May 10, 2012 A Penton Media Publication Tune in to EngineeringTV.com Better ways to catch the WIND page 42 A MAGNETIC BRAKE WITHOUT COGGING OR NONLINEARITIES, page 16 ULTRAPRECISE MACHINING HOLDS SUBMICRON TOLERANCES, page 56 SOFTWARE ANALYZES BEARING PERFORMANCE, page 60 DIMENSIONAL TOLERANCES SIMPLIFY ENGINEERING TASKS, page 64 High-speed counting The DL205 micromodular PLC is an industry workhorse, time-tested in some of the toughest industrial settings Installed in thousands of applications, its wide range of I/O and communication options ensure you’ve got the tools you need to the job And our direct prices, 30-day money-back guarantee and FREE award-winning technical support are all standard features that make that job a little easier! DISCRETE: Choose from 25 discrete modules that support AC, DC and relay I/O types All modules have removable terminal blocks for easy wiring and module replacement Our newest DC output module performs electronic short circuit protection ANALOG: 19 analog modules offer interfaces to current and voltage signals, as well as thermocouples and RTDs Connect devices such as process transmitters, proportional valves and AC drives CHECK OUT OUR PRICES ON PLC MODULES PLC modules HIGH-SPEED/MOTION: Counter modules include a simple counting input module or a high-speed input/pulse output module for interfacing to stepper or servo drives Using our SureServo or SureStep motion systems with the DL205 gives you a very cost-effective motion control system COMMUNICATIONS: The DL205 series makes Ethernet communications easy and inexpensive Get fast peer-to-peer access to HMI, other PLCs and PCs on the factory floor at one of the lowest costs per node in the industry DirectLOGIC DL205 Allen-Bradley CompactLogix Discrete Modules AC 16-pt input DC 16-pt input DC 16-pt output Isol relay 8-pt out $135.00 $91.00 $99.00 $100.00 $282.80 $240.38 $314.11 $289.87 Analog Modules 4-channel input (current) 4-channel thermocouple in 8-channel output (voltage) $201.00 $301.00 $271.00 $485.81 $986.77 (6-ch) $1,454.40 Communications Ethernet interface $301.00 $783.00 * All prices are U.S published prices Prices and specifications may vary by dealer and configuration AutomationDirect prices are from April 2012 Price List Allen-Bradley prices are based on www.rockwellautomation.com/en/e-tools 2/20/12 www.automationdirect.com/plcs Test-drive the software for FREE! Our fully functional PC-DS100 programming package can create and download programs to all our DirectLOGIC PLCs (max 100 words runtime; unlimited programming package PC-DSOFT5 is $395) Download the software online at: http://support.automationdirect.com/downloads.html RS# 101 www.automationdirect.com Go online or call to get complete information, request your free catalog, or place an order 1-800-633-0405 High Accuracy Pressure Transducers Insta Pricent ! Design Your Own Custom Transducer Online `^VX Over a Million Combinations with 1-Week Delivery! 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AI>%!*DVcZVd DeRcedRe $%(& =4#!" 2]]>`UV]d $%)& (/(0,*$& ",*-3* (/(0,*$& ",*)" (/(0,*$& ",*-3* omega.com R No ® RS# 102 VOLUME 84 ISSUE MAY 10, 2012 ELECTRICAL/ELECTRONIC Authored by: Robert Repas Associate Editor Key points: • Embedded systems take on the disguise of ordinary devices, not computers • Industrial trends tend to mirror those in the consumer space • One critical missing aspect is a simple programming method for the embedded system Resources: Microchip Technology Inc., www.microchip com National Instruments, www.ni.com Texas Instruments, www.ti.com WinSystems, www.winsystems.com FEATURES Xilinx, www.xilinx.com A Development cycles have shortened dramatically So much so that there is no longer enough time to devise computer-powered applications starting with a standalone computer or processor Consequently, computer and chipmakers have added new and more-powerful functions into the silicon of a computer chip The result heralds the advent of computerized platforms comprised of a processor, a communication interface, and I/O functions targeting specific end-use categories such as mobile phones, computer graphics, and industrial control One of the earliest examples of such a single-purpose design is the PC/104, a single-board computer architecture about the size of a 3.5-in floppy disk that had stackable accessory boards to fit numerous application needs As small as the PC/104 system is, some applications required even-smaller processors Stepping down in size, the system-on-module (SOM) and system-on-chip (SOC) combined all aspects of the single-board computer into a single module or integrated-circuit form SOMs take the individual dies of multiple devices such as a processor, memory, and I/O, and mount them onto a common substrate material The tighter integration has led to smaller but more-powerful systems in the form of self-contained devices that can drop into any piece of equipment for a specific purpose Examples of these devices include digital signal processors (DSPs), network interface and communication services, and even complete computing platforms Computers-on-modules (COMs) are a subset of SOMs that integrate an entire computer on a single modular device While still considered as embedded systems, the versatility of their general-purpose computer lets COMs handle more functions with a single package than typical of the other embedded approaches The push to make systems still smaller has freed chipmakers to form all devices onto a single die, the SOC Instead of individual IC dies of discrete components mounted to a substrate, all devices are etched onto a single die of silicon or other suitable material But there is a problem with this approach Many design teams may use the same SOC or SOM as the basis of a product When those design teams compete with one another, it is sometimes difficult to come up with final designs that are distinctively different from those of competitors So most design teams augment the SOC or SOM with additional discrete components and programmable logic For example, field-programmable gate arrays (FPGAs) let design teams add specialized process- ing, improve performance, and future-proof the design with the ability to update the logic at any time during development or even after they have deployed the embedded system FPGAs have always been used as the “glue” logic that ties various parts of the system together But as their performance rose while power and cost dropped, FPGAs took on the additional task of handling signal processing Today FPGAs perform the functions of digital filters, process Fast-Fourier Transforms (FFTs), and provide the logic needed for proportional-integral-derivative (PID) control loops, among many other things Most times these processes take place in parallel with the computing side of the system, boosting processing speed while giving more deterministic control of the application The addition of FPGAs to embedded systems has become so common that new SOC releases now contain both a complete microprocessor and an FPGA in a single package One example being released in 2012 is the Zynq-7000 Extensible Processing Platform (EPP) from Xilinx, San Jose The Zynq integrates a dual-core ARM Cortex-A9 processor with a Xilinx Series programmable FPGA and an industry-standard AXI interface The combination gives embedded design teams the ability to Reconfigurable processors hold the key to future products using embedded systems SOFTWAREDEFINED FUTURE 42 for Better alternatives for wind power Innovative new designs for wind turbines promise to cure problems ranging from noisy props to poor efficiency in moderate breezes 52 embedded controls 52 MACHINE DESIGN.com National Instruments LabView graphicalinterface software is one of the first to adopt a noncode approach to writing application programs, relying on operational block diagrams to program the system MAY 10, 2012 MAY 10, 2012 52 A software-defined future for embedded controls The future of embedded computing includes devices with more power, features, and simpler programming systems OEM SERVICES of 56 Fundamentals ultraprecision machining It no longer takes exotic machining to hold submicron tolerances the essentials 60 Analyzing of bearing performance Software that examines bearing fundamentals leads to better designs with 64 Working dimensional tolerances Understanding the nuances of tolerances makes life easier for engineers 73 MACHINE DESIGN’s LITERATURE EXPRESS Fundamentals of ultraprecision machining It no longer takes exotic machining to hold submicron tolerances Ultraprecision machining (UPM) comes from the optics industry so not many designers are familiar with the process However, the technology has the potential to revolutionize the way manufacturers, in general, finish parts or make fine-featured patterns First, recall that “high precision” in traditional machining generally refers to tolerances in the single-digit micron range In inch units, machinists talk about holding “tenths” (ten-thousandths of an inch, or 0.0001 in.) And the best conventional machining and grinding machines typically get Ra values no better than 0.1 μm In contrast, ultraprecision machining provides accuracy an order of magnitude better by holding submicron tolerances UPM also obtains surface finish Ra values better than 0.5 nm When using diamond tooling on nonferrous materials, UPM produces yet more-impressively smooth finishes Ametek Precitech, in Keene, N. H., manufactures UPM equipment and has provided the benchmark for this technology Precitech’s machine layout resembles that of standard equipment, but the details make all the difference Programming input resolution, the precision level of the machine inputs, is 0.01 nm for linear and 0.026 arc-sec for angular position Workpiece spindle speeds hit 18,000 rpm and milling spindles rotate at 15,000 or 50,000 rpm Workpiece positional accuracies of 1 micron linear and ±2 arc-sec are standard and — because these errors are repeatable — software compensation can be used to reduce them by a factor of 10 The company’s machines have a solid foundation made with a sealed granite base that provides physical and thermal stability Mounted on pneumatic isolators, the base remains protected from external excitation including footfalls, road traffic, and nearby mechanical equipment In addition, the UPM machines have an axis stiffness as high as 875 N/μ as well as Adaptive Control Technology (ACT), which analyzes feedback, including disturbances ACT also provides active cancellation (analogous to noise-canceling headsets) that continually 56 MACHINE DESIGN.com Ultra Precision three-axis diamond turning creates a toric with a sine-wave pattern in brass Final surface is produced without postpolishing MAY 10, 2012 56 Access our Reader Service Web site to quickly find and request information on the products and services found in the pages of MACHINE DESIGN www.machinedesign.com/rsc MACHINE DESIGN.com MAY 10, 2012 MACHINE DESIGN.com 53 C-more operator touch panels offer: D 4.*:'' ,747:-2;84*A; (6-inch STN models also available) D 6*470[...]... Subscription Policy: MACHINE DESIGN is circulated to research, development, and design engineers primarily engaged in the design and manufacture of machinery, electrical/electronic equipment, and mechanical equipment To obtain a complimentary subscription see our Web page at submag.com/sub/ mn For change of address fill out a new qualification form at submag.com/sub/mn Printed in U.S.A., Copyright © 2012 Penton... subscription rates: U.S.: one year, $69; two years, $99; Canada/Mexico: one year, $79; two years, $119; All other countries: one year, $99; two years, $149 MAY 10, 2012 POSTMASTER: Send change of address notice to Customer Service, MACHINE DESIGN, P.O Box 2100, Skokie, IL 60076-7800 The Truth About Compressed Air! If you think compressed air is too expensive and noisy - read this The facts will surprise... $2,235 *Based on national average electricity cost of 8.3 cents per kWh Annual cost reflects 40 hours per week, 52 weeks per year What’s new online machinedesign.com FREE WEBCAST: OPTIMIZE MACHINE PERFORMANCE WITH THE LATEST SERVOTUNING TECHNOLOGY May 24, 2012, 2:00 ET This Webinar by Yaskawa will first present some of the latest servotuning technologies, including advance autotuning, vibration suppression,... where a combination of techniques provides the best results Servotuning can help simplify designs, improve throughput and performance, increase component life, and reduce machine commissioning time Learn more and register at http://machinedesign com/training Ball-shaped robot EDITOR’S WEB PICKS Engineers from STMicroelectronics show off the Sphero, a small robot that looks like a baseball It houses... U.S., Inc 155 Northboro Road Southborough, MA 01772 Tel: 508-485-2244 • Fax: 508-485-2430 For complete information, visit www.novotechnik.com/ncr 1300 E 9th St Cleveland, OH 44114-1503 10 MACHINE DESIGN.com RS# 110 MAY 10, 2012 Lubriplate® %" "*/& ( 0 -& */ *$" WHEN IT COMES TO SPECIFYING H-1 LUBRICANTS FOR ORIGINAL EQUIPMENT Lubriplate® CAN MEET YOUR REQUIREMENTS 5 " -.+#0 -& /&+* ... subscription see our Web page at submag.com/sub/ mn For change of address fill out a new qualification form at submag.com/sub/mn Printed in U.S.A., Copyright © 2012 Penton Media, Inc All rights reserved MACHINE DESIGN (ISSN 0024-9114) is published semimonthly except for a single issue in January, February, June, July, and December by Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66212 Paid... two years, $299 Cost for back issues are U.S $10.00 per copy plus tax, Canada $15.00 per issue plus tax, and Int’l $20.00 per issue Product Locator, $50.00 plus tax Prepaid subscription: Penton Media (MACHINE DESIGN), P.O Box 2100, Skokie IL 60076-7800 Periodicals Postage Paid at Shawnee Mission, Kans., and at additional mailing offices Can GST #R126431964 Canadian Post Publications Mail Agreement No.40612608... knives Content includes product information, design features, brochures, catalogs, application profiles, and video links — covering applications from milk cartons and bottled water to ketchup and motor oil MACHINE DESIGN.com YouTube training channel Wago Corp.’s new YouTube channel features more than 30 stepby-step training and product support videos that cover a broad spectrum of content on electrical interconnections... transceiver, remote I/O EtherNet/IP fieldbus, and CoDeSys programming The videos include instructional text, letting users follow along with their own computer Access the channel at www.wago.us MAY 10, 2012 UPCOMING WEB EVENTS WATCH PRODUCT OVERVIEW AND TUTORIAL VIDEOS AT YOUR CONVENIENCE AutomationDirect’s YouTube channel features industrial-control product overviews and tutorials Recent uploads include:... industry needs more inventors Next time your TV viewing habits include watching the Cleveland Indians playing at home, keep an eye out for the ballpark’s newly installed wind turbine It is an innovative design, but it’s only there because the Indians didn’t have to pay for much of it Cleveland’s vice president of ballpark operations recently admitted that the club used grants, subsidies, and other spiffs