Motion Control Tips

Automation • Motion Control • Power Transmission

Miniature brakes, clutches, and torque limiters from Mach III for shaft sizes to a half-inch

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Brakes, clutches and torque limiters are now available from Mach III for shaft sizes of half-inch and smaller. The ten new products include:

• A spring-engaged brake for power off applications

• An air-engaged brake for stopping and holding applications

• Five air-engaged clutch configurations for connect and disconnect applications

• Three mechanical torque limiters for overload protection applications.

These products are currently used in MRI scanners, a variety of food packaging and labeling systems, remotely operated inspection cameras, quality control equipment, and machinery that produces faux eyelashes.

Miniature brakes clutches and torque limiters from Mach III for shaft sizes to a half-inch with Mach-III-Mini-Clutch shown here

Development of these smaller sized products was driven by client demand.

“Over the past couple of years, we have experienced a high volume of inquiries from machine designers looking for products for half inch and smaller shafts,” said said Mach III application and design director Ron Ashbrook. “In some cases, these were new machine designs. In others, the engineers were seeking replacements for products that performed poorly, became too costly, or had inordinately long lead times.”

After developing a number of custom designs for these clients, it made sense to expand the Mach III catalog line to encompass these smaller sizes.

The outside diameters of the miniature units are between 2.58 and 3.28 in., and the lengths of most are less than 3 in. Torque capacities are to 200 lb-in. at 80 psi. All are available bored and keyed to spec for imperial and metric shafting and have an average two-week lead time. All can be customized with enclosures and special finishes to suit application requirements. Get full specifications and 3D models at the machiii.com page detailing the miniature clutches and torque limiters.

Mach III is an application-focused designer and manufacturer of air and spring engaged friction brakes, clutches, combination clutch-brakes, and mechanical torque limiters. Mach III products are used in machinery to connect and disconnect, stop, hold, control tension, and protect machine components from overload. Torque requirements up to 60,000 lb-in. can be accommodated. Engineering, sales, production, customer service, and product support are all located under one roof in Walton, Ky.

GAM Enterprises SPH planetary gearbox for cyclic or continuous high-speed applications

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The SPH inline planetary gearbox is GAM’s latest setup for today’s demanding motion control challenges. With helical gears, the SPH is designed for dynamic and cyclic applications and can also be optimized for high speed and continuous-duty applications.

It is available in six frame sizes with nominal torque ratings 15 to 900 Nm. The SPH features precision cut helical gears that are ground for smoothness, quiet operation, and high accuracies. The face width of the SPH gears are up to 70% longer than the gears in comparable gearboxes on the market, which means more tooth contact and greater overall torque density.

GAM Enterprises solar-power application SPH planetary gearbox for cyclic or continuous high-speed applications

To carry the higher torques, SPH gears are case hardened which imparts strength deeper into the gear compared to nitriding which hardens just the surface. With several output configurations available, machine integration is simplified. SPH Series benefits include:

  • Helical gearing and low backlash
  • Low noise levels and smooth torque transmission

For more information, visit the distributor page on the gearbox at electromate.com.

Conveyor manufacturer Dorner now includes FlexMove and Geppert-Band companies to transform automation

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In a move that combines more than 100 years of conveyance expertise, Dorner Holding Co. (the parent company of Dorner Mfg. Corp.) FlexMove and Geppert-Band GmbH is merging the three entities into one consolidated brand of Dorner.

The new Dorner boasts a global workforce of more than 400 and brings a diverse conveyor automation product line and extensive application knowledge to industries around the world. The headquarters will remain in the United States, with manufacturing facilities in Germany, Malaysia and Mexico, and a sales and engineering office in Canada.

“Dorner has been integrating the various locations over the last few years, and the new Dorner is the next step in that process,” said Terry Schadeberg, president and CEO, Dorner. “Consolidating the brands allows us to focus marketing efforts, streamline customer support, and provide a unified product line around the world. We’re excited to move forward as one unified global company that’s transforming conveyor automation.”

Dorner was founded in 1966 by brothers Wolfgang, Horst and Werner Dorner. Initially, the company was a tool and die shop, but adjusted its business to focus on conveyors in the early 1970s. In 2012, the brothers sold the business to a private equity firm; Dorner was again sold last year to EQT Mid-Market US fund.

Penang, Malaysia-based FlexMove is a flexible chain conveyor system and components manufacturer for food, beverage, automotive, electronics, and other industries. FlexMove joined Dorner Holding Company in December 2015 and has since began manufacturing and selling Dorner conveyor lines, as well as supplying product to Dorner’s other locations. The FlexMove product line will continue to be offered globally with assembly in Malaysia, The United States, Germany and Mexico.

Jülich, Germany-based Geppert-Band GmbH is a belt and modular belt conveyor manufacturer founded in 1967. Geppert-Band is known throughout Europe for its engineering expertise, industry leading deliveries, and an established sales and support structure. The company joined Dorner Holding Company in 2016.

Dorner also has a sales office in Burlington, Canada, and recently began manufacturing operations in Guadalajara, Mexico, following an acquisition of Sautem in 2017. Brand merger of the three companies is in its initial stages and will take several months to complete. All products are now available at www.dornerconveyors.com.

Lafert North America appoints new inside-sales team members

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Lafert North America, a manufacturer of metric AC Motors, metric gearboxes and coolant pumps, has appointed Joel Fernandes and Jesse Sagoo to new positions.

Joel Fernandes will fill the role of sales representative. Fernandes brings 9 years of sales experience to Lafert with time spent in the construction and power distribution industry. A graduate of the University of Toronto, Fernandes brings the ability to problem solve and provide the support needed to meet industry needs.

Jesse Sagoo will also fill the role sales representative, bringing 12 years of technical sales in the power distribution market segment. Sagoo holds an Electrical Engineering Technology designation from Humber College. He uses this training and experience to build customer relations and deliver positive value.

For more information, visit lafertna.com.

How do cam clutches work, and what are other overrunning clutch options?

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Mechanical overrunning clutches, sometimes called one-way or backstop clutches depending on the context, transmit torque in one drive direction but let the output axis continue to turn (freewheel) when the driving motor slows or stops. Such clutch function is useful in large and small designs for material handling, packaging, conveying, medical, turbine auxiliary drives, and off-highway applications.

Common mechanical overrunning clutches include those that use ratcheting, roller ramps, wrap-spring, and cam action for one-way axis engagement.

Ratchet clutches are basic two-element overrunning clutches that use a tooth that interlocks with a frame in one direction and freewheels in the other. Roller-ramp clutches have cylinders that lock into steps on a wheel or (upon reversal) roll freely. Wrap-spring clutches have helical springs that tighten down onto on a cylindrical sleeve to transmit torque in one direction.

Of these designs, cam clutches (sometimes called sprag clutches, especially in transportation industries) are relatively new and power dense. An array of bars profiled with asymmetrical cam-shaped geometry ring the circumference of the clutch. Cages at each end keep the bar cams evenly spaced. Upon input rotation, the cams act as rising wedges to lock between the races on the inner and outer clutch halves.

More specifically, cams in some cam-clutch variations fill the space between the races to quickly act as a sprags and hold the clutch halves together via locking friction. Upon reversal, the cams quickly release (and then tolerate high overrunning speeds). In other cam-clutch designs, centrifugal force makes the bar cams turn into liftoff to disengage the clutch halves. Then upon slowing or reversal, a spring at each cam pushes them back into sprag-type engagement.

Cam clutches are especially rugged. Top: BS-HS Series clutches from U.S. Tsubaki Power Transmission are high torque and rated for high maximum overrunning speed. The red-highlighted areas are where the cams backstop when the inner race turns clockwise. Bottom: BR-HT Series cam clutches use a slightly different mode of engagement based on centrifugal force. When the inner race turns clockwise with sufficient speed, the cams pivot so their geometry clears both races. Otherwise, springs cause the cams to pivot back to a default and lock the clutch halves together.

No matter the variation, the geometry of cam clutches’ load-bearing cams tightly pack into the clutch body. That means it’s often two other factors that limit torque capacity:

  • Bore size (and connecting shaft size with it)
  • The effects of tangential forces where the cams meet the races.

But some cam clutches exhibit comparably less ID and OD race deflection and contact stress than other designs thanks to distributed loading during engagement. That in turn extends life and makes for smoother engagement. Some cam clutches even use ground alloy-steel races to maximize uniformity of load distribution. Because jamming under load can occur where wear is excessive, some cam clutches for demanding applications feature precision-formed cams to resist wear and prevent failure from fatigue.

As mentioned, other overrunning clutches include those that use ratcheting, roller ramp, and wrap-spring action.

Ratcheting clutches are basic two-element clutches that use a single-tooth arm that engages a toothed wheel in one direction and freewheels in the other. These are most common in powered consumer products and light industrial tools.

Roller-ramp clutches engage through ground steel rollers that run and lock on a wheel precision machined with incline ramps. Note that some roller-ramp clutch literature describes roller engagement with a cam. This isn’t to be confused with the cam arrays of cam clutches, as here the cam is singular and refers to the assembly’s wheel that’s machined with ramps.

Hilliard Corp. overrunning clutches are for high-torque applications needing positive engagement. The roller-ramp design transmits power from the input (motorized) shaft’s precision roller-and-wheel assembly. Ball bearings support this assembly’s roller cage and align it to the output shaft. Because the clutch has large areas for variable roller contact, it prevents localized wear to extend reliability and service life. Torque is from 275 to 925 lb-ft (373 to 1,253 Nm) with speeds to 16,000 rpm.

Operation relies on concentricity between inner and outer races, so most roller-ramp clutch iterations include compression springs to maintain roller-to-wheel contact. The springs install at angles engineered to optimize initial actuation and holding grip. Because of the way the cylindrical rollers lock into flat steps on the inner wheel, these clutches transmit high torque and withstand high overrunning speeds. In addition, roller-ramp clutches are low cost and easy to repair even while offering high overrunning speed and torques.

Wrap-spring clutches have springs that coil around a cylindrical output to tighten down when turned in the drive direction. This creates friction to lock the assembly and transmit torque. Wrap-spring clutches excel in applications of moderate speed — commonly to 2,000 rpm or so.

Zero-backlash servo rotary indexing table from Sankyo Automation

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The Sankyo Automation RollerDrive Reducer is a precision gear reducer that uses a zero-backlash roller gear mechanism. The unit is constructed from an input shaft and a turret (output shaft) that is assembled with roller followers. The roller followers are preloaded against a screw-like input shaft to eliminate backlash.

Sankyo servo indexing tables offer a constant lead cam with a servo motor drive for programmable motion. Sankyo servo indexing tables provide fast highly accurate motion, with the added capability to move medium to heavy loads. The preloaded cam and turret provides a high performance zero-backlash servo indexing table for all  automation needs.

The RU Series servo indexing table is available in 11 different sizes. These servo-indexing tables come with varying ratios to maximize the motor’s torque capacity, speed requirements and enhance the overall accuracy. Special applications may need double reduction ratio of the internal cam (and an additional reducer) to provide large torque capacities or slower speed. Additional features of the RU Series servo indexing table include:

  • Zero-backlash operation, as the RollerDrive uses a preloaded mechanism to completely eliminate backlash and deliver output motions that are faithfully true to input commands
  • RollerDrive technology that incorporates a cam with a high gear reduction to deliver large torque capacities with smaller servo motors
  • A second reducer option … as multiple reducer options keep the servo at optimal rpm

In addition, the reducer’s rigidity makes it suitable for machining applications. An exclusive output turret bearing and cast-iron housing tolerates heavy vibrations associated with machine tool applications. Plus the table is versatile for retooling … so the RU Series can keep pace with the ever-changing tooling requirements.

Plus short settling times mean the RollerDrive provides fast and highly accurate dynamic motion.

For more information, visit the Electromate page on the Sankyo RollerDrive RU Series Reducer.

WITTENSTEIN Galaxie drive systems now include new sizes and ultra-flat and hypoid versions

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WITTENSTEIN, manufacturer of motion-control products, servo systems, and mechatronic systems, has now expanded its Galaxie system product line to include more sizes, a hypoid version, and a new ultra-flat version. The new products will be launched at the upcoming Hannover Messe Fair in Germany this April 23 to 27, 2018.

The expanded Galaxie product line includes:

  • The compact Galaxie D in size 085 for use in smaller cutting heads or handling axes where special requirements apply regarding torsional rigidity and freedom from backlash.
  • The new ultra-flat Galaxie DF in sizes 110 and 135, which saves up to 30% of the normal installation length.
  • The Galaxie GH with its optional right-angle input stage.

Several moving demos will demonstrate how the flexible encoder interfaces allow Galaxie to be easily integrated into existing machine concepts. These demos will show the drive system in action, highlighting Galaxie products’ technological superiority in machine tools, cutting heads and robot welding guns, to name but a few.

For the first time, WITTENSTEIN will also show how operating data can be transmitted to an IoT cloud using a Galaxie Drive System equipped with sensors.

This data can be accessed anywhere and on any device throughout the drive lifecycle, regardless of the control system.

High-performance engineering for dynamic performance

The Galaxie includes dynamic teeth instead of a rigid gear ring, the tangential and hydrodynamic tooth contact over the full surface when loaded and the new type of bearing with a segmented outer race ring. All of this adds up to a novel design principle, with the result that Galaxie is clearly superior to other, established principles in all key technical disciplines compared to the market standard. In short, Galaxie is a disruptive innovation causing displacement of traditional design. For more information, visit wittenstein-us.com.

AeroDef Booth #1053: Physik Instrumente (PI) motion simulation for image stabilization and rover-proven actuators

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PI (Physik Instrumente) is showing an application of its six-axis hexapod for motion simulation such as used to optimize stabilization systems on vessels, drones and even for cell phone cameras. PI hexapods come in a variety of sizes with bases ranging from 100 mm to 1m, different stiffness configurations, and supportive of loads from 2 kg to 1,000+ kg.

In addition to hexapods, PI will also show a variety of its world leading piezo ceramic actuators and transducers, such as the PICMA Multilayer actuators and the DuraAct flexible transducers.

Long-life temperature tolerant actuators: PI’s PICMA piezo actuators were tested by NASA/JPL for the Mars mission and passed 100 billion cycles of life testing without failures. They also work over a large temperature range and are vacuum compatible.

Piezoceramic flexibility and adaptability: A very versatile thin lightweight device, PI’s piezoelectric patch transducers reach a bending radius of 20 mm (0.8 in.) which allows it to be attached to moving structures where it gets deformed and generates charge transfers. Such adaptive technology and size allows bendable transducers to be used as both a sensor and an actuator in applications ranging from structural health monitoring to adaptive structures on aircraft.

PI has in-house engineered setups with over 4 decades of experience working with customers to provide products that meet application demands and can quickly modify existing product designs or provide a fully customized OEM part to fit the exact requirements of the application. For more information, visit www.pi-usa.us.

Motion Trends — engineering insight and expanded technical features

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Each year, Design World publishes a Motion Trends issue — a standalone issue that’s the second in its regular four-part Motion Series. Following are links to the expanded versions of some of that issue’s articles.

Connectivity and IoT expand control design functionality (a Motion Trends report)

Connectivity in manufacturing is not a new idea — it’s been around for decades — but what is new in IIoT is the volume and type of equipment (and devices) on the market that now offer connectivity. For an extreme example, there are now smart toilet-paper roll holders that let one know (from a mobile device) that one needs to change the roll. Products like this didn’t exist a decade ago …

Think B2C ecommerce growth is big? Check out B2B (and design-engineering) habits

Forrester Research projects that by 2021, ecommerce will represent about 13% of all U.S. B2B sales. Other research from Statista Inc. confirms this estimate and goes a step further — projecting that B2B ecommerce represented $7.7 trillion in sales globally last year — which is slightly more than triple that of B2C sales …

Motion trends: Linear actuators leverage modularity and connectivity

Pre-integration is increasingly common, and actuators lead this trend. Some of the fastest growth is in motion designs destined for compact applications, many of which are being automated for the first time. Some have seen the most rapid growth in applications using NEMA 34 and 60-mm and smaller motors — including those in hybrid stepper, step servo, servo, and BLDC variations …

Linear Motion Trends: Consumer health-monitoring devices and more driving innovation

More mechanical-component manufacturers are selling linear actuators complete with motors — as well as robotic joints complete with motors. Another trend is sensor systems that design engineers can order with mechanical products …

Long-stroke robotic RTU applications pose new challenges for cable carriers

New applications for mechanical devices present unique requirements. Consider the exceptionally challenging application for cable management in robot-transfer units (RTUs) and linear tool-tray transfer systems. RTUs are long tracks to carry robots between workstations. As an inverse solution, linear tool-tray transfer systems move workpieces past a stationary robot for various material handling or fabricating tasks. Both are seeing upticks in use with the general migration to flexible manufacturing …

Engineered materials and upfront design work (are leading trends for mechanical components)

Seals, chains, cable carriers, springs, retaining rings, and general power-transmission (PT) components continue to see new materials at critical surfaces; proliferation of application-specific versions (especially for compression and wave springs); and increasingly practical online purchasing for both off-the-shelf components and customized orders. Here we explore some of these trends …

Distributor insight: Conversation with Warren Osak on motion-control trends

In a recent phone interview, we got to chat with Warren Osak, CEO of Toronto-based Electromate Inc. — a distributor founded in 1986 that focuses on electromechanical motion control. More specifically, Osak’s company sells primarily servo systems and stepper systems — often for demanding or challenging applications requiring high precision, accuracy, and bi-directional repeatability. Electromate also specializes applications destined for harsh environments and high duty cycles. Here’s what Osak had to say about current trends in the motion industry …

Electric motors: Trends in stepper, battery-powered, and integrated motion designs

From induction motors in electric vehicles to tiny coreless dc motors in drug-delivery equipment, electric motors continue to proliferate. Last year we saw consumer products, implantable medical devices, and automation of previously manual tasks spur the most innovation in motor design and use. This year those trends continue — and now we see increased use of servo and stepper motors in robotics …

Multi-axis stages and tables: Manufacturer involvement and software yield turnkey motion systems

There’s increasing demand for stages, tables, gantries, and indexing tables with simplicity or turnkey operation — largely because of industry moves toward focused expertise and abstraction. No wonder that motion-system manufacturers are now doing more integration for plant engineers and OEMs …

Belt drives offer practical option for performance designs: Motion Trends report

Belt drives include belts and pulleys (as well as clutches and mechanisms for ratio variation) for power transmission between shafts. In cases where these drives function as a conveyor, the load rides on the belt. Elsewhere (as in actuators or machine-axis coupling) belt drives function as the device to convert rotary motion of an electric motor to linear strokes. Key benefits include vibration and shock damping. Global Industry Analysts Inc. USA (GIA) projects that the global market for belt drives will reach $6.9 billion by 2022 — due in large part to demand for heavy industrial, conveyor, and construction equipment …

Gears of new materials and in custom variations (with emerging helical, planetary, and other gearing uses)

Power transmission through gearsets is a mainstay of motion control, as gears allow full use of electric-motor capabilities. Recent years have brought gear innovations with new materials; custom gear variations; and all-new applications for helical, planetary, and strain-wave gearing. We asked several industry experts to share their thoughts these trends and the proliferation of OEM and end-user designs; here’s what they said …

Brakes and clutches: Top trends in IoT — and uses on ac-motor conveyors and servodesigns

Clutches and brakes work in motion systems to stop or hold or index axes — but must do so to application specifications. No wonder then that the trend in this technology is away strictly stock parts. According to Lesli Riehemann, president at Mach III Clutch Inc., customized brakes and clutches are now 75 to 80% of her company’s annual production. What’s more, an increasing number of clutch and brake manufacturers are now looking to supply non-catalog products — and so customization has become normalized …

Kuebler Sendix S36 motor-feedback encoders win first place SPS IPC Drives Automation Award

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Kuebler recently won the first place Automation Award for its new Sendix S36 motor feedback encoders — getting 31.9% of all SPS IPC Drives show-visitor votes.

Shown here are Filippo Zerbo and Arnold Hettich of Kuebler with Michael Corban — chief editor of electro Automation.

The Automation Award is a leading prize in the international automation industry and is presented annually at the SPS IPC Drives trade fair in Nuremberg, Germany. Five products are nominated in advance by a jury from the field of science, VDMA, ZVEI, and the elektro AUTOMATION staff.

The Sendix S36 encoder has an open interface (in the form of an SCS open link and a BiSS Line) for single-cable connectivity.

The Sendix S36 encoder from Fritz Kübler GmbH was nominated for the category Standard Components & Sensor Technology. Visitors voted for their favorite during the three days of the fair.

Due to its compact design of only 36 mm, the Kuebler encoder reduces the motor variants with a maximum resolution of 2048 SinCos per revolution or 24 bits fully digital.

These features reduce overall design footprint and trim design cost. Plus the encoder’s construction makes it shock and vibration resistant.

Various versions of the encoder allow design engineers to pick from various electrical interfaces for maximum design flexibility:

RS485 + sin/cos (Hiperface compatible)

BiSS • BiSS Safety • BiSS Line (single-cable setup)

SCS open Link (single cable setup)

Sendix S36 motor feedback systems provide a sturdy and compact design with high signal quality.

A taper or blind hollow shaft with different torque stops is available for standardization.

There’s also a wider range of options regarding functional safety: Depending on the preference of the taper or blind hollow shaft, the drive manufacturer can freely select the preferred mechanical connection for its safety concept.

“We are pleased with this award and thank all visitors who voted for the Sendix S36,” said product manager position and motion sensors Arnold Hettich. “Kuebler is taking a significant innovative step in the field of motor feedback systems and is already causing a great stir.”

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