Dng de-09012012

$27.00 | September 2012
PM40069240
14 Mobile CAD has its appeal but
still faces challenges
24 Spec’ the correct motor for your
application’s requirements
34 Linear servo system creates
unique transport application
Motion Control
Roundtable
Canada’s motion control
leaders discuss the slowing
MC market, product trends
and network security.
Motion Controls
Buyers’ Guide p. 29
Motion
Control
2012
1-DES.indd 1 12-09-20 10:16 AM

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Straight Line 10/24/07 12:06 PM Page 1

5IN THE NEWS
8 Engineers Canada
appoints Catherine
Karakatsanis
president
8 Discovery Air,
Hybrid Air Vehicles
deal expires
8 COM DEV completes
instrument for
space telescope
8 Robotics industry
posts record quarter
10 SNC appoints new
president and CEO
10 Siemens Canada
celebrates 100 year
anniversary
10 MCAD market
growth projected
12 Eurocom debuts
“Over the Top”
mobile workstation
30 Dal researchers
Secure funding
for pneumatic
motor design
30 PTMC Sector
Growth Slows in Q2
Annual Subscription Rate
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READER SERVICES
Contents | Volume 58, No. 4
14 CAD Report
Mobile CAD has its appeal but still
faces challenges
22 Idea Generator
The latest in industrial products including
sensors, fluid power electrical
27 Canadian Innovator
Prototype Equipment Design specializes in
finding unique solutions for very specific
problems
44 Shop Talk
Diagnosing tricky motor trouble requires a
close inspection of power loads
46 Motion Product Showcase
Coverage of the latest in positioning,
power transmission and automation
products
Columns
18 Snake Handler
Hydro-Quebec heightens safety of plant
operations with modular “snake-arm”
manipulator
34 Choosing the Right Motor
How to match your application requirements
with the correct motor
38 Motion Control Roundtable
Canada’s motion control leaders discuss the
slowing MC market, product trends and
network security
42 Slot Car Racer
Beckhoff’s smart servo motor system, XTS,
creates a unique linear transport application
Features
14
27
44
34
18
www.design-engineering.com September | 2012
2-5-DES.indd 5 12-09-04 10:42 AM

6 EditorialViewpoint
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September | 2012 www.design-engineering.com
When astronaut and self-described “nerdy engineer” Neil Armstrong hopped
down the ladder of the Apollo 11 lander module in the summer of 1969
to become the first person on the Moon, it marked not only a “giant leap for
mankind” but also one of the few times when an engineer has risen to the level
of cultural icon.
Even in the months leading up to the launch, Armstrong and the Apollo 11
crew’s celebrity had grown to such an extent that they stashed stacks of potentially
valuable autographed envelopes as a means of providing for their families should
they not make it back. Not surprisingly, buying life insurance was astronomically
expensive for a group of men who were about to spend more than a week off
planet with the very real possibility of never returning.
In the years following the Apollo program, Armstrong and his fellow
mechanical engineer Buzz Aldrin became indelibly imprinted as exemplars
who, for a time, coupled the profession with words like heroic and visionary.
In the process, they inspired a generation of young STEM-inclined men and
women, many of whom would find their way into the Shuttle program 20 or
so years later.
Four decades on, Armstrong’s passing in late August at 82 seems to have
coincided with a popular resurgence and fascination with space travel and the
engineers who make it possible. Through much of the Shuttle program era,
with the exception of the Challenger disaster in 1986, launching people into
orbit fell out of the public consciousness. The Shuttle became akin to a rocket-
fueled semi-trailer, hauling “ho hum” cargo to and from low Earth orbit.
The successful landing and deployment of the Mars Curiosity Rover in
early August, however, seems to have reignited the wonder missing for more
than forty years. Of course, the Opportunity rover grabbed its share of atten-
tion in 2004, but geologic surveys and looking for signs of water doesn’t reso-
nate with the same impact as Curiosity’s mission—searching for past Martian
life and prepping for future human exploration, among its other objectives.
As important, the rover has drawn attention to the people behind its com-
plex but flawlessly executed decent to the Martian surface. Much of that focus
has centered on the mission’s flamboyant flight director, Bobak Ferdowsi. The
young aerospace engineer became an instant Internet sensation shortly after
the TV broadcast of Bobak and his fellow Jet Propulsion Laboratory colleagues’
ecstatic celebration of the landing. At 32, he seems too young to be in charge,
especially when you throw in his trademark Mohawk hair cut, red and blue
highlights and star-spangled sideburns.
And, admittedly, “Mohawk Guy” is a world away from the Apollo 13’s steely
and straight-laced Gene Kranz, with his flat top hairstyle and white vests. But
Ferdowsi’s catapult to celebrity status, even if momentary, shows the next
generation that what we, as a culture, admire and aspire to is just as much
about intelligence, ingenuity and vision as athleticism or walking the red
carpet. Like Armstrong’s first footprint on the Moon, it’s a small step that
leaves an enduring impression.
Mike McLeod
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6-7-DES.indd 7 12-08-30 2:28 PM

8
Karakatsanis Appointed Engineers
Canada President
Engineers Canada elected
Catherine Karakatsanis,
M.E.Sc., FEC, FCAE, P.Eng., as
its 2012-2013 president. In the
role, she will lead the organiza-
tion’s board and represent its
approximately 250,000 engi-
neering profession members.
Karakatsanis’ diversified
career includes an extensive resume of profes-
sional and volunteer positions. Currently, she
is the executive vice-president of the Building,
Technology and Energy Global Business Unit
of consulting engineering and management
firm Morrison Hershfield and has been a direc-
tor on the firm’s Board since 2005.
She has also volunteered in the engineering
community for more than two decades, serv-
ing as president and chair of Professional
Engineers Ontario and president and chair of
the Ontario Society of Professional Engineers.
She is currently on the Board of Engineers
Without Borders.
As president of Engineers Canada, Karakatsanis
says she will continue her support of engineer-
ing students and young engineers through her
involvement on the Board of the Canadian
Engineering Memorial Foundation and as the
chair of the University of Western Ontario’s
Faculty of Engineering Advisory Council.
www.engineerscanada.ca
Discovery Air, Hybrid Air Vehicles
deal expires
Discovery Air Innovations Inc. (DAI) and Hybrid
Air Vehicles Limited (HAV) agreed to allow
their commercial agreement to expire. Under
that deal, the companies entered a preliminary
agreement to launch a commercial heavy lift
air vehicle program.
“The commercial agreement provided a help-
ful framework for our initial collaboration, but
we have concluded that the option structure
does not align with our current investment
horizon,” said Paul Bouchard, President of DAI.
“We remain excited about this technology’s
potential and intend to continue working with
HAV to promote the commercialization of
heavy lift Hybrid Air Vehicles.”
www.discoveryair.com
Up Front COM DEV completes
instrument for space telescope
COM DEV’s Fine Guidance Sensor (FGS) undergoing cryogenic testing at the
David Florida Laboratory. Photo courtesy of the Canadian Space Agency (CSA)
and the Communications Research Centre (CRC).
COM DEV International Ltd. announced that it has completed
work on the instrument it designed and built for the James Webb
Space Telescope, successor to the Hubble Space Telescope. The two-
in-one instrument will serve to point the telescope precisely.
Canada is providing Webb’s Fine Guidance Sensor (FGS), as well
as one of the telescope’s four science instruments: the Near-Infrared
Imager and Slitless Spectrograph (NIRISS). The Fine Guidance Sensor
consists of two redundant cameras that will allow the Webb telescope
to determine its position on the sky, locate its celestial targets and
remain accurately pointed, down to one millionth of a degree.
The NIRISS is designed to find the earliest and most distant objects
in the Universe and discover Earth-like “exoplanets” and determine
their chemical composition to seek water vapour, carbon dioxide and
other biomarkers such as methane and oxygen.
Slated for launch in 2018, the James Webb Space Telescope is a
joint project between NASA, the European Space Agency and the
Canadian Space Agency. The Webb telescope will examine the first
stars and galaxies to form after the Big Bang, study the formation of
new stars, and seek extra-solar planetary systems capable of support-
ing life on planets like Earth.
Canada’s contribution—designed, built and tested by COM DEV
at its facilities in Ottawa and Cambridge, Ontario—will buy Canadian
astronomers a share of observing time once the telescope launches.
www.comdevintl.com
Robotics Industry posts record quarter
According to statistics released by the Robotic Industries Association
(RIA), North American robotics companies sold more industrial
robots in the second quarter of 2012 than any previous quarter in
history. A total of 5,556 robots valued at $403.1 million were sold to
North American companies, a jump to 14 percent in units and 28
percent in dollars over same quarter in 2011. Orders in the first half
of 2012 totaled 10,652 robots valued at $747 million, increases of 20
percent in units and 29 percent in dollars over same period last year.
DesignNews
Catherine
Karakatsanis
8-13-DES.indd 8 12-08-30 1:44 PM

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10
SNC appoints new
president and CEO
SNC-Lavalin announced that,
effective October 1, Robert G.
Card will become its new president
and CEO, and a member of the
board of directors. According to
the company, Card was selected
based on his credentials in leading
engineering, construction and operations businesses
internationally.
Card has almost 40 years of experience in the
operations and management of infrastructure and
energy projects in the industry and with the CH2M
Hill Companies Ltd. group.
At CH2M Hill, he held a variety of positions, includ-
ing president and group chief executive of the
International division; president of the Government,
Environment Nuclear division; President of the
Facilities Infrastructure division; and President of
the Energy, Water Facilities division, as well as
having been on the board of directors.
www.snclavalin.com
Up Front
Orders for spot welding robots, used primarily in automotive
solutions, jumped 68 percent in the first half of 2012. Other big
jumps were seen in coating dispensing (+42 percent), arc weld-
ing (+20 percent), and assembly (+19 percent). Material removal
orders, a smaller application area, rose 364 percent.
Automotive related orders accounted for 65 percent of units
and 64 percent of dollars in the first half of 2012. This represents
sharp gains of 44 percent in units and 56 percent in dollars over
the opening half of 2011. RIA estimates that some 220,000 robots
are now used in the United States, placing the US second only to
Japan in robot use.
www.robotics.org
Siemens Canada Celebrates Centennial
Siemens Canada celebrated its 100-year anniversary with an event
at its new 110,000 square foot headquarters in Oakville, to be
completed in late 2012. The event was attended by Siemens senior
executives, including Siemens AG CEO Peter Löscher.
Siemens Canada’s
parent company, Sie-
mensAGwasfounded
in Germany 165 years
ago, and conducted
its first work in Can-
ada shortly after Confederation, laying one of the first transatlan-
tic telegraph cables between Europe and North America, from
Ireland to Halifax, in 1874. The company was chartered federally
as the Siemens Company of Canada Limited in Montreal in 1912.
Since then, Siemens Canada has been involved in several impor-
tant Canadian firsts, including the first national telex network
in1957; one of the first modern light rail systems in North Amer-
ica in 1975; and the design and installation of the world’s first
retractable roof at Toronto’s Rogers Centre (formerly SkyDome)
in 1989. Siemens also played a role in some of Canada’s most iconic
projects, including lighting areas of Expo’67 in Montreal; illumi-
nating both the CN Tower in 1994 and Niagara Falls in 2007.
www.siemens.ca
MCAD market growth projected
Analysts at market intelligence firm, TechNavio, forecast the Global
Mechanical Computer-aided Design market will grow at a CAGR
of 10.3 percent over the period 2011-2015. According to its report,
Global Mechanical Computer-aided Design Market 2011-2015, one
of the key factors contributing to this growth is increasing demand
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8-13-DES.indd 11 12-08-30 1:44 PM

12 DesignNews
Design
from discrete manufacturing industries. The market has
also been witnessing that vendors are developing platforms
for interoperability, to provide integrated software. However,
the lack of standardization could pose a challenge to the
growth of this market, the report contends.
“The Global Mechanical Computer-aided Design
(MCAD) vendors are developing interoperability platforms
to integrate MCAD with other applications,” an analyst
from TechNavio’s Engineering team said. “Integration of
MCAD and electronic CAD (ECAD) is one of the emerging
trends in the market. Many end-users prefer integrated
MCAD and ECAD software, which resolves various conflicts
in the market. This integrated software reduces product
development time and also reduces operating expenses.”
According to the report, the Global MCAD market is
driven by discrete industries such as industrial machinery,
automotive, electronics, and aerospace and defense. In addi-
tion, the global discrete industry is growing at a faster rate
in developing countries than developed countries and is
therefore enhancing demand for MCAD software. Further,
the report also says that the increasing demand for open-
source software affects the growth of the commercial vendors
in the global MCAD market.
www.technavio.com
Canada’s “Over the Top”
Mobile Workstation
If your work computer seems a bit on the slow side, Ottawa-
based laptop maker Eurocom recently launched a mobile
workstation that sports better specs than many high-end
desktop computers. Called the Scorpius, the notebook sup-
ports dual graphics chips including two of NVIDIA’s latest
Quadro K5000M GPUs, which pack 1344 CUDA cores and
4GB GDDR5 graphics memory per chip.
In addition, the desktop replacement
rig supports the Intel Core i7-3920XM
processor Extreme Edition (3.8
GHz); up to 32 GB of DDR3
1600 memory; and
has room for three
storage drives (SSD,
HDD, Hybrid HDD)
to accommodate RAID
0/1/5/10 setups.
Unlike many other
mobile workstations, Euro-
com’s systems, including the Scorpius, are fully upgradeable
and can be customized based on graphics, processor,
memory, storage, display and wireless technology.
www.eurocom.com
8-13-DES.indd 12 12-08-30 1:44 PM

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14
By Ralph Grabowski
CAD software operating on mobile
devices is not new. Companies in
the late 1990s, like Graebert, already had
simple 2D CAD systems running on
PDAs (personal digital assistants), pre-
cursors to today’s smartphone.
But drawbacks were serious enough
to preclude mobile CAD from becoming
common, due to low screen resolution
and mere megabytes of memory.
Fast forward to the iPhone which
defined the new generation of mobile
devices. Today, numerous CAD vendors
are releasing apps for Android and iOS
devices, but I consider them to be tenta-
tive steps. Most are just 2D/3D viewers.
Some add mark ups and the ability to
toggle layers or select viewpoints, but
none are full blown CAD systems.
With such powerful hardware, why
the weak software? There are reasons
why CAD vendors cannot issue an Auto-
CAD LT for iPad.
Challenges in Mobile OSes
Smartphones and tablets run many
operating systems, but only three are
suitable for CAD:
• Google Android: largest market
share but also the most fragmented;
it runs on many devices from hard-
ware companies, since the source
code is freely available.
• Apple iOS: second largest market-
share but is limited to hardware from
Apple; it cannot be licensed and
many details closed to developers.
• Microsoft Mobile: falling market
share and runs on some devices; it’s
licensed at cost and most details
available.
Not viable operating systems include
Nokia’s Symbian (nearly dead), Intel-
supported Meego (a.k.a. Moblin and
Maemo), and RIM’s OS (losing
traction).
Mobile CAD
As hand held devices gain in performance, running CAD on
tiny screens has its appeal but still faces challenges.
CADReport
14-17-DES.indd 14 12-08-30 1:42 PM

15
Now, let’s look at the problems faced
by CAD vendors:
OS Woes: Developers tend to write
for iPhone and iPad tablet first, even
though Android has twice the market
share, because Android suffers from
fragmentation. The operating system is
freely available, and so anyone can
modify it, resulting in hundreds of
variations. When Google issues updates,
it can be too much work to modify the
mods. Google is fixing fragmentation
slowly; nevertheless, new releases of
Android aren’t on even relatively new
devices, whereas Apple is good at sup-
porting old devices.
Apple’s iOS is not resolution-indepen-
dent, and so developers write apps twice,
once for lower resolution iPhones and
again for higher resolution iPads. Android
adjusts to any resolution of any screen.
Apple users must go through the
company’s App Store and apps cannot
be “side loaded”; CAD vendors cannot
launch iOS software on their own time-
table (they have to wait for Apple’s
approval), nor can they issue updates
quickly. Android allows apps to be
installed from any source.
CPU Incompatibility: The primary
problem that the ARM CPU used by
nearly all smartphones and tablets is its
incompatibility with Intel CPUs used by
desktop computers. Therefore, CAD
vendors have to write much of their
software from scratch.
In one attempt to overcome the prob-
lem, Intel is porting Android to Atom
CPUs. Microsoft with Windows 8 Mobile
wants to make it easy to port desktop
apps to ARM CPUs.
Small Working RAM: Available
RAM has a hard limit, as little as 256MB
(in early iPhones). Desktop Windows
has paging (data too big for computer’s
memory is moved to the hard drive
temporarily) that’s not available on
portable devices. The CAD program,
drawing data, and other running pro-
grams all have to fit inside of 512MB or
1GB of memory.
With time, the limits will lift; Sam-
sung is showing 2GB models. In contrast,
Apple doesn’t report RAM amounts,
leaving developers to guess at what’s
available.
Generally, portable devices cannot
display drawings in original CAD for-
mats, because the files are too large.
Nearly all CAD vendors convert files to
a more compact form, stripping out
unneeded information. Some CAD
systems use the Save As command to
convert files for portable devices, as does
GStarCAD. Others save drawings to the
cloud, which does the conversion (as
with AutoCAD WS).
Human Interaction: Portable devices
require that we use our relatively fat
fingers to navigate. How to see the draw-
ing under our finger? GStarsoft’s MC
uses a bird’s-eye view window, while
Samsung is reintroducing the stylus to
some tablets. Most CAD software, how-
ever, involves only viewing and so fat-
fingered editing is not an issue.
Touchscreens detect five to ten simul-
taneous touches, but there is no touch-
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14-17-DES.indd 15 12-08-30 1:42 PM

16
motion standard beyond drag-to-scroll
and pinch-to-zoom. Even panning is
inconsistent.
Semi-Accelerated Graphics: ARM
CPUs include a GPU component (named
“Mali”) for displaying graphics quickly,
but it OpenGL ES has limited support for
the OpenGL graphics used by most desk-
top CAD programs. This limits the types
of 3D shaded modes used, but ehance-
ments to Mali and OpenGL ES should
make 3D graphics faster next year.
Benefits to Mobile CAD
With many drawbacks to CAD on por-
tabledevices,whybother?“Wearewilling
to give up functionality for portability,”
explainsVectorworksCEOSeanFlaherty.
Smartphones let us view drawings on
devices we have with us all the time.
Ease of Access: In my home town, a
new mall is being built, and when I met
the project manager, he pulled out his
iPhone and showed how AutoCAD WS
let him view any detail drawings to
resolve construction issues. He was
excited by this.
CAD apps tend to be integrated with
cloud storage, like DropBox and GMail.
Provided we keep project files in our
desktop computer’s cloud folder, we can
bring up the most recent versions of files,
without having to carry multi-gigabytes
versions on our phones, or even bother
with remembering to refresh old copies
with new ones.
Free Pricing. The way that Apple
structured its app store caused a freefall
in pricing. The low 99-cent prices ben-
efit us, but are hard on CAD vendors
who have programmers to pay.
To overcome the pricing problem,
some CAD vendors tie mobile apps to
their desktop software. Vectorworks
allows access only to subscription cus-
tomers. Autodesk hints at charging for
AutoCAD WS with more features.
An exception is IMSI/Design, who
charges as much as $30 for its Turbo-
Viewer Pro, which includes advanced
functions like cloud-translation from
some 20 formats.
The Future
The future of computing is defined by
faster and cheaper, but we are only good
at predicting the future linearly, and so
we don’t know the twists faster and
cheaper will take. Just think: three years
ago, the iPad didn’t exist.
From the next year’s specs being
touted this year, we can expect portable
devices that make full CAD a near real-
ity. But, today, portable CAD software
is mostly for viewing drawings. We can
expect more in the future, right? Well,
it’s just that portable technology zigs so
fast that we cannot predict where it will
zag next. DE
Ralph Grabowski is a CAD journal-
ist and the author of 140 books on
computer-aided design. Check out his
CAD industry blog at worldcadaccess.
typepad.com.
CADReport
14-17-DES.indd 16 12-08-30 1:42 PM

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18 Automation
Snake Handler
Hydro-Quebec heightens safety of plant operations
with modular “snake-arm” manipulator.
By Steve Scanlan
Handling in small confined spaces where machinery can-
not enter is usually done manually by several workers,
complicating the task and posing a safety risk to handling
personnel and equipment. Tighter worker safety norms in
the 2009 Occupational Health and Safety Act have encouraged
employers to seek handling equipment for these tasks, as well
as safer methods for manual handling in an effort to reduce
back and joint injury resulting from heavy lifting.
Cranes, cables, forklifts and other commonly used handling
equipment can be complex and time-consuming to deploy and
employ, especially in limited work spaces. In order to reduce
job length, as well as ensuring the safety of personnel for han-
dling in confined spaces, innovative solutions are required.
To address this challenge, Montreal-based robotics
manufacturer, Robotics Design Inc., has created the
ANATERGOARM TMA-500, an assisted manipulator that
reforms the way handling heavy loads is performed. The
arm was first tested in the confined and hazardous spaces
under the rotor of Hydro-Quebec’s Robert Bourassa Gen-
erating Station. The TMA-500 designed to maximize job
output and reduce personnel in the handling, repair, main-
tenance and manufacturing industries.
This assisted manipulator provides a high safety method
for handling up to 500kg loads through tight spaces, and around
obstacles. It can be assembled and disassembled onsite with a
minimum workforce, due to the company’s ANAT technology.
The patented mechanical architecture allows any mechanical
and robotic system to be formed from identical U- and H-shaped
modules. When connected in a chain, the modules distribute
pressure evenly amongst other attached modules like cells of
the body, improving payload carrying capacity without losing
ﬂexibility.
This ANATERGOARM model is operated by a single worker
by moving the arm around its base by hand, and by pushing
the arm over a distance when it is attached to a rail. It can be
designed in a dual or quad-arm configuration, with arms
working in unison to increase carrying capacity. Larger mod-
els can be created for heavier loads. In addition, the tool-holder
is customizable for different shaped loads, or for clamping
onto the object.
Hydro-Quebec deployed this arm at the Robert Bourassa
generatingstationtoremove,repairandreplace300kgbreakunits
from a four-foot tall confined space under the turbine rotor in
2011. It helped make repairs easier and safer than attempting to
repairthecomponentson-siteandreducedthedown-timeofthe
plant, in comparison to having them repaired in place.
The equipment’s modular design was critical for this task,
as it allowed a single worker to carry the arm’s components
and install and remove them easily, although the equipment
can also be fixed in place. It can be quickly deployed and
re-deployed for different handling tasks throughout the tur-
bine, or stored along with the rail in portable cases. This
ANATERGOARM was awarded the “Work Health and Safety”
award in 2011 at the 21st exhibition of the innovation awards
by IRSST (Institut de recherche Robert-Sauvé).
The TMA-500 is designed for automobile line assembly,
materials handling, mould manipulation, positioning parts
and any other handling, repair and maintenance task where
heavy objects must be manipulated or require fine-tuning,
and is particularity effective for tasks in limited spaces.
Throughout the automobile line assembly market, work-
ers sit on assisted manipulators to attach doors, panels, win-
dows and other parts. However, these arms don’t allow the
arm to bend around more than one obstacle at a time, and
take quite a bit of space.
By contrast, Robotic Design’s machinery allows workers
to position parts using the most direct movement paths
possible, while the arm itself requires minimal working
space. In addition, its zero-gravity load design allows work-
ers to carry 500kg loads horizontally without power con-
Hydro-Quebec used Robotics Design’s ANATERGOARM to repair and
replace 300 kg break units at its Robert Bourassa Generating Station.
18-21-Automation.indd 18 12-08-30 1:41 PM

Festo Inc.
Tel: 1 877 GO FESTO
Fax: 1 877 FX FESTO
festo.canada@ca.festo.com
www.festo.ca
Total freedom!
Mechactronic Motion Solutions.
For maximum design flexibility and
optimum performance: electric,
pneumatic and servopneumatic
components for custom handling
systems.

20 Automation
7PLNT15928.indd 1 3/20/07 12:32:48 PM
T
t
t
f
C
a
s
•
•
•
w
sumption, and it maintains its vertical positioning even
when power is removed.
To date, two ANATERGOARM models have been released,
starting with the AEA-15 tool-support, which won the gold
medal and the Industrial Design award at the 31st International
Exhibition of Inventions in Geneva. This ergonomic assisted
manipulator allows users to position and manipulate pneu-
matic, electric and hydraulic tools without the effect of grav-
ity, and allows users to manipulate tools.
It is made from anodized aircraft-grade aluminum, and
eliminates the weight and absorbs torque of tools up to 15kg.
The arm also reduces repetitive motion injury in workers, as
well as workplace injury and worker fatigue. The arm can be
used for welding, tapping, de-burring, nut running, burnish-
ing and sizing, inserting helicoids, drilling, screwing, grind-
ing, torch cutting, handling and repairing objects in restricted
places and maintenance. It can also be customized to hold
tooling of any shape and size and is scalable for heavier loads
or can be tele-operated for tasks in confined or hazardous
environments.
This equipment can be customized for heavier payload
weights in tasks such as aircraft assembly and naval main-
tenance. The arm can also be motorized, and the equipment
made tele-operated for tasks that must be performed at a
distance, and can be made mobile along a removable rail,
or fixed in place. Thanks to its modularity, this arm is fully
customizable, as new systems and enhancements can be
formed from identical ANAT modules making ANAT equip-
ment the perfect solution for any handling task. This inno-
vative industrial technology allows users to create the
machine that suits their needs, without the standard high
custom-made tooling costs. DE
http://roboticsdesign.qc.ca
Like other ANATERGOARM models, the TMA-500 is composed of a
series of H- and U-shaped modules that can support up to 500 kg.

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Sensors
Position Sensor
Honeywell introduced a rotary con-
figuration to its SMART position sensor
line that provides 360 degree non-
contact angular position sensing. The
component uses a combination of an
ASIC and an array of magneto-resistive
sensors to determine the position of a
magnet collar, down to 0.01 degrees.
Repeatable output that occurs within
a 3.0mm ±2.0mm (0.118 in ±0.079 in)
air gap between the sensor and magnet collar expand application
opportunities. The sensor also provides minimal signal error with up
to 2.50mm [0.10 in] of radial error.
http://sensing.honeywell.com
Photoelectric Sensor
Carlo Gavazzi launched its PH18
Series photoelectric sensor, which
features an M18-rectangular hous-
ing that can be mounted as a
rectangular sensor or as an M18
cylindrical sensor. The housing is
also rated IP67, IP69K and has a
ECOLAB certification. The series
includes diffuse (1m sensing range),
retro-reflective (6.5m sensing range), polarized retro-reflective (5m
sensing range) and through-beam (20m sensing range) sensing
modes. The sensor series offers a choice of NPN or PNP versions,
each with normally open and normally closed outputs, two LED
indicators and three connection choices (2m PVC cable, M12 plug
or short PVC cable with M12 plug).
www.GavazziOnline.com
A/D Servo Inclinometers
Meggitt Sensing Systems intro-
duced the Sensorex SX41100
series, a servo inclinometer family
featuring analog/digital outputs
and a maximum linearity error of
less than ±0.02 percent FS. With
available ranges of ±1 to ±70
degrees, the SX41100 is designed
to provide an output signal proportional to the angle of measure-
ment. The series features the company’s Sensorex digital hybrid
compensation circuit design for inclinometers with ±5V analog,
4-20 mA, and RS232 or RS485 outputs. Units feature built-in active
digital temperature compensation, reliably operating over a tem-
perature range of -40° to +85°C (-40° to +185°F). The sensors
operate from a 9-30V unipolar power supply and feature IP65
environmental sealing. Digital versions are delivered with software
and digital data transmitted in ASCII format.
www.meggittsensingsystem.com
Digital Infrared Video
Thermometer
Omega introduced its OS-VIR50
series of digital infrared video
thermometers that feature a dual
laser that indicates ideal measuring
distance. In addition, the ther-
mometer features a color LED bar
graph for viewing trends; a 150
millisecond response time; and a
type K thermocouple input and
trigger lock function for continuous readings. OS-VIR50 can measure
temperatures up to 2200°C. With a double molded housing, the
thermometer has adjustable emissivity to increase measurement
accuracy for different services as well as adjustable high/low set
points with audible alarm alerts.
www.omega.com
Fluid Power
Solenoid Valve
Festo introduced its VUVG
solenoid valve with high
flow rates and a pressure
range of up to 10 bar. Ac-
cording to the company,
a smaller size VUVG valve,
compared to existing valves, can be used in 90 percent of ap-
plications. VUVG valves achieve up to 100 percent more flow
for faster cycle times. The component integrates 2 x3/2 way
valves in one valve housing, reducing installation space by half.
Festo’s patented cartridge principle enables a separated two-
pressure operation and no overlapping between the air ducts.
In addition, a variable electrical connection concept allows the
electronics box to be replaced with one click. The valve hous-
ing remains the same, only the connection option is changed.
The valve functions as 5/2, 5/3, 2×3/2 with flow rates (l/min)
of 100, 220, 380, 750. In addition, multiple pressure zones
can be set up in valve manifold.
www.festo.ca/vuvg
Pneumatic-to-Current
Transducers
ControlAir Inc. introduced its P200
and P290 pneumatic-to-current P/I
transducers, designed to convert stan-
dard 3-15, 3-27 or 6-30 psig air pres-
sures into a two wire 4-20 or 10-50
mA signal with a total accuracy up to
+/- 0.10 percent. The P200 comes in a NEMA 4X housing and is
FM approved and CSA certified as explosion proof for Class I,
Div. 1, Groups A, B, C, D; dust ignition-proof for Class II, Div. 1,
Groups E, FG; and suitable for Class III, Div. 1 locations. The P200
offers infinite resolution and a response time of 10 msec for 99
IdeaGenerator
22-26 DES.indd 22 12-08-30 1:41 PM

22-26 DES.indd 23 12-08-30 1:41 PM

24
percent of step change. The P290 has the same specs but with-
out the explosion-proof housing. In addition, it can be panel or
DIN rail mounted. Both transducers require a 10 VDC minimum
power supply and provide protection from both conducted and
radiated RFI from 20 MHz to 1 GHz.
www.controlair.com
Pressure Transmitter
Omega introduced its
PX5200 series of rangeable
wet/wet differential pres-
sure transmitters. The CE
compliant transmitter fea-
tures a backlit display that
rotates in 90 degree incre-
ments, stainless steel, FKM
and ceramic wetted parts.
It also features flow mea-
surement totalization/
square root extraction function, program lock function and quick
ranging with internal push-buttons. The PX5200 is housed in an
aluminum NEMA 4X (IP65) enclosure which makes this product
well suited for flow and tank level applications where low dP
measurements are required.
www.omega.ca
Vacuum Pumps
KNF introduced its N950.50
Series multi-headed dia-
phragm vacuum pumps with
a maximum flow rate up to
50 l/m and maximum vac-
uum 2 mbar abs. The pumps can be powered either with a brush-
less DC motor or a worldwide motor with range of 100-240 V /
50-60 Hz. The pumps operate without oil to eliminate any chance
of contaminating the pumped medium, exhibit high level of gas
tightness, and can perform in any installed position. Options include
speed control through external signal input, gas ballast, remote on/
off operation, and signal output for speed monitoring. Wetted
material options include PPS, PTFE and EPDM.
www.knfOEM.com
Electrical
Bulkhead Housing
HARTING has extended
the application possibili-
ties for its Han-INOX
stainless steel product series with new covers for hoods and
bulkhead housings in size 10 B. In addition, a bulkhead housing
with integral cover and coupling housing, also for size 10 B, has
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22-26 DES.indd 24 12-08-30 1:41 PM

25
been introduced. Han-INOX is IP-65 compliant and is available
in Han 10B and Han 3A sizes and can be combined with most
standard contact inserts or the flexible Han-Modular connector
series. The housings and covers provide resistance against
chemical and other aggressive substances.
www.HARTING.ca
Safety Relay
Automation Direct
announced the BH5932
speed monitor relay
module, designed to
monitor two sensor
inputs that are detecting
rotating targets on a
motor shaft. The relay
features two-channel operation and can be used for standstill and
over-speed monitoring of three-phase motors. When used as a
standstill monitor, a switch point is set just above the “safe” or
normal operating speed. When motor speed rises above this setting,
the relay opens to protect against motor damage. The BH5932 relay
module has an adjustable impulse-per-minute (IPM) range of 10 to
20,000 IPM, LED status indicators, two PNP sensor inputs, and two
normally-open and one normally-closed positive-guided contacts.
www.automationdirect.com
AS-Interface I/O Modules
Pepperl+Fuchs introduced three G11
Series AS-Interface I/O Modules. The
first two modules offer two analog
outputs each; one for 0-20 mA
operation for flat cable connectivity
and one for 0-20 mA operation with
an M12 round connector. The third
module offers four analog outputs
of either 0-20 mA or 0-10 V for flat cable connectivity that can
be powered by AS-Interface or an auxiliary power source. The
output type of each module can be selected by DIP switch or
automatically determined based on the connected load. The
modules also provide lead break detection and integrated shield
connection in the M12 connector and on the base.
www.pepperl-fuchs.us
DC Power Supply
Saelig Company, Inc. introduced
its ODP3032, a programmable
three-channel linear DC power
supply. It features dual independent
outputs with separate controls and one fixed 5V/3A supply for up
to 195W total power with an output resolution of 1mV/1mA. Four
operating modes are provided for the two variable outputs: Inde-
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22-26 DES.indd 25 12-08-30 1:41 PM

26
pendent (0~30V/0~3A), parallel (0~30V/0~6A), series
(0~60V/0~3A), and plus-minus (-30V ~ +30V/0~3A). All three
channels are isolated, and a 3.9-inch high-resolution (480 x320
pixels) TFT LCD color display. Over-voltage and over-current are
configurable for load protection, and up to 30 groups of preset
system configurations can be stored internally. Up to 100 groups
of pre-stored timed voltage profiles can be used to generate arbi-
trary waveforms for voltage test cycle profiles.
www.saelig.com
Automation
HMI Panels
Kollmorgen announced keypad ver-
sions of its AKI Series HMI Panels. The
panels are available in 5.7- and 10.4-
inch screen sizes and are equipped with
LED status indicators. AKI Series HMI Panels are programmed using
the Kollmorgen Automation Suite Visualization Builder software.
The HMI panels are available with a variety of templates for common
process screens, as well as drive operations and configurations.
When developed within Kollmorgen Automation Suite projects,
Kollmorgen Automation Suite Visualization Builder features automatic
variable/tag configuration that enables designers to bypass rudi-
mentary tasks and concentrate on style and function.
www.kollmorgen.
com
Rugged HMIs
Maple Systems intro-
duced three HMI models
including a 7-inch
(HMI5070P), 12.1-inch
(HMI5121P), and 15-inch (HMI5150P) TFT touchscreen display. The
touchscreens are housed in an aluminum enclosure and equipped
with microprocessors designed for graphic animation and heavy
data processing. The HMIs connect to PLCs, drives, and motion
controllers through two serial ports: a USB port, a CAN bus port,
and an Ethernet port (including support for BACnet and importing
tag data for Rockwell Automation and Siemens PLCs). Two video
input ports (HMI5121P and HMI5150P only) allow for the connec-
tion of two motion cameras. All of the HMI5000P Series are NEMA4
(IP65) rated and carry both CE and RoHS certification.
www.maplesystems.com
IdeaGenerator
To advertise your solution in this section call Alan Macpherson at 416.510.6756
Dust Collectors Full Line Literature Guide
This impressive guide outlines dozens of N.R. Murphy dust collectors, installations, capacities, styles
and models. A must for any reference library. N.R. Murphy Limited has been in business over 65 years
and has thousands of satisfied customers.
“Dust Collectors are all we do; so get it done right the first time. Just Ask the Experts.”
Contact: 4nodust@nrmurphyltd.com
Visit us at: www. nrmurphy.com
OMEGA’s Thermocouple/Voltage Input USB Data Acquisition Module
Omega’s new OM-DAQ-USB-2401 series of USB 2.0 full speed thermocouple/voltage input data
acquisition modules are fully compatible with both USB 1.1 and USB 2.0 ports. This module is user
programmable for type J, K, T, E, R, S, B, N thermocouples or voltage input and features 8 Differen-
tial or 16 Single-Ended Analog Inputs, 24 Bit Resolution with up to 1000 Samples/Sec throughput.
This module is powered directly by USB port or an External DC Power Supply.
Contact: info@omega.ca
Visit us at: www.omega.ca
Clippard Offers Miniature Pneumatic Products Catalog for
Scientific/Medical Applications
A leader in miniature pneumatics, Clippard provides the scientific/medical industry a variety of products
and solutions. The product range is illustrated in a color brochure featuring the most complete line
of miniature fluid power products for the medical, pharmaceutical analytical and dental fields. To get
your copy today please visit our website at the address printed below.
Contact: sales@clippard.com
Visit us at: www.clippard.com/scientific-a
DesignSolutions
22-26 DES.indd 26 12-08-30 1:41 PM

27CanadianInnovator
Ray Brougham’s company, Prototype
Equipment Design, is all about providing
unique solutions for very specific problems.
By Treena Hein
To his customers Ray Brougham is many things—engineer-
ing wizard, tweaker, possessor of numerous skills—and
the builder of a unique and growing prototype business in
Victoria, BC. Put simply, Prototype Equipment Design (PED)
is a fluid hive of problem-solving activity where engineering
ideas transform into reality.
“About half the time we work from fairly
well-established plans; about 25 per cent
of our projects are tweaking something
that’s already constructed. The other 25
per cent of the time we are building from
scratch—sometimes literally from what’s been
drawn or a napkin or two,” Brougham says.
“Right now, for example, we have a project where
it’s totally up to us how we tackle it, working with a
sculptor who needs a quick way to shape and cut large
pieces of jade.”
An unfinished jade sink, which will soon be worth more
than $25,000, is one of many one-of-a-kind items in the large
shop area. The place is chock full of unrecognizable bits and
pieces along with a large number of computer-controlled
machines that produce the unique items Brougham and his
staff of 16 create. The idea to go his own way came to Brougham
after he had worked for Redlen Technologies, a nearby
manufacturer of gamma and x-ray detectors.
“I was doing lithography, placing pixels on semiconductors
twelve years ago, and I wanted to use that experience with other
companies,” he says. Eleven years ago, he started branching
out on his own, but still works for Redlen one day a week.
PED projects span the medical, aerospace, military, security
and research sectors. For example, a contract from the Univer-
sity of Victoria and the Canadian Space Agency involved build-
ing a microgravity simulator for growing semiconductor boules
in space. One of the most challenging projects was working
with the Hertzberg Institute to create a series of identical Band
3 hetra-dyne receiver waveguides used to align the main receiv-
ers in each of the 66 radio telescope in the ALMA project array
in Chile—to a precision level of less than 10 microns.
PED also currently serves as a first-level supplier of hull
fasteners for Babcock Canada, the company retrofitting
Canada’s submarines. “We’ve built a full-scale replica of the
submarine control room so that we can make new parts that
will make repairs easier,” Brougham adds.
Deadlines are sometimes pretty tight. “We recently had
two weeks to build a submersible sonar prototype from draw-
ings that took the inventor months to create,” Brougham
remembers. He says most solutions come from individual
and group brainstorming, but sometimes from a comment
or question from an employee not working on the project—
or who actually may not be involved with the engineering
and design side of things at all.
He considers his highly-skilled and well-trained staff to
be the primary determination of the company’s success. “I
have a great team, but as we’re getting bigger and more com-
plicated, we’re having some growing pains,” he says. “It’s tough
to keep everyone moving forward because I don’t like hier-
archical situations, but my team is asking for more structure.
We need strict protocols for handling special materials and
guidelines for sharing resources.”
Although the machining side of the business is stable,
Brougham wants to diversify and gain traction in the printed
circuit board (PCB) assembly market. With the current North
American market continuing to move business offshore in
order to keep manufacturing costs down, Brougham sees an
opportunity to provide a service to companies who are look-
ing for quality with assembly of PCB prototypes.
“In Victoria, there are 800 tech companies, and at least a
quarter are doing something with circuit boards,” he says, “so I
am establishing us as an assembler and seeking out opportuni-
ties to make first runs of 20 for trade shows and so on.” DE
http://engineersmachineshop.ca
The Engineer’s “Go-To” Guy
the builder of a unique and growing prototype business in
Victoria, BC. Put simply, Prototype Equipment Design (PED)
is a fluid hive of problem-solving activity where engineering
per cent of the time we are building from
scratch—sometimes literally from what’s been
drawn or a napkin or two,” Brougham says.
“Right now, for example, we have a project where
it’s totally up to us how we tackle it, working with a
sculptor who needs a quick way to shape and cut large
An unfinished jade sink, which will soon be worth more
than $25,000, is one of many one-of-a-kind items in the large
shop area. The place is chock full of unrecognizable bits and
pieces along with a large number of computer-controlled
machines that produce the unique items Brougham and his Victoria, BC-based Prototype Equipment Design specializes in
“impossible” fabrication tasks like the crafting of this $25,000 jade sink.
27-DES.indd 27 12-08-30 1:39 PM

DMR_EssentialComponents_September-2011-outline_01.indd 1 8/15/2011 12:43:40 PM
28-292-DES.indd 28 12-08-30 1:39 PM

29MotionControl
43:40 PM
Motion
Control
Buyer’s
Guide
Contents
30 Motion Control News
• Dal researchers secure funding for pneumatic motor design
• PTMC sector growth slows in Q2
• ATS posts ﬁrst quarter proﬁts
• Phoenix Contact opens new Canadian headquarters
34 Choosing the Right Motor
How to match your application requirements with the correct motor.
38 Motion Control Roundtable 2012
Canada’s motion control leaders discuss the slowing MC market,
product trends and network security.
42 Slot Car Racer
Beckhoff’s smart servo motor system, XTS, creates a unique
linear transport application.
44 Shop Talk
Diagnosing tricky motor trouble requires a close inspection of power loads.
46 Product Showcase
50 Motion Control Product Index
51 Product Listings
65 Supplier Listings
28-292-DES.indd 29 12-09-04 10:47 AM

30
Dal Researchers Secure Funding
for Pneumatic Motor Design
Dalhousie master’s student Braden Murphy and mechanical
engineering professor Dr. Darrel Doman unveil their newly developed
pneumatic engine. (Photo credit: Bruce Bottomley)
Dalhousie University announced that the inventors of an
innovative pneumatic engine, developed at the university,
have partnered with York Bridge Enterprises, Inc. to develop
the technology.
Dr. Darrel Doman and Braden Murphy from Dalhousie’s
Mechanical Engineering department developed the engine
and say that it is lighter, more energy efficient and requires
less maintenance than existing technologies.
Rather than linear pistons whose actuation is transferred
to rotary motion, the pair’s unique design features a toroid
chamber, with pistons that rotate continuously around the
drive shaft. The result is a design that overcomes many of the
shortcomings of traditional pneumatic motors in that it is
more compact, supplies higher torque at low speeds and doesn’t
suffer from leaking and other maintenance issues.
“We are very excited to be entering a partnership with York
Bridge Enterprises to further develop and commercialize our
pneumatic engine technology,” said Dr. Doman, co-inventor,
and professor from Dalhousie’s Faculty of Engineering. “As
with any technology developed at research-intensive univer-
sities such as Dalhousie, it’s critical to have the high level of
industry collaboration that we have with York Bridge. By
partnering our engineering technology expertise with their
business acumen, we see a bright future for the engine.”
To commercialize the engine, a Nova Scotia-based start-up,
Scotia Motor Works, will work to develop the technology for
the oil and gas industry as well as lawn and garden tools,
potentially.
www.dal.ca
PTMC Sector Growth Slows in Q2
According to the Power Transmission Distributors Associa-
tion’s Business Index, the second quarter of 2012 was the ninth
consecutive quarter for business growth among PTDA mem-
bers, albeit at a slower pace. Both distributing and manufac-
turing participating members reported decelerated sales but
expect 2012 to be another year of growth with an average
forecast of 8 percent, down from 11 percent from the first
quarter survey. Notably, 82 percent of distributors and 90
percent of manufacturers expect positive growth in 2012.
On average, the PTDA Index reports that sales rose 7 per-
cent in 2Q12, down from the 9 percent growth seen in 1Q.
Distributor sales grew 6 percent in 2Q, down from 9 percent
in 1Q, while manufacturers also reported decelerated sales
growth of 8 percent in 2Q, compared with 10 percent growth
last quarter.
The growth rate of new orders saw the biggest declines, with
a net 5 percent of members reporting higher new orders in 2Q
compared to a net 62 percent reporting higher new orders in
1Q. Similarly, a net 10 percent of members reported further
backlog growth in 2Q, down from the net 33 percent the first
quarter. On the plus side, PTDA members reported continued
hiring. Overall, a net 34 percent of firms reported increased
staffing, compared to a net 49 percent in 1Q. According to the
report, manufacturers appear to be hiring at a faster pace than
distributors, which is a reversal from last quarter’s trend.
ThePTDABusinessIndexincludesU.S.andCanadianbreak-
out data in addition to historical data. Conducted jointly by
PTDA and Cleveland Research Company, the PTDA Quarterly
Business Index was modeled after the widely respected Purchas-
ing Managers Index and tracks change in business activity, new
orders, employment, supplier deliveries, inventories, prices and
backlog in the PT/MC market to arrive at an overall index.
www.ptda.org
ATS Posts First Quarter Profits
Cambridge, ON-based system integration giant, ATS Automa-
tion Tooling Systems Inc., announced that it had a $9.8-mil-
lion profit in its first fiscal quarter, based in part on reduced
losses from its solar equipment arm. By comparison, the
company reported a loss of $5 million, including a 13-cent
loss at discontinued operations from the same quarter the
previous year.
Overall, the company increased its revenue to $152.2 million
in the first quarter of fiscal 2013 up from $126.9 million a year
earlier. However, overall profit and revenue were below analyst
estimates of $161.8 million in revenue. Specifically, the com-
pany’s Automation System Group revenue rose 20 percent
MotionControl: News
N
H
M
No
th
Tr
m
go
Re
30-33-DES.indd 30 12-08-30 1:38 PM

YA S K AWA A M E R I C A , I N C .
D R I V E S M O T I O N D I V I S I O N
1 - 8 0 0 -YA S K AWA YA S K AWA . C O M
Follow us: For more info:
http://Ez.com/yai371
©2012 Yaskawa America Inc.
NOTHING GOOD
HAPPENS AFTER
MIDNIGHT
Nobody wants that middle-of-the-night-call telling you systems are down. Not you. Not us. And, certainly not
the guy with the problem. That’s one of the reasons you should turn to Yaskawa for drives and motion control.
Trust your operations to Yaskawa and the phone won’t ring at night. The boss won’t be in your ofﬁce. And,
maintenance won’t be breathing down your neck with another ﬁre to put out. Trust Yaskawa and you’ll get a
good night’s sleep.
Rest easy tonight. Call Yaskawa today.
30-33-DES.indd 31 12-08-30 1:38 PM

32
higher from the previous year, due to a larger order backlog.
Inadditionrevenuefromconsumerproductsandelectronics
rose15percent;lifesciencesincreased18percent;andtranspor-
tation swelled by 69 percent due to improvements in the global
automotivemarket,thecompanysaid.However,ATS’slumping
solar business saw a 45 percent decline in revenue.
The Automation group added $168 million in bookings
during the quarter, seven percent higher than a year ago, but
the company noted the general economic environment remains
uncertain — especially in Europe.
ATS, which employs a total of 2,400 people at 20 plants in
several countries, has been working to sell or spin off the solar
division and lists it as a discontinued operation. ATS added
that customer activity in the solar energy market has slowed,
as reduced incentives in several markets negatively affected
demand for increased generation capacity and equipment.
www.atsautomation.com
Phoenix Contact Opens
New Canadian Headquarters
Phoenix Contact Limited hosted a grand opening ceremony
to celebrate and officially open its new Canadian headquarters
located in Milton, ON. More than 150 guests from across
Canada took part in this day-long event. Milton Mayor Gor-
don Krantz joined Kevin McKenna, Phoenix Contact Canada
managing director, and guests from the company’s worldwide
headquarters in Germany in officially cutting the ribbon on
the new facility.
Phoenix Contact’s new facility is equipped to offer training
and proof of concept testing, as well as serve as showroom and
exhibition area. The new building includes a warehouse, value-
added solutions centre and high tech training facilities.
Phoenix Contact’s Technical Support Department
designed an interactive product demonstration dubbed ‘The
Candy Express’ using Phoenix Contact’s newly launched
NanoLine controller. With GSM technology, guests enjoyed
having candy delivered to them by simply texting their
choice using their mobile phone, or by using the NanoLine’s
operator panel.
www.phoenixcontact.ca
MotionControl: News
|EK11-07USA|
A
Milton Mayor Gordon Krantz and Phoenix Contact Canada managing
director Kevin McKenna presided over the ribbon cutting ceremony
on the company’s new headquarters in Milton, ON.
30-33-DES.indd 32 12-08-30 1:38 PM

|EK11-07USA|
When is 12 mm a giant leap
for servo innovation?
It is when you shrink your machine's footprint using
12 mm EtherCAT Terminals for servo motors up to 4 A.
Motion
Automation
I/O
IPC
www.beckhoff.ca/EL7201
The EL7201 servo terminal for the Beckhoff EtherCAT Terminal system integrates
a complete servo drive for motors up to 200 W into a standard terminal housing:
Direct connection of servomotor, resolver and holding brake to a 12 mm wide EtherCAT Terminal
Ideal for applications with dozens of small servo axes
Considerable reduction in space requirements as well as wiring and commissioning costs
Integrated fast control technology designed for highly dynamic positioning tasks
The servo terminal supports synchronous motors with a rated current of up to 4 A.
When used in combination with the AM3100 servo motor, the EL7201 servo terminal represents
an inexpensive servo axis in the base performance range.
Cost effectively integrate servo technology instead of stepper motors and pneumatics
30-33-DES.indd 33 12-08-30 1:38 PM

34
By Alexa Loiskandl
With so many variables to consider, it is no wonder many
designers find it difficult to choose the right motor for
their application and often overlook critical parameters along
the way. Myostat Motion Control is frequently called upon
by our clients to walk them through this, somewhat compli-
cated, spec’ing process.
The first step is to understand what motor options are
available for motion control. From DC to AC, brushed to
brushless, each motor has its own benefits and drawbacks.
This article examines a sampling of the available options and
specific parameters designers should consider during the
selection process.
When it comes to narrowing down the choices, a designer
must consider the specifics of the machine design itself and
balance the project budget with desired performance and
environmental considerations. The following check list will
help to ensure all parameters are considered.
Speed
How fast does the motor need to run? Check the rated or con-
stant speed and maximum or peak speed of the motor you are
considering. Can the motor, coupled with a ball screw or gear-
box, provide the speed required for your job?
Torque and Inertia
Torque, the amount of radial force on the motor shaft, is
another primary consideration. Can the selected motor pro-
vide enough torque to move your load? Keep in mind that
coupling the motor with a gearbox will help to achieve torque
but you must ensure you have enough speed to make them
effective. Designers must also consider the weight of the mass
they are moving and consider if the motor can handle the
acceleration and deceleration of the mass without over-
driving the motor. Gearboxes reduce the inertia by the square
of the ration and are often used to combat the inertia from
large loads.
Secondary Considerations include:
Size
Is there a size restriction in your application? If you are build-
ing a small part, or something where mass is concerned, a
large 5 lbs. motor may not be ideal for you. Often times, the
space envelope of your design will dictate which motor can
be used. You must then look at the speed and torque of motors
within that size range.
Communication
How do you plan on sending commands to your motor? Will
you need to communicate with multiple motors or be cover-
ing large distances between motor and control box? Different
motors offer different communication options and add-ons.
Motor types also vary from pulse or step/direction type to
more advanced methods such as Ethernet.
There are also specific protocols from daisy chaining
motors; you can utilize methods such as CAN or serial inter-
faces for these. Again, if your controller needs to send a
specific type of command, this may dictate which motor you
choose as not all motors offer all options.
Accuracy and Resolution
How accurate do the motors have to be? Are you measuring
minute dimensions with a sensor that requires large amounts
of precision? Are you simply moving a large plastic piece from
one conveyor to another?
Some motors, usually basic steppers, offer a lower resolu-
tion, meaning less steps, pulses or small movements per one
revolution of the motor shaft. Servos usually offer a high
resolution, offering up to 50,000 pulses per revolution. The
finer your move needs to be, the higher the resolution of your
motor should be.
Motor resolution does not necessarily equal accuracy and
the two shouldn’t be confused. A stepper motor could be
driven by a micro stepping drive with a mathematical resolu-
tion of 32,000 micro steps per rotation. However, without
sensor feedback, the motor itself may not have the right com-
Choosing the
Right Motor
How to match your application requirements
with the correct motor.
MotionControl: Motors
de-2012
The toothed rotor and stator of the stepper motor is clearly visible in
contrast to the AC servo’s smooth rotor/stator design. The stepper is
a “magnetically geared” servo motor.
34-37-DES.indd 34 12-08-30 2:23 PM

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34-37-DES.indd 35 12-08-30 2:23 PM

36
mutation to move such a small step.
Position encoders vary in type and, although they offer a
given resolution, internally they may have intrinsic, kinematic
error due to inconsistencies in component manufacturing.
Optical encoders rely on holes accurately cut in a glass disk
and resolvers rely on consistency in the windings as well as
the hardware that holds those windings.
The closed loop system of the motor also contributes to
accuracy as the tuning parameters affect both speed and
position, reaction time and settling location.
Environmental concerns
In what environment will
your motor be running? Will
there be a large amount of
dust, particulate or water
coming into contact with the
motor. An IP rating will give
you an idea of what environ-
ment the motor is suited to
run in. Some motors are
water resistant; others offer
shaft seals which help prevent
particulates from getting into
the inner workings of the
motor through the shaft.
Heat
What is the temperature and air flow like in the area the
motor is to be placed? Heat is a concern when it comes to
operating motors. They often have a specific temperature
range at which they should be run. Motors produce heat
when running, therefore fully enclosed areas with no air
circulation may cause motors to overheat.
Certain motors will only draw the amount of current
needed to perform a move or hold position. These motors
tend to run cooler as they are not
constantly drawing large amounts
of current.
Budget
How much are you looking to spend
on your motor? Often times, this
is the deciding factor. If you can
only spend $100, a high-end servo
is obviously not the right choice.
You should have an idea of how
much you are willing to spend and
look for a motor accordingly.
Each design is unique and
often, one of the factors outlined
above will hold more weight in the
decision making process.
By understanding the motor
options available and developing
a clear set of project parameters,
engineers and machine designers
will be able to avoid costly mis-
takes and ensure that the correct
motor is chosen for the job. DE
www.myostat.ca
Alexa Loiskandl is a sales engineer
for Myostat Motion Control inc.
with a B.Eng in Biomedical and
Electrical Engineering.
MotionControl: Motors
For complete RFA4000 information, visit www.novotechnik.com/rfa
Novotechnik U.S., Inc.
155 Northboro Road • Southborough, MA 01772
Telephone: 508-485-2244 Fax: 508-485-2430Siedle Group
Rotary angle measurement just got
better. With Novotechnik’s RFA4000
Series touchless position sensor you can
measure through air or
through non-magnetic
materials. Just attach
a magnetic pick-up to
your rotating application
and mount the sensor nearby.
RFA4000 Series sensors are
extremely thin and compact with
dimensions of 30x30x7 mm. The
sensors are fully encapsulated for
operation in tough environments.
Other specifications include:
• Electrical measurement range to 360°
• Unlimited mechanical life
• Update rate of 5,000 measurements/s
For An Angle Sensor That Works
Around Your Application…
• Repeatability of 0.1°
• 12-bit resolution
• Independent linearity to ±0.5%
• Single and redundant versions
Go Touchless.Go Touchless.
Stepper and servo motors can come with complete driver/controller/encoder systems integrated in
to the motor itself.
34-37-DES.indd 36 12-08-30 2:24 PM

34-37-DES.indd 37 12-08-30 2:24 PM

38
Canada’s motion control leaders discuss
the slowing MC market, product trends
and network security.
DE: According to a recent Motion Control Association report,
the MC industry saw double-digit growth in past two years.
Is 2012 looking as good so far?
Dave Buckley, Industrial Automation Products Manager,
Motion Industries Canada: Between the unemployment
levels in North America and the uncertainty in Europe, it isn’t
agoodclimatetofindbuyers.ForNorthAmericanmanufactur-
ers to be competitive while coping with extremely high labour
costs, the only solution is to automate. And there have been
some excellent opportunities to automate in Canada. Having
said that, the last couple of months have seen a dramatic slow-
down; it has gone from the cautious to the terrified level.
Kian Sanjari, Product Manager for I/O and Networking,
Phoenix Contact: 2012 looks like it may be a bit of a challenge.
We are still experiencing double-digit growth in certain areas,
but some products are struggling.
BillFaber,GroupManagerforAutomationTechnology,Omron:
The market is still growing although not as strong this year.
Even in the U.S., we’re still experiencing about 10 to 15 percent
growth. For our company, in this particular area, our growth
is closer to 25 or 30 percent.
A lot of it depends on which specific markets and appli-
cations you are heading toward. Each company’s ability to
refocus in those areas is going to determine the growth they
experience. Overall, you’ll probably see 10 to 15 percent
growth in the U.S. and 5 to 10 percent in Canada if you are
focused in those areas. If you’re not, then you might see flat
in Canada.
JoeOttenhof,RegionalManagerCanada,BeckhoffAutomation:
Overall, I would say 2012 will not exhibit the same growth as
seen in the previous two or three years. There will be certain
sectors driven by large projects that may see a bump. However,
overall manufacturing in Canada is suffering and that will be
reflected in the motion control sector. I think the market will
see a flat year in 2012, but I hope I am wrong.
DE: Which products or product categories show the stron-
gest growth in the Canadian market? What do those trends
suggest?
Buckley - Motion Canada: I’ve been around for a long time,
and I’ve found that linear rails are an amazing forerunner of
what is going to happen in the economy. When they pick up,
it happens as much as six months before the general economy.
And when linear rail sales turn down, it does so up to six
months beforehand. In this case, our linear products are
dropping off rather dramatically which isn’t a good sign.
Manufacturers know they have to automate and they have
been, until recently. Now, they are still exploring that but they
don’t want to commit to the expense with the lack of security
in the markets.
Sanjari - Phoenix Contact: We are very diverse in that we
have automation products and then we also have connectors
and terminal blocks. From the numbers right now, it seems
we have experienced pretty good growth in terms of the con-
nectors and electronic devices. Power supplies are also strong
but the biggest is I/O points. Overall, the growth has come
from a blend of different factors in the last few years. In a
nutshell, I don’t see it as organic growth due to the market.
Where we saw growth was due to the new products we intro-
duced and a sales structure that takes advantage of markets
in the West and in Quebec.
Motion
Control Roundtable 2012
MotionControl: RoundTable
Dave Buckley
“Between the unemployment levels in North America
and the uncertainty in Europe, it isn’t a good climate to
find buyers.”
—Dave Buckley, Industrial Automation Products Manager, Motion
Industries Canada
38-41-DES.indd 38 12-09-04 10:50 AM

39
Faber - Omron: We are definitely seeing strong growth in
variable frequency drives and Machine Automation Control.
Most of the growth we’re experiencing is business-driven and
not economy-driven. The downside in Canada is that the reces-
sion hit hard causing plant closings.
I think the closings were mainly due to the economy but the
recoveriesorthesalesweareseeingareduetoeffortstoimprove
productivity. When a company becomes more efficient and
competitive, they tend to grow and add more employees which
fuelstherecovery.IthinkthatisprevalentinCanada.Companies
are looking at complete control solutions because the funda-
mentaloutcomeisincreasedthroughputbecauseoflessinterfac-
ing latencies, less time down because of integrated
troubleshooting, and higher yield because of higher system
synchronization accuracies—this all means higher OEE and
more efficient lines.
Ottenhof - Beckhoff: In the area of servo drives, we think
the integration of “safety” directly into the drive will reach
maturity. Instead of simply removing power from the
drive, new modes of operation such as safe speed, safe
direction, safe limited position and safe torque will con-
tribute to the design of more compact and functional
manufacturing lines. Due to these new safe operating
modes, a multi-robot manufacturing line can be built on
a smaller footprint.
Dedicated to the Science of Motion
Aerotech, Inc., 101 Zeta Drive, Pittsburgh, PA 15238
Ph: 412-963-7470 • Fax: 412-963-7459 • Email: sales@aerotech.com
www.aerotech.com AH1111A_CSG
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AH1111A_CSG_Aerotech_Automation_7x4_875_Layout 1 8/6/2012 11:11 AM Page 1
Kian Sanjari
“2012 looks like it may be a bit of a challenge. We are still
experiencing double-digit growth in certain areas, but
some products are struggling.”
—Kian Sanjari, Product Manager for I/O and Networking, Phoenix
Contact

40
Also, size matters, so the move to incorporating servo drives
into an I/O system rather than as a separate cabinet mounted
deviceisimportant.Extremelycompact,12mm-wideI/O-based
servo drives enable the servo motor to be used in applications
previouslyhandledbysteppermotors,offeringenhancedmachine
performance.
DE:Electricpowerratesareescalating,particularlyinOntario.
Howimportantafactorisenergyefficiencybecominginprod-
uct selection, from your perspective?
Buckley - Motion Canada: It isn’t as important as the people
who provide energy efficient products would like it to be. In the
overall scheme of things, when you are trying to compete in the
world markets, the single biggest cost is labour. That’s a pretty
deadlycostcomparedtocountriesthatpayadollaranhourwith
no benefits. Yes, energy costs have risen dramatically, but if you
putthatintoproportiontoanywhereelseintheworld,we’restill
nothighlyexpensiveenergywiseinNorthAmerica.EvenChina
sees huge energy costs because they struggle with supplying
enough energy to their manufacturing. In this case, energy
everywhere has gone up dramatically, so you are still on a par
competitively.
Sanjari - Phoenix Contact: The growth in our line of UPS and
so on, goes to show that nobody wants to have downtime. In
terms of energy usage, however, I think customers want to
monitor that information on their communications platform.
If energy efficiency is important, then it’s important to get it
from the field and into the control room.
Faber - Omron: We’ve seen growth in our variable frequency
drives and which could be tied to rising energy prices. But if
people are involved in plant closings and figuring out how to
readjust, the last thing they’re going to think about is installing
VFD’s to save electricity. In terms of product selection, this is
something company’s like ours need to educate our customers
on. Similarly, if you look at motors, steppers are typically at 100
percent current all the time, whereas servos draw power on
demand, so there is cost savings there as well. There are some
companiesouttherethatarealreadyintheprocessofimplement-
ing these solutions, but many are not and this is where product
vendors must educate on the bottom line cost saving benefits.
Ottenhof - Beckhoff: We haven’t seen any direct impact in as
much as it being reflected in customer specifications ... yet.
However, it has been and remains a significant design guideline
fornewproductdevelopment.So,forus,it’sa“push”ratherthan
a“pull”conversationwithacustomer.Throughinnovativemotor
designs, we have seen an increase in motor torque for a given
drive input current. Also, on the software side, control modes
and algorithms lead to a conservation of energy through simply
making the motion profile more efficient. Wasted motion is
wasted energy.
DE: Following industrial malware attacks like Stuxnet and
Flame, do you foresee industrial network security becoming
an important issue for the industry?
Buckley-MotionCanada:Itdependsonwheretheautomation
isgoing.IntheindustrialmarketinCanada,especiallyinOntario,
72percentofthatmarketisautomotive.That’snotamarketthat
is going to be worried about that. If you were involved in the
production of military products, like L3 or another company
like that, it would be a huge concern. It all depends on the mar-
ket you’re living in.
Sanjari-PhoenixContact: Virusattacksandmalwaremaynot
be something most companies are concerned about. However,
there is general network security software that not only creates
firewalls and restrict access but also establishes secure VPN
tunnels for remote applications. For example, a customer who
builds a machine and ships it to China wants to troubleshoot
that product over the Internet. So creating that secure tunnel is
somethingheismoreinterestedinthanalwayshavingaproduct
that is constantly filtering intrusions. Bigger companies may
want to go further but that’s one or two percent of the market.
Faber - Omron: Every plant or facility should have some level
ofnetworksecurity.AtOmron,welookatprobabilityandimpact
to assess risk. Where these problems hit have been in large pro-
cess plants where the impact is much higher than in discrete
manufacturing.Ifsomebodyhacksintoyourpackagingmachine,
howmuchdamagewillthatreallydo?Unlesstheprocessishigh
impact, like a nuclear reactor, this could be more a distraction.
Toreduceprobabilityofoccurrence,wehaveimplementedafew
keythings,startingwithkeepingtheinformationandthecontrol
Bill Faber
“Most of the growth we’re seeing is business-driven
and not economy-driven. The plant closings are mainly
due to the economy but the recoveries are due to
improvements in productivity.”
— Bill Faber, Group Manager for Automation Technology, Omron

41
networks separate. We’re also not an industrial PC so there is
less threat in hacking into a known platform. Lastly, to help
protectintellectualproperty,ourMachineAutomationControl-
ler has built-in 32-digit encryption of the application code.
Ottenhof-Beckhoff:We’re a PC-based control supplier, so you
would have to think that this is a significant concern for us, and
it is on a customer-by-customer basis. However, we have to
consider this on two fronts: On the field side and the controller
side.Today,many,ifnotmost,fieldbusesinnewapplicationsuse
an Ethernet-based or derived network such as EtherCAT, Pro-
finet,Ethernet/IP,etc.thatarevirtuallyimmunetothreatsince,
among other things, they don’t use a traditional TCP/IP stack.
However,thePCcontroller(orPAC)withaWindowsoperating
system is natively at risk to infection. So the question becomes,
how to protect the integrity and performance of the system.
Perhaps the biggest risk is unintentional sabotage caused by
an infected USB drive that renders the IT firewall useless. Our
perspective, and that of many IT security professionals, is that
the IT and Production groups within an organization need to
work in tandem to ensure everyone practices safe computing,
nomatterwherethecomputerislocated.Thebestwaytoprotect
a natively vulnerable system is with proper practices regularly
updatedandstringentlyenforced.Havingsaidallthat,thenum-
ber of incidents of malware affecting industrial control systems
is, by all reports, very small. DE
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Joe Ottenhof
“Today, most fieldbuses in new applications use an
Ethernet-based or derived network that are virtually
immune to threat since, among other things, they don’t
use a traditional TCP/IP stack.”
— Joe Ottenhof, Regional Manager Canada, Beckhoff Automation

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