Machine Design 23 May 2013

May23,20l3
APentonMedlaPubllcatlon
TunelntoEngineeringTV.com
MOTION AMPLIFIERS: BIG
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FEATURES
MECHANICAL
into digital signals. Each rotation of the bearing generates
a predefined number of pulses or magnetic signatures,
which can be decoded in real time as rotational speed and
position. If there is too much EMI, the bearing and sensor
can be shielded.
Intelligent bearings such as these can serve as motor
encoders to monitor position, rotational speed, and di-
rection of motor shafts. They mount inside the motor
and provide reliable alternatives to conventional encod-
ers, which mount outside the motor. Variations on this
setup include end-of-
shaft multiturn sensors,
absolute through-shaft
sensors, and high-reso-
lution absolute-position
sensors for measuring
position, and roller en-
coders for making linear
measurements.
Steering units
Steeri ng uni t s for
steer-by-wire modules on
industrial and off-high-
way vehicles replace con-
Bearings have long been used to reduce friction, support
loads, locate shafts, and reinforce system rigidity. Today,
bearing designers are adding sensors, signal-processing
capabilities, and advanced housings, and combining seals
and lubricants in those housings. These smart bearings
offer OEMs and engineers longer service lives and more
options.
Heres a detailed look at these next-generation bearings
that will provide even higher levels of formand function.
Sensor bearings
Intelligent sensor bearings provide accurate informa-
tion on speed (rpm), direction, and incremental or abso-
lute position of rotating or linearly moving components.
They can generate signals that contains data such as the
number of revolutions, relative position/counting, and
if they are accelerating or decelerating. These intelligent
bearings contribute to productivity and reliability, and al-
lowfor more-compact equipment.
In a typical scenario, a sensor gets designed into the
bearing. The sensor is often an impulse (or code) ring
linked to the bearings rotating inner ring. The inner ring
contains a sequence of north and south-oriented mag-
nets. The sensor detects changes in magnetic fields as the
bearing and its magnets spin and converts those changes
Adding new
features and
capabilities to
bearings improves
productivity and
lowers costs.
Authoredby:
Mark Hinckley
Dlrector of Strateglc Pro[ects
SKF USA Inc.
Landsdale, Pa.
Ldlted byStephen J. Mraz
stephen.mrazQpenton.com
Resources:
SKF USA Inc.,www.skfusa.com
For some apps fromSKF,
including a Bearing Calculator:
http://tinyurl.com/ccj9g2h
BEARINGS
designed to
multitask
This cutaway drawing
of anac motor shows the
built-insensor (red/blue) that
generates speedandpositiondata,
whichcanbe usedas feedback signals.
MA 23, 20l3 MACH|NL DESIGN.com 74
MOTION CONTROL & MECHATRONICS
Small
but
MIGHTY
One example of a single-card
controller integrates upto
four solderable amplifiers,
a high-speedon-card
microprocessor, and
over 2 Mbytes of
combinedprogram
andmemory
space.
Basic motion-control system
Encoder, Hall-effect sensors
Dc-brush,
brushless-dc,
stepmotor
Amplier
Motion
controller
One, two,
or three-phase
connection
All-in-one machine-controller card
Host
Encoder feedback
Motors
Motors
Motors
Solderable
amplier
Solderable
amplier
Solderable
amplier
Signal
conditioning
Signal
conditioning
Motion
processor
Bus
decode
Bus
Limits, I/O, etc.
Motionsystems consist of three major
components: the controller, the amplifier,
andthe motor/actuator. The controller is an
integratedcircuit or printed-circuit cardthat
outputs control signals tothe amplifier based
oncommandedpositionandfeedback of
positionandvelocity informationtypically
fromencoders or Hall sensors.
Atypical
all-in-one
controller
card, in
this case
driving
four axes
using
solderable
amplifiers.
The last 20 years have seen precision amplifiers used for
positioning and velocity control make major strides in
power output, size, and control features. Applications
such as laboratory automation, semiconductor equip-
ment, and scientific automation make use of high-end
amplifier capabilities such as field-oriented control.
The cost of electronics is coming down to a point where
even industries identified with basic motion needs now
consider using high-end features, particularly where
smoothness, motor efficiency, and top speed matter.
Another key development is that of solderable ampli-
fiers, which let engineers build cards able to run an en-
tire machine. It is even possible to obtain amplifiers that
mount on the motor itself, a strategy that may simplify
wiring.
It is helpful to review exactly what modern motion-
control amplifiers can do. At their core, amplifiers accept
low-power control signals and generate higher-power
voltages to drive the motor. By far and away, the dominant
approach in amplification for motion control is to gener-
ate drive signals through a technique known as pulse-
width modulation (PWM), or just switching.
Switching amplifiers basically generate a variable duty-
cycle square wave that is filtered to give the desired out-
put signal. They take advantage of the ever-increasing
Motion amplifiers
occupying just a cubic
inch of space can handle
sophisticated tasks once
demanding multiple boards
and big heat sinks.
Authoredby:
Chuck Lewin
Pounder&vice president of Lngineering
Performance Motion Devices Inc.
8oxborough, Mass.
LditedbyLelandTeschler
leland.teschler@penton.com
Key points:
Solderable amplifiersprovide up toakilowattof powerin
packagesassmallasl.0 in.3
|mprovements inswitching amplifiersare the single biggest
factormaking suchall-in-one machine-controllercards
possible.
Resources:
Motion-control basics, http://machinedesign.com/BDE/motion/
bdemotion1/
Motion-control study guide,http://machinedesign.com/
ebook/motion-control-mechatronics/motion-control-study-
guide-0111
Motion-control trends,http://machinedesign.com/article/the-
top-three-trends-shaping-motion-control-0623
Performance Motion Devices Inc.,www.pmdcorp.com
for these effects to improve response time, efficiency, and
positioning accuracy.
Is current control always critical? For stepmotors, the
answer is yes because current control in steppers affects
nearly every aspect of performance top speed, posi-
tioning accuracy, heat generation, and more. There is a bit
more wiggle roomin dc-brush and brushless-PM-motor
applications. But as costs have dropped for electronics
and current-sensing hardware, active current control has
become the norm for all but a small number of motion-
control applications.
The term phasing refers to the selective application
of voltage or current to the windings of multiphase mo-
tors such as stepmotors and brushless-dc motors. Proper
phasing keeps these motors moving forward or backward
as directed by the host controller. Dc-brush motors, by
comparison, phase themselves using brushes or other
contacts to distribute the applied voltage to the correct
rotor coil as it spins. So dc-brush motors need no external
phasing control.
Stepmotors employ various phasing schemes such as
full stepping, half stepping and microstepping, depending
on the step increment. For brushless-dc motors, phasing
efficiency with which metal-oxide field effect transistors
(MOSFETs) and insulated-gate bipolar transistors (IG-
BTs) can switch on or off, rapidly applying a bus voltage
to a circuit load, and then disconnecting that supply from
the load to produce a particular commanded voltage.
Though switching amplifiers dominate motion con-
trol, there are still some applications where nonswitching
linear amplifiers (also called transconductance amplifi-
ers) are needed. They are three to five time times less effi-
cient than switchers, but linear amplifiers generate much
less electromagnetic interference (EMI) and thus find use
where that property is critically important.
Current control
Current control, also often called torque control in
servomotors, refers to the active regulation of current
flowing through each winding of the motor. Windings are
inductors, so they resist changes in current. In addition,
the motor itself is a highly dynamic environment that in-
duces back-EMF (electromotive force) onto the winding
as it spins. Both of these effects distort the actual current
flowing through each winding relative to its applied volt-
age. Amplifiers with current control actively compensate
MA 23, 20l3 MACH|NL DESIGN.com 46 MA 23, 20l3 MACH|NL DESIGN.com 47
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68
58
46
Servo parameters clarified
Servodrlvesonlyperformwellwhen
parametersarecorrectlyenteredlntothe
controls.Here,weclarlfythelnconslstent
termsandunltsformotorsanddrlves.
Small but mighty
Thecostandslzeofmotlonampllflershave
droppedtoapolntwherefeaturesonce
conslderedhlghendnowcanbeapplledto
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New ways to damp vibration
Llnear-axlsdamplnglmprovesthe
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Self-lubricating polymers
bolster can production
Aredeslgnellmlnateslubrlcatlonproblems
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Bearings designed to multitask
Bearlngmanufacturersareaddlngnew
featuresandcapabllltlestothelrproducts,
maklngthemmoreusefulandaffordable.
MA23,20l3 MACH|NLDESIGN.com 2
6XUH*HDU
3UHFLVLRQ
6HUYR*HDUER[HV
TheSureGearPGAseriesofhigh-precision
planetaryservogearreducersisanexcellent
choiceforapplicationsthatrequireaccuracy
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RS# 103
DEPARTMENTS
May23, 20l3
APentonMediaPublication
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SPECIAL ISSUE
Motion control
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EDITORIAL
Behlndthecorporate-strategyfacade
EDITORIAL STAFF
LETTERS
SCANNING FOR IDEAS
Customlzablecyllndersaresmallbutpowerful
Maklngaccuratemeasurementsonlargegantrymachlnes
REPORTERS NOTEBOOK
LOOKING BACK
COMMENTARY
STLMoverload
PRODUCTS
DATA FILES
BUSINESS INDEX
AD INDEX
CLASSIFIEDS
BUSINESS STAFF
BACKTALK
l0
l2
l6
20
28
35
8
80
98
l00
l0l
l02
l02
l03
ON THE COVER
ArobotlcarmbulltbyWelss.
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EDITORIAL
Behlndthecorporate-
strategyfacade
The Harvard Business Review has a reputation for carrying articles
detailing the cutting edge of management practices. Or at least that is
the impression HBR likes to cultivate. So, it is interesting to find that
fewer than 4% of the 65,000 living alumni of Harvards own illustrious
business school subscribe to HBR.
This statistic comes from Walter Kiechel, a one-time editorial direc-
tor of Harvard Business Press who recently wrote a book (The Lords of
Strategy) about companies in the strategy-consulting business. Kiechel
provides plenty of ammunition for those of us who have grown skepti-
cal about the value of a formal corporate strategy. In my own case, I
began noticing that strategies introduced in HBR articles, often with
a lot of fanfare, would invariably be discredited within a few years of
publication.
The prime example is the concept of business-process reengineer-
ing. The term became a euphemism for downsizing. Companies that
zealously reengineered their processes often found they were left
with staffs so lean that the absence of one or two workers jeopardized
the output of the whole operation.
Another invention in this category was a graph promoted by the
Boston Consulting Group. BCG advised conglomerates to plot their
businesses in one of four quadrants of a graph whose axes represented
market growth rate versus relative market share. The idea was to graph-
ically depict which businesses were stars, cash cows, dogs, or question
marks. This sort of portrayal was supposed to help managers decide
which of their businesses were worth additional investment and which
should be divested. In reality, the graph may have been more helpful
to a firms competition than to its managers. Competitors who could
figure out how your graph was arranged had a roadmap for the amount
of market-share loss that would relegate a business to the dog quadrant
and, thus, force a sale or exit.
The impression one might get reading Kiechels accounts is that man-
agers are right to treat ideas published in HBR with a certain amount of
distrust. Moreover, what you see published there may or may not have
value for business managers, but it certainly seems valuable for the writ-
ers. He says one HBR author confided that, You can get a years worth of
business, maybe two, on the strength of one (HBR) article.
And the idea that a company can gain a long-term advantage by plan-
ning strategic changes promoted by consultants may be an illusion. The
proof is anecdotal but compelling. Kiechel interviewed Tom Peters and
Robert Waterman just before their blockbuster business tome, In Search of
Excellence, came out in 1982. He asked them how the excellent compa-
nies they profiled had managed to become excellent.
According to Kiechel, Peters and Waterman didnt much want
to answer. It eventually emerged that in most cases, the excellent
practices that Peters and Waterman highlighted in their book had not
been learned at all. They had been instigated by the company founders.
Ensuing generations of management simply had the good sense not to
bollix up the works by changing things.
Thats something to keep in mind the next time management consul-
tants knock on your door with the latest brand of magic management elixir.
Leland Teschler, Editor
PS#l07
MA23,20l3
877-245-6247
www.clippard.com/cylinders
Cincinnati, OH
For the past 50 years, Clippard has been providing
quality cylinders for thousands of applications around
the world. Cylinders that are responsible for millions
of production cycles. Cylinders that provide
outstanding performance and payback.
O
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air cylinders
40
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the finest.
fast!
Performance that Engineers have Learned to Trust.
RS# 108
EDITORIAL STAFF
l300L.9thSt.Cleveland,OH44ll4-l503
EDITOR
Leland E. Teschler
leland.teschler@penton.com
MANAGING EDITOR
Kenneth J. Korane
ken.korane@penton.com
SENIOR EDITORS
Elisabeth Eitel
elisabeth.eitel@penton.com
Stephen J. Mraz
stephen.mraz@penton.com
ASSOCIATE EDITOR
Lindsey Frick
lindsey.frick@penton.com
INDUSTRY COVERAGE:
AUTOMOTIVE, PACKAGING,
MEDICAL
Stephen J. Mraz
CAD/CAM, MANUFACTURING
Elisabeth Eitel
Lindsey Frick
FASTENING & JOINING,
MATERIALS
Lindsey Frick
FLUID POWER
Kenneth J. Korane
MECHANICAL
Elisabeth Eitel
Lindsey Frick
Kenneth J. Korane
EDITORIAL PRODUCTION
Denise Greco
Editorial Production Manager
Randall L. Rubenking
Art Director
PS#l09
PS#ll0
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RS# 111
LETTERS
ateatareasonablerate,youarego-
lngtobepourlngalotofexcess
fuel down the lntake manlfold.
Computer-controlledfuelln[ectlon
certalnlyhelpslnsuchsltuatlons,
butltsnotamaglccure-all.
Llkethestlckersays,ourmlle-
agemayvary.Toobadtheydont
glveanylndlcatlonastowhy.
Brooks Lyman
The government and the corn
lobbydontwantyoutoknow,but
fuelmlleagelsalwaysmeasured
wlthpurepetroleumgasollne.On
theroad,consumersaretyplcally
uslngl0%,orevenl5%ethanol.
Thatalonecanaccountfora5to
l0% shortfall between LPA and
real-worldmlleage.
|maglnelftheLPAtested[ust
onecarongasollne,Ll0,andLl5,
andpubllshedtheresults.Thecorn
lobbywouldhavethecommlsslon-
ersheadonaplateln24hours.
Name withheld by request
Fuel from seawater
Arecentletterwrlter(1lmDegglt,
Peb.l4)lsdeadwronglnstatlng
thatCO
2
andH
2
cannotbecatalytl-
callycomblnedtomakefuel.CO
2
reactsexothermlcallywlthwaterln
thewell-knownreversewater-gas
shlftreactlontoproduceCOand
H
2
O.
COandH
2
reactexothermlcally
lnthePlscher-Tropschreactlonto
make[etfuel.Ontheotherhand,
Deggltlscorrectthatltwllltake
moreenergytobreakdownwater
tomakehydrogenthancanbeob-
talnedfromthe[etfuel.
Our current flghters need [et
fuelandltlsdlfflculttoconcelveof
aflghterdeslgnthatcouldemploy
Whos messing with
my mileage?
Ken Koranes commentar y on
mpgratlngs(WhostoBlamefor
BogusmpgIMarch6)blowsthe
whlstleontheLPAsmlleagetest-
lng.|shouldthlnkabetterwayto
gaugefueleconomywouldbeto
haveseveraldlfferentpeopledrlve
eachvehlcleoveraperlodoftlme.
Perhapstherecouldbesomesort
ofblackboxwhlchwouldrecord
the varlous condltlons tem-
perature, acceleratlon rate, ter-
ralngradlent,averagespeed,fuel
consumptlon, tlre pressure, etc.
andacomputerprogramback
lnthelabwhlchcouldbollthese
datadowntoanaveragempgfor
asmallsetofdlfferentandcom-
monlyencounteredcondltlons.
| once had a l984VW Pabblt
dlesel.|couldgetover40mpgwlth
thatcarbynottrylngtobetheflrst
awayfromtrafflcllghts,notaccel-
eratlngupsteephllls,andother
common-sensedrlvlngtechnlques
lncludlngkeeplngtlrelnflatlona
blthard(35to40psl).Andlf|had
reallyworkedatlt(coasteddown
hllls,forexample),|couldsome-
tlmes get 55 mpg. When | met
otherownersofthesamemodel,
|daskwhatklndofmlleagethey
weregettlng.Mostwouldclalm
about40mpg,butsomeowners
were only gettlng 30 mpg and
were stlll ecstatlc remember,
thlswasthemld-l980s.
|ttookallttlebltofgumptlonto
askthemwhatthetheyweredolng
wrong,butlf|watchedthemdrlve
away,|gottheanswer.Thedlesel
hadalotoflowendtorque(char-
acterlstlcoftheenglnedeslgn)and
thesehot-shotswouldfloorltas
theytookofffromastandlngstart.
Llttlewonderthelrmlleagewasso
poor.
Anotherrelatedthlng|learned
longagowhen|wasdrlvlnganun-
derpoweredTriumphHeraldwas
thatasmallenglnelsnoguarantee
ofgoodmlleageforreasonablyor-
dlnarydrlvlng.|fyouhavetoput
thepedaltothemetaltoacceler-
hydrogen as fuel.The potentlal
savlngsfromtheseawater-to-fuel
ldeacomefromtheloglstlcalcost.|
haveheardestlmatesapproachlng
$l00pergallontosupplyavlatlon
fueltocarrlersatsea.
Lloyd C. Brown
Paying the toll
The l ssue wl th l nfrastructure
spendlnglsmuchllkethatofedu-
catlon(ThePoadWellTraveled,
March20).Trlckle-downreductlons
lnspendlngatfederalandstate
levelsnecessarllymeanreduced
fundlngformunlclpalltlesandlo-
calltleswhlchbeartheburdenof
fundlnglnfrastructurerepalr.The
realproblemlsthatlnfrastructure
repalrfundlng,muchllkeschool
fundlng,lsseenbytaxpayersasa
necessaryandwelcomedexpense
andthlsmakesdollarsearmarked
forlnfrastructurelmprovements
easypreyforlobblesandspeclal
lnterestgroupsthatwantcashfor
otherpro[ectsanddlscretlonary
spendlng.TheresultILocallnltla-
tlvesralsetaxdollarsthatgetsl-
phoned and rerouted by local
comptrollers,knowlngthepubllc
wlllalwaysapprovefutureaddl-
tlonaltax-ralslngmeasures.Theso-
lutlonIPldeasportblkeorplckup
truckand[ustsaynotoaddltlonal
spendlng.
Ed Ponce
|tamazesmethattheU.S.lsadd-
lng more than a trllllon dollars
toltsdebteachyear,andyetwe
canonlyspend$90bllllononour
hlghwaysandbrldges.|ftherels
anythlngourtaxdollarsshouldbe
usedfor,ltlslnfrastructure!
Dan Bernier
Playing with those
mileage figures
Peadersknowthatmostthlngscanbe
measuredfalrlyaccurately,whlch[ustconfuses
themwhenthelrbrandnewcarsdontgettheLPAmlleageon
thestlcker.|slttheethanol,asonereadersuggestsI
'
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y
"
ContiTech products meet current and future needs in mobility, energy generation
and energy efciency, as well as health, nutrition and environmental protection.
Whatever we do, we do with one goal in mind: to provide economical solutions
for an intact environment and a better quality of life. Thats why we work with our
partners to nd innovative solutions to the most pressing issues of tomorrow. And
what we do works. Our expertise in rubber and plastics technologies makes us
theworlds preferred specialist for a range of key industries.
Rubber-stamped. Naturally.
In almost every branch of industry.
www.contitech.us
Conti Tech.Engi neeri ngGreenVa| ue
RS# 112
The new 955 eBrik linear displacement transducer.
Price and performance
so well balanced,
it just might displace
potentiometers.
Atlast,theresapurelyelectronicsolutiontopositionsensors.
Ournew955eBrikusesmagnetostrictivetechnologyso
theresnocontact,nomovingparts,nothingtowearout.No
erraticpositionsignals.Availablein1"to72"strokelengths,
itseconomicalandversatileenoughformanyapplications,
field-programmable,andtheperfectreplacementforold-style
potentiometers.Learnmoreatourwebsite.
ametekapt.com
LETTERS
LETTERS TO THE EDITOR
Pleaselncludeyourname,address,and
daytlmephonenumber.Lettersmay
beedltedforbrevltyandtofocuson
essentlalpolnts.
Mail: Letters, MACHINE DESIGN,
1300 E. 9th St., Cleveland, OH 44114-
1503, Fax: 216-621-8469
E-mail, Editorial:
mdeditor@penton.com
as|bellevethatwouldbenaive
andlnaccurate.Oh,dld|mentlon
werebulldlngFreightlinerTrucks,
Boeing 767s, and BMWs ln the
CarollnasnowI|mentlonthlsasa
seguetosaythat|grewuplnsnow
countryandchoosetollvehereln
asmalltownclosetomountalns,
lakes,andtheocean.Andnotev-
eryonelovesLAorblgcltles.
Werealreadyalanddlvldedby
a common language and many
cultures.Weshouldtryfocuslngon
theposltlvestuffweenglneers.
Kevin Hayes
by factors of 1.6 and 2.5, respectively.
If population predetermines trade
figures, the Japanese miracle in the
1960s and 1970s would have never
happened. In 1960, the population
of Japan was 93.4 million. (The U. S.
population was 179 million.) The
population of Japan grew at an av-
erage annual rate of 1.1% through
1970 while its merchandise exports
grew at an average annual rate of
16.9%. Leland Teschler
Lets just get along
|vemetandworkedwlthanum-
berofenglneersfromhlgh-tech
Callfornlacompanles(mentloned
byanearllerletterwrlterlnLvery-
onelovesLA),andwhllebrllllant
ln thelr respectlve flelds, some
couldntchangeablcycletlrewlth-
outhelpfromatechnlclan.
| wont make the mlstake of
generallzlngmycommentstoall
Callfornlaorhlgh-techenglneers
Math problems
|[ustreadyouredltorlal(Thank
God|AmNotaPreeTrader,1an.
l6),andltmademefrlghtenedby
yourlackofmathematlcalprow-
ess.ComparlngtheU.S.andBrltlsh
percentagesoftotalworldmanu-
facturlnglnl870andl9l3wlthout
anyconslderatlonoftherespectlve
countrypopulatlons,(letalonea
hostofotherpolltlcal/economlc
factors), ls utterly meanlngless.
Blamlng the change entlrely on
freetradelsludlcrous.
There l s a more-recent ex-
ampleofafreetradeagreement
youcouldhaveused,NAPTA,but
|doubtltprovldesevldencesup-
portlngyourconcluslon.
|expectmoreofafellowenglneer.
Matt Person
Population has little to do with trade
figures. Between 1870 and 1913 both
the U. K. and U. S. populations grew
PS#ll3
Solutions for Automation That Take You Straight to the Top
Unrivaled in scope and versatility, Schaefflers linear product line ranges
from shafts with linear ball bearings and monorail guidance systems to so-
phisticated actuators with drives and control systems, plus special coatings
and every conceivable accessory. You name it, weve got it.
But thats only the start. Our linear portfolio is based on a modular concept
that goes far beyond mere components. We can design a complete system
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ance systems started out as solutions to customers needs!
Class dismissed.
Superior-quality products.
Comprehensive reliable solutions.
www.schaeffler.us
2012
RS# 114
SCANNING FOR IDEAS
LdltedbyStephen J. Mraz
NPPAtle-rodhydraullccyllndersare
powerfuldevlces,buttheyregenerally
prettyhefty.Thesmalleststandardslze
usuallyhasal.5-ln.bore,accordlngto
offlclalsatNason,Walhalla,S. C.(www.
nasonptc.com).ThecompanysLl5
hydraullccyllnders,ontheother
hand,areratedforl,500psl
ofpressurebutcome
lnboresdownto
20mm,glvlng
englneersavlable
optlonwhen[obs
needlotsofforce
lntlghtspaces.
Theyremade
ofthlck-walled,
anodlzed-aluml-
numhouslngsand
endcaps,andare
assembledwlth
hardenedfasten-
ers.Chrome-plated
l045/l050-steel
plstonrodsand
steelplstonswlth
wearrlngsandrod
wlpersarestandardonall
models.Thealumlnumhouslngs
meanuserscanoptforamagnetlc
plstonforsenslngstrokeposltlon,
whlchcantbedonewlthsteelhydrau-
llccyllnders.
Self-lubrlcatlngbronzebearlngs
andlow-frlctlonnltrllesealsfactory
lubrlcatedwlthPTPLlmpregnatedgrease
helpensurelowbreakawayandrunnlng
frlctlon,hlghefflclency,andlongllfe.
TheLl5cyllnderscomelnslngleanddou-
ble-rodconflguratlons.Standardboredlam-
etersrangefrom20to50mm(0.79tol.97ln.)
andstrokesfroml5to75mm(0.59to2.95ln.),
wlthlnchormetrlcmountlngsandportsavall-
able.|nfact,becauseallma[orcomponentsare
machlned,deslgnsareeasllycustomlzedtouser
specs.AndallLl5Serlescyllnderscanberebulltln
thefleld.
RS# 401
Customizable cylinders
aresmallbutpowerful
Pabrlc-
relnforced
phenolresln
wearstrlp
Bolt-on
anodlzed
alumlnum
heads
Anodlzed-
alumlnum
houslngwlth
machlnedbore
Podwlper
Plgure-elght
hydraullc
plstonseal
Longbronze
rodbearlng
Hard-
chrome-
plated
steelrod
Request free information via our
Reader Service Web site at
www.nbcorporat|on.com
NB CORPORATION OF AMERICA
Hanover Park, IL 60133
Fax: (630) 295-8881
Toll Free: (800) 521-2045
Western Regional Office
Fremont, CA 94539
Fax: (510) 490-1733
Toll Free: (888) 562-4175
Eastern Regional Office
Ramsey, NJ 07446
Fax: (201) 236-5112
Toll Free: (800) 981-8190
With Tapped or
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*Externally threaded shafts
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RS# 115
Contrinex Inc.
Old Saybrook, CT 06475
Toll free: (866) 289-2899
Fax: (860) 388-3574
E-mail: info_us@contrinex.com
www.contrinex.com
MiniDist
TechnoIogy provides M5 sensors with a 2.5mm

operating distance more than 3X greater than standard
Mount further away from moving parts to reduce
mechanical damage and failure rates
Replace larger sensors wherever space is limited
Same electrical properties and protection functions as larger types
Contrinex Long-Range Miniature Sensors
SCANNING FOR IDEAS
Gantrymachlnesusedln
theaerospaceanddle/mold
lndustrlesprocesslarge
componentsthatneedtobe
machlnedaccurately.Butlt
lsdlfflculttomountanac-
curatescaleonagantryma-
chlneslargeworkenvelope.
Tosolvethlsproblem,engl-
neersatHeidenhain Corp.,
Schaumburg,|ll.(www.
heidenhain.us),developed
theLC200,amultlsectlon
absolutescalethatassem-
blesandmountsonagantry
orotherlarge-scalemachlne
tools.|tstongue-and-groove
deslgnletstheextruslonsofthe
scaleeasllyslldetogether.
Thescale,asteeltape,canmea-
surecomponentsandrawmaterlalsup
to28meterslongwlth5-maccuracy.
Butevenwlthlargemeasurlnglengths,the
posltlonvaluecomesfromonlytwogradua-
tlontracks.Theabsolutetrackhasaserlalcode
embeddedlnltthatprovldesunlquevaluesoverlts
entlrelength.Theothertrack,anlncrementaltrack,ls
lnterpolatedfortheexactposltlonvalue.
TheLC200soptoAS|Censureshlghoutputslgnal
quallty.Thedevlcecanbepoweredby3.6tol4-vdc
powersupplles.
RS# 402
Maklngaccuratemeasurements
onlarge gantry machines
PS#ll6
Scale-tape
groove
Bearlng-strlp
grooves
Center
element
Seallng
gasket
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RS# 117
REPORTERS NOTEBOOK
|fyouretoooldfortheSoapBox
Derby,notwell-heeledenoughfor
Pormula|or|ndyCar,andnottoo
thrllledabouthlghspeeds,butyou
stlllwanttorace,maybethethree-
yearoldPower Racing Seriesls
moreyourstyle.Thellghthearted
Serleswasbornoutoftheloveof
hlghandlow-techtlnkerlngandthe
prollferatlonofhackerspacesln-
dustrlalworkspacessetupforbulld-
lngpro[ects,especlallythosethat
repurposeexlstlngtechnologles
andequlpment.
|nthecaseofthePowerPac-
lngSerles,theorlglnalequlpment
comeslnPowerWheels,PerPeregos,
andLlttleTykes,wlthteamsaddlng
battery-poweredmotors.
Teamsaddpractlcallyanyklndof
electrlcmotors,aslongastheyrun
onl3to36-vrmsorlessandhavea
klllswltch.Powercomesfrombat-
terlesbasedonsealed-lead-acld,
llthlum-lron-phosphate,ornlckel-
metal-hydrldechemlstrles.Anytype
ofwheelsandhubsareallowedaslongasthey
arentsllcksortlreswlthraclngtreads,orper-
formancego-kartwheels.Andallthemotlve
powermustbetransferredfromthewheelsto
thetrack,sono[etenglnes.vehlclesmustalso
carrymechanlcalbrakesandmeasurenolarger
than70-ln.long,40-ln.wlde,andbenotaller
than72ln.,lncludlngthehelghtofthedrlver.
Anddrlversmustbeatleastl6-yearsoldwltha
vallddrlvlngllcense.
Teamsareencouragedtodecoratethelrve-
hlclesbutsharpob[ectsthatcouldharmother
drlversorcarsareforbldden.Andraceofflclals
wlllbanvehlclesfromraclngtheydeemdan-
geroustoothervehlclesanddrlvers,lncludlng
vehlclesthatdontlookllkethelrdrlverscan
controlthem.
vehlclemodlflcatlonsmustcostlessthan
$500,wlthafewexceptlons.Porexample,the
overallbudgetdoesnotlncludethecostofthe
lnltlalvehlcle(neworused),helmets,brakes,klll
swltches,orharnesses.Sparesandreplacement
partsarealsoexcluded.Butofflclalssuspectlng
ateamhasgoneoverthe$500allocatlonhave
theoptlonofbuylngthecarfor$500.Theof-
fendlngteamcanthenbuythelrvehlcleback
lftheyremovetheexpenslvegearandreenter
thenextraclngevent.
TheSerlesstartedwlthanlmprompturace
ln2009andhasgrowntoascheduleofflve
raceswlth29certlfledteams.Thlsyearsraces
wlllbeheldlnSanMateo,Callf.,KansasClty,De-
trolt,PortWayne,|nd.,andNeworkClty.
PowerPaclnghasltsownpolntsystem,
butasyoumlghtexpect,polntsscalesare
notqultellkethoseof|ndy.Lachteamhas
toquallfyfortheblgrace(s)ateachevent,
andthenearnpolntsranglngforflnlshlng
flrst(l00)downtoeleventh(l).Toaddsome
excltementandgetthecrowdlnvolved,
raceofflclalsletthecrowdvoteforteams
electronlcallyandlnrealtlmeasthevehlcles
race.CarshaveearnedtheseMoxlepolnts
forresembllngglantboomboxes,flrlngcon-
Hackers,startyourmotors,
lfyoucan
The red Fauxrrari from
Team Section 67 passes
another racer on the
inside at one of the
Power Racing Series
events.
Attheyear-endPlnals,threetrophlesare
handedout.TheTeslaCupgoestotheteam
thatgarneredthemostpolnts,bothforrac-
lngandmoxle.TheMoxleCupgoestheteam
thatrecelvedthemostMoxlepolnts.Andthe
ChampmanTrophygoestotheteamthatwon
themostraces.
PowerPaclngSerlesfounder1lmBurkesays
hewantstogethlghschoolslnvolvedlntheSe-
rlesandhavehackerspacesmentorteams.He
alsowantstofosterfunandlnexpenslveeduca-
tlonwlthreal-worldtrlalanderror.MD
fettlcannonslntothecrowd,andhavlngthe
drlveroutflttedasaMexlcanmaskedwres-
tler.Popplngawheellelsalsopopular.
Therearethreeawardshandedoutatev-
eryracetoflrst,second,andthlrdplace:The
Goldenes,TheSllverOK,andtheBronzeNo.
Andthereareotherawardsteamscanwlnlna
race.TheCrashandBurnAward,forexample,
goestotheteamthatspendsthemosttlmetry-
lngtogetbackonthetrackafterlnadvertently
golngcrosscounty,andTheMyPrettyPrlncess
Awardgoestothebest-looklngcarwhlch,
accordlngtoofflclals,lsrarelythefastestand
rarelylooksasgoodaftertheraceasbefore.
Resources:
Power Racing Series,
www.powerracingseries.org
A crowd favorite on the Power Racing Series circuit is Omni
Corps Detroit teams Banana Car, a rolling tiki bar with a
built-in sound system.
POWER DISTRIBUTION ENCLOSURES CLIMATE CONTROL
Thousands of enclosures
Hundreds of options
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REPORTERS NOTEBOOK
Inductive coupling
lets the Ariso system
transfer about 6 W of
power as well as four
or eight data channels
between a host and
remote devices such as
sensors and actuators.
One application
envisioned for Ariso
is in transferring data
and power between
end effectors and an
arm on an industrial
robot.
|nductlvepowertransmlsslonlsmaklngheadllnesthese
daysasameansofwlrelesslyrecharglngbatterlesln
electrlcvehlcles.Butlndustrlalusesarecropplngupas
well.ThelatestlslnasystemfromTE Connectivity,Har-
rlsburg,Pa.,whlchletsaremoteclrcultdrawpowervlaa
wlrelessconnectlonwhllealsobeamlngbackdlgltaldata.
DubbedArlso,thewlrelesslnductlve-coupllng
systemcantransfernot[ustelectrl-
calpowerbutalsodata(fouror
elghtchannelsdependlng
onthemodel)acrosssmall
dlstances,wlthoutany
contact.
Oneappllcatlon
ltsdeslgnershaveln
mlndlsasameansof
ellmlnatlngtheneed
forsllprlngssupplylng
powertorotatlngas-
semblles.|tsdeslgners
flgurethestatlonary
plecessuchasrobot
armscouldtransfer
powerlnductlvelytoa
rotatlng,lndexlng,or
flxedmobllepartsuch
asagrlpper.|nthlsway
powerbecomesavallabletopowersensors,
heaters,cameras,valves,motors,computers,orbat-
terleswhlledatafeedsbacktothestatlonaryplece.
TLalsosaysltsArlsosystemcoupllngoperatesln
suchdemandlngenvlronmentsasunderwater,lnvac-
uumchambers,lncleanrooms,whensurroundedby
greaseormud,oron
equlpmentsplnnlngat
hlghspeed.
ThecurrentArlso
deslgnlstyplcally
usedforsensorap-
pllcatlonswherethe
bandwldthneedsare
llmlted.|tcantrans-
ferdlgltalslgnalsat
aroundl kHz.Slxwatts
lsthemaxlmumpower
transferat24vdc.The
deslgnusesadc-dc
powerconverterwhlch
canalsohandlelower
operatlngvoltage
levelswlthmodlflca-
tlons.TLConnectlvlty
saysthedevlcescan
operateatlowervolt-
ageswlthoutaffect-
lngefflclency.Lnergy
transferacrosstheln-
ductlvegaplsenough
toprovldeacontlnu-
ous250mAat24vdc,
thoughhlgherpeak
currentsareposslble.
Thecompanysayslt
canalsodevlseunlts
wlthhlgherpower
ratlngsonrequest.MD
|nductlvecharglngstartstoreplacesllprlngs
Resources:
TE Connectivity,http://
connections.te.com/
SOFTWARE & SERVICES IT INFRASTRUCTURE
www.rittal.us
Acoustlccomponentshrlnksphase-arrayradars
PesearchersattheGeorgia Institute of Tech-
nologyhavedevlsedapasslvetlme-delay
componentwhlchwlllmakephase-arrayra-
darssmaller,slmpler,moreefflclent,andless
expenslve.Thethln-fllmdevlceconvertselec-
tromagnetlcwaveslntoacoustlcwavesuslng
aplezoelectrlctransducer(thechanglngelec-
tromagnetlcslgnalmakestheplezoelectrlc
materlalchangeshape,creatlnganacoustlc
wavethatmlrrorstheelectromagnetlcwave).
Theacoustlcwavestravelacrossthedevlce,
aboutafewmlcrons,thenhltsanotherplezo-
electrlctransducerthatconvertsthemback
toelectromagnetlcwaves.Thetlmespent
crosslngthosefewmlcronsasrelatlvelyslow-
movlngacoustlcwavescreatesthedelay.
Sofar,GeorglaTechenglneershavebullta
delaydevlcemeasurlng40m
2
thatcan
handletheentlreradarbandwldthwhlle
dellverlngal0-nsecdelay.
Currentphase-arrayradarsuseelectrl-
caldelayswhlcharemerelysectlonsof
cable.Padarslgnalstakeaboutanano-
secondtotravelacrosslftofcable.Thedelays
arecrltlcallnshaplngandsteerlngtheradar
beam,wltheachelementlnthearraytrans-
mlttlngafewnanosecondsaftertheprevlous
one.Wlthoutpropertlmedelays,slgnalsget
degradedbyperlodlclnterference.
Thenewdevlcecanbepackagedandln-
tegratedlntotheslllconsubstrateofaradar
component,replaclngmanyfeetofcable,ac-
cordlngtoresearchers.MD
Resources:
Georgia Institute of
Technology, www.
gatech.edu
PS#ll8
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e
w

S
t
a
n
d
a
r
d

i
n

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e
a
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e
d

A
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M
o
t
o
r
s
2 Times More Torque
High Strength, Long Life
Quiet Operations
Same Price As
Conventional Models
V Series geared
AC motors offer
distinct advantages
over conventional
geared AC motors
and now they are
offered at the same
price as our
conventional models.
Quick & Stable
Lead Time.
Visit
www.orientalmotor.com
Technical Support Tel: 800-468-3982
7:30am- 7:00pm, CST (M-F)
Stepping Motors Servo Motors AC Motors Brushless Motors
Linear & Rotary Actuators Cooling Fans
REPORTERS NOTEBOOK
Sequoia, a supercomputer at Lawrence
Livermore National Laboratory, simulated
the interactions between a fast-ignition-
scale laser with a dense deuterium-tritium
target as scientists there research fusion energy.
In this image from that simulation, the laser field is
shown in blue, the blue arrows illustrate the magnetic
field at the plasma interface, and the red and yellow spheres
are laser-accelerated electrons meant to heat and ignite the
fuel.
Pecordslmulatlonona
NatlonalLabsupercomputer
forpartlcle-ln-code(P|C)slmulatlons,tookallof
supercomputerSequolasl.5+mlllloncoresaslt
trackedanddlsplayedtheslmultaneousevolutlon
oftrllllonsoflndlvldualpartlcles.
Theslmulatlonmodeledtheeffectsapetawatt
(amllllonbllllonwatts)ofpowerfromalaserflash-
lngonandofflnlessthanabllllonthofsecond,
heatlngcompresseddeuterlumandtrltlum(fuel)
toover50mllllonC.
TheslmulatlonranuslngOS|P|S,aP|Ccode
thatusesallofSequolascodelnparallel.The
codetookl0yearstodeveloplna[olntprogram
betweenUCLAandPortugalsInstituto Superior
Tecnico.ThecodeletssupercomputersllkeSe-
quoladolnadaywhatwouldtakeamedlumclus-
terof4,000coresayeartocomplete.MD
Resources:
Lawrence
Livermore National
Laboratory,
www.llnl.gov
Sowhatdoyoudowlthacomputerthancancarry
outl6.3quadrillionfloatlng-polntoperatlonsper
secondIAtLawrence Livermore National Labo-
ratory,youslmulatethelnteractlonsbetween
ultrapowerfullasersanddenseplasmaslnaquest
tounlockfuslonenergy.Thatslmulatlon,arecord
PS#ll9 MA23,20l3
B
r
u
s
h
l
e
s
s

M
o
t
o
r

A
d
v
a
n
t
a
g
e
s
Compact, High Torque
Wide Speed Range
Continuous Duty
No Maintenance
Brushless Motors
offer all the design
exibility needed for
many different types
of applications.
Learn more about the
Brushless Motor
Advantages from
Oriental Motor.
Quick & Stable
Lead Time.
Visit
www.orientalmotor.com
Technical Support Tel: 800-468-3982
7:30am- 7:00pm, CST (M-F)
Stepping Motors Servo Motors AC Motors Brushless Motors
Linear & Rotary Actuators Cooling Fans
Plng-tabledeslgn
canhandlecarbodles
LnglneersatGerman-basedEDAGneededa
rotatlngrlngtableforsmall-lotproductlonof
cars.|thadtoholdasmanyasfourcar-body
tools,upto20tons,andhaveenoughroomln
ltscenterholetoaccommodateaheavy-duty
robot.Thetablewouldbeusedtokeeparo-
botlcarmbusyassembllngcarsaspleceswere
loadedandremovedfromtoolsnotbelngcur-
rentlyused.
Largerlngsonthemarketwerenot
strongenoughtobearthewelghtofthe
toolsnorlargeenoughtoencompassthero-
bot.ThecompanyworkedwlthWeiss North
America Inc.,Wllloughby,Ohlo,theflrm
thatdevelopedtheCPSerlesofrotaryrlngs
whlchfeaturelargeopencenters,tomodlfy
aCP2600tabletomeetkeyspeclflcatlons.
Thenewtablesdrlve-platevertlcalaxls
canwlthstandll2,400lbofdynamlcand
228,400lbofstatlcforce.Thecentralopen-
lngls6.5ftlndlameter.Andthetablelsonly
aboutafootofftheground,whlchmakes
manualloadlngeasy.
Thecustomlzedtablescanhandleman-
ualandautomatlcloadlngandalsoretaln
aspectsoftheCPSerles,lncludlngaflat
deslgn,zerobacklash,andefflclentpower
transmlsslon.MD
Resources:
EDAG, www.edag.de
Weiss North
America Inc.,
www.weissna.com
A robotic arm sits inside
the large rotary ring
built by Weiss for EDAG.
PS#l20 MA23,20l3
REPORTERS NOTEBOOK
Resources:
Stanford University,
news.stanford.edu
Panels cool
when the sun
shines
Engineers at Stanford Univer-
sity have developed panels
made from nanophotonic
materials that will keep build-
ings cool when the sun shines,
drastically reducing the energy
needed for air
conditioning. As a
bonus, the panels,
which have no
moving parts and
require no energy input, do not
contribute to the greenhouse
effect and warm the Earth. In
fact, they would cool it.
The panels would be made
of nanosized particles of quartz
and carbide, both weak ab-
sorbers of sunlight. The panels
would act as broadband sun-
light mirrors, reflecting most so-
lar energy away from the build-
ing. The particles on the panels
have also been engineered
to reflect sunlight as a narrow
band of thermal radiation at
a wavelength that does not
interact with the atmosphere.
This means the radiated heat
ignores the atmosphere, sails
through it, and gets dumped
into outer space.
Researchers estimate that
a square-meter panel would
provide 100 W of cooling,
about the same amount of
power provided by a square-
meter of 10%-efficient solar
panels. So the reflective pan-
els could replace solar panels
used to generate electricity
for air conditioning. And a
typical one-story house with
10% of its roof covered with
these no-maintenance panels
could offset 35% of its air-
conditioning needs during
the hottest hours of the day.
Researcher still dont know
what the commercial costs
will be. MD
RS# 121
MAY 23, 2013 MACHINE DESIGN.com 26
Mi c r ohy dr a ul i c s .
Ma c r o c a pa bi l i t i e s .
Lee Shuttle
Valve. Shown
actual size.
Designed to
isolate the
normal from
the emergency
hydraulic sys-
tem. So small,
it ts right
into the head
of an actuator.
W e s t b r o o k G e r r a r d s C r o s s P a r i s F r a n k f u r t M i l a n
So much reliability and performance, in so little space.
Creating high-performance ow control on a micro scale has been
The Lee Companys exclusive focus for more than 50 years. And
its been a successful mission, as evidenced by thousands of applied
Lee Microhydraulics designs ranging from less than 0.10 in. to 1.00 in.
in diameter, and 0.1 to 68 grams, for operating pressures to 8,000 psi.
But small size and light weight are just the beginning. Theres
also absolute reliability built into every Lee component through
100
%
testing and inspection. Zero defects. Its a production benchmark
that has enabled Lee to meet demanding application needs in all
sorts of industries. Aerospace, medical instrumentation, automotive,
machine tools and oil drilling, to name a few.
The innovative problem solvers.
We dont just satisfy requirements. We also solve problems
whether by simple modication, or ground-zero design engineering.
The Lee Company is the worlds most capable and proven source
for hydraulic-component innovation. And weve documented this
claim in extensive detail with the Lee Technical Hydraulic Handbook.
An invaluable reference, the Lee handbook contains essential data
on the entire Microhydraulics product line, which includes:
Lee Shuttle Valves. Detented, spring-biased, inverse,
loose ball and zero leak shuttle valves from 50-700 Lohms.
Lee Safety Screens. Best protection for critical system
elements. 75 to 500 micron hole size. Pressures to 7,500 psid.
Lee Pri. Pressure relief valves in insert form.
50 to 400 Lohm capacity. 20 to 5,400 psid cracking pressures.
Lee Directional Flow Control. 40 to 20,000 Lohms
in metered direction. 12 to 470 Lohms in free-ow direction.
Lee Restrictors. Single and multi-orice restrictors.
200 to 2.2 million Lohms.
Lee Plugs. The best way to seal drilled holes to 32,000 psi.
No O-rings, threads or sealants required.
Lee Cheks. All-metal and zero-leak check valves.
4 to 400 Lohms.
Essential reading
for designers of
hydraulic systems.
Send for your
free copy.
The Lee Company
2 Pettipaug Rd, Westbrook CT 06498-0424
860-399-6281 Fax: 860-399-2270
1-800-LEE PLUG
www.TheLeeCo.com
Innovation in miniature.
RS# 122
See us at the Paris Air Show, Hall 3 Stand A63
Phone 1-888-260-7466 Fax 516-771-6444
sales@ondrivesUS.com
www.ondrivesUS.com/Shafts
.US Corp.
Mount rotating components
Use with linear and radial bearings
Customize: Non-standard diameters and lengths
External or internal threads
Holes, grooves, ats, key slots
Diameters: 0.0312 to 1.2500 and 1 to 12mm
Diameter Tolerance: +.0000/-.0002 (+0/-.005mm)
Standard Materials: 303SS, 17-4PH, 316SS, 12L14
Hardness: HRB83 to HRC40 Surface Finish: 10in
Lengths: 3 to 60
Most sizes available from stock!
6WDQGDUGV&XVWRP
3UHFLVLRQ*URXQG6KDIWV
Reduce prototype costs with
our grooved shafts
REPORTERS NOTEBOOK
LOOK|NGBACK
10 YEARS AGO 2003
Transparent film keeps new
cars looking new: 3Msclentlsts
havedevelopedPalntProtectlonfllmto
protectavehlclesflnlshwlthoutchanglnglts
appearance.Thefllmlsaconformable,ther-
moplastlcurethanewlthaUvclear-coatlayer
heldlnplacebypressure-sensltlveadheslve.
Thefllmcanbeapplledtonearly
anypalntedsurface,lncludlngthe
frontend,rear-vlewmlrrorhous-
lngs,wheelwells,dooredges,fend-
ers,andbumpers.
30 YEARS AGO 1983
Hot/cold O-ring: Anewnltrlle
materlalfromtheO-Ring Div.of
Parker Hannifins Seal Group
functlonseffectlvelyoveranun-
usuallywldetem-
peraturerange.|t
offersoutstandlng
sealabllltyfrom65
to275P,andthls
lslmpresslvewhen
comparedtoother
goodlndustrlal
nltrllematerlals
whosetemperature
capabllltlesremaln
wlthlntherealmof30to250P,
accordlngtothecompany.Devel-
opedforalrcrafthydraullcservlce
wlthM|L-H-5606Bfluld,Parkers
newN756-75alsolssultableforuse
wlthnewer,moreflame-reslstant
M|L-H-83282hydraullcfluldsand
meetstheM|L-P-8346lspeclflca-
tlonaswell.|naddltlon,thecom-
panylsrecommendlngN756-75for
appllcatlonswlthlnthetransporta-
tlonlndustrles.
50 YEARS AGO 1963
Plastic truck body, tradenamed
UltrexbyUnion Carbide Plastics Co.,
lsfabrlcatedfromepoxyreslnflber
glasslamlnates.Thesheetlng,whlch
lsverystrongandextremelyreslstant
tolmpactandabraslon,lsbondedto
ahlgh-strengthsteelframe.Thetruck
hasallghtlyplgmentedtranslucent
roofwhlchprovldeslnterlorlllumlna-
tlonwlthoutskyllghtsandwlthouta
greenhouseeffect.Doorsare-ln.
plywood,cladwlthUltrexsheet.MD
Together, we can nd whichever
ParkerTube Fitting you need.
The new Parker FittingFinder App is the ultimate interactive resource for all Parker
tube ttings and adapters. Within seconds, you can identify replacements, nd part
numbers, pull specs and dimensions, locate nearby distributors, and so much more.
All simply through your mobile device or tablet. The new Parker FittingFinder App is
the fastest, easiest way to identify leak-free solutions onsite and inhand.
Download it from your Apple or Android app store now. Or visit
ParkerFittingFinder.com to check out the web app and get more information.
ENGINEERING YOUR SUCCESS.
www.parker.com 1 800 C-Parker
RS# 123
REPORTERS NOTEBOOK
COMPANNEWS
PARTNERSHIP
FIRST(Por|nsplratlonandPecognl-
tlonofSclenceandTechnology)
andNational Instruments(N|),
Austln,haveextendedthelrtechnol-
ogypartnershlpthrough20l9wlth
thegoalofcreatlngmoresclentlsts
andenglneers.FIRSTengagesyoung
peoplewlthmentor-basedrobotlcs
programsthathonorsclenceand
technology,lnsplrelnnovatlon,and
fosterself-confldenceandcommunl-
catlonskllls.N|provldesenglneerlng
toolsthatpowertheseprograms.
Thepartnershlpcentersaround
anext-generatlonembedded
robotlcs-controlplatformcode
namedAthenawhlch,palredwlth
N|Labvlewsystem-deslgnsoftware,
letsFIRSTteamsdeslgnsystemsfast.
StudentswllluseAthenastartlngln
the20l5seasonoftheFIRSTPobot-
lcsCompetltlon.
EXPANSION
Helukabel,Llgln,|ll.,amanufacturer
ofcable,wlre,andcableaccessorles,
wlllexpandltsNorthAmerlcan
operatlonswlththeopenlngoflts
Toronto,Ontarlo,Canadaheadquar-
ters.Helukabel Canadawlllhouse
corporate,sales,andwarehouslng/
dlstrlbutlonoperatlons.
AWARD
Rockwell Automation,Mllwaukee,
haspresentedTE Connectivity,
Berwyn,Pa.,wlthlts20l2Quallty
AwardforPactoredProducts,whlch
recognlzesasuppllerforqualltyper-
formancemeasuredbystandards
suchaspartspermllllon(ppm)de-
fects,ontlmedellvery,andwelghted
averageleadtlme(WALT).
TLConnectlvltydeslgnandman-
ufacturesdevlcesthatconnectand
protecttheflowofpoweranddata
lnproducts.
Freudenberg Sealing Tech-
nologies,Plymouth,Mlch.,has
recelvedtheFrost & Sullivan
ManufacturlngLeadershlpCoun-
cllsManufacturlngLeadershlp
l00SustalnabllltyAward.Preud-
enbergwon
forltspat-
entednarrow-
strlp-formlng
laser-weldlng
(SUL)tech-
nology.The
technology
makesthemanufactureofseals
muchmoreenvlronmentally
frlendlyandsustalnable.Thlsls
thethlrdlnternatlonalawardto
bewonbytheSULprocedure,
theothertwobelngtheGerman
|nnovatlonPrlze20lllnthe
largeenterprlsescategory,and
theGerman|nnovatlonAward
forCllmateandLnvlronment
(|KU)20ll.
PS#l24
.544ZTUFNT$PSQPSBUJPO4FOTPST%JWJTJPOt3001 Sheldon Drive Cary, NCt5FMtwww.mtssensors.com tsensorsinfo@mts.com
Temposonics
Effective & Effcient

Absolute, Non-Contact Position Sensors
SENSORS
The Measurable Difference

Temposonics
cost-effective and efficient linear position sensors offer non-contact, wear

free operation ensuring an optimum price-performance ratio. The E-Series features compact
designs and better protection from the pioneer of magnetostriction position sensors. Now
available with new mechanical housings and controller interfaces.
RS# 125
Lubriplate PGO and PGO-FGL Series Gear Oils are designed for gearboxes
operating in the most demanding conditions. They provide outstanding
thermal stability, excellent extreme pressure and anti-wear performance and
protection against micropitting. They exceed 13 stages of the FZG test. They
ofer long service life and work well over extended fuid change intervals
which conserves resources and helps ease waste oil disposal problems.
They also efectively lubricate in areas of intense water contamination.
PGO-FGL Series are NSF H-1 Registered Food Machinery Grade.
The Next
Generation
Of Synthetic
Gear Oils.
Lubriplate'PGO & PGO-FGL Series
Polyalkylene Glycol (PAG)-Based, Synthetic Oils.
Lubriplate Lubricants
Contact:E||enG|rard/OEMMarket|ngAna|yst/973-465-5731/eg|rard@|ubr|p|ate.com
ForEqu|pmentRecommendat|onsandLubr|cantSpec|cat|ons
Tov|s|tusonFacebook,Tw|tterorL|nkedIn,goto
www.|ubr|p|ate.comandc||ckonthedes|red|con.
Plant Surveys
Tech Support
Software
Machine Tags
Training
Oil Analysis
Energy Saving
Extremely Low
Coefcient of Friction.
Reduces Energy Use (Up To 7% in Worm Gears).
4x Better Oxidation Resistance
Provides Long Service Life and Extended
Drain Intervals which Conserves Resources.
100% Synthetic
Polyalkylene Glycol
(PAG)-Based Oils
Advanced, Ultra High-Performance Formula.
Backed By:
ESP
Lubriplate'
Extra Services Package
REPORTERS NOTEBOOK
COMPANNEWS
nostlcs,electronlcs,andcommunlca-
tlonslndustrles.
NEW DIVISION
Kollmorgen,Boxborough,Mass.,
hasestabllshedateamtofocus
excluslvelyoncustomerslnthe
medlcallndustryandcreatedanew
buslnessunlt,KollmorgenMedlcal&
LabAutomatlon:
Theunltwlllprovldeservlceap-
pllcatlonslndlagnostlclmaglng,ln
vltrodlagnostlcs,therapeutlcdevlces,
llfesclences,surglcalautomatlon,
andlmplantabledevlces.Kollmorgen
provldesmotlonsystemsandcompo-
nentsforOLMandendusers.
PERSONNEL
Adept Technology Inc.,Pleasanton,
Callf.,aprovlderoflntelllgentrobots
andautonomousmobllesolutlons
andservlces,hasnamedGlennHew-
sonassenlorvlcepresldentofglobal
marketlng.
FINANCIAL RESULTS
Stratasys Ltd.,Mlnneapolls,re-
portedstrongfourthquarterandfls-
cal20l2flnanclalresultsfollowlngthe
Decembercompletlonofltsmerger
wlthObjet Ltd.Pevenueof$96.4 mll-
llonforthefourthquarterof20l2
representsa23%lncreaseoverthe
$78.3 mllllonrecordedforthesame
perlodtheprevlousyear.
DISTRIBUTION AGREEMENT
TheAerospace, Defense, and
Marine UnitofTE Connectivity,
Harrlsburg,Pa,hasenteredlntoa
reglonaldlstrlbutlonagreementwlth
WireMasters Inc.,Columbla,Tenn.
Thlsnewrelatlonshlpwlllmakeprod-
uctsmoreaccesslbletocustomers
throughoutNorth,Central,andSouth
Amerlcasandlmprovecustomerser-
vlceanddellvery.
TLConnectlvltydeslgnsand
manufactureselectronlc-connectlon
productsfortheautomotlve,energy
andlndustrlal,health-care,aerospace
anddefense,broadbandcommunlca-
tlons,andconsumer-devlceslndus-
trles.WlreMastersdlstrlbuteshlgh-
performanceandhlgh-temperature
mllltary-speclflcatlonwlre,cable,and
assoclatedaccessorles.MD
resultofongolngqualltylnltlatlves
that,from2002to20l2,ylelded
lmprovementslnproductrellablllty
andearnedtopmarkslnanlndepen-
dentcustomersurveyratlngPPand
mlcrowaveproductquallty.Agllent
lsameasurementcompanyforthe
chemlcalanalysls,llfesclences,dlag-
EXTENDED WARRANTY
COVERAGE
Agilent Technologies,Santa
Clara,Callf.,nowoffersabumper-
to-bumperthree-yearrepalrwar-
rantyonltselectronlctestlnstru-
mentssoldafterMarchl.Prevlously
onlyoneyear,thewarrantylsthe
PS#l26
RS# 127
Innovation distinguishes between
a leader and a follower.
- Steve Jobs
As the leading manufacturer of OEM pumps
and compressors, our innovation in design and
technology has helped our customers create
new innovative products and become leaders
in their marketplace.
For more information on
how Thomas innovation
can help you lead
your industry, go to
gd-thomas.com.
Improving Lives through Innovation
TM
RS# 128
Improving Lives through Innovation
TM
1010 SERIES PUMP
AND COMPRESSOR
An Illustration
in Innovation
Designed for handheld gas
and leak detection warning
devices, the efficient 1010
Series compressor and
vacuum pump provides the
utmost in reliability.
Reliable (tested for 4,000 hours
of continuous operation)
Long-life, low power consumption
Compact to fulfll handheld
device requirement
Lightweight (.03 lbs/.01 kg)
Efficient operation provides
extended battery life
Maximum pressure to 8.6 psi/
.6 bar, maximum vacuum to
14.8 inHg/500 mbar
For more information on the
innovative 1010 Series, go to
gd-thomas.com.
COMMENTARY
Kenneth J.
Korane
ManaglngLdltor
STEMoverload
You may be for or against the sequester the mandatory
budget cuts that hit many federal agencies. But all the
hand-wringing over its consequences is bringing to light
some of the interesting ways our tax dollars are being
spent.
Take STEM programs. No one I know opposes sci-
ence, technology, engineering, and math education. Proponents, including
the President, say STEM education should be a national priority as it helps
prepare students for technical careers which drive innovation, enhance global
competitiveness, and help foster economic prosperity.
But as with booze and donuts, you can have too much of a good thing.
According to the Government Accountability Office (GAO), in 2010 the
Federal government supported 209 STEM programs costing $3.1 billion a
year. They are spread across 13 agencies, including 46 programs at Health and
Human Services, 37 at the National Science Foundation, and 29 at the Dept.
of Energy. Even the Dept. of the Interior, steward of our national parks, has
three.
Where does the money go? A fair portion supports research opportunities,
internships, and teacher training seemingly money well spent. And many
programs serve underrepresented groups, a laudable goal considering the
acute lack of women and minorities in engineering.
However, a recent GAO report lambasted many aspects of STEM spending,
in particular the duplication of effort. Of the 209 programs, 99% targeted the
same audience and provided a similar service as at least one other program.
And 83% overlapped in terms of operations, target group, STEM field, and
goals. Most didnt coordinate or share results with other agencies that provide
similar STEM-education services.
And no one seems to know if these programs are working. Most agencies
dont measure the effectiveness and performance of their activities. Many cant
even provide reliable information on the number of students, teachers, or in-
stitutions directly served by their programs. And of those that did evaluations,
many used questionable survey methods, had poor response rates, or did not
evaluate results against any baseline criteria.
The report was also highly critical of efforts at the K-12 level. Here, STEM
education across agencies lacked a coherent vision or careful oversight of
goals and outcomes. Little funding was targeted at efforts to bolster STEM
education, and few were concerned with duplicative efforts or even dissemi-
nating information on successful programs.
Goals, in some cases, are so loosely written that they could fund almost
anything, and they do. Under the auspices of one DOT program, some high
schools in New Jersey picked up a $100,000 grant to let several teachers get
flight training in small airplanes, ostensibly to build confidence and develop
leadership traits that will improve STEM education in the classroom.
The billions in spending doesnt appear to be translating into an abundance
of STEM-literate citizens. ACT scores indicate less than half of high-school
graduates are ready for college-level math. And U. S. students continue to lag
behind their counterparts in other developed nations on standard math and
science achievement tests.
The current fragmentation and haphazard approach make it nearly impos-
sible to determine which programs are cost effective. The GAO calls for more-
uniform methods to evaluate what is working and how improvements can be
made, as well as better dissemination of info within and across agencies. Based
on this, it says, government-wide decisions could be made about which pro-
grams to fund and which to eliminate. Good luck with that. MD
PS#l29
MOTION CONTROL
A servodrive only performs well when its drive is pro-
grammed in the units designated by its designer. The problem
is that motor-datasheet units, definitions, and conversions
vary by manufacturer. There is no unified convention for pub-
lishing servomotor data. Nor is there a standard set of units or
nomenclature for entering motor data into drives. So, its the
job of the integrator to understand and homogenize param-
eters. This task is most critical when setting up servocontrol
loops: Inaccuracies prevent servodrive control algorithms
from acting properly and reacting to the ever-changing com-
mands, loads, and feedback signals that characterize dynamic
applications.
Why the inconsistencies? Many variations arose because
there are two main electronic-control methods for permanent-
magnet, three-phase synchronous servomotors: Sine-wave and
six-step (trapezoidal) commutation. The Motor parameters
Knowledge of
servo-related
quantities,
nomenclature,
and conversions
helps engineers
accurately
compare
motors and
correctly
program drives.
Authoredby:
Hurley Gill
SenlorSystemsandAppllcatlonLnglneer
Kollmorgen
Padford,va.
LdltedbyElisabeth Eitel
eeitel@penton.com
Key points:
Predlcabledeslgnoperatlonrellesontheproper
entryofservomotorparameterslntoadrlve.
Myrladservomotorparameterscanbeentered
lncorrectlylfmotormanufacturerunlts
anddrlveparametersdontmatchorarent
understood.
Machines programmed in the wrong units may operate poorly and give no sign
that incorrectly entered data is to blame. Deeper understanding of servomotor
nomenclature lets engineers properly compare and (when required) convert motor
units to those required by the servodrive amplifier controlling them.
Servo parameters
CLARIFIED
/arTon|cDr|vL33C800.21.3332www./arTon|cDr|vL.nLt
UsinN nLw liNOtwLiNOt matLrials and an optimiaLd dLsiNn, wL OavL rLducLd tOL
wLiNOt by 30% witO no rLduction in torquL ratinNs!
HiNOLst torquL dLnsity ALro BacklasO 1 arc-min accuracy
Cross rollLr output bLarinN AvailablL in 10 framL siaLs
TOL 5,W CS.-2UH LiNOtwLiNOt SLriLs!
30% liNOtLr tOan our standard CS. .Lar
Unit but witO All tOL TorquL!
LiNOtLr is BLttLr.
RS# 130
MOTION CONTROL
K
E
(V
dc
/rad/sec) = K
t
(Nm/A
dc
), with no consideration for
the difference between motors that are cold (at ambient
temperature) or hot (at the maximum or application oper-
ating temperature.)
Two widely used Ke units are V/rad/sec and V/Krpm:
V / Krpm
V
Krpm
1,000 Ke (V / rad / sec)

60_sec/ min
2 _rad / rev
1,000
Ke (V / rad / sec)
9.55
where V = Vdc bus for most drive systems = Maximum
(crest) voltage available Not in RMS terms.
Ke

= Voltage (emf ) constant, expressed in either
V/rad/sec, V/Krpm, or other equivalent typically as-
sociated with six-step commutation (not sine-wave
commutation).
For a wye-wound armature, if a motor data sheet de-
fines the voltage (emf ) constant as the phase (line-to-
neutral) voltage developed per some velocity unit, it must
be multiplied by 3 for a final result in the line-to-line Ke
units defined above.
The B
emf
voltage constant
The voltage (Bemf) constant K
b
(also listed as K
Bemf
,
K
B
, and K
e
) is the line-to-line RMS voltage developed per
some velocity unit.
Kb (Vrms/Krpm) = Ke (V/Krpm)/2, or
Kb (Vrms/rad/sec) = Ke (V/rad/sec)/2
where Kb (Vrms/Krpm) = Ke (V/rad/sec) 1,000/9.55/2.
The voltage (Bemf) constant Kb expressed in
Vrms/rad/sec, Vrms/Krpm, or other equivalent is typically
associated with sine-wave communication (not six-step
commutation.)
If a motor data sheet defines the Voltage (Bemf) con-
conversion table in this article maps
such instances and the varied param-
eters relationships.
Motor-name variations
Servomotors can be classified as
brushless-dc motors (BDCMs or
BLDCMs), servos, brushless-dc/ac
synchronous servomotors, ac per-
manent-magnet (PM) servos, and
more. Servo manufacturers estab-
lished most of these terms in the
1980s for marketing purposes and
to underscore that ac permanent-
magnet (PM) motors (which are
electronically commutated to cre-
ate PMAC servos) can replace the
servo function of permanent-mag-
net dc-brush motors.
Over the years, some industry
sources invented explanations for the technologies
varied naming conventions. Many such explanations
relate to B
emf
characteristics clean sine-wave si-
nusoidal commutation or six-step or block commu-
tation, also known as trapezoidal commutation, in
which each electrical cycle (one electrical cycle or PM
pole pair) is six commutation steps. However, the bot-
tom line is that more than anything else, the conven-
tions aimed to overcome false perceptions of techno-
logical barriers.
Regardless of their varied naming conventions, all of
these motors are basically three-phase () ac-PM syn-
chronous machines.
Let us establish the typical units presented by motor
manufacturers, so that engineers can convert these units
for a proper comparison of one servomotor to another
when applicable. This also lets us convert motor param-
eters to the units required by the chosen drive.
For the purpose of this article, consider a three-phase
wye (Y)-connected motor capable of good three-phase
sinusoidal-emf waveforms when backdriven as a gen-
erator, with electrically balanced windings, versus a delta
()-wound armature. We use this example because most
three-phase ac-PM servomotors today utilize wye-con-
nected armatures, especially for sinusoidal commutation.
(Consideration of torque angle advance algorithms and
harmonic issues are beyond this articles intent and scope.)
Following is the commonly used nomenclature for such a
motor.
The emf-voltage constant
The voltage (emf) constant is usually abbreviated Ke,
but sometimes appears as K
emf
, K
E
, or K
b
. It is the maxi-
mum line-to-line voltage developed per some veloc-
ity unit, such that when the velocity unit is rad/sec and
Kt is in Nm/A, then Ke (V/rad/sec) = Kt (Nm/A). This
is also true for PMDC brush servomotors, for which
Rm = 2 R
or
L (line to line)
W
U
V
Clockwise rotation
U, V, W phases
Motor phase ()
One of three coils)
Wye-connected servomotor
|
|(line)
I_line
V (line to line)
V (line to line)
V_line (line to line)
V =
V (line to neutral) =
V_line/3
RS# 131
MOTION CONTROL
Kt (Nm/A) = Kt (T/a-rms)/1.5
and Kt (T/a-rms) = Kt (Nm/A) 1.5.
Therefore, continuous current Ic (rms) required by a
given motor to reach full capacity has a lower value than if
presented as an Ic (crest or dc-style) current just as one
would expect.
We will not cover the formal derivation of 1.5 for con-
verting between six-step and sine-wave commutation Kt
and current. However, its verified by the equivalency of
six-step and sine-wave power-loss calculations. (See the
Motor parameters conversion table.)
The most common miscalculation between the two
commutation methods is to mistakenly use the 2 RMS
instead of the 1.5 conversion between the two different
Kt units, or required currents. The 2 root-mean-square
conversion is not the same unit conversion as seen be-
stant as the (line-to-neutral) RMS voltage developed per
some velocity unit, it must be multiplied by 3 for a final
result in the line-to-line Kb units defined above.
The torque constant
The torque constant Kt (sometimes denoted K
T
) is
the ratio of some torque T unit over either the maximum
(crest) motor-phase current (line to neutral), or the RMS
phase current (line to neutral).
Note that the two different specifications for the term
Kt arise because of the differences between six-step and
sine-wave commutation. These differences prevent many
engineers from deducing the relationship between the two
Kt current units.
Furthermore, its generally assumed that the torque
constant is torque developed per some unit of current
through one phase of the wye-wound armature. There-
fore, manufacturers dont always publish its exact defini-
tion in literature or motor-specification sheets.
In a wye-wound armature, line-to-line current is equal
to line-to-neutral current.
1. The torque constant Kt (sometimes K
T
) associated with
six-step commutation is the ratio of some torque T to
the maximum (crest) phase () current (line to neu-
tral), where Kt is in the units T/A. For this definition
and a three-phase servomotor, current flows through
only two of the three motor coils (2-ON, 1-OFF) at a
time.
2. Torque constant Kt (sometimes K
T
) associated with
sine-wave commutation is ratio of some torque T to the
RMS phase () current (line to neutral), where Kt is in
the units T/a-rms. For this definition and a three-phase
servomotor, current may flow through all three coils at
the same time.
When manufacturers publish the torque constant for
sine-wave commutation in the units Nm/amp (crest of
sine-wave) then:
T/a-rms = 2 Nm/amp (crest of sine wave).
Conversion between the two commutation methods
for the torque constant is:
Nomenclature caveat
Adrlvesnomenclaturemaybeappearldentl-
caltothoselnthlsartlcle,butthatdoesntmean
lts requlred unlts are ln harmony wlth those
presented by a glven manufacturer. Llkewlse, a
drlvesrequlredunltsmaybeappearldentlcalto
thoselnthlsartlcle,butthatdoesntmeanthelr
denltlons are the same. Por example, ln the
power lndustry some unlts are standardlzed ln
PMS values but lack the rms subscrlpt notatlon.
The lack of speclclty for a requlred unlt ln thls
dlsclpllne of motlon control can easlly convey
thewrongmeanlngorlnterpretatlonoftheunlt.
Standard abbreviations
emfLlectromotlveforce
Bemf Back (opposlng or counter) electromotlve force
relatlng to motor operatlon the lnduced voltage
ln opposltlon to (and resultlng from) the current re-
qulred by the motor to drlve the load at any glven
polntlntlme
radradlans
secsecond(s)
orthetaAnglebetweenthecurrentandvoltage
or phl Phase llne-to-natural current through or
voltage across one branch of a wye-wound coll, and
notllne-to-llnevoltage
Wye-woundarmature
Delta-woundarmature
Crest Maxlmum voltage or current avallable. Here, the
term peak ls best avolded to mlnlmlze confuslon of
slne-wave-to-PMS-unlt converslon wlth the conver-
slonofslx-steptoslne-wavemotor-drlveunlts,orvlce
versa.
PMSorrmsPoot-meansquare
Find out by contacting your LINAK
electric motion-control expert.
linak-us.com/contact | (502) 413.0320
theres a better alternative
to the motion-control solution we use today?
RS# 132
MOTION CONTROL
RMS value of motors continuous capability per
(line-neutral).
Peak motor-current-limit units: a-rms Ip (motor)
is the RMS value describing the motor limit per
(line-neutral)
Kt constant units: Nm/a-rms Torque_unit/a-rms for
a sine-wave controller, with line-to-neutral ()
RMS current
Kb constant units: Vrms/Krpm RMS voltage line
tween the motors Kt units or the required current to pro-
duce a specific torque, from a six-step unit system to a
sinusoidal commutated unit system, or vice versa.
Drive selection
Let us assume that were selecting a drive in the form of
a sinusoidal-commutation controller requiring motor pa-
rameters in the following units:
Continuous motor current units: a-rms Ic (motor),
Motor parameters conversion table
COLUMNA COLUMNB COLUMNC COLUMND COLUMNL COLUMNP COLUMNG
Motor:X
(Wye-woundarmature)
Unlts:X
Commutatlon
slx-step:
ColumnBto
ColumnD
converslons:
Unlts:X
Commutatlon
slx-step:
ColumnD
toColumnP
converslons:
Unlts:X
Commutatlon
slnewave:
Drlveunlts
requlredforslne
commutatlon
wlthwye-wound
armature:
Tc l2.7_Nm l2.7_Nm l2.7_Nm Tc(Nm)
Tp 4l.2_Nm 4l.2_Nm 4l.2_Nm Tp(Nm)
|c(current/
l
) l3_A/
l
l3_A
l
-l.5 l0.6l_a-rms
l
|c(a-rms)/
phase()
l&7
|p(current/
l
) 53.3_A/
l
53.3_A
l
-l.5 43.52_a-rms
|p(a-rms)/
phase()l
&7
Kt l.00Nm/A l.00Nm/A l.5
l.224745
Nm/a-rms
Kt(Nm/a-rms)
KeorKb 0.57735v()/rad/sec 3
l.00v(L-L)/
rad/sec
l,000-9.55
-2
74.05
vrms(L-L)/
Krpm
Kb(vrms/Krpm)
OP
0.57735
v()/rad/sec
3l,000
-9.55
l04.72v(L-L)/
Krpm
-2
74.05
vrms(L-L)/
Krpm
Kb(vrms/Krpm)
Pm(ohms)
3
(llne-to-llne)at
25C
0.540_/
3
2
l.08_(llneto
llne)
l.08_(llneto
llne)
Pm(:llnetollne)
at25C
Lm
2
(mH) 4.25_mH/
2
2 8.5_mH(L-L)/ 8.5_mH(L-L)/
LorLm
(mH:llnetollne)
1m(lnertla) 0.00l52kg-m
2
l00
2
l5.2kg-cm
2
l5.2kg-cm
2
1m(kg-cm
2
)
Motorpoles l0_Poles l0_Poles -2 5_Pole-palr Pole-palr(PP)
Thermalreslstance 0.467C/W 0.467C/W 0.467C/W
Wlndlngtemperature
(maxlmum)
l55C l55C l55C
Watts(loss)at25Camblent }(l55-25)-0.467}w 278
}(l5525)
-0.467}w
278
}(l30C_rlse)-
0.467}w
Basedondata-
sheetlnformatlon.
Lquallty:Watts(loss)by
powercalculatlons
Power(slx-step)
5&6
v|cos
5
2|_
2
Pm_(hot)
4
|_llne
2
Pm_L_L(hot)
4
2l32(0.54l.525) 278
l3
2
(l.08
l.525)
278 Notappllcable
Checksoutbased
onglvenor
converteddata.
Power(slnewave)
5&6
3v_
2
|_cos
5
3|_
2
Pm_(hot)
4
3|_
2
Pm_L_L(hot)
4
-2
Notappllcable
Not
appllcable
Notappllcable 278
3l0.6l
2
(l.08
l.525)-2
Checksoutbased
onglvenor
converteddata.
Provided by Kollmorgen 1.1.2013
This table converts common wye-wound motor
parameters into units that can be entered into drives for
sinusoidal operation.
1. Locate the required drive units in Column G.
2. For any motor parameter presented in the units of
Column B, use the conversion factors of Column C to
get the units of Column D. Then use conversion factors
of Column E to get the units of Column F, to match the
specific units for the drive in Column G.
3. For any motor parameter presented in the units of
Column D, use the conversion factors of Column E to
get the units of Column F and match the specific units
for the drive in Column G.
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RS# 133

ATLAS Digital Ampli
amazing amount of output power in an ultra compact
design. These single-axis ampliers provide high-
performance torque control of DC brush, brushless DC,
and step motors. And, while theyre as small as a paper
clip, they offer up to 1 Kilowatt of total output power
all without breaking the bank. Learn more about the big
advantages of thinking small in digital amplication.
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Small is the big
news in motion
ampliers.
Product shown is actual size.

TOTAL POWER OUTPUT TO
1 KILOWATT
DIGITAL HIGH PERFORMANCE
TORQUE CONTROL
ULTRA COMPACT DESIGN
LOW COST
PROGRAMMABLE CONTROL
MOTION CONTROL
to line per
1,000_rpm
Rm (typically
20 or 25C room
temperature)
units: Ohms ()
line to line Two
phases in series, Rm_
= Rm (L-L)/2]
L or Lm inductance (line to
line), inductance units: milli-Henry or
mH L_ = Lm(L-L)/2
Motor rotor inertia Jm units: Kg-cm
2
Notes on common variations
Following are subscript notes for the Motor parameters
conversion table.
1. Most often the phase () current and () voltage (line
to line) is defined somewhere in the manufacturers data.
However, it commonly assumed to be understood.
2. For a wye-wound winding, if a data sheet states Lm =
L (line to neutral), multiply L by 2 for the total motor
inductance Lm (in mH, line to line).
3. For a wye-wound winding, if a data sheet states Rm =
R (line to neutral), mul-
tiply R by 2 for the to-
tal resistance Rm (line to
line). For a delta-wound
motor, resistance () is
Rm/ = Rm (line to line).
4. As temperature climbs
from 25 ambient to a maximum
of 155C, resistance of the copper
increases by a factor of approximately
1.525.
5. For a given motor and the scope of this article, when
power for six-step commutation is set equal to the power
for sine-wave commutation:
2 V_ I_ cos = 3 V_ I_ cos
The cos factors out of the equation.
6. Conventional three-phase trapezoidal commutation
drives control only two motor windings at a time. Sinusoi-
dal commutation drives can concurrently control all three
windings.
7. For sine-wave commutation (Column F in the Motor
parameters conversion table) if a drive demands that Ic
(continuous) and Ip (Ipeak) be entered in the units:
Ic (crest of the sine wave)/phase ()
PS#l34
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Ip (crest of the sine wave)/phase ()
Then the corresponding value in Column F must be multiplied by 2.
If the specific parameters are to be entered in the units:
Ic (crest to crest of the sine wave)/phase ()
Ip (crest to crest of the sine wave)/phase ()
Then the corresponding value in Column F must be multiplied by 2 2.
Note that crest is used here to minimize confusion of the myriad
terms for peak motor and drive capabilities with expressions relating to
sine-wave peak (crest) or peak-to-peak (crest-to-crest) values.
The Motor parameters conversion table can be also be used as a
quick-check nomenclature reference. For example, to verify that Kt and
Kb (or Ke) are in RMS units, divide what is thought to be Kb (Vrms/
Krpm) by Kt (Nm/a-rms). If the corresponding units are correct, the re-
sulting quotient will equal some quantity between 60 and 65, or (in a few
exceptions for rounding off) just over or under that range. The method
typically works regardless of the assumed motor temperature (operating
or ambient) or PM servo type. MD
Resources:
Kollmorgen, www.kollmorgen.com, support@kollmorgen.com
HurleyGllllsa78graduateofvlrglnlaTech.Hesworkedlnthemotlon-control
lndustryslncel980.
Measurement unitlsclearlydeflnedlntheInternational Vocabulary of Metrology
Basic and General Concepts and Associated Terms,(v|M)(3rded.),Joint Committee for
Guides in Metrology,2008,p.67.
Tomato
tomaato
Bydenltlon,aunltof
measurelsamagnltudeofsome
physlcalquantltydenedand
adoptedbyaconventlonor
lawandusedasastandardfor
thequantltysmeasurement.
Thus,ltstandstoreasonthatthe
lndustryshouldhavedeveloped
separatestandardparameters
foreachofthesecommutatlon
methods.(SeeResourcesfor
morelnformatlon.)
|nfact,theunltsand
ldentlfylngnomenclatureforthe
twomalncommutatlonmethods
areoftenmuddled.Theproblem
lscompllcatedbylnconslstent
useofparametersbymotorand
drlvemanufacturers.
PS#l35
Small
but
MIGHTY
One example of a single-card
controller integrates up to
four solderable amplifiers,
a high-speed on-card
microprocessor, and
over 2 Mbytes of
combined program
and memory
space.
The last 20 years have seen precision amplifiers used for
positioning and velocity control make major strides in
power output, size, and control features. Applications
such as laboratory automation, semiconductor equip-
ment, and scientific automation make use of high-end
amplifier capabilities such as field-oriented control.
The cost of electronics is coming down to a point where
even industries identified with basic motion needs now
consider using high-end features, particularly where
smoothness, motor efficiency, and top speed matter.
Another key development is that of solderable ampli-
fiers, which let engineers build cards able to run an en-
tire machine. It is even possible to obtain amplifiers that
mount on the motor itself, a strategy that may simplify
wiring.
It is helpful to review exactly what modern motion-
control amplifiers can do. At their core, amplifiers accept
low-power control signals and generate higher-power
voltages to drive the motor. By far and away, the dominant
approach in amplification for motion control is to gener-
ate drive signals through a technique known as pulse-
width modulation (PWM), or just switching.
Switching amplifiers basically generate a variable duty-
cycle square wave that is filtered to give the desired out-
put signal. They take advantage of the ever-increasing
Motion amplifiers
occupying just a cubic
inch of space can handle
sophisticated tasks once
demanding multiple boards
and big heat sinks.
Authoredby:
Chuck Lewin
PounderandvlcePresldentofLnglneerlng
Performance Motion Devices Inc.
Boxborough,Mass.
LdltedbyLeland Teschler
leland.teschlerQpenton.com
Key points:
Solderableampllflersprovldeuptoakllowattofpowerln
packagesassmallasl.0ln.
3
|mprovementslnswltchlngampllflersaretheslngleblggest
factormaklngsuchall-ln-onemachlne-controllercards
posslble.
Resources:
Motion-control basics,http://machinedesign.com/BDE/motion/
bdemotion1/
Motion-control study guide,http://machinedesign.com/
ebook/motion-control-mechatronics/motion-control-study-
guide-0111
Motion-control trends,http://machinedesign.com/article/the-
top-three-trends-shaping-motion-control-0623
Performance Motion Devices Inc.,www.pmdcorp.com
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RS# 136
Basic motion-control system
Encoder, Hall-effect sensors
Dc-brush,
brushless-dc,
stepmotor
Amplier
Motion
controller
One, two,
or three-phase
connection
All-in-one machine-controller card
Host
Encoder feedback
Motors
Motors
Motors
Solderable
amplier
Solderable
amplier
Solderable
amplier
Signal
conditioning
Signal
conditioning
Motion
processor
Bus
decode
Bus
Limits, I/O, etc.
Motion systems consist of three major
components: the controller, the amplifier,
and the motor/actuator. The controller is an
integrated circuit or printed-circuit card that
outputs control signals to the amplifier based
on commanded position and feedback of
position and velocity information typically
from encoders or Hall sensors.
A typical
all-in-one
controller
card, in
this case
driving
four axes
using
solderable
amplifiers.
for these effects to improve response time, efficiency, and
positioning accuracy.
Is current control always critical? For stepmotors, the
answer is yes because current control in steppers affects
nearly every aspect of performance top speed, posi-
tioning accuracy, heat generation, and more. There is a bit
more wiggle room in dc-brush and brushless-PM-motor
applications. But as costs have dropped for electronics
and current-sensing hardware, active current control has
become the norm for all but a small number of motion-
control applications.
The term phasing refers to the selective application
of voltage or current to the windings of multiphase mo-
tors such as stepmotors and brushless-dc motors. Proper
phasing keeps these motors moving forward or backward
as directed by the host controller. Dc-brush motors, by
comparison, phase themselves using brushes or other
contacts to distribute the applied voltage to the correct
rotor coil as it spins. So dc-brush motors need no external
phasing control.
Stepmotors employ various phasing schemes such as
full stepping, half stepping and microstepping, depending
on the step increment. For brushless-dc motors, phasing
efficiency with which metal-oxide field-effect transistors
(MOSFETs) and insulated-gate bipolar transistors (IGBTs)
can switch on or off, rapidly applying a bus voltage to a
circuit load, and then disconnecting that supply from the
load to produce a particular commanded voltage.
Though switching amplifiers dominate motion con-
trol, there are still some applications where nonswitching
linear amplifiers (also called transconductance amplifi-
ers) are needed. They are three to five time times less effi-
cient than switchers, but linear amplifiers generate much
less electromagnetic interference (EMI) and, thus, find
use where that property is critically important.
Current control
Current control, also often called torque control in
servomotors, refers to the active regulation of current
flowing through each winding of the motor. Windings are
inductors, so they resist changes in current. In addition,
the motor itself is a highly dynamic environment that in-
duces back-EMF (electromotive force) onto the winding
as it spins. Both of these effects distort the actual current
flowing through each winding relative to its applied volt-
age. Amplifiers with current control actively compensate
AF1212I_CSG
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manual positioning operations. A front-panel USB port is available for
connection of a keyboard and other peripherals to assist in the creation of
complex program sequences.
Up to 4 axes of brush, stepper
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Aerotech's FlashConfig feature
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Touch screen with intuitive
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-based
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RS# 137
Distributed-motion system
System
host
Stepmotor
(encoder
optional)
Distributed
amplier
Distributed
amplier
Distributed
amplier
Dc-brush
motor
Brushless-dc
motor
Ethernet, CANbus, or serial network
Solderable motion-control amplier
Dc bus
Logic supply
HV
5 V +3.3 V
Bus monitoring
Bus voltage
Bus voltage
Enable
AtRest
VaultOut
NVRAM
Trace
RAM
SPICS
SPIClk
SPISI
SPI
command
process
SPISO
Control and logic
synchronization
Commutation and
microstep control
Digital
current
loop
Motor
outputs
A
B
A
B
C
D
Power
stage
Current sense
Pulse and
direction counter
Pulse Direction
Some years ago, general-purpose industrial
networks began to host digital amplifier
command interfaces allowing a central
controller to handle multiple motors.
Solderable amplifier
modules comprise
a single packaged
unit that provides
major functions of
amplification, current
control, phasing, and
extras such as FOC
and fault detection.
They can control step,
brushless-dc, and
dc-brush motors and
may work stand-alone
or in conjunction
with higher level
controllers for velocity
or positioning
applications.
range. Needless to say, the amplifier needs enough get up
and go for your application!
Modern controllers
Motion systems typically consist of three major com-
ponents; the controller, the amplifier, and the motor/ac-
tuator. The controller is an integrated circuit or printed-
circuit card that outputs control signals to the amplifier.
But what kind of signals? The granddaddy of ampli-
fier command formats is 10-V analog. In this scheme,
the motion controller generates an analog voltage carried
is called commutation. The most-common version uses
feedback from Hall sensors positioned around the ro-
tor shaft to generate trapezoidal or six-step drive signals.
Trapezoidal commutation, while widely used, has discon-
tinuities where the Hall-effect sensors switch. This has led
to the wide use of vector control, also called field-oriented
control (FOC), which uses a sinusoidal waveform along
with more-advanced phasing algorithms. FOC provides
smoother motion, more-efficient motor operation, and
higher top speed.
As with current control, ever-improving controllers
such as digital signal processors (DSPs) are making FOC
a standard feature in more and more motion-control
systems.
There are a number of additional functions that are
likely to be important in modern motion-control designs.
One particular area is fault detection. Look for detection/
protection from overtemperature faults, short-circuit
faults, overcurrent faults, bus overvoltage and undervolt-
age faults, and more. Properly designed, these features can
protect an amplifier, motor, and sometimes even the ma-
chine in the event of a failure.
Another useful motion-amplifier feature is called I
2
t
current management. This is a general technique for lim-
iting the total energy delivered to the motor. Compared to
instantaneous current limiting, I
2
t provides a much-more
useful protection mechanism because heating comes
from current applied over a period of time.
Beyond all these features there are, of course, the basic
specifications of the amplifier itself. These include the
voltage range, continuous and maximum current ratings,
and environmental ratings such as temperature operating
RS# 138
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An example of a
solderable amplifier
is the Atlas amplifier.
Solderable amplifiers
provide up to a kilowatt
of power in packages as
small as 1.0 in.
3
differentially over two signals that
encode a desired voltage, current,
or velocity. Typically, these signals
are routed by cable to the amplifier
module.
Unfortunately, analog encoding
makes less sense when amplifiers
incorporate DSPs and other digital
logic. Why convert the controllers
digital signals to analog and then
convert them back to digital in the
amplifier?
To address this conundrum, about
20 years ago general-purpose indus-
trial networks began to host digital
amplifier-command interfaces. Now-
adays, networks hosting such inter-
faces include CANopen, Profibus,
EtherCAT, Ethernet Powerlink, and
a few others.
What does the controller actually
say to the amplifiers? In some cases
just the desired torque goes down the
wire, but often the controller sends
higher-level command streams such
as PV vectors (position, velocity).
Once the interface becomes dig-
ital, the amplifier can report prob-
lems back to the controller and assist
with tuning and setup. This ability
has made possible new generations of
module-oriented machine control-
lers where the location of the ampli-
fier is practically a nonconsideration
in the design of machines.
Network-based amplifiers seem
like the ultimate evolution of ma-
chine controllers. But its worth re-
membering that what originally mo-
tivated the separation of the ampli-
fier and the controller was the need
to manage heat. Today, those same
amplifiers no longer generate all that
much heat.
This sets the stage for what has
become an increasing counter cur-
rent to modularization: the tendency
to locate all controls on a single con-
trol card. With all controls on a single
card, there are fewer failure-prone
connectors and cables. Ditto for ser-
vice hassles: There is no need to fig-
ure out whether the motion card, the
cable connections, or the amplifiers
are causing the problem.
PS#l42
RS# 145
RS# 144
RS# 143
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For High Temperatures
Linear Actuator
Highest Torque

cyber
dynamic
mini servo motors
control, centrifuges, robot arms,
shuttles, and so forth. Now, they can
buy off-the-shelf ICs or solderable
modules and keep everything on a
single printed-circuit board.
One major category of such prod-
ucts consists of small, dedicated, sin-
gle-axis motor amplifier ICs. These
ICs come in various configurations
such as H-bridges (used with dc-
brush and stepmotors) as well as
half-bridges (used with brushless-
PM motors). Basic entries provide
just the switching function and per-
haps some overcurrent protection.
More-sophisticated versions provide
current control and additional fea-
tures such as selectable fast-decay,
slow-decay operation.
For stepmotor control, these ICs
directly produce pulse and direction
signals and provide half-step as well
as microstepping control. They uti-
lize current control techniques espe-
cially suited to the demands of man-
aging stepmotors.
An important drawback to this
category of on-card amplifiers is that
they rarely output more than 4 A or
150 W. In terms of drive sophistica-
tion. These products are fairly low on
the totem pole. If they provide com-
mutation, it is typically six-step trap-
ezoidal, and many of the higher level
features described earlier are missing.
The other major category of on-
card amplifiers pertains to solderable
amplifier modules. Solderable ampli-
fier modules resemble traditional ca-
ble-connected amplifier modules in
that they embody a single packaged
unit providing all the major func-
tions discussed earlier amplifica-
tion, current control, phasing, and
extras such as FOC and sophisticated
fault detection.
They differ from cable-connected
amplifier modules in several impor-
tant ways, however. For starters, they
Improvements in switching amplifiers are the single
biggest factor making such all-in-one machine controller
cards possible. With less heat generated, a single control
card can safely drive kilowatts of power rather than dozens
of watts as in the past. A decade ago, engineers were forced
to go off-board for higher power axes such as spindle
may be tiny, but some can produce up to a kilowatt. (Not
bad for an amplifier occupying a bit more than a cubic
inch.)
As the name implies, they are solderable. They gen-
erally use standard through-hole pin connections and
packaging that tends to have around 20 pins. These pins
PS#l46
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provide microprocessor-compatible connections, power
input signals, motor output, and other safety and control
signals.
Unlike lower power amplifier ICs, solderable modules
are full-blown motion amplifiers. In fact, many of the
same companies that offer cable-connected amplifiers
also offer solderable motion amplifiers. These products
are well suited for positioning and high-precision velocity
control.
With new paradigms come new challenges. Neither
analog 10-V signals nor full-blown digital networks are
well suited for connecting to onboard microprocessors
with solderable amplifiers. So what is
the right format?
Some amplifiers directly out-
put PWM waveforms, but doing so
means the motion controller must
perform the task of current con-
trol, a daunting prospect for many
designers. The alternative is to set-
tle for voltage-mode control of the
motor windings, a major sacrifice in
performance.
Another common approach re-
tains some flavor of analog input.
Most commonly, the module pro-
vides a unipolar analog level along
with a separate digital sign bit.
The interface that seems to be
gaining attention is serial-peripheral
interface (SPI). SPI is completely dig-
ital and uses just four signals. Com-
munications can be bidirectional and
the bandwidth is more than enough
for motion applications which tend
to update the desired torque at a rate
between 2.5 and 10 kHz.
There are other digital formats
such as RS-232. There has been talk
within the industry about whether a
standard will evolve for on-card am-
plifier connections. Only time will tell.
Finally, amplifiers small enough
to mount directly on the motor have
made a big splash. Such a configu-
ration is called an integrated motor
drive (IMD) and has special ben-
efits in the area of cable reduction.
Encoder signals and Hall-sensor sig-
nals from the motor feed directly into
the IMD and neednt go back to the
controller.
The downside of IMDs is that
they boost the weight of the mo-
tor assembly, and IMD electronics
are likely to get hotter than those
of an amplifier sitting in a rack or
in a controlled environment. The
heat affects reliability or lifetime,
depending on the harshness of the
operating environment. MD
PS#l47
RS# 148
BEARINGS
New compact hydrostatic guides operate as
complete closed-loop units. Carriages ride
on precision-honed guideways energized
by a layer of pressurized oil.
When in doubt, make it stout. That was the rule of thumb for designing strong
and durable machine tools in the past. Over the years, however, this mindset
has changed as technical advances have allowed for dramatic increases in the
performance of machine tools within the same design envelope. Better modeling
software and analysis tools, along with advancements in radial and linear bearings,
have increased machine spindle and traverse speeds. At the same time, motor,
drive, and position-feedback capabilities compensate for mechanical inaccuracies.
All of these developments have fostered faster, more-precise machining.
Nevertheless, the never-ending demand for higher speeds, deeper cuts, and bet-
ter accuracy to increase throughput continues to challenge engineers designing the
next generation of high-performance machine tools. Focusing on dynamic stability
through effective axis damping may be the key to meeting these challenges.
Linear-guide characteristics
As designers continue to push the envelope even further in pursuit of greater
throughput, some of the advances that contribute to higher speed also present cer-
tain drawbacks. The evolution from plain bearings to ball and roller-recirculating
linear guides is one example.
Plain-bearing systems, while inefficient and limited in speed, have very good
damping characteristics as a result of their large surface-contact areas and lubrica-
tion film. The effect of this inherent damping lets machinists increase the cutting
depth while maintaining good surface finishes and accuracy. Many CNC lathes built
today still use plain-bearing slides on their turret axis because of these advantages.
Linear-axis damping
improves the
performance of
machine tools as well
as other precision
equipment.
Authoredby:
Carl White
ManagerAppllcatlonLnglneerlng
LlnearandProductlonMachlnery
Schaeffler Group USA
PortMlll,S.C.
LdltedbyKenneth J. Korane
ken.koraneQpenton.com
Key points:
Punnlngmachlnetoolsfaster
canleadtovlbratlonsandpoor
productquallty.
Addlngllnear-axlsdamplngcan
permlthlgherspeeds,deeper
cuts,andbetterpreclslon.
Damplngoptlonslnclude
lntegrateddamplngelementsand
compacthydrostatlccarrlages.
Resources:
Schaeffler Group USA,www.
schaeffler.us
New ways to
DAMP
VIBRATION
RS# 149
Improve
machine
performance
Slotless
Servo Motors
Better by design!
Wilmington MA 01887
(800)237-3786
email: info@infranorusa.com
www.infranorusa.com
Increased torque:
Smaller package
Lower weight
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Increased throughput
Large rotor:
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Scan here to
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BEARINGS
This chart shows
the relationship
of stiffness versus
damping in plain and
recirculating-type
bearing guides. With
plain bearings as
the baseline, results
show that rigidity
of all systems is
similar, but there
are significant
differences in
relative damping.
0 50 25 100 75 125
Plain
bearing
Static stiffness (%) Relative damping (%)
Comparing damping values
X-arrangement
O-arrangement
X-arrangement
O-arrangement
Recirculating
roller bearing
Recirculating
ball bearing
M
o
n
o
r
a
i
l

g
u
i
d
a
n
c
e

s
y
s
t
e
m
s
5
136
8
136
5
70
6
73
100
100
A model of a three-axis machine tool shows the interaction of damping and
rigidity under different conditions. Clearly, rigidity cannot replace a lack of
damping.
0 50 100
Excitation frequency (Hz)
E
l
a
s
t
i
c
i
t
y

r
e
s
p
o
n
s
e

(
m
/
N
)
150 200
1
0.1
0.01
0.001
Case 3:
c = 600 N/m
d = 200,000 kg/sec
Case 2: c = 1,200 N/m
d = 10,000 kg/sec
Case 1:
c = 600 N/m
d = 10,000 kg/sec
Interaction of damping and rigidity
On the other hand, while ball and roller-recirculating linear guides have low
coefficients of friction and high speed ratings, they offer poor damping char-
acteristics because of the metal-to-metal point and line contacts of their ball or
roller elements transitioning between the steel bearing body and rail.
The nearby chart, Comparing damping values, shows the relationship of stiff-
ness versus damping in plain bearings and recirculating-type bearing guides.
Using a plain bearing system as the baseline, results show similar rigidity values
for all the systems. But when it comes to relative damping values, there is a sig-
nificant difference.
Structural dynamic rigidity
Some designers make the mistake of focusing mainly on a machines static
rigidity. In actuality, it is also important to consider the balance of the over-
all structural mass with highly preloaded linear bearings for increased static
rigidity, versus lower structural inertias for increasing chip-to-chip speeds.
Properly balancing rigidity and inertia increases machine dynamics which, in
turn, boost overall machine performance. High dynamics has a significant in-
PS#l50
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Multi-Axis. Easy to Use.
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GALIL MOTION CONTROLLERS
RS# 151
Visit www.rollonnews.com
for technical papers and
application help or call
1.877.976.5566
75D
61CD
Dontletdefelctionslow
]oudown.Telescopic Rail
wont]ieldtoheav]loads
evenwhenfull]extended.
s
RAPID DELIVERY
s
ONLINE DESIGN
s
LIVE SUPPORT
BEARINGS
Adaptive elements built
into the linear guides
improve damping.
Adaptive-
damping
element
Frequency (Hz)
F
r
e
q
u
e
n
c
y

r
e
s
p
o
n
s
e

(
%
)
10
1
0.1
0.01
0.001
50 100 150 200 250
Machine-tool response
FEA modeling shows modal-frequency responses at working points without
(red) and with (blue) adaptive-damping elements.
fluence on the machines structure and its elements.
Vibrations induced by cutting-tool pass fre-
quencies and wear, along with other out-
side disruptive forces, can cause
poor machine performance.
Dynamic rigidity through
proper damping can reduce
these influences.
Modeling a three-axis
machine that uses recirculat-
ing linear bearings and guide
rails shows the interaction of
damping and rigidity. In the nearby
graphic, c represents rigidity and d repre-
sents damping values of the linear bearings. Force, F, is applied to the spindle
nose and is the elastic response.
In case 1, the model has a rigidity value of 600N/m and a damping value of
10,000kg/sec. The results show a modal peak around 80Hz. In case 2, rigidity is
doubled to 1,200N/m and damping remains the same. Here, results show the
mode shifts, but the amplitude is almost the same. For case 3, the rigidity value
matches case 1, but the damping input increases to 200,000kg/sec. The result is
now a modal peak similar to case 1, but at a much lower amplitude. This vali-
dates that rigidity cannot replace a lack of damping.
Integrating linear-axis damping
Two effective methods for adding damping to the linear axes are known to
designers yet, surprisingly, they are seldom used. These methods involve the
use of adaptive elements or complete hydrostatic systems.
The adaptive method integrates a damping element within the recirculating
linear guide. The damping element, or carriage, fits on the same linear-guide
rail and has an inner profile that matches, but does not contact, the rail. The
gap between the damping carriage and rail is approximately 25m (0.001in.).
This gap is filled with oil using a gravity drip feed through ports in the carriage.
The squeeze-film effect provides damping similar to that of a shock absorber
on a car. Because the gap is very small, capillary action maintains the oil film,
and there is minimal fluid loss during linear cycling of the slide provided that
the unit contains proper-viscosity oil. The length of the damping carriage di-
PS#l52
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RS# 153
www.diequa.com
630-980-1133
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Special Designs
BEARINGS
To prove the effectiveness of hydrostatic
guides, three different slide assemblies
were tested on a motion table.
Conventional hydrostatic slide systems tend to be quite complex.
Traditional hydrostatic slide
rectly influences the magnitude of damping. Because flat surfaces are preferred
for this method, only roller-type guide rails are used.
The FEA model labeled Machine-tool response shows the modal frequency
response of a vertical-machining center at the spindle nose using roller profile
rails. The first modal response curve (in red) is based on a linear-rail system that
uses only roller guide bearings on the Y and Z axes. The second response curve
(in blue) shows results after implementing damping carriages between the roller
guide bearings on the Y and Z axes. Results reveal a significant reduction in the
amplitude of the modal frequencies generated by cutting forces at various feed
rates and spindle speeds. This, in turn, permits greater cutting depths at higher
speeds and, consequently, better machine performance.
Hydrostatics
The other method for integrating linear-axis damping is through complete
linear hydrostatic-bearing systems. While this is not a new concept, the eco-
nomics have not justified widespread adaptation. These types of systems have
pressurized hydraulic cavities or pockets within the axis table. What makes this
design so costly is that it requires a series of cross-drilled passages and ports that
have to be generated with extreme
accuracy.
Another drawback of hydro-
statics is the challenge of sealing
and controlling bypass leakage of
high-pressure fluid. Most of these
designs are open-type loss systems
which must contain fluid-collec-
tion troughs. Fluid that leaks past
the bearing has to be collected and
filtered before reuse.
Finally, these systems always
face the nightmare scenario where
failure means the complete slide
assembly must be repaired or
replaced.
New options
The drive to produce a more
cost-effective alternative has led to
PS#l54
Hydraulic regulator
Machine slider
Pressure pocket
Rail
Rail
Machine bed
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Integrated fast control technology designed for highly dynamic positioning tasks
The servo terminal supports synchronous motors with a rated current of up to 4 A.
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RS# 155
HIGH
TORQUE
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IGARASHI MOTOR
SALES USA, LLC
BEARINGS
A
c
c
e
l
e
r
a
t
i
o
n

(
m
/
s
e
c
2
)

Time (sec)
0.015 0.02 0.035 0.03 0.045 0.04 0.05 0.025
30
20
10
0
10
20
30
Roller carriage and guide
Adaptive damping
Hydrostatic carriage
Roller carriage and guide
Adaptive damping
Hydrostatic carriage
T
r
a
n
s
m
i
s
s
i
o
n

f
u
n
c
t
i
o
n

(
m
/
s
e
c
2
/
N
)

Frequency (Hz)
0 500 1,000 1,500 2,000 2,500
0.5
0.4
0.3
0.2
0.1
Impact tests on the motion table
measured modal response and
settling times. Results show that
damping carriages significantly
reduce dynamic response.
Hydrostatic systems perform even
better, as they almost completely
eliminate such effects.
Vibration settling time
Frequency response
the development of next-gener-
ation hydrostatic linear systems,
which can be engineered into a
machine in much the same way
as current linear-recirculating
guides.
These compact hydrostatic
guides operate as a closed-
loop unit. Carriages with pres-
sure pockets ride on precisely
honed guideways energized by
a steady layer of pressurized oil.
The hydrostatic guide carries
loads on these oil-filled pres-
sure pockets.
The carriage consists of a
steel saddle plate and two end
pieces. One end piece has an
integrated pressure regulator
that supplies oil to the carriages
pressure pockets. The other, a
suction-side end piece, extracts
depressurized oil and sends it
back through the oil circuit.
To prove the effectiveness of
this type of hydrostatic guide,
we tested three different slide
assemblies, one at a time, in-
stalled in a motion table. The
first configuration used stan-
dard Size 45 roller carriages
and guides; the second slide in-
cluded damping carriages be-
tween the roller guides; and the
third used hydrostatic carriages
and guides.
For each setup, we applied a
controlled impact force at the
center of the table and measured
the vibration response using an
accelerometer. Results show modal response and settling times from this im-
pact. With the standard roller system serving as the baseline, the additional
damping carriage significantly reduced dynamic response. But the hydrostatic
system achieved the best result, virtually eliminating the dynamic response.
The advantage of the hydrostatic carriage and rail is that it fits into the
same design space, with the same mounting-hole locations, as standard lin-
ear guides. Thus, engineers can spec them into machines with minimal de-
sign effort. An OEM can now offer machines using standard linear guides,
with adaptive damping carriages, or with upgrades to complete hydrostatics
on the same machine platform, depending on customer requirements. New
designs can focus on reducing structural mass for higher accelerations and
traverse speeds.
Currently, hydrostatic carriage and rail systems cost about four to five
times as much as conventional roller profile-rail systems. But like any-
thing else, as market demand increases production volume, costs will
come down. Key to driving this demand will be competition between
manufacturers seeking to offer their customers a technological edge in
machine-tool performance. MD
PS#l56
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Insight. Analysis. Opinion.
RS# 157
MECHANICAL
Traditional
round ram
has all-metal
components.
The redesigned ram
with polymer cam
followers eliminated
lubrication, cut
maintenance intervals,
and permitted higher
operating
speeds.
SELFLUBRICATING
POLYMERS
bolster machine output
Can-making equipment is nothing if not specialized. Yet the sub-
systems found on these machines offer a number of design les-
sons that can be applied more broadly by any engineer working to
improve the performance and reliability of high-speed equipment.
Consider, for example, the cam-driven ram actuators found on a
can lines necking stations. Mounted on a rotating turret and mov-
ing at up to 250 strokes/min, these rams push the round can shell
onto a series of shaping dies that gradually reduce the diameter of
the can to form its neck.
Traditionally, these rams consisted of a round pin that moved
axially within a barrel-like steel housing, with a machined keyway
to keep the pin from rotating. A pair of metal cam followers on the
rear of the pin directly drive the ram.
Unfortunately, the traditional ram design suffers from three
problems. For one, it requires aggressive lubrication to function
properly and prevent ram and cam wear. Second, it lets the pin lift
and twist in the barrel, causing premature wear. And finally, the
traditional design limits the operating speed of the necker.
A redesign eliminates lubrication
problems and increases the speed and
durability of can-making machines.
Authoredby:
Georg Bartosch
Presldent
Intech Power Corp.
Closter,N.1.
LdltedbyKenneth J. Korane
ken.koraneQpenton.com
Key points:
Tradltlonalcan-maklngequlpmentrequlresaggresslve
lubrlcatlontofunctlonproperlyandpreventexcesslvewear.
Self-lubrlcatlngpolymercomponentsellmlnated
lubrlcatlonneedsandextendedmalntenancelntervals.
Cuttlngwelghtloweredthemachlnesenergyusageand
allowedhlgheroperatlngspeeds.
Resources:
Intech Power Corp., www.intechpower.com
www.satco.com/das|gn
Lat Us Ha|p You
1-800-543-0470
0UST0N Fh0|hFF8F0
SP|h0LFS & SL|0FS
0FS|0hF0 & NAhUFA0TU8F0
T0 Y0U8 SPF0|F|0AT|0hS
RS# 158
MECHANICAL
By eliminating the need for lubrication, we addressed
all three problems with a new ram design that serves as a
drop-in replacement for traditional units. Heres how.
Excess wear
Can-making machines run around the clock and typi-
cally produce between 2,000 and 3,000 cans/min. One of
the chief problems with the traditional design was its pro-
pensity to wear out prematurely, despite lubrication.
We analyzed the wear patterns and found that much of
it came from an obvious source metal-on-metal contact
between the pin and barrel, and between the cam follow-
ers and drive cams. Without lubrication, the ram would
quickly fail.
A less-obvious source of wear emerged from a finite-
element analysis of the ram. We simulated not only the
forces needed to extrude the can neck but also the related
centrifugal and acceleration forces. What we found was
that the ram deflected upwards and twisted. This deflec-
tion significantly increased the effects of metal-on-metal
wear throughout the ram assembly. In particular, cen-
trifugal and acceleration forces contributed to wear on the
leading edge of the ram body and its keyway, resulting in a
telltale pleating defect on the can neck.
With all the metal-on-metal contact, ongoing lubrica-
tion of the ram and cam followers was essential. Thats why
these machines typically have costly automated lubrication
systems.
Better materials, less weight
Solving the wear problem involved a change in the
rams materials and pin geometry. By moving to an alu-
PS#l60
PS#l59
FEA results show high stress areas where
the cam followers mount on the tail pin.
Later design iterations reduced these
stresses by beefing up the transition
between the pins full cross
section and the thinner tail.
minum ram and
square pi n, we
cut ram wei ght
by 60% f or an
equal reduction
in centrifugal and
pin-acceleration
forces. The square
shape al so bet-
ter guides the pin
during extrusion
cycles and distrib-
utes forces evenly
over a larger area,
further diminish-
ing the potential
for wear.
Even if we did
nothing else, the
weight reduction
woul d have ex-
tended the wear
l ife of the ram,
dri ve cam, and
met al cam fol -
lowers. Yet as long
as metal-on-metal
contact remained
especially between
t he cam fol l ower
and drive cam
we could not create
a lubrication-free
system.
Eliminating lu-
brication altogether
meant replacing the
original rams metal components with self-lubricating
polymers. We proposed polymer cam followers and a self-
lubricating plastic liner on the rams inner surface.
Selecting the right polymers was crucial. However, its
easier said than done because most such materials are not
as strong as metals. And it is important to note that data
sheets for self-lubricating polymers do not accurately re-
flect changes in mechanical properties under operating
conditions.
We based material selection on a thorough under-
standing of the forces involved, which we had from our
FEA work. We also performed additional engineering cal-
culations to predict how self-lubricating materials would
behave over time under actual operating conditions. For-
tunately, we have developed proprietary material models
over the years which let us make accurate calculations.
The result of the material and geometry changes has
been impressive. Reductions in forces, friction, and wear
have at least doubled the life of a typical ram. And the
wear-induced pleating defect has dropped from 3% to less
PS#l62
PS#l6l
MECHANICAL
The square ram with polymer cam followers eliminates
720 lubrication points and nearly 1 metric ton of moving
mass from the necker.
than 1% in high-speed lines.
More important, the revamped ram completely elimi-
nated the need to lubricate the ram body and its two cam
followers. With a total of 240 rams on a typical 10-stage
necker, the redesigned ram gets rid of 720 lubrication
points on the machine. It also makes the expensive auto-
matic lubrication system unnecessary.
The payoff
With industrial machines, improvements to a seem-
ingly minor component can often have an outsize pay-
back. The square ram design is a case in point:
The rams last two to four years longer, reducing the cost
and downtime associated with ram replacement.
They eliminate cam wear and the high cost of replacing
worn cams.
They eliminate the capital expense of an automated
lubrication system, and operating costs as high as
$6,000/year for one necker.
They improve yields by reducing the pleating defect.
The redesign also generated some important
secondary benefits:
Speed. In can making, line speed equals profit. And
the traditional round-ram design imposed a speed limit
on necking operations. Made from steel with steel cam
followers, these rams typically weighed about 14 lb with a
pin that weighed 8 lb. Operating these heavy rams at high
speeds triggered high centrifugal forces that accelerated
wear. So machine speeds would be dialed down from their
design specifications to keep the rams from wearing out
prematurely.
To raise the speed limit, we cut ram weight by more
than half to 5.2 lb. The moving mass of the pin and cam
followers dropped to 3.0 lb. Reducing the weight in-
volved crafting ram components from aircraft aluminum
and polymers, rather than steel. Total weight reduction
of rotating mass on a 10-stage line is nearly 1 metric ton.
The move to lightweight materials has significantly
improved cycle time. Based on the reports from the
plants now using the square ram, necker cycle times have
dropped on average by 12 to 15% on older machines. On
new neckers, the square ram permits operation at or near
the design speeds.
Energy savings. By cutting nearly a metric ton of mass
that would otherwise have to be accelerated and decel-
erated, the square ram has lowered necker energy con-
sumption significantly. In some cases, energy costs have
dropped by 25%.
Less shock and vibration. Using lightweight materials
reduces shock and vibration, which usually represents an
important speed constraint in rotating machines. In par-
ticular, the polymers used on the rams cam followers pro-
vide a significant amount of mechanical damping with
the damping properties of the polymers peaking near the
operating temperatures of a necker.
The total cost reduction and other benefits associated
with square rams has already resulted in their adoption by
can-making operations around the globe. MD
Polymers eliminate
cam wear
Squareramscouldnotdothelr[obwlthoutacamtopro-
pelthem.And,lnfact,theblggestvalueofthesquareram
deslgn ls that lt extends ram llfe and ellmlnates cam wear.
Some measure of protectlon comes from the fact that the
llghtwelghtsquareramoperatesatlowerforcesthantradl-
tlonalroundrams.However,cleveruseofmaterlalsplaysan
even-morelmportantrole.
The ram redeslgn replaced metal cam followers wlth
ones made from a self-lubrlcatlng polymer. Because the
polymercamfollowerswlllnotgeneratewearonthemuch-
hardercamsurfaces,thlscompletelyellmlnatestheprlmary
mechanlsmbehlndcamfallure.
Whlle the cost of replaclng a ram ls not lnslgnlcant,
lt pales ln comparlson to the cost of replaclng the necker
cams. The cams themselves are preclslon ground and ex-
penslve. Then theres the downtlme and labor costs to re-
place the cams.Taken together, these factors mean that ln
thetradltlonaldeslgn,atyplcalcamchangecancosttensof
thousandsofdollarsonlytoberepeatedeveryfewyears.
FOR MAINTENANCE-FREE LINEAR WAY PERFORMANCE,
HEAD STRAIGHT FOR IKO TECHNOLOGY.
Our linear motion rolling guide
lineup scores big with maintenance-free
performance in a wide variety of applications.
Maintenance will never slide with our
self-lubricating C-Lube maintenance-
free rolling guides that run up to ve years.
Our C- Lube family of linear motion
rolling guides offers you great load capacity,
high rigidity, superior running accuracy
BALL ROLLER BALL SPLINE
Lubricant is deposited
directly to the surface of the
rolling elements.
and smooth motion for machine tools, semi
conductor and liquid crystal manufacturing
applications.
These great performers make
different from others, providing superior
cost performance for your machines
and offer an unending run of long term
maintenance-free lubrication for up to
5 years or 20,000 km.
IKO International, Inc.
www.ikont.co.jp/eg/
New York: 800-922-0337 / E-mail: eco@ikonet.co.jp UChicago: 800-323-6694 / E-mail: mwo@ikonet.co.jp
Atlanta: 800-874-6445 / E-mail: seo@ikonet.co.jp UDallas: 800-295-7886 / E-mail: swo@ikonet.co.jp
Los Angeles: 800-252-3665 / E-mail: wco@ikonet.co.jp USilicon Valley: 800-252-3665 / E-mail: wco@ikonet.co.jp
5 YEARS
12,500 MILES
MAINTENANCE
FREE
IKO C-LUBE LINEAR WAY SERIES
RS# 163
MECHANICAL
into digital signals. Each rotation of the bearing generates
a predefined number of pulses or magnetic signatures,
which can be decoded in real time as rotational speed and
position. If there is too much EMI, the bearing and sensor
can be shielded.
Intelligent bearings such as these can serve as motor
encoders to monitor position, rotational speed, and di-
rection of motor shafts. They mount inside the motor
and provide reliable alternatives to conventional encod-
ers, which mount outside the motor. Variations on this
setup include end-of-
shaft multiturn sensors,
absolute through-shaft
sensors, and high-reso-
lution absolute-position
sensors for measuring
position, and roller en-
coders for making linear
measurements.
Steering units
Steeri ng uni t s for
steer-by-wire modules on
industrial and off-high-
way vehicles replace con-
Bearings have long been used to reduce friction, support
loads, locate shafts, and reinforce system rigidity. Today,
bearing designers are adding sensors, signal-processing
capabilities, and advanced housings, and combining seals
and lubricants in those housings. These smart bearings
offer OEMs and engineers longer service lives and more
options.
Heres a detailed look at these next-generation bearings
that will provide even higher levels of form and function.
Sensor bearings
Intelligent sensor bearings provide accurate informa-
tion on speed (rpm), direction, and incremental or abso-
lute position of rotating or linearly moving components.
They can generate signals that contains data such as the
number of revolutions, relative position/counting, and
if they are accelerating or decelerating. These intelligent
bearings contribute to productivity and reliability, and al-
low for more-compact equipment.
In a typical scenario, a sensor gets designed into the
bearing. The sensor is often an impulse (or code) ring
linked to the bearings rotating inner ring. The inner ring
contains a sequence of north and south-oriented mag-
nets. The sensor detects changes in magnetic fields as the
bearing and its magnets spin and converts those changes
Adding new
features and
capabilities to
bearings improves
productivity and
lowers costs.
Authoredby:
Mark Hinckley
DlrectorofStrateglcPro[ects
SKF USA Inc.
Landsdale,Pa.
LdltedbyStephen J. Mraz
stephen.mrazQpenton.com
Resources:
SKF USA Inc.,www.skfusa.com
For some apps from SKF,
including a Bearing Calculator:
http://tinyurl.com/ccj9g2h
BEARINGS
designed to
multitask
This cutaway drawing
of an ac motor shows the
built-in sensor (red/blue) that
generates speed and position data,
which can be used as feedback signals.
RS# 164
MECHANICAL
functionality. If additional driver locations are required
on a vehicle, several steering modules can be added to the
system providing a belt-and-suspenders approach to
vehicle-steering redundancy.
Advanced housings
Bearing housings are stronger and designers are add-
ing new features, including seals, making custom housings
largely unnecessary. For example, upgraded SE plummer
block housings are now designed to be stiffer and stronger
so they better resist deformation. And larger ribs in the
center of the base improve heat dissipation by increasing
the contact area between the base and support surface,
thereby improving heat flow away from the bearings outer
ring. These upgrades also lengthen the blocks service life.
Housings have also been designed to make serving
easier by adding a grease-guiding flange that sends grease
directly from the fitting to the bearing, which lets techni-
ventional steering columns or provide an alternative to
joystick-controlled machines, which are becoming more
common.
Either noncontact incremental or absolute position sen-
sors can trace movements of a steering wheel and, in turn,
detect steering-wheel position, steering speed, and direc-
tion. For many applications, these sensors can be packaged
in a basic steering encoder which creates constant steering
friction and moderate but acceptable resolution of steering
signals. These compact encoders often combine a stainless-
steel stub shaft (on which the steering wheel mounts), two
noncontact rotary incremental sensors, a friction mecha-
nism that creates the steering feel, and rolling bearings
inside a compact and durable housing. Units can have
standard resolution (256 increments/turn of the steering
wheel) or high resolution (1,024 increments/turn of the
wheel), depending on the sensors.
For steering units with more functions and perfor-
mance, smart bearings give drivers a realistically changing
steering feel. These units detect steering-wheel position to
generate end stops and just the right amount of resistance
(or feel) to turning, which depends on current driving
conditions. These units add two independent CANbus
interfaces and an electromagnetic brake to the previously
described basic steering unit.
The vehicle controller (via the CANbus) or a micropro-
cessor in the steering unit controls the brake so that torque
resistance on the steering wheel accurately changes to sim-
ulate feedback from mechanical steering units. The brake
also creates left and right end-stops that keep the steering
wheel from turning. The brake lets go when the steering
wheel moves in the opposite direction. Unlike mechanical
or hydraulic steering systems in which end-stops are fixed,
end-stops in these units are programmable. The steering
ratio can also be programmed to vary with vehicle speed
or other operating parameters.
Bui l t -i n redundancy and
fail-safe operation are critical
for safety in steering units. This
means that both the absolute po-
sition sensor and output chan-
nels comprising the microproces-
sors and CANbus interfaces are
designed with internal redun-
dancy. For example, if one of the
two CANbus interfaces fails, the
second will continue to operate,
providing data to the vehicle con-
troller. During normal operations,
these two channels of communi-
cations are continually compared
to each other to ensure both are
providing accurate feedback. If
the vehicle controller detects a
discrepancy between the two sig-
nals, the OEM can design a limp-
home mode that lets the driver
use the vehicle , but with reduced
Bearings and efficiency
Theenglneerlngbehlndbearlngshaschangedovertheyears,lettlngdeslgnersreal-
lzegreateremclenclesandmoreperformance.etthemalntaskofbearlngsremalnsthe
same:reducefrlctlonand,lntheprocess,reduceenergyconsumptlon.
Whlle developlng new bearlng deslgns, researchers rely on sophlstlcated computer
modellng and proprletary software to attack vlrtually every source of bearlng frlctlon.
Wlth roller bearlngs, for lnstance, englneers have tlghtened bearlng speclcatlons and
rened the lnternal geometry of the polymer cage, roller, raceway, and guldlng nange.
Andbearlngcompanlesmakethesedeslgnsuslngpreclsemanufacturlngtechnlques.
Porenergy-emclent(L2)bearlngs,englneersfocusedongettlngthenumberofrollers
[ust rlght.They also wanted to modlfy the raceway to cut the welght of rotatlng parts
byaboutl0%becausellghterbearlngstakelesspowertomove,maklngthemmoreef-
clent.Thelower-welghtmovlngpartsalsohavelesslnertlaandare,therefore,lessllkely
toskldorsmear,whlchreducesperformanceandservlcellfe.L2bearlngsalsogenerate
lessheatandruncooler,extendlngtheservlcellfeofthelubrlcants.
Pelatlvetocomparablyslzedstandardbearlngs,energy-emclentverslonscanreduce
frlctlonallossesby30%ormoreandarewellsultedforgrease-lubrlcated,llght-to-normal
loads such as electrlc motors, pumps, conveyors, and fans. And shlelded verslons have
longerservlcellvesthanstandardbearlngs.
Encoders that are built-in on ac motors can monitor rpm
speed, shaft position, and direction of rotation, and come
in a variety of sizes and styles.
UPTIME, ALL THE TIME
SKINTOP
cable glands can stop electrical failures

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Seals from liquid and dust
Vibration and impact resistant
High pull-out strength
Effective EMC options

Download a free technical paper on connector optimization
from our automotive resource center at www.lappusa.com/automotive.
RS# 165
MECHANICAL
first line of defense against extremely fine contaminants.
The second barrier is the grease packed into the housing
on both sides of the sealed bearing at installation. And
the third layer of protection are the bearing seals which
keep clean lubricant inside the bearing and keep con-
taminants out.
Sealed spherical roller bearings are well suited to appli-
cations where uptime is critical and bearing maintenance
must be minimized. These bearings also mitigate grease
leakage, especially important where environmental con-
cerns are an issue. In one case, a coal-mine operator re-
placed open cylindrical-roller bearings with sealed spher-
ical-roller bearings in conveyor impact idlers and saw
service life double. Installing the spherical-roller bearings
took half the time of conventional bearings and, being
greased for life, the new bearings dramatically reduced re-
lubrication costs and disposal of used grease. In addition,
maintenance staff could focus on more critical mining
operations.
Another mining operation reported that its annual
grease use was cut by more than 220 lb at each bearing
position in a conveyor by replacing open spherical-roller
bearings with sealed versions. The investment paid off in
a year, while operational costs associated with each bear-
ing position were halved. This can add up to considerable
savings as disposing of grease can cost more than the pur-
chase price.
PosiTrac Plus seals offer distinct advantages over tradi-
tional taconite seals. The contact lip seal keeps out debris
and is protected by the bearing housing. And the Plus
seals cost less than taconite alternatives.
In short, by adopting a three-barrier solution, end users
ultimately could increase a bearings ser-
vice life by up to a factor of three, com-
pared with traditional arrangements,
and cut lubrication by 90%.
Combining bearings with
sensors, specialized housings,
seals, or lubricants, along with
advances in the bearing design,
delivers more functions with fewer
components in smaller packages for
more productivity. MD
cians lubricate the bearing efficiently from the side. Hous-
ings can also have grease-level markings at each corner in-
side the base that show when the proper amount of grease
has been applied, and an off-center hole in the housing cap
relative to the shaft axis permits a higher flow of grease
during servicing.
Bearing housings are also designed to accommodate
sensors that measure operating parameters such as bear-
ing rotation and speed, temperature, and vibration in real
time. Technicians tracking these parameters can detect
and diagnose operating problems before they escalate into
failures.
Some of these features can work to minimize envi-
ronmental impact, as well. For instance, the previously
mentioned grease-guiding flange ensures no lubricant is
wasted and only the minimum is used; and better heat
conduction in housings reduces grease consumption,
which also reduces the amount of grease that must be
properly disposed.
Bundled bearing packages
Adding lubrication and sealing to bearings can reap re-
wards in performance and reliability by extending service
life, reducing grease consumption, and protecting compo-
nents. Plus, from an OEM designers perspective, precisely
bundled bearings can be smaller, making them well
matched for todays ever-smaller design envelopes.
In one case, bearings were needed on mining equip-
ment that could survive the harsh environment. The goal
for the new design was that it last longer than current
versions and help prevent premature bearing failures
without relying on complicated and relatively expensive
auxiliary taconite seals or consume large quantities of
grease. The design teams three-barrier solution included
the housings with seals, grease, and sealed spherical roller
bearings all in a single package.
The final bearing, a proprietary design, consists of
split pillow-block housings with PosiTrac Plus seals, fac-
tory-sealed high-performance spherical roller bearings
prepacked with specially formulated grease, and then
more grease between the bearing and seals inside the
housing. This effectively delivers three layers (three bar-
riers) of protection for the bearing during assembly and
operation. The PosiTrac Plus seals in the housing are the
This SKF sensor
includes an impulse or
code ring, which links to
the rotating inner ring
of a bearing to detect
and measure rotational
speed and absolute
position input.
Combining
intelligent
bearings,
advanced housings
and seals, and
the proper grease
helps keep
bearings
operating
in harsh
environments
such as mines.
&5($7,1*62/87,216
Your Customers Can Rely On
#SteppersImproveMotionControl
1G245 V|ueya|d B|vd., No|gau h|||, CA 95O87
Te|. 4O8.919.O2OO - www.||ueug|uee||ug.com
Lin Steppers are available in a variety of
shapes and sizes and with many custom
options like:
IP Ratings
Shaft Configurations
Vacuum Ratings and much more!
Check out this quick overview on the many custom options that are available:
www.linengineering.com/customize
RS# 166
bring to
LIGHT
Hackensack, NJ 07601 USA
+1.201.343.8983
main@masterbond.com
www.masterbond.com
LED Curable
Polymer System
One Component
LED401LV
Fast curing
Cures completely
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Environmentally
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Optically clear
PRODUCTS
Request free information via our
Reader Service Web site at
Protective vents
Gore Protective Vents help keep out
water while venting gases. The vents pre-
vent failed seals and condensation by let-
ting products breathe during changing
environmental conditions. The units are
engineered with a screw-in, snap-fit, or
press-fit construction, making it easy to
integrate them into any housing design.
W. L. Gore & Associates Inc., 555 Paper
Mill Rd., Newark, DE 19711, (888) 914-
4673, www.gore.com/protectivevents
RS# 467
Configurable
drive system
When combined, DCX motors, GPX
gearheads, and ENX encoders form
a high-precision drive system. DCX
motors feature precious metal or
graphite brushes, can be equipped
with standard preloaded ball bearings
or sintered bearings, and cover a large
voltage range with six different iron-
less windings. Almost all mechanical
configurations are possible with the
motors new housing, and its mounting
flange is fully configurable, including
thread diameter, position, number of
mounting holes, and dimensions of the
centering collar. A short-configuration
motor without a flange is also avail-
able. The motors output shaft length
and diameter can be selected, with or
without flat.
A GPX22 gearhead, for use with the
DCX motor, consists of individually con-
figurable gear stages and a configu-
rable flange. With a laser weld, the gear-
head interface is joined seamlessly to
the motor. The output shaft is available
in different lengths, with or without a
flat, and with cross holes or a key.
Two matching encoders, the ENX
Quad and ENX Easy, feature a strong
design and high signal quality. The ENX
Quad is a single-pulse, two-channel
encoder suitable for speed and direc-
tion detection. With a built-in ESD
protection network, reverse-polarity
protection, and cable strain relief, it is
suited for simple closed-loop tasks. The
ENX Easy is a three-channel encoder
with line driver and a resolution of up
to 1,024 pulses/rev. Cables are configu-
rable in seven lengths, from 50 to
1,000 mm.
maxon precision motors inc., 101
Waldron Rd., Fall River, MA 02720,
(508) 677-0520, dcx.maxonmotor.
com, www.maxonmotorusa.com
RS# 465
Brushless servomotors
The AB Series of IP65 industrial-grade,
brushless servomotors come in three NEMA
frame sizes and various stack lengths. The
line exhibits a medium-to-high torque con-
stant (KT) to accommodate dc-bus voltage
ranges from 325 down to 170 Vdc.
Features include an IP65-rated design, a
heavy-duty 0.5-in. output shaft, front shaft
seals, military-style multipin connectors,
internal Hall-
effect devices
spaced at
120 electri-
cal degrees,
and two
thermostats
for overload
protection.
Available ac-
cessories include optical encoders, external
holding brakes, precision gearheads, and
mating power and sensor cables.
The motors are available in NEMA-23, 34,
and 56 mounting configurations and pro-
vide continuous stall-torque output from
3.75 to 114 lb-in. and peak torque from 11.3
to 339 lb-in. Rated speeds range from 2,800
to 5,200 rpm.
Pittman Motors, 343 Godshall Dr., Har-
leysville, PA 19438, (330) 673-3452, www.
pittman-motors.com RS# 466
PS#l67
MILWAUKEE SCHOOL OF ENGINEERING
Fluid Power Conference & Expo
June 11-12, 2013
Milwaukee, Wisconsin
Sponsored By: Produced & Managed by:
Avoiding Pitfalls of Design Mistakes
Bob Sheaf, President, CFC Industrial Training
Hydraulic System Troubleshooting
Tom Wanke, CFPE, Milwaukee School of Engineering
Closed-Loop Control with Practical Second
Order System Consideration
Peter Nachtwey, President, Delta Computer Systems
Hydraulic System Diagnostics

Effective Manifold Design; An Innovative
Manufacturers' Perspective In The World
of Automation
Attilio Treglia, PE, Chief Engineer, Lynch Fluid Controls
Diagnostic Techniques for Hydraulic Systems
Designing More Energy Efcient Systems
Designing Hydraulic Circuits with HyDraw CAD
Yudi Raina, Co-Founder, VEST Inc.
Introduction to Hydraulics
Improve your Systems with Accumulators
Jim Tobul, President, Tobul Accumulators, Inc.

Tips and Tricks for Circuit Design
Sessions presented by industry experts on uid power topics
of interest to engineers and designers.
Conference
Highlights
COCKTAIL RECEPTION
Mingle with attendees and exhibitors
and join us for hors doeuvres,
wine, beer and mixed cocktails
immediately following the conference
on Tuesday, June 11th.
Compliments of Brand Hydraulics
GROHMANN MUSEUM
The Grohmann Museum at MSOE
is one of Milwaukees newest
attractions and home to the worlds
most comprehensive art collection
dedicated to the evolution of
human work. Join us for breakfast
on Wednesday, June 12th at the
Museum and take a look around.
The Museum includes three oors
of galleries where a core collection
(The Eckhart G. Grohmann Collection
Man at Work) is displayed as well
as special themed exhibitions that
reect a variety of artistic styles and
subjects that document the evolution
of organized work.
MSOE LAB TOUR
Some industry giants including
Johnson Controls send their
professionals to the MSOE campus
for training because the laboratories
and research facilities are that good.
Take your own personal tour of the
MSOE labs and see the latest and
greatest in the industry.
WWW.FLUIDPOWEREXPO.COM/MSOE
At
EngineeringTV.com
users can browse video libraries
using technology-based navigation
to focus on specific technology
topics. They can also browse by
company brand, tradeshow, or by
publication-specific video playlists.
From tutorials to
tradeshow coverage,
Engineering TV is the video site
for design-engineering
professionals.
visit us at
EngineeringTV.com
an|mat|cs.com
408-748-8721
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Contact us today to fnd out
wOy morL major sLmiconductor
manufacturLrs rLly on
MooN Animatics for prLcision
motion control.
SLmiconductor manufacturLrs
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mattLr wOLtOLr you'rL movinN
wafLrs tOouNO vision systLms,
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dicLrs, a SmartMotor LnablLs fastLr
LxLcution spLLds wOilL savinN
spacL and cablinN costs.
PRODUCTS
Hygienic cables
A specially formulated PUR
outer jacket prevents the
Nanoflex Series of hygienic
control power and data
cables from micro-organism growth. The outer jacket is hydrolysis and detergent
resistant, letting it withstand the harsh cleaning processes used to sterilize equip-
ment, which over time degrade cable performance.
The unshielded Nanoflex HC 500 is a flexible control power cable that sup-
plies machinery with up to 600 V. Its shielded variant, the HC 500-C, is wrapped
in a tinned-copper wire braid (85% coverage) that prevents signal interference or
cross talk, and can be used to ground the cable when connected to a metallic
cord grip. Both cables safely operate in temperatures ranging from 40 to 80C
(application specific) and are available in sizes ranging from 20 to 12 AWG with
various conductor configurations.
The unshielded, flexible Nanoflex HC TRONIC data cable provides uniform sig-
nal transmission from the control panel to the machine in sterile environments.
The HC TRONIC-C cable is shielded with a tinned-copper wire braid to prevent sig-
nal interruption (85% coverage) during applications that produce large amounts
of EMI. Both cables are rated for temperatures from 40 to 80C (application
specific) and come in sizes ranging from 26 to 18 AWG with various conductor
configurations.
The entire line is UV, oxygen, ozone and radiation resistant up to 110 Mrad.
Helukabel USA, 1490 Crispin Dr., Elgin IL 60123, (877) 910-2094, www.helukabel.
com RS# 468
PS#l69
THE COUPLING. RW-AMERICA.COM
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tomation, and other small-to-medium
systems.
All Jazz controllers include four au-
totune PID loops that can be set using
the onboard temperature/analog in-
puts, and the analog or PWM outputs;
all onboard transistor outputs can
function as PWM outputs. The devices
Programmable-
logic controllers
Two new controllers have joined
the Jazz 2 Series, the JZ20-R16 and
JZ20-R10. The controllers feature 48K
(virtual) ladder-logic memory and a
built-in mini USB programming port.
The controllers can replace smart
relays for applications such as simple
autoclaves, rotating tables, home au-
also feature a full-function HMI with a
two-line LCD text display that shows
up to 60 user-designed screens, and a
16-key keypad.
Unitronics, 1 Batterymarch Park,
Quincy, MA 02169, (866) 666-6033,
www.unitronics.com
RS# 469
Network upgrade
Upgrades to the CC-Link IE Field
network include remote I/O blocks for
digital input and output, analog input
and output,
high-speed
input, a CC-Link
gateway for
simple access
to existing
CC-Link equip-
ment, and a
number of new
CC-Link IE Field
cables and accessories. The CC-Link
IE Field and CC-Link gateway provide
access to CC-Link equipment without
a PLC.
The network upgrades are ben-
eficial for packaging machines with
modular components, automotive as-
sembly lines, large material-handling
systems, and products with CC-Link IE
Field compatibility from automation-
equipment manufacturers.
Features of the network include
1 Gbit/sec transmission speed; inher-
ent determinism without Ethernet
switches; flexible topology; seamless
data communication; and integration
with TCP/IP field devices.
Mitsubishi Electric Automation
Inc., 500 Corporate Woods Pkwy.,
Vernon Hills, IL 60061, (847) 478-
2100, www.meau.com
RS# 470
PS#l70
RS# 172
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eudures the harshest iudustria| euviroumeuts
(YHQVWURQJHU(YHQIDVWHU(YHQVPDUWHU
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State of the art servo
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Comp|ete s`stem
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EZ INDEXER
EZ INDEXER
IF YOU STILL BELIEVE THE WORLD IS FLAT...

,HZ`[V0U[LNYH[L9VI\Z[*VUZ[Y\J[PVU5V4HPU[LUHUJL
A MECHANICAL INDEXER.
YOURE PROBABLY STILL USING
RS# 171
RS# 173
PRODUCTS
Integral-horsepower
ac motors
The OME Series general-pur-
pose ac motors are totally en-
closed fan-cooled ( TEFC) T-
frame motors with cast-iron
frames and a ribbed design for
maximum cooling. The industrial-
duty, three-phase, 208 to 230/460-V
motors feature Class-F insulation
and are available in 1 to 5 hp and speeds of 3,600,
1,800, and 900 rpm. The motors are inverter-
duty capable with a 5:1 speed turndown for
variable-torque applications and a 2:1 speed
turndown for constant-torque use.
Omega Engineering Inc., One Omega Dr., Stam-
ford, CT 06907, (203) 359-1660, www.omega.com
RS# 471
Pressure transmitters
The 31CS and 32CS Series intrinsi-
cally safe pressure transmitters
are CSA approved for use in haz-
ardous areas. Both transmitters
are identical with the exception
of the pressure diaphragm. The
32CS version features a thicker
diaphragm and a pressure restric-
tor that withstands cavitation or
extreme pressure spikes, allowing
for improved stability and reliabil-
ity in pulsating applications.
The transmitters feature Sput-
tered Thin Film sensing technol-
ogy, 17-4 PH stainless-steel wet-
ted parts, and ASIC-controlled
thermal compensation and signal
conditioning. The transmitters
offer long-term stability (0.2%
full scale/year drift) and high ac-
curacy (0.25% full scale), as well
as high resistance to shock and
vibration.
Gems Sensors & Controls, One
Cowles Rd., Plainville, CT 06062,
(800) 378-1600, www.gemssensors.
com
RS# 472
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RS# 177
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An "SNBNFOU.BLFS needed a way to rapidly and
ergonomically attach armor plating to its mine-
resistant fghting vehicles. Airfoat designed and built
an air-riding platform with a hydraulic arm, enabling
greater automation and productivity.
RS# 175 RS# 176
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Featuring:
Highest stroke Oength (90%)
Highest cycOe Oife
Customization
RepeataEiOity
0edia compatiEiOity
High temperature
SS, Titanium, aOOoys, etc.
6KRS2QOLQH
Transfer Pressure or Temperature into Linear 0ovement
Semiconductor, Aerospace,
Medical, Industrial, UHV,
Oil and Gas
RS# 178
Diaphragm pumps
The 1010 Series gas
diaphragm pump
offers 4,000 hr of
nonstop operation.
The efficient opera-
tion and low power
consumption of the
0.03-lb unit extends
the battery life of the
warning device. Features
include oilless operation, a
sealed air path for contamination-
free analysis, and a restart option at
low temperatures for use in cold environments. The pump
offers maximum continuous pressure to 8.7 psi and maxi-
mum vacuum to 14.8 in.-Hg.
Thomas Div., a Gardner Denver Co., 1419 Illinois Ave.,
Sheboygan, WI 53081, (920) 457-4891, www.gd-thomas.com
RS# 475
PRODUCTS
Parallel-
jaw motion
grippers
Design information
on two families of
pneumatic grip-
pers is provided in a
24-page brochure.
Synchronous,
parallel-jaw motion
models require no adjustment and come with strokes from
to 24 in. and grip forces to 400 lb at 100 psi.
Fabco-Air Inc., 3716 NE 49th Ave., Gainesville, FL 32609,
(352) 373-3578, www.fabco-air.com RS# 474
Rotary
feedthrough
The DDF-I rotary
feedthrough, with inte-
grated bus technology,
can be used for con-
necting mechatronic
gripper modules, valves, or sensors that are downstream
from a rotary axis. Up to 26 electric signals are transmitted
simultaneously, 13 of which are for the actuation of valves.
Air and vacuum are supplied to the actuators through a
fluid feedthrough and slip-ring contacts supply the tool
with power, even at high speeds.
The DDF-Is center bore allows the feedthrough of ca-
bles, liquids, workpieces, or the use of a camera. Continuous
rotary movements are also possible.
Schunk, 211 Kitty Hawk Dr., Morrisville, NC 27560, (919)
572-2818, www.schunk.com RS# 473
PS#l79
Does the
Heavy
Lifting
Sensors for Extreme Applications
800-350-2727
|
www.beisensors.com
Industr|a|equ|pmentrequ|res
re||ab|emot|oncontro|
feedback|nordertoperform
proper|yandsafe|y.BEIencoders
andpos|t|onsensorsstandupto
thetoughestenv|ronments,wh||e
prov|d|ngspeedandpos|t|on
feedbackw|ththeutmostprec|s|on.
Learnmore
abouthow
BEISensors
canhe|pw|th
yourextreme
app||cat|ons.
PRODUCTS
Hybrid stepper motor
The PJPL Series linear hybrid stepper motor converts rotary motion to linear
motion. The motors are available with a 28-mm (PJPL28) or 42-mm frame
size (PJPL42) and feature 0.005-mm resolution, 200 steps/rev, 40-mm stroke
length, dielectric strength of 500 V (1 min), and 2-2 phase excitation modes.
The PJPL28 motors offer rated voltage of 2.66 V, 0.95 A of rated
current, a resistance of 2.8 , and 1-mH inductance. The PJPL42
version offers 2.80 V of rated voltage, a rated current of 1.2 A, a
resistance of 2.3 , and 1.5l-mH
inductance.
Nippon Pulse America Inc., 4
Corporate Dr., Radford, VA 24141,
(540) 633-1677, www.nipponpulse.
com RS# 676
Inclination
sensors
New liquid-based inclination sensors,
for critical applications involving pre-
cise position control and continuous
positioning of rotational movements,
measure the deviation on a horizontal
axis of up to 360. The sensor offers
high accuracy, 0.01 resolution, and a
temperature drift of just 0.01%/10K,
making them suitable for solar-
thermal power plant and renewable-
energy applications requiring angle
measurement or constant rotary
monitoring.
Housed in an IP67-rated metal
housing, the units operate at 40 to
85C. The sensors are based on a ca-
pacitive measuring principle and are
equipped with a liquid-based measur-
ing cell. A 4 to 20-mA analog output
signal is scaled linearly over the angu-
lar range of 360C.
Balluff Inc., 8125 Holton Dr., Flor-
ence, KY 41042, (800) 543-8390, www.
balluff.com
RS# 677
PS#l80
Extensive Uses
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www.beropticpof.com
O55 ThirD Avenue, .ew York, .Y 1OO17 s Tel.. 212-OO5-2892 s Fax. 212-OO5-1O8O s E-mail. ken.eoenmitsuoishicorp.com
RS# 183
OFFERS QUALITY
MOTOR SOLUTIONS!
828/626-2901
www.ohioelectricmotors.com www.hbdindustries.com
BRUSHLESS DC MOTORS
Ferrite Magnet Type
Continuous Duty Rated
Standard or High Speed Applications
Available in NEMA 42 Frame
1/8 up to 1 HP
Low Voltage up to 320 VDC 3-Phase Motor
Since 1917, Ohio Electric has produced
a full range of standard and custom DC
motors. Shown below are three types
of the many choices of motor products
available from Ohio Electric:
WOUND FIELD MOTORS
Available in 5, 6.7 & 8" Diameters
Output Ranges from 2 to 10 HP
Speed Range: 500 to 4,000 RPM
Volts: 72 to 260
Motors - UL and CSA Approved
Other Options Available
We manufacture reliable, quality motors for customers that last.
EXPLOSION PROOF MOTORS
Available in NEMA 48 to
56 Frames
Output Ranges from 1/8
to 1.25 HP
High Start-Up Torque
Volts: 12-180
Motors- UL and CSA Approved
Other Options Available
ISO 9001: 2008
OFFERS QUALITY
MOTOR SOLUTIONS!
RS# 181
RS# 182
Brushless Motors
Ferrite Magnet Type
Continuous Duty Rated
Standard/High Speed
Custom Motors
Explosion-Proof Motors
Permanent Magnet Motors
SCR Rated Motors
Wound Field and More!
Custom Designed AC/DC
Explosion Proof Motors
Hermetic AC Motors
Military Motors
Nuclear Motors
Approved for Nuclear Plants
US Navy Specified
Sizes from 5 lb. ft. (6.8NM) to
150 lb. ft. (203.4NM) in torque
Servo Motors
Specialty, OEM & More
Brushless (PMAC) Motors
Fractional to over 700 HP
Small Size/Bi-Directional
High Torque (4,000 lb-ft)
UL Certification, Custom & More
Low Inertia/High Speed Motors
Military Motors
NEMA Design Motors
Motor Controllers
Aerospace/Aviation
Centrifugal Pumps/Pumps
Construction/Mining
Energy/Nuclear Plants
HVAC
Manufacturing/Packaging
Transportation/Railroads
US Defense and More!
www.ohioelectricmotors.com
www.peerlesselectric.com
www.powertecmotors.com
PRODUCTS
AS-Interface splitters
Two new G10 Series AS-Interface Splitters
with stainless-steel coupling nuts feature
a robust one-piece housing with IP67/
IP68/IP69K ratings for use in harsh environ-
ments. The VAZ-2T1-FK-G10-V1-V4A and
VAZ-T1-G10-1M-PUR-V1-GV4A AS-Interface
accessories mount quickly and easily in
tight spaces, are immune to vibration, and
have gold-plated and machined contacts.
The open, multivendor AS-Interface is
designed to reduce the complexity and
cost of connecting conventional inputs
and outputs, analog transducers, and
safety devices to dominant PLCs.
Pepperl+Fuchs, 1600 Enterprise Pkwy.,
Twinsburg, OH 44087, (330) 486-0001,
www.pepperl-fuchs.us
RS# 678
Pneumatic valves
The Analytical Series electronic
valves come in two or three-way,
normally closed or fully ported.
The A-E Series pneumatic valves
are designed for the analytical
industry and applications where
cleanliness is paramount.
The valve has a power con-
sumption of only 0.67 W, 5 to
10-msec response time, and
voltages of 6, 12, or 24 Vdc. The
device handles applications
where internal cleanliness, bub-
bletight operation, and long life
are imperative.
Clippard Instrument Labora-
tory Inc., 7390 Colerain Ave.,
Cincinnati, OH 45239, (877)
245-6247, www.clippard.com/
analytical
RS# 679
3D printer for orthodontics
The Objet30 OrthoDesk 3D printer is
specially designed for smaller orthodon-
tic labs and clinics as it conveniently fits
on a desktop. Users can create accurate,
smooth, orthodontic models by automat-
ing the entire workflow from CAD file to
model fabrication. The fully digital work-
flow eliminates the need for physical
impressions, and models can be stored
digitally.
The printer combines accurate,
precise 3D printing technology with a
small desktop footprint. It comes with
specialized dental printing materials
in convenient sealed cartridges. Stone
models, orthodontic appliances, delivery and positioning trays, clear aligners, re-
tainers and surgical guides can all be produced.
Stratasys Ltd., 7665 Commerce Way, Eden Prairie, MN 55344, (888) 480-3548,
www.stratasys.com
RS# 680
PS#l84
For motor solutions, call us!
800/676-3651
E-mail: sales@peerlesselectric.com
www.peerlesselectric.com
www.hbdindustries.com
...your best source for Design

and Production of Specialty
AC/DC Electric Motors.
PEERLESS ELECTRIC
RELIABLE, HIGH PERFORMANCE
DC Servo Motors
Explosion Proof Motors
Hermetic AC Motors
Military/Defense Motors
Pump Motors
Single Phase AC Motors
Traction Motors
Commercial
Industries
Centrifugal Pumps
Material Handling
Military/Defense
Applications
Motion Control
Nuclear
Specialty, Custom
Design and OEM
PEERLESS ELECTRIC PRODUCES:
MOTORS SERVE THESE MARKETS:
(1*,1((565(48,5(3(5)250$1&(
7+(%266'(0$1'65(68/76
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Satisfying competing demands is easy with Diamond roller
chain. With industry leading wear life engineers get their
performance. With the Lowest Total Cost of Ownership,
purchasing gets their cost reductions. Best of all the boss
gets results. When your business demands results, demand
Diamond.
Scan the QR code
for additional
information about
Diamond Chain
Product Performance
www.d|amondcha|n.com
1-B00-B72-424
2013 The Diamond Chain Company. MD0213
Inclinometers and
accelerometers
The DXI 100/200 Series of single and
dual-axis inclinometers and the DXA
100/200 Series of single and dual-axis
accelerometers feature a digital output
with a resolution of 0.001; provide both
high precision and performance for
tilt-sensing or acceleration applications;
come standard with an EIA-RS485
and EIA-RS422 industry-standard
outputs; and provide low noise and
high and long stability. These sensors
are for use in applications including
radar/antenna control, structural
monitoring, platform leveling, linear
acceleration/deceleration measur-
ing, automatic train-position control systems, and seismic
monitoring. Data sheets for both Series are available at http://jewellinstruments.
com/wp-content/uploads/2013/03/DXI-100_200-Digital-Inclinometer.pdf and
http://jewellinstruments.com/wp-content/uploads/2013/03/DXA-100_200-Digital-
Accelerometer-FINAL.pdf.
Jewell Instruments LLC, 850 Perimeter Rd., Manchester, NH 03103, (603) 669-
6400, www.jewellinstruments.com
RS# 681
PS#l85 PS#l86
match your needs. Ultimate flexibility for
high volume production.
Small and medium volume production or
prototypes? Then IMS.baseline is the fast
and reliable solution with a selection of
Standard Planetary Gears.
Germany | USA | Mexico | China
Gear Technology. Worldwide.
IMS Gear Planetary Gears Inc.
440 Viking Drive Suite 110
Virginia Beach, VA 23452
phone 757-227-5553 x401 www.imsgear.com
Planetary Gears.
High quality for all volumes.
IMS Gear ofers the optimum solution and the process that you need.
From prototypes to high-volume series.
Unlimited
possibilities. Unique solutions.
ITS ALWAYS GOOD TO HAVE THE CHOICE.
With our standard modular system for
Pla netary Gears you have over 10,000 con -
guration possibilities to choose from.
IMS.techline offers the customization of
the modular standard gear drives to exactly
FOR EVERY PROBLEM THERE IS ONE SOLUTION.
PRODUCTS
energy to the inverter, energy is fed
into the intermediate circuit and
other inverters in the system use this
energy. If there is no accepter for the
energy in the intermediate circuit, it is
fed back to the mains sinusoidally via
the KES compact power supply. STO
in PLe can be implemented with each
Compact inverter
The new KW200 servo inverter ex-
pands the AMKASYN family to cover
a rated power of 200 kVA. The 320
228 425-mm units renewable brake
energy contributes to its efficiency.
When the brake is applied to the con-
nected servomotor, which provides
of the devices, and additional security
is available through an optional KW-
R07 safety-controller card. The devices
have a fieldbus interface to EtherCAT,
Varan, and CANopen.
AMK Drives and Controls Inc.,
5631 S. Laburnum Ave., Richmond, VA
23231, (804) 222-0323,
www.amkdrives.com
RS# 681
Axial-piston pump
The V60N-130 joins the V60N Series
of axial-piston
pumps. The
Series now
consists of four
different sizes
with displace-
ment volumes
up to 8 in.
3
/rev,
working pres-
sures of up to
5,800 psi, and
peak pressures
of up to 6,500 psi. All pumps have
swash plates and provide required
displacement volume without over
or underdimensioning the pump
output.
The V60N-130, designed for high
pressure and high volume, directly
attaches to a vehicles power take-off
with an SAE flange. The pump comes
with a wide variety of controls and
flanges with options for connecting
additional pumps to the through
shaft.
Axial piston pumps are suitable
for construction machines, concrete
pumps, public transport and utility
vehicles, waste-disposal trucks, cranes,
forestry vehicles, as well as many
other machines.
Hawe North America Inc., 9009-K
Perimeter Woods Dr., Charlotte, NC
28216, (704) 509-1599,
www.hawehydraulics.com
RS# 682
PS#l87
2013 Newport Corporation
The rst choice in motion control delivers a new stage
of performance and reliability in laser micro machining.
Newport provides high-performance linear motor
stages, industry-leading motion controllers, and G-Code
conversion software to address a variety of applications
from marking to nano-patterning.
Discover the reliability and performance of Newport
Stages. Visit www.newport.com and Search
Stages-10 or call 800-222-6440.
The Best Moves in Laser
Micro Machining
RS# 190
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Spring
Applied
Brakes
Spring
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Brakes
www.nipponpulse.com { info@nipponpulse.com { 1-5+0-633-1677
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Nippon Pulse has been designing and
manufacturing stepper motors for the last
60 years, ensuring you get the most
reliable product available.
6,;7<<($562)5(/,$%,/,7<
(&2120,&$/
Easily integrated into any system, our
stepper motors offer a cost effective and
accurate motion control solution.
&267())(&7,9($&&85$7(
When you choose a Nippon Pulse stepper,
you'll also get one-on-one product support
unmatched in the industry. !f you have
questions about integrating, prototyping,
customizing, we have the answers.
810$7&+('352'8&76833257
67(33(5027256
Tin-can
Gearhead
Linear
Hybrid,
Synchronous
RS# 188 RS# 189
Plain, or with ridges, sea salt or unsalted,
mesquite or green onion, kettle or baked . . .
the possibilities are endless.
Every Visumatic Hand-Held Automated Fastening Tool,
comes ready to drop in place,and is backed with our
unmatched human-touch customer service.
Grab the performance tool built for durability and
accuracy, and ENGINEERED TO HIT YOUR SPOT.
And just like potato chips,
we bet you wont be able to stop at just one.
So whats your preference?
Call us to discuss the possibilities.
Smarter Machines from Creative Engineers for Smart Customers
7 * 4 6 ."5 * $ $ 0. t 8 5 9 . 2 5 5 . 7 9 0 7
Interconnections
and hardware
The 2nd edition of Catalog M60.2 is
now available. The 152-page cata-
log covers the companys full line of
interconnect components and elec-
tronic hardware. A variety of new
products and product updates are
featured. Category sections include
battery clips, contacts & holders;
fuse clips & holders; terminals & test points; spacers & stand-
offs; panel hardware; pins, plugs, jacks & sockets; PC board
hardware; and multipurpose hardware.
Over 5,000 products are featured as well as detailed
drawings, specifications, and product photographs in both
Imperial and Metric dimensions.
Keystone Electronics Corp., 31-07 20th Rd., Astoria, NY
11105, (718) 956-8900, www.keyelco.com
RS# 684
Equipment sourcebook
The 102-page Loctite Equipment
Sourcebook, Vol. 9, is a comprehen-
sive directory of dispensing and cur-
ing equipment. From simple hand-
held devices to fully automated
systems, products include cure
systems, automated and manual
dispense systems, robots, valves and
the Loctite AssureCure inline system
that assesses the degree of cure of
light-cure adhesives.
Loctite equipment dispenses
and cures a wide variety of adhesives, sealants, and indus-
trial fluids, from water-thin liquids to high-viscosity pastes.
Henkel Corp., One Henkel Way, Rocky Hill, CT 06067, (800)
562-8483, www.henkelna.com/literature RS# 685
PRODUCTS & LIT
Position sensors
The 2013 position sensors catalog
covers six innovative product lines
for a wide variety of applications
requiring feedback position sensors.
The catalog provides an overview
with technical specifications of the
products as well as the operating
principle of each. Available position
sensors include Posiwire cable-
extension, Positape tape-extension, and Posichron magne-
tostrictive, as well as Posirot magnetic angle sensors, Positilt
MEMS inclinometers, and Posimag magnetic encoders.
ASM Sensors Inc., 650 W. Grand Ave., Suite 205, Elmhurst,
IL 60126, (630) 832-3202, www.asmsensors.com
RS# 683
PS#l9l
VIDEO &
BROCHURE
available now!
www.nord-lock.com
Your trusted partner
for bolted joints
From design to operation, the Nord-Lock
Group is a world leader in bolt securing. Our
innovative solutions include wedge-locking
technology and Superbolt tensioners. Trust the
bolting experts for your critical applications.
PRECISION MACHINED NUTS
Precision machined nuts
The Precision Machined Nuts catalog covers the differences
between machined nuts and stamped nuts, and demon-
strates through engineering case studies when a precision
part would be beneficial. The catalog contains specifications
for all 11 standard series of nuts, including descriptions.
Spirol International Corp., 30 Rock Ave., Danielson, CT
06239, (860) 774-8571, www.spirol.com
RS# 687
Linear motion and design guide
The 2013 Linear Motion Catalog and Design Guide contains new product sections,
including Idea encoder-ready stepper motor controllers,
BGS linear rail systems, and a linear-rail application check-
list. The 250+-page catalog and guide illustrates a wide
range of products for use in linear-motion assemblies.
The catalog is divided into three sections: preci-
sion leadscrew and nut assemblies; linear actuators and
stepper-motor drives; and motorized and nonmotorized
linear-rail systems. Each section also includes a brief over-
view of the technology behind the products, part number
construction, sizing charts, and product comparison charts.
Haydon Kerk, 1500 Meriden Rd., Waterbury, CT06705,
(203) 756-7441, www.haydonkerk.com
RS# 686
PS#l92
PS#l93
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Pennsylvania Convention Center
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Featuring:
RS# 194
For complete ML Series information, visit www.novotechnik.com/ml
NovotechnikU.S.,Inc.
Telehone.5084852244
Email.inlo@novotechnik.com
(In A
Rotary
Sensor)
TheML Series olabsolute
rotarysensors,madebythe
ContelecDivision,acksmodels
with6, 10, 25, 50 or 100mechanical
turnsintoahallinchrolile.
Key specifications include:
Lonqlileol>15millionturns Linearityto0.25%
hiqhresolutionbetterthan0.1% Frictionclutchonendstos
Reeatabilityol0.17%orbetter
Swissmadeby
800.787.7325
e-mail: industrial@sealeze.com
www.sealeze.com
ISO 9001 Certifed
For more than 25 years,
Sealeze has helped
design and manufacturing
engineers form solutions.
Its not the brush
dissipating static.
Its safety improved.
Problem solved.
Our experienced Sales
Representatives, in-house
engineering staff and
design experts work with
you to develop the most
appropriate brush-based
solution for your application.
Get the answers you need.
Call us today.
PRODUCTS & LIT
Rings and springs
The newly released 2013 50th Anniversary Parts and Engineering Catalog
combines all of the companys 10,000 products into a single entity. Covered
products include the Spirolox Retaining Ring and Wave Spring Series, as well
as the new Metric Hoopster and Laminar Seal Rings.
Laminar-seal rings, an alterna-
tive means of sealing components
in assemblies from contamina-
tion, have been available from the
company for years. The rings better
withstand higher temperatures
and corrosive environments than
common O-rings or conventional
rubber seals. Their increased popu-
larity in metal seals allowed for the
series to be incorporated into the
catalog for the first time. Laminar
Rings can withstand higher tem-
peratures and more corrosive envi-
ronments than common O-rings or
conventional rubber seals.
Smalley Steel Ring Co., 555 Oak-
wood Rd., Lake Zurich, IL 60047, (847)
719-5900, www.smalley.com
RS# 688
PS#l96 PS#l95
POSITAPE
Tape Extension Position Sensors

utilize the functional principle of the
Cable Extension Position Sensors.
Constructed with a specially designed stainless steel
tape they are perfectly suited for applications that re-
quire pulleys due to tight locations.
ASM Sensors, Inc.
650 W. Grand Ave., Unit 205
Elmhurst, lL 60126, USA
(630) 832-3202
info@asmsensors.com
www.asmsensors.com
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New BEI Sensors Selection Guide Covers Products,
Environments and Technology for Motion Control
BEI Sensors product selection guide
explains the fundamentals of various
speed and position sensing technolo-
gies and how to choose which is best
suited to a particular application.
BEIs extensive line of rugged products
include rotary encoders, rotary and
linear potentiometers and rotary
Hall effect sensors, all of which are
displayed in easy-to-read charts that
summarize the most critical specifca-
tion criteria side-by-side.
www.beisensors.com/guide
RS# 255
Wondering if we carry a cable that meets your specs? Need to
complete your cabling system with the right accessories? Then the
2012/2013 HELUKABEL
Cables and Wires and 2013/2014 Cable

Accessories Catalogs are must have items for your office.
Inside our catalogs you will fnd:
Spec Sheets for 30,000+ Line Items
Cable & Wire Selection Tables
Cable, Wire & Accessory Technical
Information
With our Cable, Wire & Accessories
Catalogs on your desk, the solution to
your cabling problem is only an arms
length away!
Get Your HELUKABEL
Cable, Wire & Accessories

Catalogs Today!
847-930-5118 cables@helukabel.com www.helukabel.com
Motion Control
Its What We Do
1. 800. 377. 6329
. c om
High Performance
Motion Controllers
Backed by
Our Exceptional
Customer Support
ElectronicSupport @hydraforce.com s 847-793-2300
hydraforce.com
10 pitfalls to avoid when
going electro-hydraulic.
An engineers perspective
Cross-referenced to metal
cam followers for
easy replacement
Only our patent pending iCamFollowers
offer all these advantages: plastic tire elimi-
nates rail wear; no lubrication is required in
the bearing or on the rail; reduce noise up
to 10dB; absorb shock and vibration; high
load capacity; ball bearings permit higher
linear speeds; lighter weight reduces inertia;
are suitable for use in clean rooms; wash
downs; work well in subzero temperatures
(-40F). For load ratings and sizes go to
www.intechpower.com/icam.
Intech Corporation, 201-767-8066
SELF-LUBRICATING GEAR
SOLUTIONS CALCULATED FOR LIFE
The Intech Power-Core gears are precision
machined and offer solutions to applications
in which lubrication, wear, noise, vibration,
inertia, shock load, moisture and chemicals
present a problem for nylon, Delrin or metal
gears. Metal Core provides for a secure at-
tachment to the shaft and higher torque trans-
mission. Gear design and sizing is backed
by durability calculation using proprietary
software.
Intech Corp., 250 Herbert Ave., Closter, NJ
07624. (201) 767-8066; Fax: (201) 767-7797.
www.intechpower.com
RS# 251
RS# 260
RS# 263
RS# 254
RS# 259
RS# 262
SERVO INDEXERS AT MECHANICAL INDEXER PRICES
EZ Indexers from Centricity provide high precision state of
the art servo indexing technology at mechanical indexer prices.
Load capabilities from ounces to tens of thousands of pounds
and dial diameters from 8 to over 20 . Complete servo system
includes Microsoft Excel spreadsheets for simple setup. Easy
to integrate, robust construction, and no maintenance required.
Standard sizes available from
stock.
CENTRICITY CORPORATION
www.centricity.net
330-545-5624
Low Backlash Bevel Gearboxes
A different spiral bevel
gearbox with performance
exceeding standard industrial
product. Including 8 sizes in 11
ratios and multiple shaft
confgurations, these are best
used for high precision, high
speed, high shock or with
customized designs.
DieQua Corporation
www.diequa.com
630-980-1133
DATA FILE LITERATURE ADVERTISING
Access our Reader Service
Website to quickly find and
request information on the
products and services found
in the pages of MACHINE DESIGN.
RS# 257
RS# 264
New tutorials and podcasts on Learn Web site
What is a PLC plus many more
topics on industrial control prod-
ucts including new videos and
podcasts on AutomationDirects
free self-service learning site.
Visit http://learn.automationdirect.com
to watch these and other tutorials
on a range of industry topics.
2013 Washers Catalog
The complimentary 2013
Washer Catalog illustrates
Bokers 27,000 non-standard
fat washer sizes, wide range
of outside diameters, from
0.080 to 5.140, variety of
inside diameters and
thicknesses, as well as its
over 2,000 materials. With
its extensive selection and
custom capabilities, Bokers
provides endless washer
possibilities and manufactures
solutions to your exact
specifcations. ISO 9001:2008
Registered
www.bokers.com/mdds
RS# 252
RS# 261
ACE Stainless Industrial Shock Absorbers
for Long Life Applications
Made of V4A high quality stainless
steel for long life and extreme
environment applications. The ACE
PMC Series includes a Tefon bellows
cap that protects against damaging
environmental agents.
Ideal for packaging, food processing,
medical, marine and more. Energy
capacities from 175 to 30,000 in. lbs/
cycle (20 to 3,400 Nm/cycle).
ACE Controls Inc.
Farmington Hills, MI
(800) 521-3320 (248) 476-0213
Email: shocks@acecontrols.com
www.acecontrols.com
RS# 256
RS# 250
RS# 253
RS# 258
DOWNLOAD PHOTO ETCHING PARTS BROCHURE
Brochure describes capability to
etch intricate components from
thin metals for many diverse
mechanical and electrical
applications, as well as complex
fexible printed circuits. In house
forming, laminating and fnishing.
www.tech-etch.com/photoetch
508-747-0300
sales@tech-etch.com
Tech-Etch, Inc.
Trim-Lok Inc., Buena Park, CA
Vinyl & Rubber Extrusions
Trim-Lok Inc. releases a brand new
FREE Catalog 500 featuring How
to Order steps for the frst time
customer, along with an expanded
line of complete trims and seals.
FREE samples may be requested.
Latest additions include our Flap
Seal, Fire Retardanct Trim, adn
Hatch Seal. Contact us toll fee at
1-888-874-6565, e-mail us at info@
trimlok.com or visit us on-line at
www.trimlok.com
6-Axis Positioners

PI Hexapods are perfect tools for
micro-assembly & alignment:

6 Axis Precision Motion
Sub-Micron Precision
Controller and Software
Load from 2 kg to 5 Tons
20 Years Experience
PI (Physik Instrumente) LP
www.hexapods.net
www.masterbond.com
UV Curable Epoxy
Optically Clear UV16
UV Curable Epoxy
Optically Clear UV16
Unsurpassed
thermal stability
Fast curing
0816...SR DC Motor Delivers High Torque in a Compact Space
800-807-9166 + www.micromo.com
MICROMO is pleased to an-
nounce the new FAULHABER
high power 0816SR Series DC
Micro Motors. The 0816...SR mo-
tor deliver best in class perfor-
mance in a compact 8 mm diam-
eter with continuous torque up
to 0.7 mNm and a stall torque of
1.2 mNm. Weighing in at just 4.5 g, the 0816SR is the perfect
choice for applications where light weight and high torque are
essential. These coreless DC Micro Motors are highly efcient by
design and ideal for battery operated device integration.
SEALS, ACTUATORS,
GRIPPERS AND BAGS
Solve difficult closure prob-
lems with custom-built, fab-
ric-reinforced, fully molded
elastomeric Seal Master
infatable seals. With close
tolerance capability and re-
sistance to compression,
theyre ideal for imaginative production and processing
applications too. Engineered specialties include fabric-
reinforced bags, bladders, plugs and other custom rubber
products. Design assistance offered.
Alignment Dowels/Bushings
SPIROL roll-formed, hardened Spring Dowels and Dowel
Bushings are designed to align mating components, eliminate
drilling of a separate bolt hole,
protect bolts from shear loading,
and maintain joint integrity. The
12-page design guide provides
product specifcation data and
helpful design guidelines. Four
pages of applications are included.
Visit www.spirol.com/s/md-bush/
High- Performance
Magnets
New catal og features hi gh
performance magnet materials
such as NdFeB and SmCo,
molded magnets, ceramic and
al ni co magnets. MCE offers
magnet ci rcui t desi gn,
custom fabrication, assembly,
and advanced coati ngs.
Complete traceability is offered.
P h o n e : ( 3 1 0 ) 7 8 4 - 3 1 0 0 ,
Fax:(310)784-3192; mcesales@mceproducts.com;
www.mceproducts.com
Magnetic Component Engineering
RS# 265
RS# 273 RS# 272
Smalley Steel Ring Company
New Smalley Engineering
& Parts Catalog
Smalleys new catalog combines
existing Spirolox Retaining Ring
and Smalley Wave Spring selec-
tions with series recently released
from Smalley. Now a single catalog
includes new: Hoopster Rings, Met-
ric Wave Springs, Constant Sec-
tion Rings and more. Over 10,000
standard parts in carbon and stain-
less steel; free samples available.
Specials manufactured with
No-Tooling-Costs from .200-120.
rJOGP!TNBMMFZDPNrXXXTNBMMFZDPNHFUDBUBMPH
WITTENSTEIN - Experience a revolution in linear
technology with the most compact reliable and
robust linear system for your applications.
Learn more at www.wittenstein-us.com
RS# 276 RS# 275
RS# 279 RS# 278
RS# 268
RS# 267
The Lee Companys new 8th Edition Electro-Fluidic
Systems Handbook contains many new products that can
help solve your complex fuid control problems. Detailed
information can be found on
Lees miniature solenoid valves,
dispense valves and pumps,
custom manifold systems and
other inert fuid handling
components used for automated
liquid handling in medical and
scientifc instrumentation,
analytical/clinical chemistry and
in-vitro diagnostic applications.
The Lee Company
Westbrook, CT
TAYLOR DEVICES FLUIDICSHOKS
(North Tonawanda, N.Y.) - Taylor Devices Fluidicshoks are the most
compact hydraulic shock absorbers in the industry. Fluidicshoks are
available in 26 standard sizes, with capacities from 3in-lbs. to 56,000in-
lbs. They come in both self-adjusting and custom-orifced styles, with
a variety of available mountings. An exclusive non-exposed stainless
piston rod is featured on many models, with reset by coil, air or Taylors
exclusive liquid spring. Fluidicshoks are also available in pure damper
styles.
For additional information, contact: Taylor Devices Inc.,
90 Taylor Dr., N. Tonawanda, NY 14120-0748. Phone: 716.694.0800.
Fax: 716.695.6015. Web site: www.taylordevices.com
RS# 266
RS# 270
RS# 271
RS# 274
RS# 277
RS# 269
Standard and Custom Clutch, Brake
& Power Transmission Solutions
291 Boston Turnpike Bolton, CT 06043
Phone: 860-643-1531
Reliability
inaClutch
...a clutch, brake or power
transmission part for that
matter. Since 1903 Carlyle
Johnsonhassolvedsomeof
historys toughest motion
controlchallenges itswhat
welovetodo.Ourprecision
electrical,mechanical,airand
hydraulicpowertransmission
products consistently prove
reliable and dependable in
everyapplication.Underwater,
onthegroundandintheair,
CJMiseverywhere.
www.cjmco.com
BUSINESS INDEX
Thlslndexlncludesallslgnlflcant
referencestoparentcompanles
mentlonedlnfeatureedltorlalmaterlal
wlthlnthlslssueofMACHINEDESIGN.|t
doesntcltecompanlesllstedsolely
lntheProductsandLltSectlon.Page
numbersllstedrefertothepageswhere
theartlclesbegln.
NatlonalPluldPowerAssn. 6
Natlonal|nstruments..... 30
NatlonalSclence
Poundatlon............ 35
Ob[etLtd................. 32
ParkerHannlflnSealGroup,
O-PlngDlv.............. 28
PerformanceMotlonDevlces
|nc. .................... 46
PowerPaclngSerles...... 20
PaspberryP|............... 6
PocketChemlcalCo. .... l03
PockwellAutomatlon..... 30
SKPUSA|nc. .............. 74
SchaefflerGroupUSA..... 58
StanfordUnlverslty....... 26
StratasysLtd.............. 32
TLConnectlvlty....... 22,30
TLConnectlvlty,Aerospace,
Defense,andMarlne
Unlt................... 32
UnlonCarbldePlastlcsCo. 28
WD-40Co............... l03
WelssNorthAmerlca|nc... 25
WlreMasters|nc. .......... 32
3M....................... 28
AdeptTechnology|nc..... 32
AgllentTechnologles..... 32
BostonConsultlngGroup.. 8
Convalr................ l03
Dept.ofLnergy........... 35
Dept.ofthe|nterlor....... 35
LDAG.................... 25
Lxlar...................... 6
FIRST ..................... 30
PreudenbergSeallng
Technologles........... 30
Prost&Sulllvan ........... 30
Georgla|nstltuteof
Technology............ 23
GovernmentAccountablllty
Offlce.................. 35
Harvard Business Review.... 8
HealthandHuman
Servlces................ 35
HeldenhalnCorp. ......... l8
Helukabel ................ 30
HelukabelCanada........ 30
HenkelCorp............... 6
|ntechPowerCorp........ 68
Kollmorgen.......... 32,36
Kontron ................... 6
LappGroup............... 6
LawrenceLlvermore
NatlonalLaboratory .... 24
LlnLnglneerlng........... 6
Nason.................... l6
PS#l97

While every effort has been made to ensure the
accuracy of this index, the publisher cannot be
held responsible for any errors or omissions.
ADVERTISER INDEX
RS# . . . . . .COMPANY . . . . . . . . . . . . . . . . . . . PAGE
l36....... AeroflexMlcroelectronlcSolutlons .. 47
l37....... Aerotech,|nc. ........................ 49
l76....... Alrfloat.............................. 86
l04....... AllledLlectronlcs.....................5
ll3....... Ametek.............................. l4
l98....... AMKDrlvesandControls...........l0l
l69....... AnlmatlcsCorporatlon .............. 82
l03....... Automatlondlrect.com...............3
l49....... AutonlcsUSA|nc..................... 59
l7l....... B&P|ndustrlalAutomatlon.......... 84
l55....... BeckhoffAutomatlonLLC........... 65
l80....... BL|Sensors.......................... 88
l75....... Bellowstech,LLC..................... 86
202....... BlmbaManufacturlngCompany....BC
l48....... BlsonGear&Lnglneerlng........... 57
l97....... Carlyle1ohnsonMachlneCo.......l00
l73....... CentrlcltyCorporatlon............... 84
l39....... C-PlexBearlngCompany,|nc......... 52
l53....... ClcollCorp........................... 63
l08....... Cllppard|nstrumentLaboratory,|nc..9
ll2....... Contltech............................ l3
ll6....... Contrlnex|nc........................ l8
l33....... ControlTechnlques.................. 43
l85....... DlamondChaln...................... 9l
l54....... Dlequa.............................. 64
l74....... DornerMfgCorp .................... 85
l78....... PloydBell|ncorporated.............. 86
l5l....... GalllMotlonControl|nc............. 6l
l30....... HarmonlcDrlveLLC ................. 37
l64....... HaydonKerkMotlonSolutlons ...... 75
l84....... HBD|ndustrles|nc................... 90
l93....... HelukabelUSA|nc................... 95
l43....... HlnderPust.......................... 54
l2l....... HlwlnCorporatlon................... 26
l4l....... Hydraforce,|nc...................... 52
l56....... |garashlMotorSales ................. 66
l05....... |gus,|nc...............................6
l57....... |HSGlobalspec ...................... 67
l63....... |KO|nternatlonal|nc................. 73
l87....... |MSGear............................. 92
l50....... |nfranorUSA......................... 60
l3l....... |ntelllgentMotlonSystems,|nc. ..... 39
l44....... KNPNeuberger,|nc.................. 54
l65....... LappUSA............................ 77
l22....... LeeCompany........................ 27
l66....... LlnLnglneerlng..................... 79
l32....... Llnak................................. 4l
l06....... LlquldmetalTechnologles ............7
l26....... LubrlplateLubrlcantsCo............. 32
ll0....... MagnetlcComponent
Lnglneerlng,|nc...................... l0
l67....... MasterBond,|nc..................... 80
l47....... MaxonMotorUSA................... 56
l27....... M|CPOMO........................... 33
l09....... MlnalexCorp........................ l0
l83....... Mltsublshl|nternatlonalCorporatlon89
lll....... MoogComponentsGroup.......... ll
l25....... MTSSystemsCorp................... 3l
ll5....... NBCorp............................. l7
l90....... NewportCorporatlon ............... 93
l35....... NexenGroup|nc.................... 45
l88....... NlpponPulseAmerlca|nc........... 93
l95....... NovotechnlkU.S.,|nc................. 97
l89....... Ogura|ndustrlalCorp. ............... 93
l82....... OhloLlectrlcMotors................. 89
l02....... OmegaLnglneerlng|nc..............l
........... Ondrlves.us.......................... 28
ll9....... OrlentalMotorUSACorp............ 24
l20....... OrlentalMotorUSACorp............ 25
l86....... PeerlessLlectrlc..................... 9l
l34....... PerformanceMotlonDevlces,|nc. ... 44
l79....... PeterPaulLlectronlcsCo.|nc ........ 87
20l....... ProtoLabs,|nc......................|BC
l99....... QualltyBearlngs&Components...l03
l72....... QualltyTransmlsslonComponents .. 84
l70....... P+WCoupllngs ..................... 83
l59....... PeellPreclslonManufacturlng....... 70
l60....... PeellPreclslonManufacturlng....... 70
l6l....... PeellPreclslonManufacturlng....... 7l
l62....... PeellPreclslonManufacturlng....... 7l
ll8....... PlttalCorporatlon............... 22-23
l52....... Pollon............................... 62
200....... SABAssoclatedWlreProducts......l04
l8l....... SantestCoLtd....................... 89
ll4....... SchaefflerGroupUSA............... l5
l96....... SealezeCorp......................... 97
l40....... Servometer
......................... 52
l58....... SetcoUSA........................... 69
l0l....... SLWLurodrlve......................|PC
l24....... SmalleySteelPlngCompany........ 30
l07....... Splrol|nternatlonalCorporatlon......8
l45....... StockDrlveProducts................ 54
l92....... Superbolt............................ 95
l38....... TDK-LambdaAmerlcas|nc .......... 5l
l28....... ThomasDlvlslon..................... 34
l29....... ThomasDlvlslon..................... 35
l23....... TubePlttlngs......................... 29
l94....... UBMCannon........................ 96
l77....... v|CControls ......................... 86
l9l....... vlsumatlc............................ 94
l42....... Wlttensteln.......................... 53
l46....... Wlttensteln.......................... 55
ll7....... ZLPO-MAX .......................... l9
RS# 198
BUSINESS STAFF
LlectronlcDeslgnMachlneDeslgnMlcrowaves&PPMedlcalDeslgnSourceLSBHydraullcs&PneumatlcsGlobalPurchaslng
DlstrlbutlonPesourcePowerLlectronlcsTechnologyMoblleDevelopmentandDeslgnLnergyLmclency&Technology
DefenseLlectronlcsMotlonSystemDeslgnAutoLlectronlcsLlectronlcDeslgnLuropeLlectronlcDeslgnChlnaLnglneerlng
Tv Pluld Power Lxpo Medlcal Slllcone Medlcal Prototyplng One Powerful Day Combatlng Counterfelt Conference
P E NT ON ME DI A, I NC .
CHIEF EXECUTIVE OFFICER: DAVID KIESELSTEIN david.kieselstein@penton.com
CHIEF FINANCIAL OFFICER/EXECUTIVE VP: NICOLA ALLAIS nicola.allais@penton.com
SENIOR VP, DESIGN ENGINEERING GROUP: BOB MACARTHUR bob.macarthur@penton.com
1166 Avenue of the Americas, 10th Floor, New York, NY 10036
DE S I GN E NGI NE E R I NG & S OUR C I NG GR OUP
VICE PRESIDENT & MARKET LEADER:
BILL BAUMANN
GROUP DIRECTOR OF OPERATIONS:
CHRISTINA CAVANO
GROUP DIRECTOR OF MARKETING:
JANE COOPER
RESEARCH MANAGER:
JULIE RITCHIE
MARKETING & EVENTS MANAGER:
ADRIAN PIAZZA
MARKETING COMMUNICATIONS SPECIALIST:
CYNTHIA RODRIGUEZ
E DI T OR I A L
EDITOR IN CHIEF: LELAND TESCHLER (216) 931-9221, leland.teschler@penton.com
MANAGING EDITOR: KENNETH J. KORANE (216) 931-9412 , ken.korane@penton.com
EDITORIAL PRODUCTION MANAGER: DENISE GRECO 216 9319402, denise.greco@penton.com
ART DIRECTOR: RANDALL L. RUBENKING (216) 931-9857, randall.rubenking@penton.com
A R T DE PA R T ME NT
CREATIVE DIRECTOR: DIMITRIOS BASTAS dimitrios.bastas@penton.com
GROUP DESIGN DIRECTOR: ANTHONY VITOLO tony.vitolo@penton.com
P R ODUC T I ON
GROUP PRODUCTION DIRECTOR: CAREY SWEETEN (913) 967-1823, carey.sweeten@penton.com
PRODUCTION COORDINATOR: COURTNEY DENISON (913) 967-1738, courtney.denison@penton.com

AUDI E NC E MA R K E T I NG
AUDIENCE DEVELOPEMENT MANAGER: DEBBIE BRADY (216) 931-9882, debbie.brady@penton.com
ONL I NE
ONLINE SALES & MARKETING MANAGER: VIRGINIA GOULDING (216) 931-9893, virginia.goulding@penton.com
CLIENT SERVICES COORDINATOR: JOANN MARTIN (216) 931-9624, joann.martin@penton.com
S A L E S & MA R K E T I NG
BRAND DIRECTOR: PAUL MILNAMOW (312) 840-8462 paul.milnamow@penton.com
AZ, CA, ID, OR, NV, UT, WA, British Columbia: PAUL MILNAMOW,
paul.milnamow@penton.com (312) 840-8462, Fax: (913) 514-3957
AL, AR, FL, GA, KS, LA, NM, MS, MO, OK, TX: FRANNY SINGLETON,
franny.singleton@penton.com (678) 947-8563, Fax: (913) 514-6884
CO, IA, S. IN, KY, MN, MT, NE, ND, S. OH, SD, TN, WI, WV, WY: PAUL MILNAMOW,
paul.milnamow@penton.com (312) 840-8462, Fax: (913) 514-3957
IL: MELINDA HURLEY, melinda.hurley@penton.com (847) 784-9825, Fax: (913) 514-6625
N. IN, N. OH, MI, NY, PA, Ontario: BILL RODMAN,
bill.rodman@penton.com (216) 931-9636, Fax: (913) 514-6841
DE, DC, MD, NJ, NC, SC, VA: BRANDY BISSELL,
brandy.bissell@penton.com (919) 773-1875, Fax: (913) 514-6357
CT, ME, NH, MA, RI, VT, Quebec: LIZ STOTT, liz.stott@penton.com (857) 636-9737, Fax: (913) 514-6914
INTERNATIONAL SALES DIRECTOR: MIKE HANCOCK, mike.hancock@penton.com
011-44-1372-824284, Fax: 011-44-1372-824322
United Kingdom, Scandinavia, France, Spain, Portugal: STUART PAYNE,
stuart.payne@husonmedia.com, +44 (0)1932 564999, Fax: +44 (0)1932 564998
Belgium, Netherlands, Luxemburg: RODRIC LEERLING,
rodric.leerling@husonmedia.com, 011-31-229-841882 , Mobile 31-683-232625,
Germany, Austria, and Switzerland: CHRISTIAN HOELSCHER,
christian.hoelscher@husonmedia.com, 011-49-89-95002778, Fax: 011-49-89-95002779
Italy: CESARE CASIRAGHI, Casiraghi Pubblicit Estera, 011-390-31-261407, Fax: 011-390-31-261380
Tokyo, Japan: YOSHINORI IKEDA, Pacic Business, Inc., 011-81-03-3661-6138, Fax: 011-81-03-3661-6139
CLASSIFIEDS
To Advortiso in
5)+016-,-;1/6;
ClnssiBods Soction,
contnct Pnul Milnnnow nt
(312) 840-8462,
pnul.nilnnnowponton.con
PRODUCTS/SERVICES
THUMBSCREW
THE ORIGINAL
INSTANT
In most cases, advertisements contained
in Machine Design employment section
indicate that the companies are equal
opportunity employers. The Federal Civil
Rights Act of 1964, and other laws, prohibit
discrimination in employment based on
race, color, religion, national origin, sex, or
for any reason other than lack of professional
qualification for the position being offered.
It should be noted that employment
advertisements in Machine Design are
published for the readers convenience and, in
no way, to the best of our knowledge, promote
unlawful discrimination.
BACKTALK
WD-40
Did you know ...
WaterDlsplacement40thformula,
betterknownasWD-40,lsthecre-
atlon of three technlclans at the
Rocket Chemical Co.lnSanDlego
looklngtocreatearust-preventatlve
solvent and degreaser to protect
mlssllepartslnl953.Thetechnlclans
flnallysucceededonthelr40thattempt
attheformulatlon.Oneoftheorlglnal
founders,KenLast,saystherelsnoth-
lnglnWD-40thatcanhurtyou.The
companywasrenamedtoWD-40 Co.
Inc.ZZltsonlyproductlnl969.
Somelnterestlngfactslnclude:
AerospacecontractorConvairflrst
usedWD-40toprotecttheouter
sklnoftheAtlasMlssllefromrust
andcorroslon.Becauseltworkedso
well,severalemployeessnucksome
cansoutoftheplanttouseathome.
Afewyearslater,PocketChemlcalCo.
founderNormLarsenexperlmented
wlthputtlngWD-40lntoaerosolcans,
bellevlngthatconsumersmlghtusetheproductat
homellkehlsemployeeshad.|nl958ltmadeltsflrst
appearanceonstoreshelves.
|nl960,thecompanydoubledlnslze,growlngto
sevenpeople,whosoldanaverageof45cases/day
fromthetrunkofthelrcarstohardwareandsportlng
goodsstoreslntheSanDlegoarea.
|nl96l,theflrstfulltruckloadorderwasfllledwhen
employees produced addltlonal concentrate to
meetthedlsasterneedsofthevlctlmsofHurrlcane
CarlaalongtheU.S.Gulfcoast.WD-40wasusedto
recondltlonfloodandraln-damagedvehlclesand
equlpment.
|nl973,thecompanywentpubllcandwasllsted
Over-The-Counter.Thestockprlcelncreasedby6l%
ontheflrstdayofllstlng.
|nl993,WD-40wasfoundtobeln4outof5Amerl-
canhouseholdsandusedby8l%ofprofesslonalsat
work.Saleshadgrowntomorethanlmlllloncans
eachweek.
|n2003,thenewWD-40BlgBlastcan,featurlnga
wlde-areaspraynozzle,waslntroduced.
|n2005,theWD-40SmartStraw,whlchfeaturesaper-
manentlyattachedstraw,waslntroduced,solvlngthe
numberonecomplalntaboutWD-40productsloslng
thellttleredstraw.
|n2006,theWD-40No-MessPenprovldedconsumers
wlthaportable,preclslon-appllcatlondellverysystem.
TheWD-40PanClubreachedanastonlshlngl00,000
members,atrlbutetoltsfanatlcalfanbasearoundthe
globe.
|n2008,thepopular-slzeWD-40canswerecon-
vertedtoWD-40SmartStrawcans.
|n2009,WD-40TrlggerPro,anonaerosolprod-
uct,waslntroducedtobettermeettheneedsof
lndustrlalconsumers.
|n20ll,theWD-40Speclallstllneofbest-ln-
classspeclaltyproductsgearedtowardtrade
professlonalswaslntroduced.
Today,thereareover2,000+usesforWD-40.
Herearesomesubmlttedtothecompanyon
thelrWebslte.Userscansubmltsuggestlonsat
www.wd40.com/about-us/history.
Loosenrustynutsandscrews,cleanandkeepgarden
toolsrust-free
Cleansplanokeys
Keepswlckerchalrsfromsqueaklng
Lubrlcatessmallrolllngtoys
Cleanspatlodoorglldestrlp
Pemovesscuffmarksfromceramlctlle
Keepsmetalwlndchlmesrust-free
Helps[olnplastlcshelvlngtomakedlsassemblyeasler
Pemoveswaterspotsfrommlrrors
Lubrlcateshlngeonprunlngshears
Lubrlcatesscrewsonlawnfurnlture
Pemovescrayonfromwallsandclothesdrlers(makesure
PS#l99
Nortn Amori oa
spcclalty 6cxlblc cablcs bullt for spcclal rccds ard approvals for thc
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For norc lrfornatlor or to rcucst a Full Llrc Acccssorlcs catalog or a Flcxlblc
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thc provcr lcadcr lr thc dcvclopncrt ard narufacturlrg of supcrlor
For ovcr 60 ycars, 8AB has bccr
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BACKTALK
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Lubrlcatesgatelocks
Pemovescrayonfromcompressedwoodfurnlture
Loosensrustypartsonlawnmower
Lubrlcatesstlckydrawers
Pemovestapemarksfromthewallwherepostershung
Shlnesleavesofhouseplants
Keepssnowfromstlcklngtoshovel
Andthellstgoeson...MD
tounplugdryer)
Lubrlcateshydraullcramsonslldeoutofflfthwheel
Cleansbathtubs
Cleansandpreventsrustonolltankexterlor
Cleansandprotectsbedofwheelbarrows
Preventsrustonswampcoolernuts
Pemovesteastalnsfromcountertops
Pemovescrayonfromwallpaperandcarpets
PS#200
Real parts. Really fast.
Its easy to work with Proto Labs. Just upload your
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Copyright 2013 Bimba Manufacturing Company. All Rights Reserved. *This life estimate may not include cylinders with design modications, those exposed to harsh operating conditions or any unintended applications.
RS# 202

Machine Design 23 May 2013

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Mechatronic Drive System

COPYRIGHT 2013 OMEGA ENGINEERING, INC ALL RIGHTS RESERVED

More than 7,000 sizes available.

plastic bearings can replace

Alloy delivers precision, strength,

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