Five-axis milling robot designed by Bornemann specifically for Otto Bock, using the SINUMERIK 840D CNC.

The biggest challenge for Otto was how to remain flexible in its manufacturing, given the constant flow of one-off work. Because of the nature of this field, the majority of devices produced at their facility are custom productions. In this case of the prosthetic and orthotic devices, Otto quickly realized the need to manufacture in Minnesota for constant evaluation of the available technologies for machining. Using ABT carvers, which mirrored its operation in England for the last ten years, Thermwood routers were used for its foam products. The collaboration with Bornemann led to the use of carvers, Thermwood routers and the development of carving technology using the latest CNC protocols. Because the product lines at Otto range from orthotic support seating to various prosthetic shapes, cosmetic covers and neck-to-pelvis body jackets, the products are often made from very large blanks of specially formulated and costly material. It was critical to have machines that run efficiently, but also have the flexibility for fast changeover and interpolation of large data files.

Three-axis milling of hard foam for creation of a positive model of the patient’s limb, to be used in the thermoforming process.

The previous carving method for the seating systems, contrasted the method that Bornemann’s robotic five-axis milling machines now used. Previously, a plaster cast would be made, then that mold would be used to reverse engineer the cutting path on the router. It was slow and imprecise. Now, the Otto Bock Seating System (OBSS) is used. With this system, the patient is seated in something similar to a beanbag chair, then the bag is evacuated, followed by the bag surface being digitized using Otto’s proprietary software. The software version of this CAD program is then translated through ProfiCAM into the Windows-based, CNC machining program. Through the use of this advanced, clean and non-invasive laser scanning technology, an extremely accurate image can be made of the patient’s torso from the seat bag surface. Initiating the design process, the software is then manipulated from CAD to Proficam and finally to the CNC on the machine, through OBSS. Otto upgraded the NCU/PCU with Siemens SINUMERIK CNCs to accept the most advanced version of this translation.

Using Bornemann carvers, Otto cut proprietary rigid and flexible polyurethane foams into the seat cushions used to support spinal injuries, as well as the various upper and lower limb prosthetic devices and supports produced at its Minnesota facility. The facility in England provides the software used to capture the patient’s particular characteristics, such as limb length, circumference and degrees of soft tissue containment. Once the prosthetist or orthotist collects the data, the product goes to the fabrication software support engineer.

The SINUMERIK 840D, the CNC running the Bornemann machine, also equipped with a SIMODRIVE 611U drive package for precision motion control.

In a typical manufacturing operation for a seat cushion, a 26 in. x 26 in. x 14 in. block of material is secured in the vacuum bed on the Bornemann machine. A probe determines the zero offsets on the blank. For a prosthetic device, a rotary axis, two-ribbed, cone-shaped arbor is mounted on the machine. A predetermined coordinate fixture verifies the offsets and rotation angles. For foam cutting, a 12-in. long hollow tube of tool steel and 40-mm ball end rasp are used. The rigid polyurethane blanks uses the same design of cutting tool, only 7-in. in length with a ball endmill.

In the work envelope of the machine, one axis is used to move the seat cushion; two axes are used to move the tool. A 0º rotation achieves most material removal with a 30º undercut typical. On the prosthetics, three axes rotate the material in a vertical helical pattern. Once made, a prosthetic device is checked, using a specific diameter check ring, as well as digital calipers, to verify the contour surfaces as accurately as possible.

What took two to three hours using the old tool path generation method now takes perhaps 10 minutes. A wheelchair cushion that used to take 90 minutes to manufacture on the old system takes Otto less than 20 minutes to produce. In terms of overall productivity, these levels would not have been achieved without the Bornemann machines and Siemens CNC technology.

Siemens
www.SiemensCNC.com

Design World

Integration with VisionPro software provides access to a comprehensive library of patented computer vision tools—from geometric object location and inspection to identification and measurement algorithms. Combined with a flexible and powerful PC-based development interface, VisionPro software makes it easy to create and deploy solutions for the most challenging machine vision applications.

Cognex offers a three-year warranty for the CIC series of cameras as well as a hot swap program. These new Cognex Industrial Cameras are available now:

• CIC-300: 640×480 resolution (VGA), 120 frames per second, CCD sensor, global shutter
• CIC-2000: 1628×1236 resolution (2MP), 20 frames per second, CCD sensor, global shutter
• CIC-4000: 2048×2048 resolution (4MP), 25 frames per second, CMOS sensor, global shutter
• CIC-5000R: 2592×1944 resolution (5MP), 14 frames per second, CMOS sensor, rolling shutter

Cognex
www.cognex.com

Design World

The Chemlube Plus Series lubricants are made with a very thermally and oxidatively stable polyol ester (POE) blend.  These oils were designed to take advantage of superior lubricating properties inherent in polyol esters, and yet be economical, by combining them with less expensive synthetics.

These fully synthetic premium lubricants are formulated to form less varnish under high temperature applications and to be more resistant to acidic intake air than the polyalkylene glycol (PAG) coolants.  Under normal operating conditions users can expect to obtain up to 11,000 hours of lubricant service life in rotary screw compressors.  The line is available in ISO grades 32, 46 and 68.

Typical industrial applications for the Chemlube Plus Series include: rotary screw compressors, rotary vane compressors, centrifugal compressors, and vacuum pumps.  Chemlube Plus Series lubricants offer these performance benefits:

• outstanding thermal and oxidative stability
• extended drain intervals reduces oil disposal
• wide operating temperature range
• excellent anti-wear protection
• compatibility with most compressor oils
• improved safety – high flash point

Ultrachem
www.ultracheminc.com

Design World

Different by Design: picoMAX uses the contact force from one Cr-Ni CAGE CLAMPS contact spring to clamp a conductor and connect the header pin. Minimizing height, the female header is virtually encased within a male header for shock- and vibration-resistance without extra-cost measures, e.g., threaded interlocks. Furthering international appeal are clear terminations: Push-in for solid and ferruled conductors; push-button-actuated for stranded conductors.

Applications include: medical devices (analyzers, incubators), transportation (elevator/escalator controls), test/measurement (calibration and energy-monitoring devices), building control (BACnet devices, fire/security and lighting control systems) and IT (network gateways, routers).

Economical, Compact – picoMAX eCOM: Providing additional efficiency to cost-sensitive machinery, picoMAX eCOM Pinstrip Pluggable Terminal Blocks do not feature a pin housing. Pluggable female connectors can be directly soldered to PCB and wired as a terminal block. The female header can be removed for PCB maintenance without altering wiring.

WAGO
www.wago.us

Design World

How does Moore’s Law apply to data logging? It applies because data logging devices are getting smarter. When the first data logging devices were released, they were used to take down data and notate on paper (e.g. old chart recorders). Even a few years ago, data logging devices sole purpose was to log data. With Moore’s Law, the trend and increased processing allows data acquisition devices to play greater role in intelligence process.

DAQ vendors continue to push limits when it comes to acquisition rate. By including intelligence, it allows the device to become smart in its own behavior. Rather than simply being a fixed functionality device, devices can adapt to conditions. For example, a device can log data at a continuous speed. If it detects a condition that is erroneous, it can choose to speed up how it collects data, can send data to the cloud or a device, or it can choose to save data at that point in time. This intelligence can be built into a device with the right platform. With certain applications (such as the smart grid), the goal is to perpetually log data at a certain cadence (which can be slow). But over time, if an anomaly is detected, switching to a more busty acquisition mode may allow for greater data detection rates. Traditional data acquisition devices always had intelligence (through their connection to a PC and software), but it is the concept of offline intelligence (through the integration of intelligence within the device) that is arising.

From the DAQ Series: What is a data acquisition system (DAQ), the two images of data acquisition system (NI and MATLAB’s view), there is intelligence in the system, but in the form of a laptop or desktop computer with software in it. The desktop and the DAQ device are separate entities. In this example, the DAQ device transmits to a bus, and intelligence happens at the computer. However, differentiation will happen because of Moore’s Law. Computation will reside in DAQ device.

The ways in which Moore’s Law has continued to hold true is interesting. At first, the approach taken was through making smaller transistors and stuffing more data into the same space. Now, there is an evolution toward multicore processors.

National Instruments
www.NI.com

Test & Measurement Tips

Design World

New products have been added across the company’s broad range of Drive & Control technologies, including Tightening Systems, Electric Drives & Controls, Linear Motion and Pneumatics; more than 550 additions were made in the area of industrial and mobile hydraulics. Included are popular directional valves, Rineer motors, A10VO variable displacement pumps and newly offered configurations for both fixed and variable displacement motors. Rexroth’s recent factory expansion in Fountain Inn played a key role in adding the mobile hydraulics products to the GoTo program.

As before, the updates are reflected in all of the latest catalogs at www.boschrexroth-us.com/goto, and users of Rexroth’s GoTo Products apps for iPhone and iPad can retrieve all of the updates instantly by using the apps’ sync-on-demand feature. A new Fit4Filter app for both iPhone and Android platforms is also of interest, allowing users to find replacement filter elements that are in the GoTo program and/or available through Amazon.com.

Links to all Bosch Rexroth apps can be found at www.boschrexroth-us.com/apps.

Bosch Rexroth
www.boschrexroth-us.com

Mobile Hydraulic Tips

Design World

Visitors to IMS exhibition booth #1459 will learn more about Rogers’ next generation RO4000 circuit materials, notably RO4835 high frequency laminates. These materials are specially formulated with enhanced oxidation resistance for applications requiring outstanding electrical stability over time and temperature, while maintaining the cost advantages of standard thermoset materials. In fact, low-loss circuits on RO4835 laminates can be fabricated using standard processes used for epoxy/glass (FR-4) circuit materials.

Just as with Rogers RO4350B circuit materials, RO4835 laminates offer a dielectric constant of 3.48 and a low loss tangent of 0.0037 at 10 GHz, plus a low z-axis coefficient of thermal expansion (CTE) for excellent plated-through-hole (PTH) reliability under a variety of processing and operating conditions. These improved oxidation resistant circuit materials exhibit x- and y-axis expansion coefficients similar to those of copper, for excellent dimensional stability. RO4835 laminates are RoHS-compliant and do not require special preparation, minimizing production costs.

Visitors can also learn about Rogers’ newest PCB material: RO4360G2 laminates. RO4360G2 laminates, with an improved relative temperature index (RTI) for a higher UL maximum operating temperature (MOT), exhibit a dielectric constant of 6.15 at 10 GHz. These glass-reinforced, ceramic-filled thermoset laminates offer the ideal balance of performance and processing ease. They are RoHS compliant and compatible with lead-free processing methods; in fact, they can be processed with the same methods as for FR-4 to minimize production costs. RO4360G2 laminates feature low loss and low z-axis CTE, with characteristics well suited for demanding RF/microwave circuits, such as amplifiers.

As part of the IMS 2013 technical program, John Coonrod will present at the Microwave Application Seminars (MicroApps). His presentation, “Determining Circuit Material Dielectric Constant from Phase Measurements” is scheduled at 3:30 PM Tuesday, June 4 in the MicroApps Theatre on the IMS exhibition floor. MicroApps presentations typically run about 15 to 20 minutes in length.

Rogers Corporation
www.rogerscorp.com

Design World

LOCAs that are not cured properly in shadowed areas can cause bubbles, delamination, MURA and/or adhesive migration into the backlight unit of the LCD. Application of the primer that ensures full cure in shadowed areas is a simple, non-invasive process that takes place off-line, directly before parts are fed into the laminating equipment.

The Loctite 200 D-Series Dispensing Robot applies solvent-based Loctite 7389 Primer to the cover glass and/or LCD using a foam transfer pad, and allows the solvent to evaporate in less than 10 seconds. The panel is then loaded into the laminating equipment, the adhesive is applied, and light cure occurs. At this point, the primer assumes responsibility for adhesive in shadowed areas, typically curing in less than 90 minutes and guaranteeing that there is no uncured adhesive that remains in the assembly.

The automated Loctite 200 D-Series robotic workstation includes an adhesive reservoir, dispense controller, and a volumetric dispense pump for accurately supplying primer to the foam transfer pad. This system is easily integrated with Loctite® robots or third-party automation systems. Studies have shown that the workstation ensures high process capability and provides application accuracy from 50 to 150 microns, values that approach those of CCD alignment.

Loctite 3196PR LOCA is a low durometer, low modulus, low shrinkage acrylic adhesive that delivers high tensile and adhesion strength on polarizer films, PMMA, glass and ITO-coated glass. This ultra-soft LOCA reduces the potential for MURA while filling gaps from 200 to 300 microns. Typical cure time in shadowed areas is 50 minutes for gaps of 100 microns and 90 minutes for gaps of 250 microns.

For more information on Loctite 7389 Primer and Loctite 3196PR LOCA, or to download a copy of the Loctite LOCA brochure, go to www.henkelna.com/loca.

Henkel Loctite
www.henkelna.com

Design World

Even with the best of manufacturing methods, no surface is perfectly smooth. In bearings, proper lubrication helps smooth out the roughness between bearings and raceways and other parts that interact. If the amount of lubrication is insufficient, or the lubricant is reaching the end of its life, or other factors that compromise lubricant quality arise, the initial signs could be surface distress.

Surface distress can show up as small cracks. These cracks are different from fatigue cracks, which originate beneath surface. Surface distress cracks can be microscopic. But they can increase to the point where they interfere with bearing performance. They can contribute to the development of sub-surface fatigue cracks, which shorten bearing life.

Proper lubrication is the best preventative for surface distress.

Just as a reminder, there are a number of causes that contribute to failure, including:

–material fatigue

–operating with a heavier loading than specified

–inadequate or unsuitable lubrication

–careless handling

–poor sealing

–bearing balls or rollers installed too tightly, with insufficient internal bearing clearance.

Each of these contributors leaves known clues on the bearings or the races, so it is fairly easy to determine what happened. However, multiple contributors can be at play in each cause, so it’s useful to have an understanding of each contributor and each cause.

The primary types of damage are:

–Wear

–Identations (or brinnelling)

–Smearing

–Surface distress

–Corrosion

–Electric current damage

Other forms of damage show up as flaking or cracks.

Leslie Langnau
llangnau@wtwhmedia.com

Linear Motion Tips

Design World

Konnect-It single-level terminal blocks handle cur­rents up to 175A, accept a wide range of wiring sizes from 26 AWG to 2/0 AWG and have a 100kA SCCR rating. Prices start at $30 for a 100-pack and are available in a variety of colors.

Double-level terminal blocks come in 20A and 30A versions and a variety of colors. Optional features include LED indicators, diode and di­rect cross level connections, as well as terminal blocks with an added grounding leg. Double-level terminal blocks start at $83 for a package of 100.

Konnect-It triple-level terminal blocks handle up to 24A and accept a wide range of wiring sizes from 24 AWG to 12 AWG. Optional fea­tures include NPN and PNP sensor blocks with LED indication, as well as terminal blocks with an added grounding leg. Sold in packs of 20, prices start at $27.

Grounding terminal blocks with screw-down or snap-on clamp­ing ground connections offer low contact resistance and corrosion-free connection points. Starting at $69 for a 50-pack, the yellow-green color of the housing provides for easy identification.

Konnect-It miniature terminal blocks are available in 20A and 30A capacities. Starting at $36 for packs of 100, miniature terminal blocks are mountable on 15mm DIN rails; miniature grounding blocks are also available in packs of 50 or 10 starting at $19.

Fuse holder and disconnect terminal blocks provide an easy solu­tion to enable circuits to be opened or to per­form tests while the system is powered. Fuse holder terminal blocks are designed for easy installation and removal of 5mm x 20mm glass fuses up to 6.3A. Fuse holder terminal blocks start at $83 for a 50-pack; disconnects start at $61 for a 50-pack.

Available Konnect-It accessories include end brackets and covers, separators, jumpers, marking tags, as well as top covers and label holders. You can see the full line of Konnect-It terminal blocks and accessories here.

AutomationDirect
www.automationdirect.com

Design World