3D Printing
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Understanding
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Giving Robots
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JUNE 2021 machinedesign.com

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JUNE 2021 VOLUME 93, ISSUE 6

IN THIS ISSUEFEATURES
COVER STORY: The PLC Breaks Out

24

A new architecture takes advantage of technologicaladvances to boost performance.

The New Era of Machine Control

28#UUGUUƂXGMG[CTGCUYJGPTGXKGYKPIVJGOQFGTPRNCVHQTO

24

Lattice Design Enables 3D-Printed Nasal
Swab Production

32#&RTKPVKPIEQORCP[WUGUKVUNCVVKEGVGEJPQNQI[VQJGNRTGUQNXGVJGPCVKQPCNUJQTVCIGQHPCUQRJCT[PIGCNVGUVKPI
swabs during the pandemic.



Getting Up to Speed

36

Understanding ball screw potential and limitations.

Redesigning a Test-Tube Handler for
Robot-Based COVID Testing

38

6JGWRFCVGFOCEJKPGECPJCPFNGVGUVURGTFC[28

The Robots Have Eyes

42

Machine vision is growing at an astronomical rate—andtransforming manufacturing in the process.

38

DEPARTMENTS
4

MACHINE DESIGNCONNECTED

10

NEWS

51

NEW PRODUCTS

54

CLASSIFIEDS55

AD INDEX

42

COLUMNS
6

EDITORIAL

56

ONE MORE THING...

Redesigning the
Designer’s Role

Predicting Wind Power
Costs for the Next
30 Years

Printed in U.S.A., Copyright © 2021. Endeavor Business Media. All rights reserved.
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JUNE 2021

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Connected
MachineDesign
Magazine(@MachineDesign)

Machine-DesignMagazine

CSIA Exchange
Find a system integrator here:
https://www.csiaexchange.com

Pushing the Limits of Micro-Sensing
Applications in MedTech

What’s the Difference: Identifying Cordset
Options for Automation Sensors

https://www.machinedesign.com/medical-design/
article/21161662/pushing-the-limits-of-microsensingapplications-in-medtech

https://www.machinedesign.com/automation-iiot/
article/21157352/whats-the-difference-identifying-cordsetoptions-for-automation-sensors

The Basics of Flexible Printed Heaters

How do Medical Organizations Use
Additive Manufacturing?

https://www.machinedesign.com/leaders/medicaldesign/article/21159616/the-basics-of-flexible-printedheaters

https://www.machinedesign.com/3d-printing-cad/
article/21160482/how-do-medical-organizations-use-additivemanufacturing

ANOTHER LOOKFROM THE ARCHIVES

Sensor-Based IoT Platforms Monitor
Vaccines at the Frontline

Goldilocks’ Automation: Not Too Much,
Not Too Little

Tracking COVID-19 vaccines is a monumentall effort
eff
fffor
ortt thatwill go down in history as an exercise in overcomingming
n an epic
logistical hurdle. Sensors play a critical role in thehe vaccine
delivery system.

Automation can introduce inflexibility that decreases
asees va
vvaluelue andproductivity—but too little automation can drive up
up laborlaabor costs.

https://www.machinedesign.com/automation-iiot/
article/21161911/sensorbased-iot-platforms-monitorvaccines-at-the-frontline
4

https://www.machinedesign.com/automation-iiot/t//article/21140150/goldilocks-automation-not-too-much-nottoo-little

JUNE 2021

MACHINE DESIGN

Editorial
BOB VAVRA | Senior Content Director
bvavra@endeavorb2b.com

   Successful design has historically been the outcome of atrial-and-error approach, but technological advances arechanging the rules of the game.

S

pencer Silver is not a nameyou’d know at first glance, but
he was partially responsible
for one of the most successful
products in global history. Silver died lastmonth at the age of 80, and if you needto make a note to yourself to look up his
biography, you might use one of his creations to do it.
A 3M chemist and researcher, Silver
invented the glue that gave us Post-It
Notes. Silver’s unique glue composition
could be stuck and unstuck repeatedly
without harming the surface or losing adhesion. But while an interestingchemical discovery, there wasn’t an obvious use for the glue until another 3M
colleague, Art Fry, was looking for aneasy way to put up a reminder that didn’t
require a pin or tape. Fry remembered
the glue Silver has created, used it ona small piece of paper, and a productempire was born.
As in Silver’s case, successful design
is so often a matter of trial-and-error—
and what first may look like an error isin fact a solution in search of a problem.
But such an approach is viewed by thoseoutside the design universe as expensive,
often unproductive and as a result mostly
unprofitable. Speed to market and eliminating the error part of the process have
driven much of the innovations of the last
few years, the COVID-19 vaccine mostrecent among them.
As MIT professor Wojciech Matusik
writes in this month’s issue, the emer-

gence of artificial intelligence (AI) andmachine learning will change the way
researchers conduct experiments anddevelop innovations.
“We’re on the cusp of a revolution indesigning and manufacturing products,”
Matusik writes.
Where does this leave the Spencer
Silvers of the world? In a different
role, but one that is no less crucial tothe process. Jesse Coors-Blankenship,senior vice president of Technology
for PTC, offered this thought: “Thesedevelopments will shift the role of theengineer to curating parameters and test
conditions, and then choosing the best
design from a range of permutations
generated by AI.
“Eventually even the design-selection
process will require AI assistance, as
the sheer range of generated solutions
outpaces the engineer’s ability to sort
through them,” Coors-Blankenship added. “Liberated from the tedious trial anderror of refining their designs, engineers
can focus on what their design needs toaccomplish rather than how the design
will be realized.”
Luck can be defined as when opportunity meets preparation. Silver earned 37
patents in his 3M career, so if the temptation is to think of Post-It Notes as lucky,
it was luck borne of hard work and talent.
If the future of innovation will be better
realized by AI, it still will be fueled byinnovation that is more intuitive thanartificial.

JUNE 2021

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JUNE 2021
EDITORIALSENIOR CONTENT EDITOR: BOB VAVRA bvavra@endeavorb2b.com
MANAGING EDITOR: JEREMY COHEN jcohen@endeavorb2b.com
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JUNE 2021

MACHINE DESIGN

AI MAKES A DEEP IMPRESSION
on Industrial Manufacturing

A survey confirms AI adoption gained traction with industrial manufacturers over thecourse of the pandemic.

F

rom design to process planningand production, manufacturers
will be looking to advanced technologies such as artificial intelligence (AI) to step up resilience planning.
This finding was reinforced overthe course of the past year, according
to a KPMG survey, “Thriving in an AI
World,” which solicited feedback fromseven industries.
According to the survey, 49% of
industrial manufacturing business leaders reported that AI is fully functional atscale within their organization, and 61%
of industrial business leaders noted thatan increase in productivity is its greatest
potential benefit.
Business leaders also reported that AI
is at least moderately functional in theirorganizations, including those in industrial manufacturing (93%), financial

10

The sur vey’s historic finding,according to David Neely, managing
director, Intelligent Information, KPMG,
was that the reported adoption rate washighest of all industries in industrial
manufacturing.
“It runs a little bit
contrary to what wewould have expectedbased on some of theinteractions we’ve hadwith clients in thisspace,” Neely said.

The industrial manufacturing (IM) sector was the most mature at using thesetechnologies, but revealed the highest
levels of angst when it came to employing
AI technologies from a security, privacy
and regulatory standpoint.
He further explained that AI adoption
in industrial manufacturing is observed
along two realms. Firstly, IM adoptionof technology automation has been concentrated in the back office for routine,
value-added activities, where enabling
efficiencies, productivity and cost reduction are key drivers.
Secondly, IM has for many years beena leader at incorporating AI technologies on the product side—for technology
going into self-driving vehicles, aircraft,aerospace and defense products. IM has
lagged when it comes to implementing
AI technologies into business functions,
Neely said.
For Roy Mathews, managing director,
Data and Analytics, KPMG, IM can befurther classified into three buckets: smart
factories, smart products and smart office.
“Smart office is the area in which industrial manufacturing
is lagging,” he said.
“But smart factories
and smart products
are the areas that are
natural to IM, given
the proliferation ofDavid Neely, managing director, Intelligent

Roy Mathews, managing director, Data andInformation, KPMG.

Analytics, KPMG.

services (84%), technology (83%), retail(81%), life sciences (77 %), healthcare(67%) and government (61%).
The Big Takeaway

JUNE 2021

MACHINE DESIGNNewsIndustry 4.0 initiatives. There is an incentive to automate. AI is a huge catalyst for
Industry 4.0.”
There is a natural tendency to adapt AI
for factory settings, said Mathews. The
data associated with AI in IM environments is generally structured. Sensors
capture structured data from equipment,
which is easy to process and enable, hesaid. This is unlike financial services orhealthcare, where there’s a lot of unstructured data.
Deﬁning AI

For the study, AI was defined as any
type of solution that generates insightsfrom data or from patterns. The definition also extended the definition toautomating tasks, which would include
such concepts as machine learning, cognitive computing and robotic process
automation.
A further classification would be tothink of AI as those technologies thatemulate human decision making. “Contrast this to technologies that emulate
human activities—which is more in therealm of process automation or robotic
automation,” said Neely.

“

There has since been a huge shift to initiatives moving into mainstream andproduction mode.
Other Findings

1. 61% of industrial manufacturingbusiness leaders say that an increase inproductivity is the greatest potential benefit of AI adoption, and most (95%) agree
that AI technology would make their company run more efficiently.
2. According to industrial manufacturing business leaders, in the next two years,
AI technology will have varying impacts
and will experience growth dependent on
industry needs:• 21% for product design, development and engineering• 21% for maintenance operations• 15% for production/assembly
Mathews said that leveraging AI to gain
efficiencies across maintenance, operations, product design and engineering,and supply chain will be integral to building enterprise resilience.
Neely agreed. “That’s going to be
increasingly important in the future, given

The use of AI over the last decade has
generally been experimental, but inrecent years we have started to see a move fromexperimental stage to a production at scale mode.”
Experimental to Mainstream

While AI is native to technology companies such as Google and Apple, the restof the industry is now adapting it andmaking it part of the business function,
said Mathews.
“The use of AI over the last decade
has generally been experimental, but inrecent years we have started to see a movefrom experimental stage to a production
at scale mode,” he explained. Prior to that,organizations would embark only on
innovation-related initiatives until they
had a proof of concept, noted Mathews.

the learnings of the COVID-19 disruption,” he said. “Companies are looking
closely at how they build resilient supply chains and how they’ll recover from
disruptions and brand disruption on a
global scale.
“Whereas those problems were historically tackled from a mathematical modeling and optimization standpoint, new
AI technologies provide a more sophisticated means for analyzing data, looking
at alternatives and optimizing in an evenmore powerful and sophisticated way,” heconcluded.

JUNE 2021

MACHINE DESIGNNewsNASA ROVER Extracts Oxygen from Martian AtmosphereNASA RECENTLY TESTED its “Mars oxygen

in-situ resource utilization experiment” onboard the Perseverance Mars rover. This
toaster-sized device converts the CO 2-rich Martian atmosphere into oxygen, as
well as carbon dioxide as a waste product.
Moxie heats the incoming atmosphereto about 1,470°F (800°C) to carry out theTechnicians at NASA’s Jet Propulsion Laboratory lower the Mars oxygen in-situ resource
utilization experiment (Moxie) into the belly of the Perseverance rover. (NASA/JPL-Caltech)

After warming up for two hours, Moxie began producing oxygen at about six grams perhour. After an hour of operation, about 5.4 grams of oxygen were produced, enough to keepa person alive for about 10 minutes of normal activity. (MIT Haystack Observatory)

14

extraction. This means it had to be madeof heat-resistant materials, such as 3Dprinted nickel alloy parts, which heat andcool the gases flowing through them. It
also has a layer of a lightweight aerogel
for insulation to retain the heat inside thedevice. A thin gold coating on Moxie’s surface reflects infrared heat, keeping it fromradiating outward and potentially damaging other parts of Perseverance.
In its first test, Moxie created about
five grams of oxygen, enough to keep
an astronaut alive for about 10 minutes.
Moxie will undergo eight more tests
which fall into three phases. The firstphase tests will check out and characterize Moxie’s performance; the second
phase looks at its performance in varying
atmospheric conditions, such as different times of day and seasons; and in thethird-phase tests, NASA will push theenvelope and try new operating modes
and scenarios, such comparing operations at three or more different temperatures. By the end of the testing, NASA
expects Moxie will demonstrate its targeted production rate of extracting 10
grams of oxygen per hour.
If Moxie meets NASA expectations, thetechnology it is based on could be used tosupply future Mars explorers with oxygento breathe and with a major proponentof the rocket fuel they will need to returnto Earth.
To burn fuel, the returning rocket musthave more oxygen by weight. Getting four
astronauts off the Martian surface and toan orbiting return spaceship, for example,
would require approximately 15,000 lb of
rocket fuel and 55,000 lb of oxygen. In
comparison, the four astronauts living andworking on Mars would require just 2,200
lb of oxygen to breathe.
The alternative to using Moxie-type
technology to get oxygen on Mars would
be to carry about 60,000 lb of it on thetrip from Earth to Mars. It would be more
efficient and less costly to carry a 2,000-lb
Moxie-based O2 extractor that could supply that same oxygen. 

JUNE 2021

MACHINE DESIGN

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newsletter, a source forfacts, opinions, and industry
CV[[8FMMSFHJTUFSZPVUP
XJOB'3&&(nBTIESJWFNewsA SHRIMP-INSPIRED CAMERA Helps Detect Tumors
ENGINEERS AT THE University of Illinois took a clue from the mantis shrimp when

they developed a camera for helping surgeons identify tumors in patients. The
shrimp’s eyes can discern up to 12 different colors, including some in the IR range,
thanks to stacks of light-sensitive cells that make up the sensing part of the shrimp’seyes. Humans, on the other hand, can only perceive combinations of three colors—
red, green and blue—using the single layer of light-sensing cells lining the retina.
To partially replicate the shrimp’s visual capabilities, the engineering team combined semiconductors and optical filters to build a camera that can capture the threecolors of visible light doctors would normally see, as well as three colors of invisiblenear-infrared light they cannot.
The camera is used during tumor-removal surgery on patients who have been
injected with tumor-targeted probes. The probes seek out tumors and accumulate intheir cancerous tissues. They also emit near-IR light, which the new compact camera can detect and display to surgeons.
“The combination of the bioinspired camera and tumor-targeting drugs will ensure that surgeons leave no cancer cells behind in the patient’s body,” says GoranKondov, a professor and chief surgeon who used the camera on a patient. “This
additional set of eyes will help prevent recurrence of the disease, providing patients aquicker and easier path to recovery. And the device can potentially be manufactured
at low cost since it is so simple, making it accessible to hospitals around the world.“
The engineering team is now adapting the camera to mount on endoscopic
probes, letting minimally invasive tumor surgery be done in other hospitals. The human eye perceives only three colors: red,green and blue. The mantis shrimp uses stacks
of light-sensitive cells at the tip of its eye to “see”
up to 12 colors. (Steven Drake/Beckman Institute forAdvanced Science and Technology)

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JUNE 2021

MACHINE DESIGNNewsRESEARCHERS EFFICIENTLY Turn Wood into Ethanol
RESEARCH TEAMS AT Lawrence Berke-

ley and Sandia National Laboratories
have jointly develop a streamlined andefficient process for converting woody
plant matter, such as forest overgrowth
and agricultural waste—material that iscurrently burned either intentionally orunintentionally—into liquid biofuel. Until
now, wood has been difficult to chemically break down.
The teams found that commerciallyavailable enzymes, which are nontoxic, can be combined with a speciallyengineered strain of yeast along withwood in a single container or “pot,” tomake ethanol. Using a single reactor
lets the process use less water andenergy. The work is the first-ever endto-end process for ethanol production
from woody biomass featuring both highconversion efficiency and a simple onepot configuration.
Technological and economic analysis
helped the teams identify the improvements needed make ethanol from the new
production process at $3 per gasoline gallon equivalent.
The process presents several opportunities. “Removing woody biomass fromforests, such as overgrown pines of the
Sierra, and from agricultural areas suchas almond orchards of California’s Central
Valley, we can address several problems
at once: disastrous wildfires in fire-prone
states, air pollution hazards from controlled burning of crop residues and ourdependence on fossil fuels,” says Lalitendu Das, a postdoc fellow at Sandi and
the Joint BioEnergy Institute (JBEI). “On
top of that, we would significantly reduce
the amount of carbon added to the atmosphere and create new jobs in the bioenergy industry.”
Ethanol is already used as an emissions-reducing additive in conventional
gasoline, typically constituting about
10% of the gas used in cars and trucks
in the U.S.
Ethanol derived from plant biomass
can also be used to make more complex

18

A researcher at Berkeley Lab prepares woody biomass to be broken down into fermentablesugars. (Berkeley Lab)

diesel and jet fuels, which are helping
decarbonize the difficult-to-electrify aviation and freight sectors. Currently, themost common source of bio-based ethanol are corn kernels, a starchy material
much easier to break down chemically,
but which takes land, water and otherresources to produce.
The teams found that woody biomass
can be efficiently broken down and converted into advanced biofuels in a processthat is cost-competitive with starch-based
corn ethanol. The process can also turnout “drop-in” biofuels chemically identicalto compounds already in gasoline anddiesel fuel.
One benefit of the new process is that
it would reduce the amount of dry woodthat accumulates over the years and in-creases the risks of wildfires. “According
to a recent report, by 2050 there will be 38
million tons of dry woody biomass available each year, making it an exceptionally abundant carbon source for biofuel
production,” says Carolina Barcelos, anengineer at Berkeley Lab’s Advanced Biofuels and Bioproducts Process Development Unit.
The next steps in this effort are to develop, design and deploy the technology
at the pilot scale, which is defined as aprocess that converts one ton of biomass
per day. The Berkeley Lab teams areworking with Aemetis, a renewable fueland biochemicals company that wants tocommercialize the technology and launch
it at larger scales once the pilot phase iscomplete. 

JUNE 2021

MACHINE DESIGNNewsRESEARCHERS DEVELOP the Whitest Paint Ever
TO SAVE ENERGY, engineers at Purdue

University have developed a paint that iswhiter than any other, which means it reflects more light. Putting it on roofs andsides of buildings will keep them cool andreduce the need for air conditioning.
“If you covered a roof about 1,000
square feet with it, you could get the 10
kilowatts of colling power, which is morethan the central air conditioners found in
most houses,” says Xiulin Ruan, a mechanical engineering professor at Purdue.
The new paint reflects up to 98.1%
of visible sunlight and also repels infrared heat. When painted on a surface, it
can make it cooler than the surrounding
air. Typical commercial white paints get
warmer rather than cooler. Paints on themarket designed to reject heat reflect only
80% to 90% of sunlight and can’t makesurfaces cooler than their surroundings.
In tests, the paint kept surfaces 19°F
cooler than their ambient surroundings
at night. It also cooled surfaces 8°F lower
than the surroundings under strong noontime sunlight. The paint’s solar reflectanceis so effective, it even worked in the middle of winter. During an outdoor test with
ambient temperature of 43°F, the paintlowered the test sample temperature by
18°F.
The new ultra-white paint seems to
be on the opposite end of the spectrum
as Vantablack, a coating that has been
dubbed “the blackest black.“ Vantablack,
was invented by Surrey NanoSystems; it
absorbs up to 99.9% of visible light.
The key to the new coating’s ability is
its high concentrations of barium sulfate, achemical used to make photo paper andcosmetics white.
“ We l o o k e d a t v a r i o u s c o m m e rcial products—basically anything that’s
white,” says Xiangyu Li, a postdoctoral
who worked on this project as a Purdue
Ph.D. student in Ruan’s lab. “We foundthat barium sulfate can make things really,
really reflective, which means that they’rereally, really white.”

20

Xiulin Ruan, a Purdue University professor of mechanical engineering, holds a sample of thewhitest paint on record. (Purdue University/Jared Pike)
An infrared image(right) shows how asample of the whitest
white paint (left) cools
the board below
ambient temperature,something not evencommercial “heatrejecting” paints cando. (Purdue University/
Joseph Peoples)

The team also used a range of different-sized barium sulfate particles. Including large to small particles let the paintscatter and reflect a wider range of lightfrequencies found in sunlight.
The team could’ve made the painteven whiter, but then it would be lessuseful as paint. “Although a higher barium-sulfate particle concentration is better for making something white, you can’t
increase the concentration too much,”says Li. “The higher the concentration,
the easier it is for the paint to break or
peel off.”
This white paint is the result of six yearsof research, building on attempts goingback to the 1970s to develop radiative
cooling paint as a feasible alternative to
traditional air conditioners.
Ruan’s lab had considered more than
100 different materials, narrowed themdown to 10 and tested about 50 different
formulations for each material. Their previous ultra-white paint was made of calcium
carbonate, a compound commonly foundin rocks and seashells.
The researchers predict that their new
ultra-white paint should be able to withstand outdoor conditions. It should also
be easy to make, as it was made using
a technique compatible with commercial
paint fabrication. 

JUNE 2021

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News

COULD THIS RECYCLABLE MATERIAL Revolutionize the Plastic Industry?

The average personin the U.S. generates
about 220 lb of plastic
waste annually,
most of which goes

Recycled PDKs are already drawing
interest from companies sourcing plastics.
The Berkley team has been conducting
market research and meeting with industry people and have determined that thebest initial application for PDKs are markets where manufacturers will get theirproducts back at the end of their lifespan, such as the auto industry (throughtrade-ins and take-backs) and consumer
electronics (through e-waste programs).
These companies can then reap the benefits of 100% recyclable PDKs, namely
sustainable branding and long-term savings. Plus, some countries plan to charge

straight to a landfill.

A TEAM OF researchers at Lawrence
Berkeley National Laboratory has been
studying large-scale production of a newplastic, poly(diketoenamine). It has all theuseful properties of traditional plastics but,unlike traditional plastics, PDKs can berecycled indefinitely with no loss in quality.
The team found that PDK-based plastic
could quickly become commercially competitive with conventional plastics, and the
products will get less expensive and moresustainable as time goes on.
The problem with traditional plastics
is that so far, more than 8.3 billion tonsof them have been produced, and thevast majority of it has ended up in landfills or being burned in waste incineration
plants. Only a small proportion of plastics are recycled “mechanically,” meaning
they are melted down and re-shaped into
new products. Unfortunately, this technique is limited because plastic resins
are mixed with many different additives
for different textures, colors, and capabilities, such as pigments, heat stabilizers
and flame retardants.
So, when many different plastics aremelted down together, the plastic polymers get mixed with many potentially incompatible additives, resulting in a newplastic with much lower quality than thosemade using virgin resin from raw materi-22

als. As such, less than
10% of plastic is mec h a n i c a l l y re c y c l e dmore than once, andrecycled plastic usually must contain a significant amount of virginresin to compensate forthe dip in quality.
PDK plastics sidestep this problem byusing resin polymers Brett Helms, foreground, pictured at work in the Molecularthat easily break down Foundry developing PDK and the processes to make it. (Thor
into individual mono- Swift/Berkeley Lab)mers when mixed withan acid. The monomers can then be sep- significant fees on plastic products madearated from any additives and collected of non-recycled materials. That should
to make new plastics without any losing give companies a strong incentive toany performance or quality. The team’s move away from virgin resins and drive theearlier research shows that this “chemical demand for recycled plastics.
recycling” uses little energy and creates
The team is also working on way to
few CO2 emissions. It can also be re- improve the process by using microbepeated indefinitely, creating a completely made precursors. The process currently
circular material lifecycle unlike the cur- uses industrial chemicals but was initiallyrent one, which is essentially a one-way designed with microbes in mind. This
ticket to waste.
would let nearly the entire polymer be“The next step is to determine how made from plant material fermented bymuch it will cost to scale it up, what the af- engineered microbes.
fect will be on energy use and emissions,
PDK technology is available for liand how to get there from where we are censing and collaboration. If interested,
today,” says Brett Helms, a staff scientist please contact Berkeley Lab’s Intellectual
Property Office. 
at Berkeley Lab.

JUNE 2021

MACHINE DESIGN

Cover StoryDAMON PURVIS | PLC Product Manager, AutomationDirect.com

AT A GLANCE:• As end-users take advantage ofmore capable PLCs, they mustalso consider security.
• By increasing the overall
computing power of PLCs,
controller vendors have maderoom for additional capabilities.
• Improvements in computing
power have created asophisticated PLC that cansynchronize servo drives orcontrol complex process loops
while transmitting data andsupporting an HMI.

A new architecture takes advantage of technologicaladvances to boost performance.

Anyone who has servedin the military or evena large company understands the concept ofhierarchy—it identifies who’s in charge,
the chain of command and how eachindividual fits in that structure. Somepeople find security in the structure,
while others with ambition can feel
stifled. Similar situations apply in

1. The Purdue Architecture delineates clearly defined layers, reflecting older thinking basedon available technologies.

24

industrial automation. A hierarchicalstructure defines what type of equipment goes where, and what actions aresupposed to happen at each level. Thisapproach is explained in detail by the
Purdue Enterprise Reference Architecture (Fig. 1).
It puts process and field devices at thebottom, control equipment in the middle
and enterprise information technology(IT) systems at the top. Operational technology (OT), with its PLCs, generally
exists at the basic control level where
they interface with field devices, executecontrol loops and control motion. When
there is a need to send data to higherlevel systems, it must be passed up thechain of command, moving from layer
to layer.
This situation has two major faults:• It calls for a lot of developer effort
and computing resource overhead
with multiple communication protocols.
• It does not recognize or utilize thegrowing capabilities of today’s generation of PLCs.
Classic industrial automation architectures represent concepts and equipment
limitations of the 1990s. PLCs of that era
were less powerful and therefore had tobe specialized and focused to perform
specific high-speed control functions.
Higher-level systems were required toprovide more advanced data-processing
capability. But moving data between thelowest and highest levels called for a significant effort.

JUNE 2021

MACHINE DESIGN

Users generated custom code configurations to select, arrange and manage
data. A lot of parts and programmingwere frequently involved: PLCs, gateways, PCs, software packages, network
configuration and supporting code. Even
when data connectivity could be patched
together, it was often at the expense of
security. Traditionally, PLCs had few (ifany) cybersecurity provisions, especiallyfor internet-connected systems.
Change and Improvements

Much has changed in the industrial
space over the past few decades. One
issue is that overhead remains a problem.
Plants want flatter and less-complex control systems for processes and machines.
The concept of having so many layers ofspecialized equipment is wasteful, but canbe streamlined with more versatile controllers capable of performing multiple
overlapping roles. Older PLCs could nothandle their high-speed requirements
while being distracted by other data
management functions.
Improvements in computing power(Fig. 2) mean today’s PLCs can now synchronize servo drives or control complex
process loops while transmitting data andsupporting a human-machine interface(HMI). A sophisticated PLC can straddle
more than one level.
Second, as just noted, PLCs have comea long way—but adoption of all improvements is not uniform across vendors. Somecompanies have decided that traditional
structures are safe and elected to remain
within those constraints, even though limited communication capabilities makes
integration with up- and downstream
equipment difficult. Synchronization isstill possible, but it is complex to implement and requires additional overhead.
By putting technological improvements
to work and increasing the overall computing power of their PLCs to handle
basic functions with far less sweat, some
vendors have made room for additional
capabilities. For example, by including alonger list of communication protocol
options, a PLC can bridge over inter-

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2. Some modern PLCs also incorporate advanced data handling features andcommunications protocols so they can easily interface OT field data with IT enterprisesystems.

mediate network layers and reduce thecomplexity of interfacing with the enterprise. Even a relatively simple PLC can
operate in an environment dominatedby equipment from a different vendor.
Additionally, it can communicate with
IT-centric assets using a representational
state transfer application programming
interface (REST API) or secure message
queuing telemetry transport (MQTT/S)
over wired or wireless networks. This isa far cry from older PLCs that only speak
MODBUS.
This ability can extend even farther
with IoT connectivity direct to the cloud.
Even a small or medium PLC may becertified to have native connectivity to
Microsoft’s Azure Platform. Certification
assures users that the device is tested towork with the Azure infrastructure andprovides clear documentation about how
to connect. Azure offers many industrial
IoT capabilities to help users visualize andoptimize their operations, including:• Cosmos DB for data storage• Power Apps for easily building lowcode solutions• Web and mobile visualization• Machine learning and analytics tobuild advanced predictive models

Consider this situation: A PLC must
pass data upstream to a corporate network
for advanced processing. Using the traditional approach, it moves via the chain
through all the layers, possibly converted
to a different protocol a time or two, andultimately reaches its destination. The
alternative is an Azure-certified PLC
able to interface with an Azure IoT hub
without the need of a gateway: a directconnection, less complex and with far
less overhead.
Applying the Standards

Some of the most popular serial andEthernet protocols for OT purposes
include ASCII, Modbus RTU, K-Seq,
Modbus TCP and EtherNet/IP. On theother hand, IT systems use protocols like
SNTP DNS, MQTT, SMTP, SSL and web
services. A PLC bundling these capabilities together becomes a bridge from OT
to IT, creating many ways to connect
new and legacy factory floor equipment
to today’s enterprise systems.
When all data integration elements
are built-in and reside natively in a
PLC, setup is much faster. IT users
typically prefer open-source solutions
because they are already familiar with25

PLC PowerW

hen all
data
integration elements
are built-in and residenatively in a PLC, setup
is much faster. IT users
typically prefer opensource solutions because
they are already familiar
with this approach,rather than specialized
environments common
to industrial products.

3. AutomationDirect BRX Series PLCs include several data connectivity options, and each isa Microsoft Azure Certified Device.

this approach, rather than specialized
environments common to industrial
products.
When these technologies are available,
users can select from a range of options
based on process requirements (Fig. 3).
They can:• Store data in the PLC and forward it
to other systems using FTP• Present information as web pages
hosted by an internal web server• Expose data to external clients witha REST API• Communicate data to other systems
using MQTT over TLS
The last of these options, MQTT, hasrisen to become a popular standard for
PLC-to-cloud communications. The
PLC in the field initiates conversations
as outbound messages to a centralized
broker, which can be on premises but
is most often in the cloud. This enables
two-way communications while avoiding firewall and IT management issues
which would occur with many types ofinbound communications.

26

MQTT communications are responsive, but at the same time can withstandnetwork and communication outages
commonly found at edge locations. A
PLC using MQTT is ideal for transmitting data to an IIoT platform located ona cloud computing service like Microsoft
Azure. Users can access the data withenterprise or mobile clients, or they cancreate other applications to use this PLCsourced MQTT data.
Security and Flexibility

Improved PLC connectivity unfortunately leads to greater cybersecurity risks.
Therefore, new PLCs must include builtin security features, such as:• Closed by default to requests fromthe outside world• On-board storage of username andpassword credentials managed by
OT personnel• IP whitelisting to control which
external clients are allowed to communicate with the PLC• Secure communication over TLS
when possible

As end-users take advantage of morecapable PLCs, they should ensure thatthese security capabilities are available
and are configured properly.
Yesterday’s PLCs and other industrial
automation products were largely incapable of advanced computing tasks thatusers want and need today, because they
were specialized and limited in terms ofdata handling. The processing power
incorporated in today’s OT digital devices
provides greater capabilities for supporting IoT and analytical endeavors at theenterprise level and in the cloud. Merging
proven OT-based technology with carefully coordinated IT-friendly communications and security results in a potent PLC
combination. Modern PLCs can connect
directly to the cloud, making it easy to
break out of traditional restrictions.
DAMON PURVIS is the PLC productmanager at AutomationDirect.com. He
has more than 22 years of industrial automation experience. Previous roles haveincluded designing and deploying automated solutions in a variety of industries
and managing product development of
manufacturing data management andbusiness intelligence applications.

JUNE 2021

MACHINE DESIGNAutomation & IIoT
ALLEN TUBBS | Product Manager, Bosch Rexroth

Assess five key areas when reviewing the modern platform.
AT A GLANCE:• The goal is to allow the PLC to
be continually upgraded like asmartphone instead of being
doomed to obsolescence.
• Controller manufacturers havecreated their own app storesto provide links for designand operational software tocustomers.
• A new generation of machine
controllers allows designers
to leverage open architecture
tools to drive manufacturing
innovation.

The PLC—the programmable
logic controller, or automation
controller—has been the central
tool used to drive advances in
automation efficiency, productivity andflexibility for several decades. Automation
machine controllers have evolved throughseveral generations of hardware andsoftware, taking advantage of advancesin processor power, sophistication andhigh-speed, Ethernet-based automation
protocols to drive increases in automation
throughput and productivity.
Until recently, machine controller
architectures—both hardware and software—evolved somewhat in isolationfrom the broader computing and IT platforms that have transformed the globe.
However, a new generation of modern
machine controllers is revolutionizing theindustry, providing technology that offers
a whole new kind of openness and easeof use, while still supporting the complex
functionality that current and future automation systems demand.

28“Old vs. New”: Limitations ofPrior Controller Platforms

Prior generations of machine controllers made effective use of advances inprocessor technology and communication interfaces to provide support for evenfaster automation control requirements.
They also provided other functionality,
such as increased use of sensors and visionsystems. However, a significant limitationof these systems was the way that controller technology developed in isolation frombroader trends in the world of IT.
The broader IT world has an open software architecture, unlike many controller
platforms. Today’s smartphones provide
the perfect model. Smartphone operat-

ing systems provide the foundation for an
unending array of specialized programs
and apps that are easily downloaded
and intuitive to use. This openness andinteroperability have enabled constantcreativity for outside developers toenhance smartphone functionality.
In contrast, controller technology
has continued to be much more closed,
thereby limiting the ability of automation
OEMs to have long-term flexibility andcontrol of their systems. For example: If a
packaging systems OEM wants to develop
a new generation of machines, it is typically forced to make an early judgment in
the design process about which controller
family to use.

A new generation of machine controllers is emerging, allowing the automation community
to leverage the openness and sophistication of these new tools to drive manufacturing
innovation. (Bosch Rexroth)

JUNE 2021

MACHINE DESIGNFrom that point on, that family ofmachines is wedded to that controller
platform and how the supplier supports
the controller over time. Because of thesearchitecture constraints, it could be very
difficult to switch to a different platform
or alternative controller: Each controller
uses a different operating system or proprietary software, making it more difficultand expensive to offer the same machinewith options for a different machine controller.
Because the software architecture ofthese proprietary controllers has been
so tightly controlled, the platform often
did not support newly emerging capabilities or applications. Automation OEMs
were limited in their ability to support new
applications, particularly for functionality
sought after in Industry 4.0 manufacturing operations.
If a manufacturer wanted to be able tomonitor and collect machine performancedata from all its machines plantwide andcleanly link up that data through cloud
applications for real-time analysis andlong-term systems management, that kindof functionality often had to be speciallydeveloped through custom drivers andspecialized communications.
However, a new generation of machine
controllers is emerging to overcome theselimitations and free the automation community to leverage the openness andsophistication of these new tools to drive
manufacturing innovation.

than half of the value creation in automation engineering. For machine manufacturers and end-customers, efficient engineering and straightforward application
programming offer a considerable potential for savings and degree of freedom.
The most obvious model for thisapproach is the smartphone, with highly

stable, robust operating systems incorporating features such as encrypted data layers that enable multiple automation apps
to communicate and share information
with each other.
In modern machine controllers, theopen software architecture with flexible
app technology lets OEMs select the apps

Openness: Key Traits of New
Machine Controllers

Today’s state-of-the-art machine controllers are rapidly moving away fromthe closed, proprietary architectures ofprior systems. Here are five key traits thatmachine builders and automation endusers should consider when assessing
different platforms.
1. Apps-based architecture. One of
the most significant differences between
past and current machine controller platforms is how open and app-based the mostadvanced of them have become. Nowadays,
software development accounts for more

GO TO MACHINEDESIGN.COM

29

Machine Control

that they need or use any open-source
software. They can use software they
developed themselves on the open platform and use their expert automation andcontrols knowledge to create machinespecific apps in whatever popular programming language fits their needs.
Leading controller manufacturers suchas Bosch Rexroth are even creating “appstores” where compatible apps for specialized machine functions, such as visioninspections systems or predictive maintenance tools developed by companies thatspecialize in that kind of software, can be
downloaded for use—a further exampleof the smartphone model.
2. Hardware. The performance
demands placed on this new generationof controllers requires top-notch hardware. There are controller providers who
are launching Linux-based multicore
processors with the speed and sophistication to support the most demanding
requirements.
Multicore processors provide a criticaladvantage in the app-driven architecture:
Controllers are now being asked to handle
a much wider range of functions simultaneous to the core automation, I/O andmotion sequence control of the machine.
No matter how powerful, a single processor handling 64 axes of deterministic

Some controller suppliers offer a wide range of controller
options. Bosch Rexroth’s ctrlX CORE control can be deployed
as a standard cabinet-mounted controller, either as part of anindustrial PC or in a distributed, drive-based controller solution.
(Bosch Rexroth)motion control as well as supporting datacollection and other app functions is likely
to bog down.
With a multicore processor, one corecan be dedicated just to machine control, while another core supports leading-edge apps like machine learning or
database maintenance. The use of Linux
as the foundation for the operating system makes sense because it is a proven,open-source platform that has millionsof developers updating and enhancing
its capabilities.
There are versions of Linux that havebeen developed to support real-time,
high-speed processing in other applications and have demonstrated reliable,robust performance, making it eminently
suitable for use in the most demanding
automation applications in combination
with the multicore processor architecture.
3. Connectivity. The need for open
and fast communications capabilities isevery bit as important as the advances insoftware architecture and hardware performance. The automation industry has

made great
strides toward
the use ofhigh-speed,
Ethernet-based
bus architectures that promise greater
openness and interoperability.
The newest controllers are rapidly
promoting support for the EtherCAT
protocol, which is being adopted as a defacto standard bus in demanding industries such as semiconductor fabrication.
EtherCAT also has the advantage of being
more motion-centric, a valuable asset for
automation applications.
However, it’s important to assess whether a controller line is open to supporting
other popular protocols such as Sercos,
EtherNet/IP or PROFINET. In addition,
there is growing support for emerging
protocols such as OPC-UA and TimeSensitive Networking (TSN); machine
controllers equipped with an open architecture to support these options besides
EtherCAT can provide a valuable, futureproof solution.

There are significant advantages to selecting a machine controller that’s part of a larger automation portfolio, like Bosch Rexroth’s ctrlX
AUTOMATION platform. Such systems are engineered to communicate and work efficiently. (Bosch Rexroth)30

JUNE 2021

MACHINE DESIGN4. Stable and scalable. In the past, controller portfolios would often be restrictive
in how scalable they were. To use that
platform across the entire machine, automation OEMs were sometimes forced to
select controllers with more features andpower than a given machine axis or setof axes needed.
Smart scalability is a key advantageof the new generation of open machine
controllers, with base platforms that canbe scaled up with additional app functionality as needed. Instead of having dozens or hundreds of different controllers
with specific functionality determined byhardware, the core architecture lets theautomation OEM scale as needed.
Many of the leading-edge controllers
provide powerful tools to let the OEM
periodically access the controller’s core
to provide software updates, patches andrevisions—exactly the same way mostmajor business applications and PC programs are supported.

In addition, some controller suppliers
offer a wider range of controller options.
A single control can be deployed as astandard cabinet-mounted controller
as part of an industrial PC or in a
distributed, drive-based controller
solution. The same control, with thesame OS and interfaces, can even makeit possible to implement hybrid solutions
combining drive-integrated and cabinetbased controller platforms on a single
machine, without requiring specialized
knowledge or different programming
capabilities.
5. The total automation platform.
While the industry has plenty of companies that focus almost exclusively on
supplying PLCs or motion control drives,
there are significant advantages to selecting a machine controller that is part of alarger automation portfolio, all designed
and engineered to communicate and work
together with the highest degree of efficiency and versatility. Key elements of a 

complete automation platform, including drives, HMIs, I/O and programming
platforms that share common hardware,
firmware and software, can significantly
simplify and save engineering time andresources.
In these total platforms, system functions seamlessly complement each otherand can also be extended by apps andthird-party hardware and software thanks
to the absolute openness of the system.
Superior connectivity is supported with
virtually all relevant automation protocols,
as well as offering freedom in the choice ofdevelopment environment and programming language.
The “new” machine controller,
responding to the needs of Industry 4.0,
will deliver the openness, app-driven easeof use and flexibility that will soon make itpossible for automation builders to thinkof their PLC like a smartphone for automation instead of a component destinedfor obsolescence.

Small And Mighty
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Medical Design
REHANA BEGG | Senior Editor

A lattice sample.

A 3D printing company
uses its lattice technology
to help resolve thenational shortage ofnasopharyngeal testingswabs during the
pandemic.
AT A GLANCE:• A national shortage ofnasopharyngeal testingswabs motivated the additive
manufacturing community
to demonstrate its ability “todesign fast, trade fast and put it
into production very fast.”• Hardik Kabaria,
director of software
engineering, Carbon,
developed a viableswab prototype
within a couple ofhours.
• Carbon Design
Engine, a lattice design
generator, is being democratized
so users can pay back throughfeedback.

32

M

anufacturing disruptions due to stay-athome orders last year
exposed weaknesses
in the supply chain that brought manufacturing to a standstill. In the middle ofthe mayhem, manufacturing communities
banded together to bridge gaps in resilience strategies. Some would turn to additive manufacturing for tactical measuresin meeting supply chain resilience.
Consider the nasopharyngeal swab
shortage. Consisting of a plastic shaft
and a swab head that is typically covered
with an absorbing material such as cotton,polyester or nylon, these narrow sticks
were in short supply and held up coronavirus testing. It would take both ingenuity
and the experience of working with latticetechnology to propel a new swab design
to market and remedy the scarcity.
“In 3D printing we always think about
different ways that the technology we havecan benefit not just the society, but help
people create parts at the right time, whenit’s needed,” said Hardik Kabaria, directorof software engineering for the 3D printing technology company Carbon.
But it wasn’t until the news of the swab
shortage was in circulation that the 3D
community jumped in, acknowledged

Kabaria, who viewed the situation as achallenge that 3D printing technology
should be able to solve. “This is what wehave imagined our technology to be usefulfor,” he said.
The nasal swab was not an item 3Dtechnology would conventionally print,
pointed out Kabaria, because they are relatively cheap and easy to manufacture by
conventional methods. The 3D printing
intervention was needed, he said, because“the supply chain broke.”
For Kabaria, the medical device shortage created the “right problem statement”
and was an incentive for the additive manufacturing community to demonstratethat it was able “to design fast, trade fastand put it into production very fast.”
At a conceptual level, Kabaria was motivated to apply his knowledge and the technology Carbon had developed. And oncea directive from higher up landed in his
inbox, it was all he needed to go ahead andlook up how swabs are designed, figureout what it is made of and to consider
whether Carbon’s lattice design concept
could be applied.
Lattice Design

Additive manufacturers use lattice
structures—two or three-dimensional

JUNE 2021

MACHINE DESIGN

micro-architectures made up of nodes
and struts—to design products. They areused across the body of an object andhave been used across the 3D printing
domain for achieving mechanical stability or stiffness. Lattice design offers
the advantage of reducing weight while
retaining structural integrity, as well as
an ability to defy the constraints of traditional manufacturing, often in favorof higher-performing products withexcellent shock absorption and impact
protection.
The use of lattice design isn’t new. Look
to civil engineering for historical examples, where support systems for bridges
are based on uninterrupted, crisscrossed
diagonals that form overlapping loadbearing triangles, known as trusses.
Until now, pointed out Kabaria, lattice design has not been used widely, orat a mesoscale, in a way that it might beconventionally associated with helmets,
saddles, shoes or even swabs. “However, 3D printing is a backbone that canenable it,” he asserted. Kabaria’s doctoral
research in mechanics and computation at
Stanford University was directed towardbuilding a robust, efficient and automaticmesh generation tool for two- and threedimensional geometries.
Carbon’s Digital Light Synthesis (DLS)
technology, for instance, is used in bicycle
saddles. It enables the saddle to reboundquickly, giving riders the experience of
having a suspension built into the saddle. The lattice can achieve a mechanicalresponse—which is not only different, as
Kabaria explained, but more superior than
traditional foam applications.
Swab Test“Using lattice design concepts, we could
create a cage of lattice, such that whenever the swab is inside the nasal cavity,
one may rotate it and it would be able
to capture the biological sample that isneeded,” said Kabaria.
Not only would he be able to put his
theory to the test using Carbon’s Design
Engine computational design software,
but once the design and performancerequirements of a medical swab wereapplied to the program, he was able todeliver a viable design within two hours.
His team printed a prototype that sameday. “This tells you how fast the cycle canbe, from a product conceptualization tochoosing the material and printing it on a
printer the same day,” Kabaria said.
Over the course of the following three
weeks Carbon’s design team, in consultation with its medical devices partner Resolution Medical—an FDA-registered invitro diagnostic and medical device manufacturer—would iterate the design. The
finalized, colorless Resolution Medical
Swab had a unique dome tip and consistsof a soft lattice cage around a flexible helical core, which allows the swab to moreeasily conform to the organic pathway of
the nasal cavity. It was constructed from
KeySplint Soft Clear material.
The first shipments of the swabs were
submitted for clinical assessment at
Stanford University and Beth Israel and
Deaconess Medical Center in Boston toprove that the lattice-based design was
performing at the same level as the golden
standard, said Kabaria.
Accelerating Design Cycles

Kabaria would never have guessedthat the swab would garner his employer
a spot on the Top 10 list of Fast Company’s“Most Innovative Companies” (March/
April 2021).

Resolution Medical Lattice Swabs.

GO TO MACHINEDESIGN.COM

33

3-D Printed Nasal Swab

Nor could he have imagined that hewould engineer a nasal swab to help stema national medical supply shortage during
the pandemic. Resolution Medical wasable to scale capacity to print more than
1 million swabs per week using Carbon’s
printers.
“It shows that if you can print locallyand design very fast, even a large clinicalstudy can happen in a very short amountof time,” reflected Kabaria. “Of course,
there was pressure from the shortage, butthat allowed Resolution Medical and Carbon to put this swab in the market forclinical institutions to purchase and use,along with the right clinical data within
20 days.”
Earlier this year, Carbon announced
that its subscribers would have access to
its Carbon Design Engine software. The
system automates the process of creating
performance-oriented lattices—a timesaver for design engineers.
This step toward democratizing thesoftware, Kabaria said, will help relieve
a bottleneck. Carbon’s team of mechanicalengineers uses the tool to help customers.
However, they are limited by the numberof queries they can assist at any given time.
Making the software available to companies that own Carbon printers will allow
customers to explore their own ideas.
The software application can beaccessed through the cloud. It is built
around five structures, each offering
unique mechanical behaviors, such as
the ability to plot for stiffness-to-mass
ratio, long stress plateau for memory
foam or nonlinear mechanical response.
The application also helps users selectparameters based on volume production.
Once the user uploads a part, the platform
automatically populates the lattice, whileat the same time taking on the burden of
the algorithmic work and computational
geometry.
Working with CCM, an official licensee of on-ice hockey equipment for the
National Hockey League (NHL), Carbon
used Design Engine to produce custom
Super Tacks X helmets. “Each helmet is
unique to the player who wears the hel-

34

The Super Tacks X helmet, crafted with the Carbon DLS 3D printing process, replaces
foam padding with the NEST Tech lattice for increased breathability, comfort andprotection. (Carbon)“

We used thesame tool toautomatically generate
a design specific to aparticular head shape,
without any humanintervention.”met,” said Kabaria. “We used the same tool
to automatically generate a design specificto a particular head shape, without any
human intervention.”
Similarly, opening the platform todesign engineers in Carbon’s ecosystem
will enable users to find new applications
that can be taken from design to production, said Kabaria. It allows users to beinnovative while being collaborative andproviding feedback.
For Kabaria, therein lies the lightbulb
moment. The value for Carbon is the

Carboninsight gained from design engineers.
The idea is to keep adding computational power to generate complex shapes
quickly across different industries. “Fromconsumer products, automotive components to medical devices,” said Kabaria,“the universe of parts that we can affectis pretty wide.”
WATCH THE Machine Design Insider
Interview with Ellen Kullman, CEO
of Carbon, at https://machinedesign.
com/21163484.

JUNE 2021

MACHINE DESIGN

Motion Systems
THANIEL SMITH | Manager of Application Engineering, Thomson Industries, Inc.
IAN MILLER | National Services Business Development Manager, Motion Canada

Understanding ball screw potential and limitations.

The ability to operate consistently
at higher speeds is why motion
system designers often specifyball screws over lead screws.
However, ball screws have speed limitations of their own. Understanding thosewill help you optimize ball screw assembly performance in applications ranging
from small laboratory fluid pumps to large
overhead gantries and high-performancemachinery.
Ball Screw Basics

A ball screw assembly consists of ascrew and a nut with recirculating ballbearings. The connection between thescrew and the nut is made by ball bearings, which roll in the matching ball forms
within the nut and screw shaft. This distributes forces over many bearings, givinga relatively low load per ball and a low
coefficient of friction, contributing tohigher speed operation capability (Fig. 1).
The screw and nut usually have uniquemaximum RPM limits, so selecting
the most effective ball screw assembly
requires attention to both.
Ball Screw Design Features

Primary screw shaft design features
impacting maximum RPM are end
mounting, screw lead and screw diameter.
Every ball screw has a natural frequency
at which it vibrates excessively, which is
known as its critical speed. When the

1. Ball screws have a low coefficient of friction because the load is distributed acrossmultiple bearings, which recirculate while the shaft turns. (Thomson)

application speed aligns with the critical
speed, the screw vibrates in harmony (Fig.
2). Imbalances inherent in the screw thenresonate with it, causing excessive bending,bowing, vibration and, eventually, failure.
End mounting. Mounting options
include fixing it at one end in a thrust bearing, supporting it at both ends in floating
bearings, fixing it at one end while supporting it at the other end in a floating bearing,or fixing it at both ends in thrust bearings.
The highest speeds are attainable when ballscrews are fixed at both ends. The fixedends resist bending moment loads so theball screw tries to remain perpendicular tothe planes of the support bearings.

However, fixing at both ends can be
more expensive and difficult to installthan the other mounting options. When
fixed at both ends, the distance between
support blocks is not adjustable andcan make aligning the mounting holesa challenge.
Screw lead. Higher leads will increase
the linear speed by moving the nut
along the screw faster, assuming constant input speed. When comparing twoscrews with different leads of a constant linear speed, the higher lead will
decrease the input motor speed. Higher
leads do, however, increase the torquerequired to turn the screws.

2. The screw shaft can vibrate at high RPM. (Thomson)

36

JUNE 2021

MACHINE DESIGN3. A comparison of ball return systems (from left to right): internal, button and external. (Thomson)

Screw diameter. Larger-diameterscrews increase the load capacity and the
maximum RPM rating. Smaller diameterlong screws will have a lower RPM. With
the same lead, the larger diameter screw
will have a higher speed rating.
What Limits Maximum RPM?

The ball nut maximum RPM is limitedby the speed of the ball bearings circulating through the ball nut. Exceeding theball nut maximum RPM may result in permanent damage to the ball re-circulation
components. The ball bearings may breakout of or jam the return system, potentiallyresulting in the unit’s complete failure.
There are three major types of returns
systems: internal, button and external (Fig.
3). The purpose of the returns is to provide
re-circulation of the ball bearings in thenut. The return system design affects thenut’s speed limitations.
The external return systems typicallyutilize a small finger that extends into
the ball groove to deflect the ball into thereturn path. At high speeds, this finger
can flex from the ball bearings hitting it
and eventually break off. The button andinternal designs are generally more robust
and typically can operate at higher speeds
than the external return system.
Optimized for Speed

A system optimized for speed above all
else would likely require the following:• Fixed end supports for the screw
assembly• Higher leads to increase linear speed• Large-diameter screws to increase
the load capacity and the RPM rating• Internal return systems for the ballnuts

GO TO MACHINEDESIGN.COM

The maximum speed for a 1-in. diameter screw like this one will vary greatly depending on
length—ranging from 2,938 RPM at 36 in. and 184 RPM at 144 in. (rated at 80% of its critical
speed, simple supports). Values can be referenced in the Machinery Handbook. (Motion)T

he ball nut maximum RPM islimited by the speed of theball bearings circulating
through the ball nut.
However, many other factors comeinto play, including load characteristics,
positional accuracy, repeatability, required
life expectancy, dimensional constraints,
input power requirements, environmental
conditions and available budget.
The impact of most factors affecting
speed can be calculated. Ball screw manufacturers typically recommend maximum
speeds for their products and provide toolsthat will help you precisely measure thephysical tradeoffs.

IAN MILLER, P. Eng. is national services
business development manager of Motion
Canada. He has more than a decade of hydraulic and electrical experience in the field,
including system design, troubleshooting,on-site installations and technical training/support.
THANIEL SMITH is manager of application engineering, Thomson Industries, Inc.
He is responsible for managing the North
American application engineering team.
Smith earned his Bachelor of Science in mechanical engineering from Brigham Young
University and has worked at Thomson for
21 years.
MORE INFORMATION ABOUT Motion Industries can be found at www.motion.com/
machinedesign.

37Medical Design
MATTHEW DURACK | General Manager and VP of Engineering, Tekmill
SEBASTIAN BARAN | Sales Engineer, Festo

The updated machine canhandle 100,000 tests perday.

W

hen the COVID-19
pandemic struck lastyear, the demand forfast and accurate
testing of patients’ nasal-swab samples
skyrocketed, with some labs going fromneeding 10,000 swabs checked daily tomore than 100,000. To meet that risingdemand, engineers at Tekmill and Festoredesigned one of Tekmill’s automatedrobotic machines that handles 50-ml test
tubes of agricultural samples and places
them in a rack while they waited to betested. They coupled the updated machinewith a new approach to testing to come up
with a system that could handle 100,000
samples per day.
Up until this time, a patient’s nasal swab
would be sealed in a test tube for processing at a screening laboratory, where
it underwent the Center for Disease Control’s (CDC) protocols for reverse transcription quantitative polymerase chain
reaction (RT-qPCR) testing. At the lab,
the test tube’s cap is removed, reagentsare added, and the samples undergo aseries of lab processes that determine
whether the swab is positive or negative
for COVID-19.
Designers knew the one-sample-pertest-tube approach needed to be changed
to get to high-volume testing. Not only
does the one-swab approach create amountain of backlog when demandrises so steeply, it eats up incredible
amounts of consumables—reagent, test
tubes and caps—which are costly and

38

The Tekmill CTF-COV was designed to speed testing of patients’ samples to check for
COVID-19.

A test tube is positioned for having its cap removed. Several COVID-19 test swabs are in thetube, part of the pool processing approach.

JUNE 2021

MACHINE DESIGN

quickly became hard to come by in suchlarge volumes.
To sidestep these hurdles, labs adopted
pool processing. In this approach swabs
from several patients are placed in asingle test tube and processed as a single
diagnostic sample. If the multi-swab test
tube—say, a group of 10 people—is negative, no action is required and they are allcounted as negative. If, on the other hand,
the tube tests positive, then only those 10
individuals need to go through the more
expensive but useful rapid testing that
identifies positive results in under 30 min.

H

andling
10,000test tubes per day issignificantly easier thanhandling 100,000 tubes,
but it is still a challenge
for labs. To streamline
the process further,
automation and robotics
needed to be applied.

Using the example of 10 swabs per test
tube, 10,000 tubes can be analyzed perday, effectively screening 100,000 people
for COVID-19 daily. Pool processing also
cuts the use of consumables by about 90%.
Handling 10,000 test tubes per day is significantly easier than handling 100,000
tubes, but it is still a challenge for labs. To
streamline the process further, automation
and robotics needed to be applied. This iswhere Tekmill’s and Festo’s expertise wasbrought to bear.
Tekmill, a contract design and fabrication company located at the University
of Illinois in Research Park, had alreadydeveloped an automated 50-ml conicalcentrifuge tube handler for decapping,
adding reagent, recapping and placing
the 50-ml tubes into a standard testtube rack of 24 tubes. It freed up skilled

lab workers who would otherwise spend
hours manually taking caps off, pipetting
reagent, placing caps back on and thenracking thousands of 50-ml tubes.
The machine was reliable and fast,with a throughput of over five tubes
per minute. It delivered reagents withan accuracy of ±3% error for volumes
less than 3 ml. The device included atemperature-controlled reagent compartment, quick change-and-clean features, aperistaltic-based pump for sterility andaccuracy, and a display screen-based userinterface.

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39

Robot-Based COVID Testing

The Festo EXCM mini-gantry robot’s gripper (background) is about to lower itself and grip
the cap as the test tube is rotated. The small footprint of the gantry made it well suited for
ensuring the overall machine was compact for lab use.

The automated machine was compact
and could be easily wheeled to where it
was needed. It was also flexible, thanks to
the EXCM mini-gantry robot from Festo,
a global company that designs electricaland pneumatic automation equipment.

The gantry robot raised the cap as thetest tube was spun, lowered the cap as thetube rotated the opposite way after filling
and then placed the test tube in the rack.
The robot could easily be reprogramed
as conditions changed.

The first step in pooled testing is
decapping the tubes and accurately
adding reagent. The Tekmill machine
could already do this, but not at thetargeted rate of 10,000 tubes per day.
With support from Festo, Tekmill electrical and mechanical engineers began a
rapid redesign to revamp the machine’s
robotic gantry.
One of the first tasks was to redesign the cap handling. In the originalmachine, a test tube was rotated while
the Z-axis on the mini-gantry robot
used its parallel gripper to hold the cap
as it came off the test tube, and later
held and lowered it as the tube swiveledclosed. After the redesign, the robot nolonger removed the cap, added reagentsand then put the cap back on. Instead,
it removed the cap, dropped it into a
newly added disposal bin and thenadded reagent.
Although machine vision and barcode
reading and tracking were not required

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JUNE 2021

MACHINE DESIGNThe gantry robot provides the speed and precision needed tohandle 10,000 test tubes per day.

on the original redesign of the machine, Tekmill engineers
wisely planned for this upgrade should it ever be needed. This
pre-planning saved time and effort when a vision subsystemand barcode reading were added to the pooled testing machine
to track samples and lower the risk of errors. Fluid handlingin the original machine migrated seamlessly to the new one,
including the benefits of keeping the reagent sterile by using aperistaltic pump.

T

ake a look at Tekmill’s robotic
sample tube handler in action:
https://youtu.be/89b-AUBl8F4During testing of the new machine, dubbed the COF-CTV,
it was noted that some tubes arriving to be capped were overtorqued to the point that the caps could not be removed without
damaging them. Tekmill installed torque sensors to identify
over-torquing. When offending tubes are encountered, the mini
gantry moves them to a bin designated for manual opening. This
preserves the integrity of the 10 samples in the offending tube
while maintaining the speed of the other tubes through the unit.
Tekmill engineers also increased the per-load capacity to morethan 400 test tubes, which means it only needs to be loaded
once per hour, an efficient use of lab staff. The flexibility of
the EXCM mini-gantry robot made this transition in speed
and quantity a matter of programming. Overall, the upgrades
increased throughput from old to new machine by about 20%.
Running around the clock, each CTF-COV tube-handler
makes it possible to process 100,000 COVID-19 tests per day
using pool testing, a clear demonstration of the power of robotics
to increase throughput in today’s automated labs.
Take a look at Tekmill’s robotic sample tube handler in action
here: https://youtu.be/89b-AUBl8F4.

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41

Robotics

Alexander Oganezov | Dreamstime

ASSAF EDEN | Director of Product Management, Bright Machines

Machine vision is growing at an astronomical rate—and transforming manufacturing in
the process.

Machine vision as a category is growing rapidly; the 3D machinev i s i on m ar ke t i s
expected to double in size during thenext six years, and today, the technology is a vital component of most modern
automation solutions.
There are many factors contributing to
the increased adoption of this technology
in a manufacturing context. First, demand
for automation solutions in general has
increased as manufacturers continue to42grapple with labor shortages. Second, thecost has decreased dramatically—whencameras, sensors, robotics and processing
power are inexpensive, they can be applied
to more solutions.
Technology performance also is
increasing, giving machine vision systems the ability to process large amounts
of information in a fraction of a second.
Finally, advanced artificial intelligenceand machine learning algorithms aremaking the data collected from machine
vision even more valuable, and manu-

facturers are realizing the power of thoseinsights.
But what exactly is machine vision,and how can it be incorporated into
automation solutions to produce better
outcomes?
Giving Robots Eyes and a Brain

A vision system typically includes aseries of disparate parts, including cameras, lenses, lighting sources, robotic
components, processing computers andapplication-specific software.

JUNE 2021

MACHINE DESIGNThe cameras are of course the “eyes”
in this system—there are many types ofcameras in use for machine vision, andeach camera can be assigned for different application needs. There are also differences in how cameras are configured
within an automation solution.
Static cameras are placed in a fixed
position, have a more bird’s-eye view ofthe process unfolding below and can beused in scenarios where speed is imperative. There are also dynamic cameras,
which are positioned on the end of therobot arm and much closer to the process,thereby delivering higher accuracy.
Computing power is also an important
aspect of the vision system—essentially,
the “brain” that helps the eyes conduct
their work. The computation resources
required for machine vision that leveragemachine learning algorithms will be different than those needed for traditional
machine vision applications. Many companies offer software libraries for implementing vision capabilities.
Some capabilities are designed for
application users; others are intended foruse by software programmers. Regardless, it’s software that gives machine vision
advanced capabilities that have dramatic
impact for manufacturers, with programs
to control tasks and the ability to feedback
valuable insights from the line.
Machine Vision Applications

The concept of replacing basic humancapabilities with a vision-guided solution
is gaining steam, as vision for assemblylines can be used in an increasing range
of applications and processes.
A typical “electronics in a box” assembly process provides one example. This is
a product category that spans many shapes
and sizes and is relevant across a numberof industries (including but not limited
to medical equipment, power tools andhome appliances). The assembly process
for these hardware components consistsof placing the electronics, such as a circuitboard, into the housing, or box.
Many of the assembly steps involved inelectronics in a box assembly can benefit

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from the use of machine vision becauseof the precision required.
Inspection. Machine vision can beused to inspect all top and bottom covercomponents as they enter the assembly
line, looking for defects such as cracks
in the metal—if these components arein poor condition, it can lead to quality issues for the assembled unit. Withmachine vision, cracks are detected
quickly, and if they are larger than aspecified size, the component is automatically rejected. In addition to cracks,
color variations can also be inspected; acolor camera can identify discoloration
damages and reject faulty units.
Product tracking. Required in theautomotive and healthcare industries,
product tracking is used during the entire
manufacturing process. So usually, thefirst vision task for circuit boards during the assembly processes is to read the
product label, serial number or barcode.
The product label identifies the specificunit so it can then be tracked throughout
the entire assembly process.
The label location can be pre-defined
and the vision system is used to read thelabel and communicate its findings toother factory systems. Applying labels is
a common requirement in assembly lines
and another perfect use case for machine
vision, which can detect any obstacles on
the surface and ensure perfect placement.
Installation. Adding components toa circuit board can require vision capabilities both for quality control and for
positioning. As an example, for a varistor that needs to be added to a circuitboard, machine vision would first inspect
the varistor to verify that both legs are
straight and not damaged. Vision canalso inspect the varistor’s identification
to confirm it’s the correct part, and thevaristor’s orientation for proper assemblyon the circuit board.
Finally, vision capabilities can identify
the correct location on the circuit board
where the varistor will be installed andsoldered in place. During the soldering
process, vision is used to monitor conditions such as the wetting area, lead

lengths, solder balls, contact angles andsolder fill.
Machine vision also aids in similar
processes that require consistency andprecision, like thermal paste dispensation
application and metal shield insertion.
Dispensing sealant is another example;
a vision system can reference the expected
path and compare it to the achieved result.
Final assembly. Fastening methods,
such as screwdriving, also are frequently
used to assemble products. This process
can be more consistent with a visionsystem. Machine vision can be used to
identify the screw hole and to navigate therobot with the screwdriver accurately tothe specified location. Once complete, avision system can verify that the screw has
been fastened properly. If there is morethan one screw, the vision system can beused to navigate to additional holes andimplement the screwing process as manytimes as needed.
Machine vision can also be useful incomponent feeding, guiding detailed part
assembly, part sorting and closed-loop
activities such as DIMM card insertion
using force feedback control (any process
where human inputs are not needed, andthe system is designed to achieve known
outcomes).
The ROI of Machine Vision

To achieve next-generation automationand fully realize the benefits of the technology, machine vision on an assemblyline isn’t just “nice to have”—it’s vital. This
technology enables diverse capabilities forinspection, robot navigation and quality
control, and the use cases for machine
vision are continuing to expand in scopeand complexity as the technology continues to evolve.
That translates to tremendous potential for manufacturers, as vision solutions for automated lines can improve
production capacity, production stability
and production yield. As both the hardware and the algorithms involved withmachine vision continue to improve,so does the ROI for manufacturers who
invest in these solutions.

43

Produced by THE WORLDFOLIO

How do Japan’s machine tools and material manufacturers remain ahead of the competition?

Leader Roundtable
What sets you apart fromyour competitors?

What is the main challenge/goalfor your company or industry?

YOSHIHARU INABA,
Chairman,
FANUC“We are the pioneers of automation androbotization for manufacturing sites.
Throughout our years of operation, we havedeveloped a unique set of skills based on
experience. This accumulation of expertise
allows us to advance and progress in a toughcompetitive environment. Our technicalexpertise is coupled with the preciseness ofJapanese manufacturing.”“Relying on automation processes and robots will
be one of the solutions to answer our decreasing
workforce and aging population. However, thissolution is clearly not limited to Japan for it will
be applicable to the entire world. Our industry is
focused on developing robots that can help humanbeings. The idea is to have machines, robots andsuch, do the heavy and monotonous labor, while
humans focus on precise and unique work.”

NAOTAKA KONDO,
President,
Toyo Tanso Co., Ltd.

“Our products have attracted attention because
we can express the full potential of isotropic
graphite. Our graphite has many applications
because of its excellent properties: it is stronger
than conventional graphite; resistant to extreme
temperatures, has excellent electrical conductivity;
it is also stable and lightweight. One of the
products we developed is CNovel, which is used
for many kinds of batteries, particularly fuel cells.”“With technological advances, semiconductors
are now used for the development of nano-scale
devices. Consequently, the demand for accuracy
and precision has drastically increased, andmachining processes played a central role inachieving this level of precision. At TOYO TANSO,
we supply materials critical to the production
and adequate-functioning of these nextgeneration machining systems.”

AKIHIRO NIKKAKU,
President,
Toray Industries INC.

“We are continuously striving to improve our carbonmCFSUFDIOPMPHJFTCZQSPEVDJOHNPSFSFTJMJFOUBOE
TUSPOHFSNBUFSJBM"NPOHBMMUIFmSNTJOUIFXPSME 
I think Toray is the one that has most continued
UPQVSTVFFYDFMMFODFJODBSCPOmCFSUFDIOPMPHZ
Various emerging carbon manufacturers are able
to produce materials at the level of T700 today,
however, we have already gone beyond that andsuccessfully developed the ‘T1100’ in 2014.”

w8IFOJUDPNFTUPDBSCPOmCSFT UIFZXFSFmSTU
developed by Professor Shindo, in 1961, and we werealso involved in that process. It was only in 1971 that
XFXFSFBCMFUPFGGFDUJWFMZQSPEVDFDBSCPOmCFS
material. We’ve taken around 60 years to develop
this technology and it is still undergoing intensive
research today. Toray’s R&D efforts can be crystallized
in the philosophy of ‘never giving up,’ ‘never feelingdefeated’ and persistently pursuing R&D.”

HIROJI GOTO,
President & CEO,NS TOOL“We were the pioneer of the smallest end millavailable on the market with a size of 0.01mm.
We focus on putting efforts into our highprecision machines in creating miniaturizedcomponents at a nano level, where othercompanies do not have the capability of doing so– this is our competitive advantage. We have highexpectations and put a lot of effort and investment
into pursuing research and development.”“We want to contribute to even bigger
EFWFMPQNFOUJOUIJTmFMEBOEDPOUJOVFUPCFUIF
pioneer in high-precision measurements. We
invested 1.4 billion yen to build our new R&D
facilities to further develop our technology. The
building itself is a vibration proof building thatis designed to support the R&D environment formaking high-precision tools, as you need to ensurethat there are no external vibration factors.”

YOSHIO WATANABE,
President,
YAMAWA“We have engineers who design anddevelop our machines and engineers who
operate the software. This is to ensure wehave what is needed to develop the bestproduction system to create high-precisionand high-quality products. Furthermore, ourmachines are researched and developed toperform well in producing at a fast rate.”“Our market is focusing deeply on high-precision
processing only. In that case, we believe that ourcompany can strive further in the high-precisionindustry as our strategy moving forward.
Infrastructure is getting bigger each day, andwe believe that it has high potential for growth.
Our company is competent in supplying tools andequipment for infrastructure.”

Produced by THE WORLDFOLIONS TOOL: micro-machining for
macro impact in hi-tech fields
Q Crafting tomorrow’s industries

by pioneering miniaturization in
high-precision machining.
With increasing demands for higherquality, lighter-weight and miniaturizedcomponents in automotives, electronics and ICT,
many top companies turnto the high-precision processing technology developed by NS TOOL.
In the face of increasing
competition from China,
NS TOOL has set itself apart by focusing
on high-quality and following the trendsof miniaturization, which led the company
to develop the world’s smallest end mill,
at a size of 0.01mm, back in 2005. Since
its launch, this cutting tool has increased
steadily in terms of numbers of users,

which include high-end manufacturersof smartphones and sensors.
“Our principle and philosophy strongly
highlight the importance of making thesekinds of tools and machines a reality, so
we can make it possible for industry to

Micro milling on a human hair

move further towards miniaturization,”
explains president, Hiroji Goto.
NS TOOL sees ample opportunity in developing end mills that will be used in the
manufacture of the latest technologies,
such as electronic vehicles, 5G, advanced

NS TOOL Core Linesemi-conductors and sensor technologies
for AI and IoT. The company has thus
recently made a JPY 1.3bn
investment in its R&D facilities to further develop
its technologies.
“We are focusing on our
high-precision machines tocreate miniaturized components at a micro level,” says
Mr. Goto. “We aim to contribute to even bigHFSEFWFMPQNFOUJOUIJTmFMEBOEDPOUJOVF
as the pioneer in high-precision machining.”

www.ns-tool.com/en/

Produced by THE WORLDFOLIO

Leading Japanese Tier-2 supplier makes
decisive push into EV components
QLeveraging its long-standing experience working with major brands,
such as AISIN, ADVICS, BOSCH and HITACHI, Kurota is developing
state-of-the-art components for electronic and hybrid vehicles.
With almost a century of histal concerns and regulations
tory in innovation, Kurota bespurring demand for greener
gan its engagement with thevehicles, Kurota has put forJapanese automobile industry
ward a range of components
in its nascent post-war period.
suited for the hybrid and elecEver since then, the company
tric vehicles (EVs) that will be
has progressed in line with the
UIFQSPNJOFOUmYUVSFTPOUIF
advancements of the automoroads of tomorrow.
TOSHIHIRO KURODA,
tive industry, supplying highi*OUIFmFMEPGCSBLFDPNQPPresident, KUROTA
performing aluminium brakenents, we can still supply ourpistons and engine components to leading FYJTUJOH QSPEVDUT UP &7 NBLFST BOE UIFJapanese, European and American clients. production of our aluminium brake pistons
Today, as the industry undergoes its most for EVs and hybrids has increased in recent
profound transformation with environmen- ZFBST wFYQMBJOTQSFTJEFOU 5PTIJIJSP,VSPEB“A new area of product development isin electric pumps for EVs. We are currently
producing shafts for electric pumps. As they
are used in the cooling system of inverters,
these components require a high level of accuracy and reliability. With the EV era coming
Aluminium brake pistons

Kyowa FineTech: high-precision
processing technologies
that meet ourcustomer’s demands

TPPOFSUIBOFYQFDUFE XFBSFFYQMPSJOHWBSJPVTPQUJPOT GPDVTJOHPOOFXmFMETXIFSFXF
can utilize our strength and technologies.”
Responding to the rapidly changing
demands of the industry will remain key
for Kurota moving forward. As it looks
towards its 100th anniversary in 2025,
the company’s main goal is to further
become a reliable manufacturer on the
global market as a supplier of high-quality
automotive parts. “Thanks to our status
as a tier two supplier trusted by brandnames, including AISIN, ADVICS, BOSCH
and HITACHI, we are in a good position toachieve that goal,” concludes Mr. Kuroda.

www.kurota.com/e/High-precision gear pump
and applying device foradhesive of automobile
components

Q 7KHßUPÖVHFRIULHQGO\VROXWLRQIRUOLWKLXPEDWWHULHVKDVEHHQdeveloped in reaction to market needs, providing a critical edge tocompete in new sectors of industry.
As the trends of global manuFYQMBJOTUIFDPNQBOZTQSFTJEFOU 
facturing evolve – an industry
Muneyuki Hashimoto. “Lithium
which is perpetually tasked
batteries are one issue that wewith innovating to meet sohave successfully managed tociety’s modern challenges –overcome. This type of battery
Japan and its army of SMEs
has holes that leak solvents asthat characterize the sector ispollutants. We came up with aleading from the front.
pioneering solution in making
Kyowa FineTech, which man- MUNEYUKI
solvent adsorption equipment
ufactures machines based on HASHIMOTO,
to be able to inspect and adsorb
President,mOEJOHTPMVUJPOTUPUIFXPSMET Kyowa FineTechthe solvents to create a more ecoenvironmental problems, is one
friendly environment.”
TVDImOFFYBNQMFi8FTUBSUPGGCZLOPXAn increasing utilization of batteries ining what the problem is in the market and manufacturing is for electric vehicles, a rappropose machines to tackle those issues,” JEMZHSPXJOHNBSLFUEFmOFECZUIFOFFE

for sustainability, and so one that Kyowa’s
adsorption equipment is primed for.
“Electric vehicles are a promising trend
in the industry,” says Mr. Hashimoto. “Likemany other industries, the automobile industry needs the utilization of technology.
Therefore, it is a huge opportunity to enter
these markets with our advanced technology,
GPSFYBNQMFPVSIJHIQSFDJTJPOHFBSQVNQ 
and compete in the new sectors of industry.”

www.kyowa-ft.co.jp/en/

Produced by THE WORLDFOLIONISSEI supplies you with technology,
not the locking bolt itself
Q Rolling a low-cost, anti-loosening bolt “PLBv2” at last! This practical and effective bolt does not rely on friction.

TOSHINAKA SHINBUTSU,
President, NISSEI

We might think there are no technical improvements left to be made on a bolt, but
let’s think again: what about the problem ofloosening? It is a fact of mechanical life thatbolts loosen. Many techniques for keeping
bolts tight have appeared. From the point ofview of practical usage, cost effectiveness,and the ability to truly prevent loosening,making better bolts is an old but new problem. Nissei invites you to look at their fresh
solution, PLBv2. PLBv2 (Perfect Lock Bolt,
version 2) relies on double nuts and multiple
threads rolled onto a single shaft.
For fasteners such as bolts, loosening is
the enemy. The need for periodic tightening
and problems arising when bolts need to be
replaced or re-used are common. In the battle against loosening, many solutions havebeen attempted—all, until now, have been
mediocre. Relying on friction to prevent
bolts from loosening is not good enough. A
mechanical solution built into the structureof the bolts is what is needed.
Principle and Features of PLBv2
Here is one mechanical method to protect
against loosening. Roll the lead of eachbolt with two different threads, then add
one nut to follow each thread. Because thelead that the inner nut follows is longer
than the one for the outer nut, when vibration inevitably makes the nuts start torotate loose, the inner nut will be blocked
by the outer nut. This is because the leadfollowed by the outer nut is more closelypacked, and so the outer nut must rotate
more slowly. This is mechanical blocking.

Manufacturing method
A major value of PLBv2, above and beHow to mass produce bolts with two sepa- yond its anti-loosening properties, is practirate and distinct threads? It cannot be done cality in actual use. By tightening the outerreliably by cutting threads into the bolt nut, the inner nut is also tightened. Bothshaft, but it can be done with thread rolling. bolts, one action. With ordinary double nuts,
Nissei, an innovative maker of rolling ma- each nut has to be tightened individually.
chinery located in Yamanashi Prefecture in With PLBv2, the inner nut follows the outer
Japan, has tackled this problem to produce nut naturally. It is like having to fasten only
uniform and reliable bolts that cannot be POFOVUJOTUFBEPGUXP/P1-#WTQFDJmD
loosened by normal
tools are required,vibration: PLBv2.
ordinary tools do
Machines thatthe job. Ease andcould make diespracticality incapable of rollingusage are addiMultiple
Singlea complicated pattional advantages
threads
threadnut
nuttern were not readof PLBv2.
ily available when
The process
we started ourof rolling bolts
Perfect Lock Bolt
with thread rollBig advancement Small advancement
PLBv2 bolt combines by one rotation
by one rotation
project. In 2018,
ing machines isa single thread andwe c o m p l e t e dadvantageous tomultiple threads.
round dies, then inbolt makers. InnBUEJFT EFother, more ordiveloping new technary processes,niques one after
after cold forgthe other. We ening, heat treatvisioned planetary
ment processing
dies as the means
is recommended.
PLBv2 bolt combines a single threadto this end. All in all, and multiple threads. Threading of PLBv2 The same proit has taken 15 years requires specialty dies made by NISSEI.
cesses are applied
to reach the level at The dies can be used on an ordinary thread to PLBv2 withwhich our machines rolling machine. The dies can roll PLBv2 in the same system.
can roll two kinds of one action.
There is no need tothreads—simultabuy new systems
neously—on one anti-loosening bolt.
when you have the license. The threads
can be rolled simultaneously on existing
Can be rolled with your company’s
thread rolling machines, provided they areexisting equipment
FRVJQQFEXJUI1-#WTQFDJmDEJFTNBEF
The anti-loosening bolt that Nissei has de- by Nissei. “Being able to roll these bolts
veloped and named PLBv2 has been tested on machines already in place is a big adand conforms to international standard vantage,” says Shuichi Amano, chief engi*40'PSUIFTQFDJmFEWJCSBUJPODSJ- neer/engineering director at Nissei. “It’s aterion relative residual clamp force of 2000 competitive cost advantage to get a better
cycles, other companies’ products received bolt from existing equipment.”a rating of “acceptable loss of clamp force”,
which in ISO16130 terms means they perform adequately from 40% to, at best,
85% of the time. PLBv2 is rated ISO16130
www.nisseiweb.co.jp/e/index.php“Good self-locking behavior”, meaning percontact: plb_bolt@nisseiweb.co.jp
formance is good 93% of the time.

Produced by THE WORLDFOLIOREAD: custom-made solutions for high-precision
manufacturing
Q A cutting-edge leader, READ uses AI and Big Data to enhance the quality of its products and services.
Amid increasing regional competition in the EFDBEFT 3&"%NBOVGBDUVSFTIJHIQSFDJTJPOmFMEPGQSFDJTJPOQSPDFTTJOH +BQBOFTFDPN QSPDFTTJOH HSJOEJOHBOEDVUUJOHUPPMT)BW
panies will keep a competitive edge through ing gained the highest trust and reputation
a strict adherence to monozukuri +BQBOFTF BNPOHDMJFOUTJO+BQBO UIFDPNQBOZBJNTDSBGUTNBOTIJQ BOE kaizen DPOUJOVPVTJN UPHPHMPCBMBTJUBMTPMPPLTUPQFOFUSBUFOFXQSPWFNFOU QBSUJDVMBSMZJOUIFmFMEPGIJHI JOEVTUSJFT TVDIBTNFEJDBM TFNJDPOEVDUPST QSFDJTJPONBDIJOFSZ XIFSF3&"%
automotive and solar panels.
remains at the cutting edge.
“We utilize and develop our
i+BQBO FYDFMT JO QSFDJTJPOUFDIOPMPHZCBTFEPOUIFBCJMJUZPGNBDIJOFSZ BOE UIBU JT XIFSF
PVS DPNQBOZ UP DSFBUF UIF IBSEUIF TUSFOHUIT PG monozukuri
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and kaizenDPNFUPMJGF wBSHVFTGPSQSPDFTTJOHNBUFSJBMTUIBUBSF
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i*OPVSDBTF XFQSPEVDFPSJHJOBM YOSUKE NABEYA, XF IBWF CFFO GPDVTJOH PO TVDIQSPEVDUT BOE UFDIOPMPHZ UIBU President of READ EJGmDVMU NBUFSJBMT VTFE JO PUIFSPOMZXFBSFBCMFUPNBOVGBDUVSF
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0VSGPDVTEFQFOETPOPVSBCJMJUZUPDPOUJOVF“We would like to improve ourselves
ESBXJOHUIFTUSFOHUITPG monozukuri and UPHFUIFSOPUPOMZXJUIPVSDPOWFOUJPOBMXIBUSPMFXFDBOQSPWJEFUPUIFXPSMEw
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we are willing to provide our technological
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www.read.co.jp/englishver/

Ogura Jewel Industry: more than a century
of experience in jewel processing
Q Ogura’s high-precision micro-machining technology is a cut above
the competition.
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JOEVTUSJBMBQQMJDBUJPOTEVFUPUIFJSFYDFMMFOU
NFDIBOJDBM  PQUJDBM  QIZTJDBM BOE DIFNJDBMQSPQFSUJFT)PXFWFS UIFTFFYUSFNFMZIBSEZFUCSJUUMFNBUFSJBMTDBOCFEJGmDVMUUPDVUBOETIBQF XIJDIJTXIZUIFNPTUIJHIQSFDJTJPONBDIJOFSZBOEUFDIOPMPHZJTSFRVJSFEUPQSPDFTTUIFTFQSFDJPVTKFXFMT=P[YPÄLKIVUKdiamondwheels'PSNPSFUIBOBDFOUVSZ 0HVSB+FXFM
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demanding clients operating in a wide
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drilling process (which is

Coil winding nozzles & Enameling diesVUJMJ[FE BT B XJSF HVJEF GPS &MFDUSJDBM%JTDIBSHF.BDIJOJOH DPBUJOHEJFTGPSNBHOFU XJSFT  BOE OP[[MFT GPS XBUFSKFUT*OSFTQPOTFUPUIFTIJGUJOHUSFOETJODVTUPNFSEFNBOET UIFDPNQBOZBMTPQSPWJEFTUIFSPUBUJOHBYJT CFBSJOH GPS
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www.ogura-indus.co.jp/en/

Produced by THE WORLDFOLIO

Tsukiboshi: “We focus on our people and their mental brilliance,
as well as a monozukuri that is environmentally friendly”
Q In building a strong corporate culture with its employees and in turn providing its automotive customers with high-quality products, Tsukiboshi aims to differentiate itself by engendering strong values of monozukuri and sustainability.

With Japanese companies continuing toface stiff price competition from elsewherein the east Asian region, the country’s SME
manufacturers – particularly in the highly
competitive market for industrial parts andproducts – continue to set themselves apartthrough the uniquely Japanese characteristics of monozukuri.
“With respect to prices, China, Taiwan andSouth Korea are increasing their competitiveness with mass production. Nevertheless,the strength of small-and-medium-sized Japanese enterprises in the manufacturing industry is their ability to pay keen attention tocustomer needs. We differentiate ourselvesin quality by fully understanding our customers’ purpose of use and developing a suitableproduct,” says Wataru Uchimoto, Presidentof Tsukiboshi Manufacturing Co. Ltd.
“Our passion for monozukuri is based on
the deep-rooted culture of our employees.
Each Tsukiboshi employee strives to create superior products, and we as a company desire
to integrate what each employee has created
to provide a superior service for our customers. That is the starting point of monozukuri.”Founded in 1947, Tsukiboshi employs aunique manufacturing method to produce

WATARU UCHIMOTO,
President

high-quality bolts, nuts, rivets, and washers for the automotive sector. This includes
bespoke designs it creates through theforging process, which provides additional
WBMVFUPJUTmOBMQSPEVDUTi#ZQSPWJEJOH
our customers with products made bymachinery built in-house, we are not only
differentiating ourselves from other companies, but also engendering this strong
attachment toward monozukuri in our
employees,” explains Mr. Uchimoto.
#Z UIFHMPCBMIJHIQSFDJTJPOJOEVTUSZFYQFDUTUPSFBDIBWBMVFPGCJMMJPO 
with the automotive sector to contribute
BQQSPYJNBUFMZCJMMJPO MBSHFMZESJWFOCZ
a fast-accelerating transition to electric vehi-

cles (EVs) worldwide. For a company whose
internal combustion engine-related products
DVSSFOUMZQSPWJEFSPVHIMZPGJUTPVUQVU
for the automotive sector, this irreversible
EV trend is a strong motivator not only toinnovate and adapt the business strategy
accordingly, but also employ an increased
focus on sustainability across the board.
“With the trend toward EVs, we are focusing our energy on the development of
new EV-related products, with emphasis on
safety parts,” says Mr. Uchimoto. “For this
we are contemplating a layout for our new
factory presently undergoing constructionthat is scheduled to be completed next year.
According to that layout, in-plant physicaldistribution will be reduced by approxiNBUFMZ IFMQJOHUPWBTUMZJNQSPWFUIF
sustainability of our operations.”
This will only help further differentiate Tsukiboshi from its low-cost, massproducing regional competitors, says Mr.
Uchimoto. “We focus on the people whoare manufacturing the products and theirmental brilliance, as well as monozukuri thatis environmentally friendly.”www.tsukiboshi.co.jp

New Products
TRANSPORT CONTROLThe mechatronic eXtended Transport System (XTS) now includes anapplication-specific HMI control for visualization of dynamic producttransport. The XTS technology already supported collision-free motion
with movers working independently or in groups and delivering
dynamic, high-precision positioning on customer-specific trackgeometries. The new HMI software extension generates matchingvisualizations from an existing XTS track configuration with just one
mouse click. The generated XTS HMI Control is automatically linked
with all necessary parameters from the user’s application and candirectly display the current positions of all movers within the system.
The solution consists of three levels and readily combines with other HMI Controls, or even with animated images, as
required. This means that users can create highly realistic representations of complete systems with minimal effort.
BECKHOFF AUTOMATION LLC, www.beckhoff.com

ETHERNET SWITCHThe SX5E-HU085B 8-port unmanaged industrial Ethernet switch provides many managed switch
features to support the rapidly expanding quantity of Ethernet, IoT and IIoT devices used in criticaland challenging commercial and industrial locations. No software configuration is needed, andflexible installation options make this an economical yet high-performance solution. This switch
operates at 10 and 100 Mb/s, with auto negotiation of speed and full or half duplex mode, andevery port automatically detects and adjusts for straight-through or crossover cable connections.
IDEC CORPORATION, us.idec.com/SX5E-8port

INDUSTRIAL ROBOTS
The 6-axis IRB 1300 industrial robot includes new protection elementsthat enable it to be used in tough industrial applications and contamination-free production processes, opening new opportunities for increased
productivity, improved product quality and reduced cycle times in a variety of industries including electronics assembly, automotive and metals
fabrication. Originally launched in 2020, the IRB 1300 is now available
in IP67, Foundry Plus 2 and cleanroom ISO 4 versions. This will expand
its use in tough environments, with high levels of liquids and dust. Thisis achieved by preventing intrusion by sealing all electrical components,
which enables a variety of processes in multiple industries.
ABB ROBOTICS & DISCRETE AUTOMATION, go.abb/robotics

ROTARY ENCODERSThe IXARC high-precision magnetic absolute rotary encoders are now available with a
BiSS-C interface. Encoders with this interface are ideal for commutation and position
feedback on BLDC servo motors and are also an excellent fit for motion control
applications, such as medical equipment. They feature robust design, 17-bit resolution
and excellent dynamic response (up to 12,000 RPM). Multiturn variants feature a 32-bit
rotation measurement range (over two billion revolutions). The rotation counter is self-powered,using Wiegand energy-harvesting technology, eliminating the need for backup batteries or gear drive systems.
POSITAL, www.posital.com

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51

New Products

SAFETY LASER SCANNERS
Safety laser scanners offer an ingenious, cost-effective way toprotect an entire area. This can be a static application such asa robot cell or the area surrounding a moving device such as
an AGV. They are ideal for providing safe access to potentially
dangerous locations or areas. These laser area scanners are
configurable and feature a 275-deg. viewing window that allows
for several user-defined zones of protection. I/O and dust filtering
are other options configurable through the unit.
AUTOMATIONDIRECT, https://www.automationdirect.com/safety-

laser-scanners

LINEAR MOTION BEARINGS
Slide Ways are non-recirculating linear motion bearings usedprimarily in optical and measurement equipment where highprecision movement is required. The SV style consists of two roller
cages with precision rollers in a cross arrangement and four railswith V-shaped raceways. The SVW has one rail with V-shaped
grooves on both sides and 2 SV rails. The catalog contains
all dimensions, drawings and ratings necessary for specificapplications. 3D CAD is available.
NB CORPORATION OF AMERICA, www.nbcorporation.com

ON/OFF CURRENT SENSOR
The EISH Series of On/Off current sensors can detect current
as low as 200 mA AC and up to 60 Amps AC, making it optimal
for applications in a variety of markets including HVAC, water
treatment, data centers, tunnel/airport lighting and other areas ofcritical infrastructure. The EISH Series features a space-saving andversatile housing which can be either DIN rail- or panel-mounted.
It has a built-in current transformer with a solid state normallyopen output. A 12 mm through hole easily accepts insulated wire.
The EISH Series is self-powered from the input current, making it
simple and cost-effective.
CARLO GAVAZZI, www.GavazziOnline.com

FUSE BLOCK HEX SCREWS
Hex-screw head options for the 60-A LFR and LFT series of fuseblocks are ideal for manufacturing automation, helping OEMs
simplify the tightening process for their components to reduce
assembly errors. The hex-screw 60-A fuse blocks accommodatea wide range of existing mounting configurations and feature asnap-to-release DIN-rail mounting for easier installations, as well as
reinforced fuse clips for increased reliability.
LITTELFUSE, Littelfuse.com/FuseBlocks

52

JUNE 2021

MACHINE DESIGNHYDRAULIC HOSESThe MEGASys MXT with XtraTuff Plus cover (MXT-XTP) is a universally applicable hydraulic hose featuring
patent-pending wire-braid technology. MXT-XTP offers compact size, light weight, flexibility and highperformance with added durability from the XtraTuff Plus (XTP) cover. MXT-XTP is suitable for the mostdemanding fluid power challenges across a broad array of industries and applications, including
construction and mining, material handling, machining and metal processing, injection molding and otherstationary machinery, agriculture and forestry, aerial lifts, and more.
GATES, www.gates.com/mxt

PRESSURE INSTRUMENTS
The new Cerabar and Deltabar pressure and differential pressure
instruments feature a Bluetooth interface for easier operation, as
well as improved efficiency in regulatory control, safety and othersystems. Heartbeat Technology creates the data basis for predictive
maintenance and allows the instruments’ functionality to be verified
without process interruption. Intuitive operation is now provided via
the SmartBlue app, which includes guided operating sequences forparameterization and commissioning of the pressure sensor, bridging distances of up to 50 ft. Thus, even measuring points that are
difficult to reach or in hazardous areas are easy to maintain, even if
they are only integrated into the process via a 4–20mA interface.
ENDRESS+HAUSER, www.us.endress.com

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53

DATA FILE / CLASSIFIED ADVERTISING

AUGUST 2021
ISSUE PREVIEW
Cover Story
The Monthly focus:

Mobility Design
Applications.
Putting ideas to work:

Cobots lend a hand,as humans the strategy
Trends. The cutting edge
ideas in design:

Cloud computing:
Who needs it, and why?
Product Digest. Innovations
and design trends:

Materials and fastening
Design U: Design

The cloud brought down to earth
Ad Close:

7/2/2021
Materials Due:

7/12/2021

54

JUNE 2021

MACHINE DESIGNDATA FILE / CLASSIFIED ADVERTISINGAD INDEX
ALTECH CORPORATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,8,12

Looking for justthe right part,at just the right price...

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AUTOMATION24 INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AUTOMATIONDIRECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC
DIGI-KEY ELECTRONICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DURA-BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
EBM-PAPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
EXAIR CORP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FABCO-AIR INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FLOYD BELL INC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HARDY PROCESS SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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INTERPOWER CORPORATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
KEYSTONE ELECTRONICS CORP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBC
KNF NEUBERGER, INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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METAL POWDER INDUSTRIES FEDERATION . . . . . . . . . . . . . . . . . . . . . . 39
NB CORPORATION OF AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ORIENTAL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PBC LINEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REELL PRECISION MANUFACTURING . . . . . . . . . . . . . . . . . . . . . . . 40, 53
RUFFY CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SIKA USA, INC.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SPIROL INTERNATIONAL INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TDK-LAMBDA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
THE LEE COMPANY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC
THE WORLDFOLIO LTD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-50
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VISUMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
XENON CORPORATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
IN MOST CASES, ADVERTISEMENTS CONTAINED IN MACHINE DESIGN EMPLOYMENT SECTION INDICATE THAT THE COMPANIESARE EQUAL OPPORTUNITY EMPLOYERS. THE FEDERAL CIVIL RIGHTS ACT OF 1964, AND OTHER LAWS, PROHIBIT DISCRIMINATIONIN EMPLOYMENT BASED ON RACE, COLOR, RELIGION, NATIONAL ORIGIN, SEX, OR FOR ANY REASON OTHER THAN LACK OFPROFESSIONAL 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, PROMOTEUNLAWFUL DISCRIMINATION.

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55

One Last Thing...
STEPHEN J. MRAZ | Senior Editor         W

ind power companies will see levelized cost of energy
drop by 17% to 35%
by 2035 and 37% to 49% by 2050, driven
by bigger and more efficient turbines,
lower capital and operating costs, andother advancements, according to a survey of 140 wind-power industry observers
taken by researchers at Lawrence Berkeley
National Laboratory.
The survey also looked at levelizedenergy costs across three types of windpower plants: onshore (land-based), fixedbottom offshore and floating offshore.
There are greater absolute reductions(and more uncertainty) in the levelizedenergy costs for offshore wind comparedwith onshore wind, and a narrowing
gap between fixed-bottom and floating
offshore wind, according to the survey.
Still, predicted future costs for all three
types are half what a similar 2015 survey
predicted.
The federal government is trying to“maximize offshore wind potential” andidentifies wind power as a key component of the nation’s efforts against climate change. Wind power could play animportant role in reaching net zero carbon
emissions by mid-century.
Five key factors affect the levelized costof energy: upfront capital cost, ongoing
operating costs, capacity factor, project
design life and cost of financing. Experts
anticipate continued improvements acrossall these factors.
A key driver in these improvements
is turbine size, according to the survey.
For onshore wind, growth is expected not
only in generator ratings (to an averageof 5.5 MW in 2035, up from 2.5 MW in2019), but also in two other factors that
increase capacity—rotor diameters andhub heights.

56

These illustrations show the changes in dimensions and capacities for onshore and offshore
wind turbines.

A survey of windpower industry
observers
predicts
substantial cost
reductions foronshore, fixedbottom offshore
and floating
offshore wind
power, but there
is considerable
uncertainty inthose future
costs.

Offshore wind turbines are expected
to grow to an average of 17 MW in 2035,
up from 6 MW in 2019. Floating offshore
wind is predicted to gain market share,
going from its current pre-commercial
state to account for 25% of new offshore
wind projects by 2035.
The survey indicates that cost reductions have accelerated in recent years,
faster than previously predicted by mostforecasters and faster than historical rates
of decline.
“All else being equal, these trends will

let wind play a larger role in global energy supply than previously thought while
facilitating energy-sector decarbonization,” says Joachim Seel, a researcher at
Berkeley Lab. “Analysts, investors, planners
and policymakers should avoid outdated
assumptions and forecasts.” At the sametime, as documented in the survey, uncertainties in the magnitude of future cost
reduction are significant, illustrating theimportance of including this uncertainty
in modeling, as well as in policy, planning,
investment and research decisions.

JUNE 2021

MACHINE DESIGN

www. t he l e ec o .c o m

Go ahead, push us to your limits.

We love a good challenge.
If you need a ﬂuid handling component for whatever reason, no matter
how extreme, talk to The Lee Company. We’ve been solving complex
ﬂuid control problems in all kinds of industries for more than 70 years.
Our extensive family of precision ﬂuid control products offers unsurpassed
reliability in just about every conﬁguration you could imagine, including:• Miniature Solenoid Valves

We’re not just talking about off-the-shelf solutions, either. A Lee
engineer will be happy to discuss your application, and develop acustom design if needed. From managing nanoliter droplets tocreating fully integrated ﬂuidic systems, we’re unsurpassed in breadthand experience to deliver the precise, reliable performance you require.
Whatever problem you face, make the solution easy.
Contact The Lee Company today.

• Fixed and Variable Volume Pumps• Atomizing and Dispense Nozzles• Micro Dispensing Valves• Integrated Fluidic Manifolds• Custom Engineered Designs

2 Pettipaug Road | Westbrook, CT 06498-0424
Tel: 860-399-6281 | 800-533-7584 | www.theleeco.com
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