for mapping the ocean floor

and monitoring pockets of the sea.

By Kaylie Duffy, Associate Editor

Programming Intelligent Underwater Robots

www.pddnet.com 23

safely move between the areas. The glider even decided where to go based on the locations and routes of other vehicles, so that they could simultaneously operate safely together.

Throughout the course of the three-week experiment, the team’s Slocum Glider operated safely among the company of other autonomous vehicles. Although the other vehicles used traditional sequences, Williams hopes that they will all eventually be commanded in terms of high-level goals.

“The first few days at Scott Reef were spent making sure that the Slocum Glider functioned properly, and that its acoustic sonar was doing an effective job of collecting data,” explains Williams. “Over subsequent days we added functions that enabled it to be commanded in terms of goals.”

First, the team added algorithms for the Slocum Glider to plan energy efficient paths, while safely navigating within close proximity to seamounts and other parts of the reef. They then added a capability that allowed the vehicle to monitor the state of its environment and to coordinate with the ship to gain information about the other vehicles’ locations. The glider used this information to adapt its routes after receiving updates each time it surfaced.

Next, the engineers added the ability to select, order, and schedule scientific goals, such as mapping out a certain location of the ocean floor. Due to this added capacity, the glider was able to adapt its goals, plan of activities, schedules, and routes every time it came to the surface.

Finally, the team used these capabilities to have the Slocum Glider achieve its goals while navigating around vehicles operating in the reef at the same time. “To be safe, gliders normally operate far away from reefs and the coast, where there is little concern about collision,” explains Williams. “We demonstrated that the gliders could operate safely and autonomously near places that are both interesting scientifically, but would be too dangerous for vehicles that operate using traditional approaches.”

SEA MEETS SPACEWilliams and his team have been working on high-level

programming for about 15 years. After NASA lost contact with the Mars Observer spacecraft just days before its insertion into Mars’ orbit in 1993, the agency realized it needed an autonomous system that would allow spacecraft to identify and fix problems without human aid.

By 1999, Williams, who was working at NASA’s Ames Research Center, had developed and demonstrated the new system on NASA’s Deep Space 1 probe, which successfully performed an asteroid flyby. “The system we demonstrated in March is similar, but the planner is much faster and more capable, and unlike the spacecraft, it reasons about how to move the vehicle around,” he adds.

The updated system’s hierarchal approach was actually inspired by the Star Trek Enterprise’s top-down command center. In fact, Williams even named his system after the fictional spacecraft.

At the highest level, the vehicle needs to decide which of the scientist’s goals it will achieve and which ones it will drop, acting as a communication officer – as Uhura did in the original Star Trek. At the next level, the vehicle needs to act as a captain to come up with a plan and a schedule for how to achieve its goals, just as Captain Kirk would do. Finally, at the lowest level, the vehicle needs to act as a skilled navigator (Star Trek’s Chekov), by planning how to move from one location to the next, while not colliding into the sea floor or other vehicles.

NASA’s system, Remote Agent, had the ability to plan and schedule activities, as well as to diagnose and repair its hardware; however, the system took eight hours to develop a plan, and needed a lot of guidance. “Our current system is able to come up with plans for more complicated systems within a fraction of a second, without needing guidance from a human,” says Williams.

FURTHER APPLICATIONSThe cognitive programming system was designed to work in

a large number of applications. According to Williams, enabling AUVs to do a better job of monitoring the environment will allow researchers and officials to manage natural resources more effectively.

Aside from underwater vehicles, Williams is also working with collaborators in Brazil to demonstrate how these techniques could be used to monitor crops with autonomous air vehicles. Additionally, the MIT team is working with the Caltech Jet Propulsion Laboratory to show how similar methods can be used to safely operate Mars rovers.

By providing robots with control over higher-level decision making, engineers and scientists would have more time to focus on scientific objectives, while the autonomous robot determines its own mission plan.

The new programming system would significantly reduce the size of the operational team’s need on research cruises, and AUVs would be able to traverse more rugged environments. Williams affirms, “In the future, we will want all the vehicles commanded in terms of goals, and we will want them to work collectively to achieve these goals.”

Researchers watch underwater footage from a number of AUVs exploring Australia’s Scott Reef (left). The MIT team’s Slocum glider that was used to test their system as seen in the water (right). (Images courtesy of the researchers)

24 JUNE 2015

HYDR

AULI

CS &

PNE

UMAT

ICS

Threaded Line VACEXAIR’s (Cincinnati, OH) new aluminum 3/8NPT and 1/2 NPT Threaded Line VAC AirOperated Conveyors convert ordinary pipe intoa conveying system for parts, scrap, trim, andother bulk materials. Features include:■ CE compliance.■ Instant response.■ Infinite control of the conveying rate.www.exair.com

Hydraulic ChucksERI America (Lake Zurich, IL) has announced Precision Hydraulic Chucksfrom WTE Präzisionstechnik GmbH (Germany). WTE manufactures standardhydraulic chucks with axial and radial adjustment in the most common shankforms. Features include:■ Temperature stability.■ Strong holding forces.■ Vibration damping.■ High radial stiffness.■ A solid construction and sealed clamping system.www.eri-america.com

Hydraulic MotorsBosch Rexroth (Buchanan, MI) has repackaged the compact series ofHägglunds hydraulic motors. The new Hägglunds CA 10 to 40 motors aresmaller and lighter, yet nothing has changed in their output. This gives themincreased power density, with the ability to deliver full torque and full speedsimultaneously. Features include:■ Motors that will extend the Hägglunds

series downward to 10 Nm/bar.■ A reduction of the motor diameter

while refining the internalconstruction.

■ 4 basic models and a varietyof displacements.

■ 14 configurations in smalltorque steps.

■ Hydraulic radial pistonmotors with a built-in abilityto withstand shock loads.

www.boschrexroth-us.com

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www.pddnet.com 25

TEST & MEASUREM

ENT

Harsh-Duty Photoelectric SensorsAutomationDirect’s (Cumming, GA) new FMseries harsh duty photoelectric sensors are IP69K-rated sensors in 3-wire NPN or PNP styles and areavailable in 27 washdown models. Features include:■ 10-30 VDC rectangular sensors.■ 316L stainless steel housings.■ Availability in diffuse, diffuse with background

suppression, and polarized retroreflective styles.■ Availability of through-beam models that are sold

as an emitter and receiver separately.■ Either an attached 2 m output cable, or an M8 or

M12 quick-disconnect.■ A selectable light-on/dark-on output setting.■ Available sensing ranges up to 10 m.www.automationdirect.com

OEM Pressure Transmitters &SwitchesGems Sensors & Controls (Plainville,CT) has announced the launch of itsModel 3800/3820 Series. The new seriesis a family of compact OEM pressuretransmitters and switches for hazardousarea and other hostile environments.

The Model 3800 Series features:

■ Availability in 7 ranges from 0 to 10,000psi (0 to 689 bar).■ A choice of loop powered (4-20 mA) orlow power (1-5 VDC) output.■ A ±0.25% URL (BFSL) linearity, hysteresis

and repeatability specification, with < 5 msresponse times.

■ Burst pressures that extend from 4x up to40x FSPR, with 2x or 3x overpressures.

■ NEMA4X IP66 housings.■ All stainless steel wetted parts.■ Hermetically sealed enclosures without O-rings.■ Optional dual seal approval and flush mounting.■ Field adjustability with a 5:1 turndown ratio (2:1 for 100 PSI).

The Model 3820 Series features:

■ An all stainless steel OEM pressure switch-transmitter.■ A standard 4-20 mA output and optional 1-5 VDC output.■ A 30 V, 120 mA normally open solid state relay switch with

±2% URL accuracy.■ Field adjustable pressure switch set points and pressure

measuring range via an optional calibration kit.www.gemssensors.com Ultrasonic Leak Detector

OMEGA (Stamford, CT) has announced anew series of CE compliant ultrasonic leakdetectors. The HHLT-1 series detectors aresuitable for pressure and vacuum system leakdetection, exhaust system, tanks and pipe leaktesting, as well as steam trap inspection andgas leaks. Features include:■ An ultrasonic sound range of 20 to 100 kHz.■ Suitability for chemical processing,

refrigeration, vacuum, and steam traps.■ The ability to detect cracks and openings.www.omega.com

Dual Channel TDRMegger (Norristown, PA) has announced the TDR2010,a dual channel, high resolution time domain reflectometer(TDR) for locating faults on all metallic cables, includingtwisted pair wires and coax cables. The TDR2010includes an auto set-up mode that enables the unit to beused instantaneously. Features include:■ Trace tagging.■ 5 output impedances: 25, 50, 75, 100, and 125 .■ A velocity factor between 0.20 and 0.99.■ An IP54 rating.■ An 800 x 400 pixel large color display.■ A resolution of up to 0.1 m.www.megger.com

26 June 2015

In the Product Design & Development Brainstorm we talk with industry leaders to get their perspective on issues critical to the design engineering marketplace. In this issue, we ask:

What future automation systems should design engineers know about now in order to stay ahead of the curve?

Aurelio Banda,President, North America,Beckhoff Automation

Rather than looking to the future, engineers should look to what is already available today to grasp and retain a competitive edge. What technologies are

truly open? Which are highly-connected? Forward-thinking design engineers should become well-acquainted with the ideals of Industry 4.0, which is being referred to as the fourth industrial revolution. The core Industry 4.0 concepts including increased connectivity in automation devices, the creation of “Smart Factories,” and cyber-physical systems already have the potential to revolutionize the manufacturing industry today.

The evolution of pervasive Internet connectivity in all devices has enabled instantaneous delivery of information, and this is not limited to consumer tech. This connectivity can now provide manufacturers a wealth of production and efficiency information and can foster better predictive maintenance, continuous improvement initiatives, and even object-oriented production methodologies. Increased connectivity and data analysis is already changing the operations of factories and the ways we think about modern manufacturing.

PC-based control technology perfectly addresses the requirements that go along with the integration of Industry 4.0 concepts. Many companies have been long-time proponents of Industrial PC (IPC) technology, due to the convergence of automation technology and information technology in one universal control platform. This means users of PC-based control already have available all standard hardware, multi-core processors, network capabilities, on-board security, and the software necessary to successfully enable the concepts of Industry 4.0 and Internet of Things. This includes standard Ethernet and Internet tools, industrial Ethernet, and emerging horizontal communication standards, such as OPC UA. Beyond connectivity, an IPC with PC-based control software can handle all the roles of a wide variety of components, implementing such functionality as PLC, motion control, kinematics, and condition monitoring, all in one hardware device with a compact form factor.

As manufacturers continue to search for better ways to streamline their operations, increase throughput, and speed time to market, initiatives that integrate the principles of Industry 4.0 provide a clear and present path to achieving these goals. Leveraging the customizable, highly-connected control solution of PC-based control enables companies to upgrade their systems as their needs and industry developments dictate, as they are no longer constrained by the limitations of traditional control systems.

Randall Restle, Director, Applications Engineering,Digi-Key

The next thing that everyone will have to know does not come to mind easily. Instead, it’s more of the same that I see coming. Electronic Design Automation (EDA) and Computer Aided Design (CAD) tools will continue to merge, which means engineers implementing schematics and printed circuit boards will also deal with 3D models to assure final assemblies fit as expected.

Digital fabrication, whether done with one’s own 3D printing facilities or sent to a fab house, will continue to grow. 3D printing can be done with all kinds of materials including metals – not just plastic. This could be useful for RF, EMI, and other electrical uses, so staying current is likely to be time well-spent.

More sophisticated tools will increasingly be used by more people because distribution models will evolve. I see a time coming when you will order a license for specialized software, maybe “cloud” software, for only the time period needed or for the emergency that just occurred. This will mean engineers might have to come up to speed on new tools because they could become affordable. It’s probably important to stay up to speed with what’s available and coming available.

Online training, known as Massively Open Online Courses (MOOCs), is growing as outlier educational organizations join the movement. It’s hard to see how these content originators can perpetuate given you can simply audit them for free, but they are important. You can bring your knowledge up to date by attending

material’s porosity is sealed, making it resistant to air, water, and stains. The process is why the company specializes in producing fully functional intake manifolds and other under-hood components. The manifolds can even be run on vehicles and dynos over many days of testing, and they remain fully functional in pressures well over 100 PSI.

“What we specialize in is so far removed from other types of technologies,” says Lewis. “We’re able to better mimic products that engineers would have in final production.”

www.pddnet.com 27

these virtual classes. I’ve brushed up on Statistics, Predictive Analytics, Database Systems, and many more topics much to my delight. They are very well done especially by the top universities like MIT and Stanford.

Theresa Woodiel, Global Communications Manager,Brian Phillippi, Product Manager,Embedded Systems, National Instruments

A number of factors provide insight into how design engineers can anticipate trends that are impacting the status quo:

1: Interdisciplinary development Historically, design engineers have not had

to design systems that took into account mechanical, electronic, and software into a single system. The days of building mechanical products are no longer just mechanic. This

convergence of interdisciplinary development isn’t going away and piecing together a complex system through different vendors and custom hardware is possible. However, design engineers will need to ask themselves, “But at what cost?”

2: Interoperability As design engineers build products,

they will increasingly need to build bridges between hardware and software platforms to coordinate interactions between these teams. As a consequence, design platforms need to be adaptive and scalable through software or added functionality that easily integrates into the overall solution.

3: Connectivity across distributed networks

A blind spot often refers to an area where a person’s view is obstructed. Drawing a parallel to automation processes, a blind spot typically means a lack of visibility into the process or network which is further complicated as processes become increasingly distributed. The answer, simply put, is designing and deploying using a platform based approach. The essence of a solid platform is that it is based on standard Ethernet technologies and capable of adapting to evolving standards to enable a more open and deterministic network that meets latency, determinism, and bandwidth requirements while maximizing interoperability between systems providers.

Platforms are proven to simplify the complexity of system design while increasing efficiency. Reconfigurable platforms capable of adapting and scaling over time are essential to meeting dynamic requirements over time. The tight integration of a real-time processor with a user programmable FPGA that is connected to modular I/O and programmed with system design software will facilitate rapid algorithm engineering and openly support multiple models of computation.

Doug Sanford, Sr. Technical Support Engineer, Newark element14

As a design engineer, there are multiple emerging automation systems to be aware of to stay ahead of the curve. First, we have seen an influx in inexpensive and mobile HDMI displays – like IDEC’s Groov software – that are allowing for the use of inexpensive tablets and smartphones and will take the place of traditionally stationary and costly displays. Second, wireless

switches – like Honeywell “Limitless” limit switches and Square D “Harmony” pushbutton switches – are reducing installation costs by eliminating the time it takes an installer to make long wire runs and by eliminating the wire itself.

Energy harvesting presents another major automation opportunity for design engineers. Installation and operating costs for those automation systems will continue to fall as energy harvesting technology provides power to sensors, actuators and nanotech sensors that will make wireless devices more versatile and last longer. Examples of this include: energy harvesting via machine vibration, piezoelectric energy harvesting

converting mechanical strain into energy and thermoelectric generators harvesting energy from industrial heat sources like motors and ovens.

The Internet of Things plays into the automation trend as well. The rise of IoT devices coupled with DCS (Distributed Control System) on PCs may supplant traditional PLCs with point-to-point wired sensors.

Lastly, centralized control residing within a single PLC may give way to more distributed peer-to-peer networks within a system. This will result in automation systems becoming more flexible and adaptive, to the point of diagnosing and repairing problems when they occur. They will also be able to perform more advanced functions like recognizing when the problem is too difficult for self-repair and requesting human assistance.

Are you a thought leader in your industry?

To participate in the next Brainstorm, email

[email protected]

Energy harvesting presents another major automation opportunity for design engineers. Installation and operating costs for those automation systems will continue to fall as energy harvesting technology provides power to sensors, actuators and nanotech sensors that will make wireless devices more versatile and last longer.

28 JUNE 2015

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Integrated HPLC InjectorVICI Valco’s (Houston, TX) new Cheminert C52 SeriesInjector presents the company’s first integrated motor/valve assembly designed specifically to be built into anOEM system. Using the Cheminert HPLC injector designand the 24 V motor from VICI Valco’s microelectricactuators, the C52 needs only to be connected to theinstrument’s power supply. Features include:■ A single contact closure.■ Determination of the injector’s position by whether the

closure is held high or low.■ An optional serial interface that

permits confirmation of valveposition and access to otherfeatures.

■ Availability in in 4, 6, 8,and 10 port configurations,stainless or PEEK.

www.vici.com

Custom Direct Drive Motor SystemsApplimotion (Loomis, CA) has introduced custom directdrive motor assemblies using its UTS frameless motor kitsand MicroE encoders. Features include:■ A low profile with large through holes for light beams,

wires, or slip rings.■ Zero-cogging UTS motor kits

inside.■ High resolution and

positioning accuracy■ Industry standard

compatibility withcontrollers and drivesfrom 24 to 300 V.

www.applimotion.com

Hybrid Linear ActuatorsHaydon Kerk Motion Solutions (Waterbury, CT)has announced linear stepper actuators for solenoidvalves in applications such as security door actuationsystems. The actuator reduces several problemscommonly associated with solenoids in securitydoor actuation systems, such as loud actuation andbuzzing during operation, spikes in inrush current,lack of power, and excess heat generated by thesolenoids. Features include:■ More than 200 thread designs.■ 4 motor frame sizes

below 43 mm.■ Low noise.www.haydonkerk.com

Absolute Rotary EncodersHeidenhain (Schaumburg, IL) is expanding its range ofabsolute rotary encoders by introducing new devices withthe SSI interface into its current 1000 series. Featuresinclude:■ An SSI standard resolution of 13 bits singleturn and 12

bits multiturn.■ A high-resolution position value through

external interpolation of the 1 Vppoutput signals.

■ 512 signal periods per revolution.■ An extended power-supply range

from 4.75 to 30 V.■ Inputs for programming the

direction of rotation and settingthe zero position of the absoluteposition value.

www.heidenhain.com

Vertical Lift StageOptimal Engineering Systems (OES) (Van Nuys, CA) has announced the AT10-120 Motorized Vertical Stage, a high resolution, low profile, high load vertical lift stage that can be integrated into various applications. Features include:� A large 220 x 140 mm (8.7 x 5.5”) drilled and tapped

platform.� A vertical travel of 110 mm (4.3”). � A resolution to 5 µ (non-microstepping) and 0.50 µ (10

Microstep Driver).� A repeatability to 10 µ at travel speeds of 5 mm/sec. � A low profile of 90 mm (3.54”).� A construction with black-anodized aluminum alloy.� A weight of 6 kg (13.23 lbs). � A load capacity to 15 kg (33 lbs).www.oesincorp.com

Vertical Lift Stage

PRODUCTDESIGN & DEVELOPMENT® RESOURCE GUIDE

Marketplace

Linear Position TransducersCatalog describes both low cost OEM models as well as rugged environmentally sealed models for heavy duty industrial measurement applications. Use catalog selection guide to determine which linear position transducer is most suitable for the application. Electrical outputs include voltage divider, 4 to 20 mA, 0 to 10 VDC, ±10 VDC and digital. Thirty measurement ranges from 0 to 2 in. to 0 to 2000 in. are available.

Unimeasure, Inc.(541) 757-3158 Email: [email protected]: (541) 757-0858 www.unimeasure.com

Catalog describes both low cost OEM models as well as rugged environmentally sealed models for heavy duty industrial measurement applications. Use catalog selection guide to determine which linear position transducer is most suitable for the application. Electrical outputs include voltage divider, 4 to 20 mA, 0 to 10 VDC, ±10 VDC and digital. Thirty measurement ranges from 0 to 2 in. to 0 to 2000 in. are available.

Advanced Ceramic SolutionsAstro Met’s unique advanced ceramics provide cost effective solutions to material performance problems in a wide range of demanding applications. “Amalox 68” a 99.8% alumina ceramic and “Amzirox 86” an yttria stabilized zirconia provided superior wear resistance, corrosion resis-tance, high temperature stability, low ther-mal expansion, high stiffness to weight ratio, biocompatibility and high dielectric strength.

AstroMet, Inc.(513) 772-1242; Fax: (513) 772-9080E-mail: [email protected] www.astromet

Astro Met’s unique advanced ceramics provide cost effective solutions to material performance problems in a wide range of demanding applications. “Amalox 68” a 99.8% alumina ceramic and “Amzirox 86” an yttria stabilized zirconia provided superior wear resistance, corrosion resis-tance, high temperature stability, low ther-mal expansion, high stiffness to weight ratio, biocompatibility and high dielectric strength.

AstroMet, Inc.

AdvertiserIndex Astro-Met Inc . . . . . . . . . . . . . . . . . . . . . . . . 29

Automationdirect.com. . . . . . . . . . . . . . . . . . . . 2

Brecoflex Co LLC. . . . . . . . . . . . . . . . . . . . . . . 18

Digi-Key Corporation . . . . . . . . . . . . . . . . . . . 1, 3

Keller America . . . . . . . . . . . . . . . . . . . . . . . . 19

Minalex . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pivot Point, Inc.. . . . . . . . . . . . . . . . . . . . . . . . 31

Proto Labs, Inc.. . . . . . . . . . . . . . . . . . . . . . . . 5

Scientific Systems Inc. . . . . . . . . . . . . . . . . . . . 24

Shear-Loc Products . . . . . . . . . . . . . . . . . . . . . 29

Sony Electronics . . . . . . . . . . . . . . . . . . . . . . 21

Stratasys Inc . . . . . . . . . . . . . . . . . . . . . . . 12-13

The Lee Company . . . . . . . . . . . . . . . . . . . . . . 15

THK America . . . . . . . . . . . . . . . . . . . . . . . . . 32

Unimeasure Inc . . . . . . . . . . . . . . . . . . . . . 28, 29

www.pddnet.com 29

To place a Marketplace ad call: Nick Pinto at 973-920-7745 or

[email protected]

Educated Guesses & Immediacy in the Desert

30 June 2015 www.pddnet.com

With the industry now revolving around instant gratification and part availability, companies need to be careful to not over-promise and under-deliver with new product introductions.

I n mid-May, hundreds of manufacturing, distribution, and independent sales reps descend

upon that shiny spot in the Nevada desert to conduct more business over a four-day span than most do over the four previous months.

This year, the 2015 EDS Summit proved to be no exception to previous iterations, and while the show found a new home at the Mirage Hotel and Casino, most attendees seemed onboard with the transition from the glitz and glamor at the much newer Cosmopolitan Hotel, which hosted the event the three previous years. Personally, I enjoyed the new venue; it was much easier to meet with industry pros without the Cosmo’s mood lighting and trendsetting bar locations. It was always difficult to rendezvous for an interview at a bar that existed between floors and had exceptionally poor lighting for a destination dubbed the Chandelier Bar.

Since the summit is less a tradeshow with an exhibition floor, and more of a common ground for closed-door meetings in suites, it was met with similar pain points as previous years, particularly a crux at the elevator bank at the top every hour. I find the yearly confusion and anger both maddening and quite entertaining. Standing in a line with the industry’s top lieutenants who are slowly becoming more and more agitated and, worse, late for their next meeting has taught me two things: We are not a patient people, and while many in attendance are designing, manufacturing, and selling the very components that make that elevator capable and reaching the 30th floor in less than five seconds, we are

lost when it comes to the limitations of architectural engineering and the basic flow of human crowds—no sir, I don’t believe that we can fit one more. Before the next event, I plan to send all registered attendees a basic crowd dynamics modeling and analysis tool.

Issues with patience and gross over-caffeination aside, the event provided opportunities to meet with some of the industry’s top suppliers to get their take on the current state of the industry, and find out more information on how they are making it possible for design engineers to continue to innovate while simultaneously cutting costs and/or time to market.

For Dave Doherty, executive vice president of operations at Digi-Key, the answer is not only part availability, but also listening to engineers to find out exactly what it is that they are looking for. While the MN-based company has 1.1 million parts in stock (and more than 4 million listed on its site), Doherty admits, “Engineers need to tell us why they like a product, because we’re making educated guesses every day. If there is one engineer that says [the part] has a purpose, how many more are out there thinking the same thing?”

Digi-Key is continuing efforts to expand its product line, with a particular focus on design tools (starter kits, modules, reference designs, etc.), but Doherty adds that the industry now revolves around instant gratification and part availability, so companies need to be careful to not overpromise and under-deliver with new product introductions. “Nothing frustrates an engineer more than to see a promised new part not materialize,” he says.

Instant gratification was a common

theme throughout the show, then again, it’s not often that you find a distributor still in business who chooses slow and steady over accurate expedience.

In a discussion with Steve Newland, senior vice president of Americas sales and global sales operations at Mouser Electronics, immediacy as well as accuracy were not only common themes, but differentiators. “When you look at what we do, it looks the same as what everyone else is doing,” he says. “Our differentiator is how we do it.”

According to Newland, as the company is shipping an order every three seconds to design engineers around the world, it’s critical for the company to get the order right every single time.

Mouser President and CEO Glen Smith echoes similar sentiments, but shifts the focus back on part availability. During an all-industry event at EDS 2015, Smith mentioned the 591,000 parts that Mouser has in stock, but adds, “If we don’t have it on the shelf, it’s not going to be designed in.”

For me, the biggest takeaway for design engineers harkens back to Doherty’s statement. If a distributor doesn’t have the part, let them know what you’re looking for. After all, you’re at the beck and call of more than 10 global distributors that are aggressively competing for your business (for example, the OEM is the biggest and fastest growing part of Mouser’s business).

What’s your take? Email [email protected].

David Mantey, Editorial Director

www.pddnet.com 31

32 June 2015

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