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The IoT’s
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March 2019 VOLUME 91, ISSUE 3
IN THIS ISSUE
FEATURES
38 MD&M 2019: Medical Materials
Materials take on new challenges in the medical industry as companies
exhibiting at this year’s MD&M educate us on what is needed.
38
44 11 of the Best Images from the 2019 Medical Design &
Manufacturing West Conference
MD&M hosts several thousand medical exhibitors and holds the largest
MedTech conference in North America.
46 The IoT Ushers in a Healthcare Industry Revolution

Introducing IoT as a platform and concept has redefned the machine-to-
human (M2H) interaction for effcient healthcare facilities—and increased
the vulnerability to hackers.
51 Is Vibration Detection the Canary in the Mines for

Manufacturing?
Keep excess vibration in check using IIoT-enabled condition-monitoring
44
sensors.
56 Designing with Motion Control in Mind

What OEMs and design engineers need to know about motors, drives,
and controllers.
64 Will Commercial Cloud Providers Increase the Cost of

Federal Data?
If federal agencies choose to save money by putting data (and lot of it) on
46
commercial services, will the cost of that data go up and its use decline?
67 Book Review: Simplify Work

As new technology such as the IoT creates more complex systems,
simplifying work will take on greater value.
70 Advancements in Robotic Safety

Collaborative and traditional robots have safety limitations, but can you get
the best of both worlds?
72 11 Myths About Additive Manufacturing, Part 1
51
AM is surrounded by much hype, but are you getting the whole story?
DEPARTMENTS COLUMNS
4 ON MACHINEDESIGN.COM 6 EDITORIAL
It’s That Time Again: The JOIN US ONLINE
12 NEWS
Fourth Annual Engineering
77 AD INDEX Bracket Challenge twitter.com/machinedesign
78 CLASSIFIEDS 80 R&D—PRODUCT facebook.com/
DEVELOPMENT MachineDesignMagazine
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Specifying the Right

Hydraulic Cylinder for the How to Get More Bang for
Right Job Your Buck
Many OEM engineers play it safe by over-engineering cylinder
specifcations. But less can sometimes be more when it comes to Servomotors and hydraulics are working together for a more
complex hydraulics. precise, power-dense future.
https://www.machinedesign.com/motion-control/specifying- https://www.machinedesign.com/motion-control/industrial-
right-hydraulic-cylinder-right-job motors-how-get-more-bang-your-buck
Could 5G Be the Missing How Does One Get Started

Puzzle Piece for Self-Driving with PLM and the Digital
Cars? Twin?
At the Consumer Electronics Show this year, 5G has taken the Te future of computer-aided design systems in an Internet of
spotlight as the next big technology paradigm shif. What does Tings world is the Digital Twin. Digital Twins leverage data
that mean for self-driving cars hitting the market in the near from CAD systems, product lifecycles, manufacturing systems,
future? and sensors to create a realistic virtual model of your product.
https://www.machinedesign.com/motion-control/could-5g-be- https://www.machinedesign.com/cad/how-does-one-get-
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VALVES ItÕs That Time

Again:
S OLE N OID VALV ES The Fourth
Annual
Engineering
Bracket Challenge
Help us choose the best engineering school in the U.S.,
and win some prizes along the way.
O
ver the next five weeks or so, readers of Machine Design and
Electronic Design, as well as a host of interested engineering
students, will be voting for their favorite engineering colleges.
Over five weeks of voting, they will winnow down a field of 32 top-
notch schools to just one.
The winning school will then enjoy a day of interesting and compelling engineering
shows and challenges, product demonstrations from sponsors, free food, and non-stop
gift giveaways of iPads, Fitbits, Apple Watches, and gift cards. One of the top prizes, for
example, is an InstaLab kit from Digi-Key. The $2,000 kit contains just about every-
thing budding engineers need to tinker and experiment in their basement (or attic) lab.
FREE The grand prize giveaway at the event will be an all-expense trip to a Maker Fire in San
Francisco (May 2019).
Engineering Those voting can also pocket some prizes, as long as they continue to vote in each
Services! of the five rounds.
Sponsors for this year’s extravaganza include Digi-Key, Reneseas, TE Connectivity,
Nordic Semiconductor, Maxon Motors, Texas Instruments, and Alltech Inc.
Fast The entrants in this year’s Bracket Challenge include:
Quotes • Massachusetts Institute of • U. of California-Berkley • Penn State U.
Technology (MIT) • Purdue U. • Texas A&M U.
5-Day • Cornell U. • Columbia U. • U. of Maryland
Prototypes • U. of California Los • U. of Michigan • Northwestern U.
Angeles • U. of Illinois • Harvard U.
Inventory • California Institute of • U. of Texas • U. of California-Santa
Programs Technology • U. of California-San Diego
Barbara
• Stanford U. • U. of Pennsylvania
• Carnegie Mellon U.
• Ohio State U.
• Princeton U. • U. of Minnesota • Arizona State U.
• U. of Southern California • Johns Hopkins U. • U. of Washington
• Georgia Institute of • U. of Wisconsin • Virginia Tech
Technology • Duke U. • Rice U.
Wisconsin won last year and Purdue the year before.
For more details on voting and winning prizes, visit the webpage at https://bracket.
electronicdesign.com/.
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MARCH 2019 MACHINE DESIGN
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Teaching AI to Predict
PEDESTRIAN BEHAVIOR
Autonomous cars will need to second-guess what pedestrians will do next to avoid
hitting them.
R
esearchers at the Uni- humans in motion and then recreate “Prior work in this area typically
versity of Michigan are them in 3D computer simulations. looked at only still images—it wasn’t
teaching self-driving cars With that, they’ve created a “biome- concerned with how people move in
to recognize and predict chanically inspired recurrent neural three dimensions,” says Ram Vasudevan,
pedestrians’ movements with greater network” that catalogs human move- a UM assistant professor of mechanical
precision than current technologies by ments. engineering. “But if vehicles are going
zeroing in on their gait, body symmetry, The network lets AI machines predict to operate and interact in the real world,
and foot placement. poses and future locations for one or we need to make sure our predictions
Data collected by vehicles through several pedestrians up to 50 yards from of where a pedestrian is going doesn’t
cameras, LiDAR, and GPS let the the vehicle. That’s about the size of a city coincide with where the vehicle is going
researchers capture video snippets of intersection. next.”

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Equipping vehicles with the neces- Much of the machine learning used But using video clips that run for sev-
sary predictive power requires that to bring autonomous technology to its eral seconds lets researchers study the
the network dive into the minutiae current level has dealt with two-dimen- first half of the snippet to make predic-
of human movement: the pace of a sional images—still photos. A computer tions, and then verify the accuracy with
human’s gait (periodicity), the mir- shown several million photos of a stop the second half.
ror symmetry of limbs, and the way sign will eventually come to recognize “Now, we’re training the system to
foot placement affects stability during stop signs in the real world and in real recognize motion and making predic-
walking. time. tions of not just one single thing—
whether it’s a stop sign or not—but
where that pedestrian’s body will be at
the next step and the next and the next,”
says Matthew Johnson-Roberson, an
associate professor in UM’s Depart-
ment of Naval Architecture and Marine
Engineering.
To explain the kind of extrapola-
tions the neural network can make,
Vasudevan describes a common sight.
“If a pedestrian is playing with their
phone, you know they’re distracted,” he
explains. “Their pose and where they’re
looking tells you a lot about their level
of attentiveness. It’s also telling you a lot
about what they can do next.”
Results show that this new approach
improves a driverless vehicle’s ability
to predict what’s most likely to happen
next.
“The median translation error of our
prediction was approximately 10 cm
after one second and less than 80 cm
after six seconds,” says Johnson-Rob-
erson. “All other comparison methods
were up to 7 meters off…We are better
at figuring out where a person is going
to be.”
To rein in the number of options
for predicting the next movement, the
researchers applied the physical con-
straints of the human body, such as the
inability to fly or the fastest possible
speed on foot.
To create the dataset used to train
UM’s neural network, researchers
parked a vehicle with Level 4 autono-
mous features at several Ann Arbor
intersections. With the car’s cameras
and LiDAR facing the intersection, the
vehicle recorded several days’ worth of
data at a time. Researchers bolstered that
real-world, “in the wild” data with tradi-
tional pose data sets captured in a lab.

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News
WINDSHIELD WIPERS More Accurate than Weather Radar for

Monitoring Rainfall
ENGINEERS AT THE University of Michigan falls. The team networked a small test fleet The engineers tracked when wipers
have added some serious tech to auto- of cars in Ann Arbor so that it could track were being used, matching that data with
motive windshield wipers, building a mo- where the cars were and if they had their video from onboard cameras to document
bile network more accurate than weather wipers on; cameras were also added so rainfall. They found that tracking wind-
radar at tracking and monitoring local rain- the team could see and gauge rainfall. shield wiper activity can provide faster,
more accurate rainfall data than radar and
rain gauges currently in place.
Water departments and city managers
Yourr
armed with such real-time data could move
Rod Ends and more quickly to prevent flash-flooding or
Spherical sewage overflows and make better use of
“smart” stormwater systems outfitted with
Partnerr
Bearings designed autonomous sensors and valves. Local
and manufactured to flooding represents a rising threat to prop-
erty, infrastructure, and the environment.
Aurora’s exacting
movingr
“Networked vehicles such as these
standards for quality offer a way to get rainfall information at
resolutions we’d not seen before,” says
and durability. Branko Kerkez, a UM engineering profes-
forwardd
sor. “It’s more precise than radar and lets
us fills gaps in existing rain gauge net-
works.”
The best current warnings for flood
Registered and Certifed conditions come from the combination
of satellite radar tracking and rain gauges
to ISO_9001 and AS9100. spread over a wide geographic area.
Both have poor spatial resolution, mean-
From economy ing they cannot capture what’s happen-
commercial ing at street level.
“Radar has a spatial resolution of a
to aerospace approved, quarter of a mile and a temporal resolution
we’ve got it all! of 15 min.,” says Ram Vasudevan, an-
other UM engineering professor. “In con-
trast, wipers have spatial resolutions of a
few feet and temporal resolutions of a few
seconds, which can make a huge differ-
ence in predicting flash flooding.”
Earlier this year, the European Academy
of Sciences reported the number of floods
and extreme rainfall events increased by
more than 50% this decade and happen
four times more often than they did in
1980.
R “Because of the sparseness of ra-
dar and rain gauge data, we don’t have
Aurora Bearing Company enough information about where or when
901 Aucutt Road it is raining,” Vasudevan explains. “If you
Montgomery IL. 60538
have fine-grain predictions of where there
complete library of CAD drawings and 3D models available at: is flooding, you can efficiently and effec-
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News
tively control water networks to prevent of this data collection at a system scale,” but there will surely be more examples
all sorts of dangerous chemicals from Kerkez says. “Right now, we’ve made of data sharing between interconnected
contaminating our water supply due to connections between cars and water, infrastructure systems.” 
runoff.”
Creating a blanket of sensors across
a city for street-level data on rain events
would be costly. But using connected ve-
hicles taps a resource that can be easily
put in place now and will only grow larger
in the future as more cars are added into
the IoT.
Researchers collected data from a set
of 70 cars outfitted with sensors embed-
ded in windshield wipers and dashboard
cameras. That program, called Safety
Pilot, was the world’s largest connected
vehicle test program with roughly 3,000
participants. It is now called the Ann Arbor
Connected Vehicle Test Environment.
Kerkez and Vasudevan say their re-
search represents the first step in creat- Analysis of a single vehicle trip occurring 21:46 to 22:26 on Aug. 11, 2014. The top two panels
ing a smart infrastructure network fed by show video footage during the trip’s rainy (left) and dry (right) segments. The bottom left
and responding to data collected from panel maps the vehicle’s trip, with wiper intensity indicated by color. A radar overlay shows
vehicles on the road. But more work will average rainfall intensity over the 40-min. period. Blue circles represent the gauges nearest
be needed to bring the concept to fruition. to the vehicle path. The two bottom right panels show precipitation intensity as estimated
“One day, when everything is con- by radar and gage measurements (center), and the 1 min. average wiper intensity (bottom).
nected, we’re going to see the benefits (Courtesy: Scientific Reports)
WORLD’S FINEST GOLD SPECIMEN PROBED

With Los Alamos Neutrons
A TEAM OF researchers at Los Alamos Found in 1887 at the Ground Hog Mine
National Laboratory scientists has peered in Red Cliff, Colo., the Ram’s Horn is mys-
inside one of the most unique examples of teriously shaped like a twisted bunch of
wire gold using neutron characterization wires instead of the more recognizable
techniques. It has helped the research- golden nugget. It has baffled mineralogists
ers understand the specimen’s structure since its discovery. The unknown: What
and possible formation process. The 263- is its fundamental structure and how did
gram, 12-centimeter tall specimen, known it form?
as the Ram’s Horn, belongs to the collec- “Some native metals or metal alloys
tion of the Mineralogical and Geological found in nature can occur in what is called
Museum Harvard University (MGMH). wire morphology,” says John Rakovan,
“Almost nothing other than the exis- professor of mineralogy at Miami Univer-
tence of the specimen is known about sity in Ohio. “Much more common in sil-
This gold wire specimen was bequeathed wire gold,” says Sven Vogel, a physicist at ver, the wire morphology is rarely seen in
to Harvard University in 1947 as part of the Los Alamos National Laboratory’s neutron gold samples and this specimen is without
A.C. Burrage Collection. It is now housed in science center, LANSCE, a half-mile-long question the finest known example.”
the Mineralogical and Geological Museum at particle accelerator that provides high- Because of its rarity and associated
Harvard, one of the oldest and continuously and low-energy protons and neutrons for monetary value it is not possible to cut into
operating mineral museums in the U.S. a wide variety of scientific research. or break open the specimen, and because

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air cylinders you need. diagnostics can only investigate exterior to the gold in the crystalline structure at
surfaces, so no scientific studies have the atomistic level.
ever been published on the internal nature The results of this study will have impli-
of this specimen—until now. cations for geoscientists who are trying to
The research results suggest wire gold understand the geochemical processes
is very different from wire silver. “Wire silver that are at play in the formation of gold
is a mosaic-like polycrystalline aggregate deposits, as well as for materials scientists
with many hundreds to thousands of crys- and engineers who may use the unique
tals in a single wire,” says Rakovan. “The properties of these materials in techno-
The Original Pancake® gold appears to be composed of only a logical applications.
few single crystals. Furthermore, we dis- The sample will be the centerpiece of
covered that these samples are not pure a new exhibit at the Harvard Museum of
gold, but rather gold-silver alloys with as Natural History in the spring of 2020—
much as 30% silver substituting for gold in “The Rare and Beautiful”—highlighting the
the atomic structure.” aspects that make an object valuable, and
“We knew that on the surface this gold how humankind’s appreciation for beauty,
Pancake® II
sample was about 70% gold, but nobody rarity, uniqueness, and culture have
Compact Interchange
knew if that was only true for the surface,” shaped those values. The gold wire is not
adds Vogel. “Using a neutron source we just the world’s finest gold specimen, but
normally use to study materials such as it also represents unique circumstances of
uranium alloys and nuclear fuels, we veri- formation that reveal its forming process
fied that this sample is homogeneous, and ultimately the history of Earth. The
F and H Series meaning the whole sample is a 70-30 mix exhibit is a rare opportunity for the public
on-repairable of gold to silver.” to see this gold specimen, normally kept
Round Body In a separate study, Rakovan and in a bank vault out of sight.
colleagues recently discovered that the “These academic collaborations really
growth of wire silver leads to an unex- push the envelope for us,” says Vogel.
pected isotope enrichment. The Los Ala- “We usually use the LANSCE accelerator
mos team is using the neutron spectros- to characterize materials that are relevant
copy data to evaluate if gold-silver alloys to the Los Alamos mission, but we some-
also have isotope enrichment. times get to apply it to geological samples
Another surprising discovery in the gold like this very famous gold specimen. It’s a
sample was the uniformity of its gold/silver win-win for the Laboratory and the univer-
mixture. Because the alloy is highly homo- sities.” 
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AIR FORCE USES 3-D PRINTED PARTS on
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AFTER SEVERAL WEEKS of printing, in- of 3D printing (also known as additive
spections, and component testing, the manufacturing). Engineers redesigned
Air Force recently installed 17 3D-printed the handles to be more ergonomically
FPA parts in both polymer and metal on a C-5 friendly, lighter, and more able to oper-
OEM Series Galaxy transport jet in less than three ate despite minor installation variations.
days. The parts are used in various parts They also reduced the build time and
of the cabin and crew bunk areas of the eliminated the two-tone, multi-coat paint
Want to learn more? plane and included overhead panels, scheme that has been used since the
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News
eye on cost and reducing

cycle times was critical. (Photo by Tech. Sgt. Justin D. Pyle)
A i r F o rc e e n g i n e e r s
worked with the company
that supplies the polymeric
raw material to get the
printed material to be “gun-
ship grey,” so parts could
be printed in the color re-
quired for the interior cabin.
This eliminated the need
for painting prior to instal-
lation.
Many of the parts that
were replaced with their
printed counterparts were
not available for purchase
or had long lead times. So using 3D print- metal printed components on the aircraft. production will increase.
ing may only take a couple of days to Some will be made of titanium and other The RSO estimates that future field pro-
print parts instead of the weeks, months, high strength alloys, driving the technol- duction of just these 17 parts alone could
or even years it takes to acquire parts ogy to the next level. save tens of thousands of dollars, at the
through traditional measures. As the Air Force’s additive manufactur- same time improving part performance
In the near future, the Air Force planes ing library of parts continues to grow, the and continuing to improve aircraft readi-
to install at least 20 more polymer and cost benefits of additive manufacturing ness. 
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News
THE POWER OF THE HEARTBEAT to Charge Medical Devices

MEDICAL HEART DEVICES like pacemak- test results demonstrated a maximum under a National Institute of Health fund-
ers and defibrillators rely on batteries for electrical output yield of 0.5 V and 43 nA ing grant and has two years left to finish
power, but these batteries have to be re- under the frequency of 1 Hz. The team the pre-clinical process and obtain regula-
placed every 5 to 10 years. Every surgery, found that adding a proof mass of 31.6 tory approval. Engineers on the program
even ones that are routine like battery re- mg on the dual-cantilever tip results in a have also started to investigate how the
placement, can introduce new complica- 1.82 times power enhancement. technology can be used to charge other
tions and can be costly. To help prevent The research team is currently working implanted devices as well. 
these types of surgeries, researchers at
Dartmouth College are developing new
methods to generate electricity by leverag-
ing the strength of the human heartbeat.
Engineers at the Thayer School of En-
gineering at Dartmouth have designed a
dime-sized piezoelectric cantilever that is
both flexible and porous. The new design
incorporates a polyvinylidene fluoride-
trifluoroethylene thin film within a dual-
cantilever structure wrapped around a
pacemaker lead with two free ends. The
free ends extend out from the pacemaker
to harvest energy from the heart’s motion.
“We’re trying to solve the ultimate prob- Rendering of the two designs of the cardiac energy harvesting device. (Art by Patricio Sarzosa)
lem for any implantable biomedical de-
vice,” says Dartmouth engineering profes-
sor John X.J. Zhang, a lead researcher
on the study which was conducted with
help from clinicians at UT Health San An-
tonio. “How do you create an effective
energy source, so the device will do its job
during the entire life span of the patient,
without the need for surgery to replace
the battery?” Along with creating a power
source that would last for the duration of
the patient’\’s life, the device needs to not
interfere with the body’s normal function.
“We knew it had to be biocompatible,
lightweight, flexible, and low profile, so it
not only fits into the current pacemaker
structure but is also scalable for future
multi-functionality,” adds Dartmouth re-
search associate Lin Dong, first author on
the paper.
The research paper “Energy Harvesting:
Flexible Porous Piezoelectric Cantilever on
a Pacemaker Lead for Compact Energy
Harvesting” (https://onlinelibrary.wiley.
com/doi/10.1002/admt.201970002) was A) Concept of piezoelectric thin film energy harvester for implantable cardioverter defibrilla-
published last month and detailed the first tor and a flexible porous PVDF-TrFE dual-cantilever energy harvester on the AICD lead.
three years of research on the project in- B) Video analysis of chronically implanted pacemaker leads from a dog. C) A dual-cantilever
cluding animal testing results. The initial energy harvester within a soft tube on the AICD lead. (Image credit: Dartmouth College)

News
MARTIAN OPPORTUNITY ROVER: RIP

ONE OF THE MOST SUCCESSFUL inter- tenna at NASA’s Goldstone Deep Space mand send at part of an eight-month re-
planetary exploratory missions, that of Complex in California. It was the last com- covery effort to get the rover to talk back.
NASA’s Opportunity rover, came to an
end after almost 15 years roaming the
surface of Mars. NASA lost communica- NASA’s Opportunity rover.
tion with the rover last June when a plan-
etwide dust storm apparently put it out
of commission. Some scientists believe
dust from the storm covered its solar ar-
rays, causing it to run out of power.
Designed to last just 90 Martian days
and travel 1,100 yards (1,000 meters),
Opportunity went above and beyond the
call of duty in its endurance, scientific
value, and longevity. In addition to ex-
ceeding its life expectancy by a factor of
60, the rover traveled more than 28 miles
(45 kilometers) by the time it reached its
most appropriate final resting spot on
Mars, Perseverance Valley.
The final transmission from Earth was
sent using the 230-ft Mars Station an-
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News
panels from recharging its batteries. Its All those accomplishments were not
last communication with Earth was in without the occasional extraterrestrial ac-
March 2010. cident. In 2005, for example, Opportunity
During its life, Opportunity set several lost steering to one of its front wheels; a
milestones: heater got electrically stuck in the “on” po-
• Setting a one-day Mars driving re- sition, which threatened to limit the rover’s
cord (March 20, 2005) of 721 ft (220 available power; and a sand ripple almost
m); trapped it for good. Two years later, the
• Returning more than 217,000 im- rover had to withstand a two-month dust
ages of Mars, including 15 360- storm. In 2015, Opportunity lost use of
deg. color panoramas; its 256-megabyte flash memory and,
• Exposing the surfaces of 52 rocks in 2017, it lost steering to its other front
to reveal fresh mineral surfaces wheel.
The rover landed on Mars on Jan. for analysis, while clearing 72 ad- Mars exploration continues. NASA’s In-
24, 2004, seven months after being ditional targets with a brush to Sight lander, which touched down on Nov.
launched from Cape Canaveral Air Force prepare them for inspection with 26, is just beginning its seismic investiga-
Station in Florida. Its twin rover, Spirit, spectrometers and a microscopic tions. The Curiosity rover has been explor-
which was also planned for a 90-day imager; ing Gale Crater for more than six years.
mission, landed 20 days earlier on the • Finding hematite, a mineral that Looking ahead, NASA’s Mars 2020 rover
other side of Mars. Spirit operated for forms in water; and and the European Space Agency’s Exo-
seven years and logged almost 5 miles • Discovering strong geological in- Mars rover will launch in July 2020, be-
(8 kilometers) before its mission ended dications at Endeavour Crater of coming the first rover missions designed
when it became stuck in sand. It was the remnants of an ancient body of to seek signs of past microbial life on the
stuck at an angle that prevented its solar water. Red Planet. 
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News
INTERNET OF THINGS for Pneumatic Systems

THE PAST FEW YEARS have witnessed IoT can be defined in terms of gathering and
significant interest around the Internet analyzing meaningful data that can be acted
of Things (IoT) and Industry 4.0. In the upon.
manufacturing world, the concept is of-
ten referred to as the Industrial Internet
of Things (IIoT) and it is noticeably mak-
ing gains in every corner of the factory
floor. Enhanced computing power and the
advent of big data is helping to turn the
promise of IIoT into reality—connected
components within larger systems that
bring machine intelligence to the device
level. ment across nearly every industry. Medical with dynamic machinery and automated
The point is to seamlessly gather data, device assembly, automotive production, equipment are beginning to rely ever more
analyze it on the fly, and turn that informa- food processing, and numerous packag- heavily on real-time data analysis. IIoT en-
tion into actionable results that increase ing applications are all beginning to reap ables up-to-the-minute assessments via
uptime, efficiency, and productivity. the benefits of connecting smarter de- an extensive network of smart sensors
From robotic systems and highly au- vices with onboard intelligence. that allow pervasive, system-wide data
tomated assembly lines to discrete com- harvesting based on a robust commu-
ponents like pneumatic valves and ac- DATA ANALYTICS AND ACTION- nication backbone infrastructure. In this
tuators, IIoT is working its way into the ABLE RESULTS way, large amounts of data are continu-
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For example, consider the impact IIoT

is beginning to have on the packaging in-
dustry. Enabled by smart components
supported by the appropriate comput-
ing and network infrastructures, manu-
facturing problems could be prevented
before they even occur. Imagine a smart
pneumatic device, for example, that could
report a clogged or dirty filter before it gets
bad enough to slow or halt a packaging
process. The goal is to make the shift from
a merely diagnostic capability and men-
tality to one that is truly prognostic and
forward-looking.
Another way to look at this productivity
evolution is to think about it as a journey
from reactive to preventive to predictive
Plants don’t always have the necessary infrastructure due to competing IoT standards such maintenance. IIoT data gathered at the
as EtherNet/IP, Profinet, and others. device level can be used to drive improve-
ments in machine reliability in terms of
availability (maximum run time), perfor-
mance (ideal cycle time), and quality (good
part count with minimal scrap).
IMPLEMENTING IIoT
Although the potential benefits of a
well-executed IIoT system are extremely
promising in terms of productivity im-
provements, the path to full implementa-
tion is not without challenges. First, the
basic infrastructure is still evolving. By its
very nature, IIoT generates a tremendous
volume of data that must be aggregated,
analyzed, and then acted upon. Manu-
facturing applications require real-time
Future-proof IoT platforms start with embedded intelligence at the device level that can data that calls for an entirely new class
enable local analytics. of components—those with dedicated
device-level intelligence. Both edge and
device level of the factory floor environment effectiveness or OEE—in other cloud-based computing strategies need
ment. Once collected, this raw data is words, maximizing productivity and mini- infrastructure capable of handling the new
analyzed and turned into useful informa- mizing (or even eliminating) unplanned realities of big data, and these systems
tion. Smarter devices than those installed downtime. The concept is straightfor- are still taking shape.
even a few years ago are now required to ward and offers numerous benefits, such In addition to the work-in-progress
support real-time local analytics, device as higher yields and improved quality, a status of today’s IIoT landscape, stan-
analytics, and system-level intelligence, holistic view of system integrity, better in- dards are equally haphazard. The reality
including both edge and cloud computing ventory control, lower cost of ownership is that no unified standard exists to drive
strategies. due to energy optimization, and the abil- IIoT infrastructure on a global basis. From
The goal of data gathering and analysis ity to access analytic results remotely on Industry 4.0 and the Industrial Internet
is to convert all of that activity into action- a 24/7 basis. The capacity to gather and Consortium to China Manufacturing 2025
able results. This simply means using the use data to drive decisions that directly and Smart Factories, various regional and
information gleaned from analyzing de- impact productivity is the very essence industry-specific strategies exist when
vice-level data to improve overall equip- of IIoT. it comes to developing IIoT standards.

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News
Add that to the usual decisions around in- diagnostic and prognostic information-
dustrial communication protocol choices gathering happens at the device level. This
such as Ethernet/IP, Profinet, IO-Link, is also a technically superior approach
and others. The result is a patchwork IIoT due to computing power at the device
infrastructure spread across the broad level that enables analysis of sensor-level
manufacturing world. data in real time. In addition, as the IIoT
infrastructure develops and matures, the
DEVICE-LEVEL ANALYTICS device-level information stays relevant. Fi-
The evolution of IIoT standards and nally, this strategy allows predictive main-
infrastructure are largely being driven tenance today due to the availability of
by PLC manufacturers. Therefore, one device prognostic data.
platform that is truly future-proof starts When properly analyzed, IIoT data
with embedded intelligence at the device can lead to the right kind of prognos-
level. For example, consider a pneumatic tic information that makes true predic- Device analytics can gather relevant and
fieldbus valve manifold such as the ASCO tive maintenance a reality. This in turn useful information on smart pneumatic
Numatics G3 platform, which extends in- allows for accurate predictions involving devices regardless of plant infrastructure.
telligence to perform a variety of IIoT data machine performance and avoidance of
analytics locally—at the device level. This component and system failures. All of SMARTER PNEUMATICS
approach offers several benefits. this data analysis translates to reduc- Achieving the full promise of IIoT
First, it provides the ability to gather tions in downtime, lower maintenance and significantly improved productivity
relevant and useful information on smart and inventory costs, improved machine benchmarks is going to require smarter
pneumatic devices regardless of overall health, higher and better-quality yields, devices across the entire manufactur-
plant infrastructure. Further, no changes and increased equipment effectiveness ing spectrum. Let’s consider a scenario
are required to the PLC program because and productivity. with a modular, scalable, distributed I/O
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FREE WEBINAR
March 21, 2019 | 2:00pm EST
Registration URL: https://www.electronicdesign.com/webcasts/simulation-focused-ultrasounds-medtech
SIMULATION
OF FOCUSED
ULTRASOUNDS
FOR MEDTECH
Focused ultrasound signal generated by 16 piezoelectric transducer elements.
Ultrasounds are widely used in several industries

SPEAKERS:
and use cases, like the nondestructive testing (NDT)
of metallic parts or for medical imaging, one famous Thomas Clavet, Principal Engineer,
example being echography. EMC3 Consulting
Thomas Clavet founded EMC3 Con-
The advantage of ultrasounds is being able to reach a sulting in February, 2014, to support
volume inside matter without afecting the surface and companies (including SMEs, major
industrial groups, and research
what is between the surface and the zone of interest.
laboratories) in their use of digital
simulation for acoustics, thermal,
In the medical technology (medtech) industry, high- mechanical, and flow (CFD) ap-
intensity focused ultrasound (HIFU) surgical tools are plications. Prior to becoming a COMSOL Certified Consultant,
designed based on focused ultrasounds and produce a Thomas was a mechanical engineer in the nuclear industry
localized elevation of temperature and necrosis of bio- and an applications engineer at COMSOL in the UK and Ire-
logical tissues, for instance, for the treatment of some land, where he was able to meet many COMSOL Multiphysics®
types of cancer. users from a variety of backgrounds and industrial sectors.
Thomas is an Arts et Métiers ParisTech engineer and holds a
Simulating the acoustics and heat transfer phenomena master’s degree in mechanics and numerical methods from
involved in such tools allows engineers and research- the Royal Polytechnic Institute (KTH) in Stockholm, Sweden.
ers to select the combination of parameters that will
deliver the right amount of energy in the targeted zone James Gafney, Applications
Engineer, COMSOL
and limit the damage to the surrounding healthy tis-
James Gafney works at COMSOL
sues. There are numerous parameters, including the
as an applications engineer for
size of the transducer that transmits the ultrasounds, acoustics. He studied acousti-
the frequency of the signal, and the duration of the cal engineering at the University
treatment. of Southampton, where he also
earned his doctorate degree. His
In this presentation, Thomas Clavet from EMC3 Con- research involved predicting the
sulting will discuss how HIFUs can be produced and key fuselage installation efects from engine fan tones with ana-
points about how to model this multiphysics problem. lytical methods.
Hosted with
News
O
ne of the chief benefits of device-level analytical capabilities
is that they can circumvent the PLC. This means zero
programing changes to the PLC and no data mapping required. However,
it is still possible to map data to the PLC as needed. In addition, with an
integrated web server and LCD display, it’s easy for plant personnel to
check on device health either in person or by using a simple app on a
mobile device.
system integrated into a pneumatic valve
manifold used in applications such as
bottling, packaging, and medical device
assembly. In this setup, both centralized
and distributed applications use the same
modules to increase flexibility and reduce
complexity. On the manifold, an integrated
graphic display is used for configuration Properly analyzing IoT data lets plant managers accurately predict and avoid component and
and point-of-use diagnostics—and now system failures, thus reducing downtime and increasing OEE.
prognostics. Finally, adding device ana-
lytics makes the valve manifold “smart” tabs on critical parameters such as air the system level. Application develop-
and capable of making a real impact on leaks and mission time. Following are ment is simplified via Node-RED graphic
productivity. a few examples of IIoT in action at the tools. Pre-packaged smart pneumatics
One of the chief benefits of device-level device level: solutions are available and do not require
analytical capabilities is that they can cir- Monitoring valve cylinder perfor- cloud computing, although the cloud can
cumvent the PLC. This means zero pro- mance. Smart valve manifolds with de- be used if desired. Node-RED is a visual,
graming changes to the PLC and no data vice analytics are able to track the time flow-based programming tool for IIoT, with
mapping required. However, it is still pos- it takes for the cylinder to extend and more information available at nodered.org.
sible to map data to the PLC as needed. retract. The manifold then determines if These are just a few simple examples
In addition, with an integrated web server the cylinder extend/retract time varies by of what IIoT can accomplish today at the
and LCD display, it’s easy for plant per- a previously user-determined percent- device level in terms of pneumatic com-
sonnel to check on device health either age. If the variance exceeds the preset ponents. In the short term, onboard de-
in person or by using a simple app on a threshold, the manifold warns the user vice analytics can offer connectivity and
mobile device. Apps are able to promptly so corrective action can be taken before analysis. Taking IIoT to the next level will
report critical issues that affect machine productivity is affected. The key here is involve an edge computing strategy where
and component functions, heading off that no PLC action is required and existing an infrastructure edge gateway device will
larger problems that may otherwise go cylinder sensors may be used. enable system analytics. The long-term
unchecked. Finally, although higher-level Tracking pressure variances over view will involve cloud computing and true
computing resources are not required for time. Intelligent valve manifolds with de- enterprise-level analytics.
device-level intelligence, edge and cloud vice analytics can also be used to monitor As billions of smart devices continue
computing are both supported by many of the efficiency of the filter element—again, to join the IoT framework and 5G begins
today’s smart devices. with no PLC involvement needed. The to be commercially deployed on a global
manifold sends a message to the user basis, IIoT strategies across the manu-
IIoT IN ACTION when the filter element needs attention or facturing world will strive to keep pace.
Let’s take a closer look at what type of replacement. In other words, the warning There is no reason to delay testing the IIoT
information can be collected at the pneu- is sent before machine performance is waters with device-level intelligence as a
matic device level. Smart valve manifolds compromised. first step. 
are able to capture and analyze data to Implementing edge computing.
monitor the performance of parts such as Edge computing gateways expand data ENRICO DE CAROLIS is vice president
valve cylinders and filter regulator lubrica- management, aggregation, and analysis of Global Technology at Emerson (www.
tor (FRL) filters, in addition to keeping capabilities across multiple devices into emerson.com).

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Medical Materials
JEFF KERNS | Technology Editor
MD&M 2019:
Medical Materials
Materials take on new challenges in the medical industry as companies exhibiting at
this year’s MD&M educate us on what is needed.
E
ntering the Anaheim Con- sion, advances in medical treatments, Medical professionals having the ability
vention Center in California and rising labor costs. Previous medical to access all patient’s information in one
for the MD&M show, it’s shows have showcased smart medical location while still abiding by HIPA and
always exciting to see what solutions that range from new materi- other regulations is imperative. Track-
companies are presenting. Global health als to advanced connected devices and ing parts, devices, and doses can be a
care spending is projected to increase software. The following is only a small difficult and labor-intensive process.
at an annual rate of 4.1% in 2017 to taste of just some of the medical material Companies offering a full digital thread
2021, an increase of 1.3% from 2012 to companies that will be at MD&M—not to track everything from the resource
2016. According to a 2019 report from to mention, there are four other shows provider, to manufacturer, to hospital, to
Deloitte, global health care expenditures featuring material companies happen- patient will increase the speed and qual-
are expected to continue to rise as spending in the same building. ity of today’s healthcare.
ing is projected to increase at an annual
rate of 5.4% between 2017 to 2022. This MD&M WEST 2019 EASTMAN CHEMICAL CO., BOOTH
growth means the market could grow Already on day one there is a trend 2301—MAINTAIN STRENGTH
from $7.724 trillion to $10.059 trillion. to move digital. This isn’t a huge shock, AFTER MULTIPLE CLEANINGS
Deloitte attributes this growth in as manufacturing in multiple industries Last year Eastman was talking about
the market to an aging and increasing is taking advantage of this in line with its Tritan copolyesters. This grow-
population, developing market expan- other developments in manufacturing. ing family of medical grade plastics is
aimed at medical devices and housings.
An Eastman representative said many
devices are designed to be mobile that
give way to it being dropped. While
designed for this inevitability, disin-
fecting agents can breakdown polymer
chains causing the housing to break pre-
maturely, especially if dropped.
The relatively new polymer will
probably also be on display this year,
as it is able to work in a wide range of
industry needs that have previously
been unmet. The clear formulations of
Tritan are known not only for maintain-
ing functional integrity after repeated
In a recent report from Global Market Insights, the medical gas equipment market alone is sterilization, resistance to lipids, and
projected to grow at 7.6% CAGR between 2018 to 2024, exceeding a revenue of $7.2 billion disinfecting agents, but also for greater
by 2024. toughness, heat resistance, processabil-

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A
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expenditures are expected to continue to rise as spending is
projected to increase at an annual rate of 5.4% between 2017 to 2022. This
growth means the market could grow from $7.724 trillion to $10.059 trillion.
ity, and design freedom compared with AVANTOR, BOOTH 2305— formulations. A wide range of NuSil
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Avantor announced on Jan. 14th that adhesion to various substrates. In addi-
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patible silicone adhesive at the show. The highlight several other NuSil biomate-
silicone solutions help medical device rial solutions, including lubricious sili-
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also debut soft skin adhesive and an Nick Packet, medical device manu- DowDuPont Specialty Products Divi-
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cal packaging material for protecting global technical service consultant, Packaging Impacts Life Cycle Costs &
lightweight, lower-risk Class I and II
devices.
Dow Corning will be featuring brand
medical-grade silicones, which include
silicone elastomers, and solutions for
siliconization. In addition, teams will
share industry leadership and expertise
during presentations:
Roger Hendrick, technical service
and development scientist, DowDuPont
Specialty Products Division, will give
a presentation titled, “Healthcare Liq-
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ature Overmolding Applications” on
Tues., Feb. 5, from 10:15-11 a.m. PST.
Hendrick will discuss the character-
istics of low-temperature-cure liquid
silicone rubber, improvements in cure
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Medical Design & Manufacturing West Conference
CARLOS M. GONZALEZ | Content Director
11 of the Best Images from

the 2019 Medical Design &
Manufacturing West Conference
MD&M hosts several thousand medical exhibitors and holds the largest MedTech
conference in North America. Here are some of the highlights we saw this year.
T
he Medical Design & Man-
ufacturing (MD&M) West
conference is an annual
gathering place for the
global medical manufacturing commu-
nity. The conference hosts more than
1,900 medical suppliers from differ-
ent medical sectors including automa-
tion, research & development, medical
device components, materials, robotics,
and 3D printing.
This year the show focused its con-
ference tracks, which is the largest
MedTech conference in North America,
on 3D printing and smart manufactur-
ing. The conference tracks totaled more
than 30 hours of deep-dive coverage in CVC’s Simple Smart packaging solutions.
how to leverage these tech innovations
such as 3D printing for medical research AETHON try. TUG is built to be an Industry 4.0
and integrating advanced robotics and TUG is Aethon’s mobile robot which solution for robotic mobility, offering
automation features into one’s medical looks to change the healthcare indus- safe travel around hospitals via lasers,
production. Here are some of the high- ultrasonic, and infrared sensors. The
lights of the MD&M West Show. TUG can carry up to 1,400 lb. of sup-
plies and navigates via digital mapping,
CVC TECHNOLOGIES requiring no fixed infrastructure like
One of the key benefits of automation magnets or beacons for guidance. TUG
is being able to speed up one’s process. can also handle real-time requests from
CVC Technologies (http://www.cvcusa. operators and automation equipment
com/index.html) is a leading manufac- like PLC controllers.
turer in the tablet, powder, and liquid
packaging equipment industry world- ONROBOT
wide. Its electronic counters highlighted OnRobot offers an in-depth prod-
above are economically designed for uct line of end effectors which can be
either semi- or fully-automatic count- mounted to any robotic arm. Their line
ing of tablets, soft gels, and capsules into of end effectors includes traditional
bottles. The machine can either operate grippers but also features multi-func-
at mid or high speed to expedite medical tional vacuum and material adhering
packaging. Aethon presents mobile robot “TUG.” grippers. The Gecko Gripper, the large

OnRobot one stop shop for end effectors. Apple Rubber providing medical sealing solutions.
end effector on the table, is inspired exposed to prevent contamination. All Pittman motion solutions. They spe-
by nature and uses a special adhering the wiring is internal, and the backup cialize in custom application needs for
material to pick up objects. Once the battery is installed outside the robot for any motion driven system. Their motors
force is applied it can pick up objects cleaning ease and space savings. vary in size and one of their main mar-
with clean surfaces like glass or metal. kets are miniaturized motors for medi-
The VG10 vacuum gripper requires no APPLE RUBBER cal applications. Future compact medi-
external air supply and can be config- In the medical field, sealing solutions cal devices, especially those that can
ured into multiple shapes. that meet the requirements of cleanroom be implanted, will require mini-sized
certification are extremely important. motors that can deliver the required
DENSO Apple Rubber offers an entire line of torque or linear motion.
The DENSO VS-050-S2 is a 6-axis simple seals to custom complex silicone
robotic arm is specifically designed for parts for different cleanroom and medi- TE CONNECTIVITY
pharmaceutical, medical, and life sci- cal applications. Their seals are ISO Class TE Connectivity is known for its elec-
ence applications. This robot has a pro- 7-certified, meaning they can be used in trical connectors and devices. However,
tective outer coating and sealed joints inspection rooms and main cleanrooms. they offer an extensive lineup Smart
which allow for sterilization with hydro- For microminiature medical applica- Form catheter and medical guidewire
gen peroxide and UV light. This is cru- tions, they offer seals measuring from products. The lineup includes standard
cial for biocontamination control for 0.990 mm inner diameter down to 0.305 angioplasty balloons to complex shapes
many medical applications. The robotic mm inner diameter sizes. These sizes for advanced clinical applications. Their
arm has a smooth surface with round- will become more important as medical materials include nylon, PET, polyure-
ed edges and no external screws are device manufacturing becomes smaller thane, and Pebax and can be used for
and more compact in the future. various medical applications including
dilation.
AMETEK MOTION SOLUTIONS Innovations in simulation technol-
Ametek Motion Solutions includes ogy have allowed for new training tools
products from both Haydon Kerk and to emerge. This includes using simu-
Ametek Motion Solutions provides motors TE Connectivity’s catheter and medical

DENSO’s medical applications robotic arm. for all medical applications. guidewire product lineup.
(Continued on page 77)
Technology Trends
ANANYA BHANDARI | Research Analyst, Medical Devices and Healthcare IT, Grand View Research
[email protected]
The IoT Ushers in a

Healthcare Industry
Revolution
Introducing IoT as a platform and concept has redefined the machine-to-human
(M2H) interaction for efficient healthcare facilities—and increased the vulnerability
to hackers.
A
s we a l l k now, t he though, IoT and M2M are two different be connected by 2020, up from 15 bil-
Internet of Things concepts. lion in 2015—nearly a 1,233% increase.
(IoT) is a connected The most important element that On a global scale, 200 billion connect-
network of devices, the companies should focus on before ed devices approximately equate to 26
wherein the devices are connected to implementing IoT or M2M concerns smart devices per person. The surge in
each other and to the internet with their business model, specifically the adoption of smartphones or any smart
the help of wireless technology. These need to provide add-on value to its devices is one of the key factors depict-
devices are rooted with sensors, actua- customer. Before investing in any such ing the level of awareness regarding con-
tors, electronics, and software solutions, technologies, the companies should nected applications.
which enables these connected devices think about its effectiveness in its busi- • According to statistics published
to deliver experience in real time. ness model and return on investment in industry journals, over 25.3% of the
When we talk about IoT, people often (ROI). global population was reported to use
get confused with the term machine-to- smartphones in 2015, which rose to
machine (M2M) communication. M2M THE IMPACT OF IoT IN SMART 33.3% in 2017.
communication and IoT is essentially DEVICES • According to the industry esti-
based on the same concept, i.e., commu- The rate of IoT implementation is mates in 2014, the number of mHealth
nicating or exchanging data with anoth- growing exponentially. Based on the apps on the two leading operating plat-
er machine/device without any human estimates from Intel research, it’s expect- forms, Android and iOS, had reportedly
intervention/interfacing. Technically, ed that nearly 200 billion devices will reached over 100,000 in last 2.5 years.

• Based on the industry data, it’s ment Information Systems (HMIS), is
reported that Western Europe, North expected to expand the scope of IoT
America, and the Middle East and Afri- in the healthcare industry. In addition,
ca have a smartphone penetration rate demand for the first-generation smart
of over 65%, 64%, and 13.6% of their devices is impacting IoT’s penetration
total population, respectively. into the healthcare industry.
According to Grand View Research
IoT TECHNOLOGY TRENDS FOR estimates, the IoT in healthcare mar-
HEALTHCARE ket was valued at approximately $98
Growing demand for connected billion (USD) in 2016. IoT in health-
health services to improve the qual- care involves wireless communication
ity of care and surge in adoption of systems of devices and applications to
connected medical devices and smart- connect patients and healthcare pro-
phones are a few factors that have viders to track, diagnose, monitor, and
significantly contributed to the tech- store the vital statistics and medical
nological advances in IoT healthcare. information.
The penetration of these technologies, Increasing demand for immediate
such as remote disease management, medical attention during medical emer-
telemedicine, and Health Manage- gencies and natural disasters, which
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IoT Healthcare Revolution
has boosted the adoption of wearable initiatives. IBM announced an invest- laboration with OpenMarket, to ensure
medical devices, drives the demand for ment of $3 billion (USD) in IoT in 2015. the accessibility and availability of criti-
real-time medical intervention. Fur- In April 2018, Microsoft announced it cal medical hardware. In 2017, Philips
thermore, IoT in healthcare is also used will invest $5 billion (USD) in IoT over received a “most innovative IoT solu-
to constantly monitor clinical measure- the coming four years. tion” award for its e-Alert system. In
ments such as blood pressure and glu- 2010, the company also introduced a
cose, as well as track any movements, ONGOING IoT DEVELOPMENTS medical alert service, called Lifeline
medication doses, and real-time home- FOR HEALTHCARE INDUSTRY with AutoAlert, targeting independent
care treatment. IoT implementation in hospitals can living senior citizens to detect patient
Various top IT players operating in significantly reduce the wait times in fall. Other developments include
this space have entered the IoT health- emergency rooms. For instance, Mt. closed-loop insulin delivery (Ope-
care market through acquisitions and Sinai Medical Center in New York City nAPS), an implantable long-term con-
collaborations with healthcare compa- partnered with GE Healthcare in 2013 tinuous glucose monitoring (CGM)
nies. For instance, IBM collaborated to develop IoT-driven software called system, activity trackers, connected
with Medtronic PLC to provide IoT ser- AutoBed. This software can process up inhalers, ingestible sensors, connected
vices. Such technologies that are used to to 80 bed requests, track occupancy for contact lenses, the Apple watch app for
monitor and track the quality of care are 1,200 beds, and track basic patient infor- fighting depression, and Arthritis—
key factors expected to impact the use of mation, such as nurse proximity. This Apple’s ResearchKit software.
these products. development had reduced the wait time
According to Grand View Research by 50% in the emergency department COGNITIVE IoT: THE NEXT LEAP
analysis, the market is oligopolistic in of Mt. Sinai Medical Center. Similarly, FOR THE HEALTHCARE INDUSTRY
nature with few participants dominating in 2015, TeleTracking Technologies Inc. What is cognitive computing?
the IoT in the healthcare market, namely also announced a collaboration with The term cognitive is essentially
Microsoft, Philips, Cisco, Cerner, and GE Healthcare to design an integrated defined as “thinking.” Of course, we’re
IBM. These companies have adopted operational platform to reduce waste, aware of the fact that computers/
various strategies to gain larger market improve care delivery, and optimize machines don’t yet have the capability
share: acquire a smaller firm with tech- hospital operations. to think like human being. However, in
nical expertise, increase R&D invest- Moreover, Philips developed an IoT- this case, we’re referring to three terms—
ments, and boost collaborative research driven solution, called e-Alert, in col- understanding, reasoning, and learning.
The chart illustrates the estimates and forecasts in the global healthcare market from 2014 to 2025. (Source: Grand View Research)

By understanding, it means the abil- records. IoT in healthcare is expected
ity to take both structured and unstruc- to involve mass participation of end
tured data in its system and establish users, which may lead to a variety of new
a model of relationship, concepts, and potential risks concerning data privacy
entities out of it. By reasoning, it means and security issues. The escalation in
without separately programming for incidences of data privacy and security
each problem, we can derive a solution issues is one of the key factors expected
from the established model. Similarly, to hinder the growth of IoT in healthcare
by learning, it means the ability to infer market.
new knowledge from the stored data, According to the office of Civil Rights
both structured and unstructured. in HHS, there were approximately 199
protected health information (PHI)
What’s the significance of cognitive breaches affecting over 7 million patient
computing in IoT? records in 2013. Moreover, despite
• Applying machine learning is the huge benefits of Electronic Health
important for scaling the data derived Records (EHRs), public acceptance of
from the connected devices/machine. EHR technology has been inhibited due
The huge amount of data generated to the risks involving the privacy and
from these connected devices can easily security of PHI.
overwhelm a human’s ability to analyze For example, in February 2015, the
and derive patterns out of it. Anthem company was hacked, and the
• This enables us to move beyond attack exposed over 80 million patients’
machine interface paradigms, which PHI. According to various reports, the
requires a human to learn specialized cases of data breach in the U.S. have
interface programs to interact with the increased from approximately 13 in
device/machine. Cognitive computing 2008 to over 256 in 2013. As a result,
enables humans to interact with the IoT incidences of privacy breaches increased
using its natural language. from around 0.5 million to over 9 mil-
• Integration of multiple data sources lion in 2014.
and types. However, growing government inter-
In December 2015, IBM announced vention against healthcare cyberattacks
the opening of global Watson IoT head- or crimes is one factor that’s looked
quarters in Munich, Germany. The at as helping to boost the adoption of
company also announced the launch IoT in various healthcare applications.
of several new capabilities, offerings, Other potentially key growth factors for
and a different ecosystem of partners to IoT healthcare include the presence of
expand the power of cognitive comput- designed information security, privacy,
ing to a wide range of connected devices, and data-protection authority.
systems, and sensors. IBM Watson and Since 2006, the U.S. government has
Microsoft Cognitive Services are among spent over 100 billion on the develop-
the popular cognitive-computing plat- ment of cybersecurity infrastructure.
forms out there. According to the esti- Furthermore, for the fiscal year 2016,
mates made by Grand View Research, the President’s budget proposed $14
the global healthcare cognitive-comput- billion (USD) to fund cybersecurity
ing market was valued at nearly $738.5 research and critical initiatives. The
million (USD) in 2014. budget was allocated as follows:
IS THE IoT A THREAT OR OPPOR- • Securing federal networks: $582 mil-

TUNITY TO THE HEALTHCARE lion for the U.S. Department of Home-
INDUSTRY? land Security (DHS) to implement the
Capturing patient-generated health Continuous Diagnostics & Mitigation
data is one of the vital parts of patient (CDM) program.
IoT Healthcare Revolution
• Outreach to private sector: $149 mil- laboration among them as well business activity, and extend cyberse-
lion to support R&D at civilian agencies as enhance the ability to collabo- curity ecosystems to suppliers, partners,
for innovative cybersecurity technolo- rate with the private industry and and business networks are some of the
gies. external partners. factors that can expand an organization’s
• National security and cyber threats: • The U.S. government formed the capabilities to deal with these cyberat-
$514 million for the Department of Jus- Cyber Threat Intelligence Inte- tacks. Following the leading cybersecu-
tice to investigate cyber intrusions that gration Center in 2015 and allo- rity approaches and aligning them with
pose serious threats to national secu- cated a budget of $35 million to business objectives can help impede
rity and economic stability, as well as to respond against cybersecurity cybercrime activities, too. Organiza-
prosecute the offenders. threats. tions should start positioning security as
• $160 million for information tech- a business enabler, not as an obligatory
nology and cybersecurity of the weap- CYBERSECURITY MANAGEMENT cost. Such a step could ultimately make
ons program at the Energy Department’s AND IoT INNOVATIONS MUST RUN the IoT ecosystem risk-free for each and
National Nuclear Security Administra- HAND IN HAND every organization.
tion. Organizations in a state of readiness
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Internet of Things
FREDERIC BAUDART | CMRP, Lead Application Specialist at Fluke Accelix
Is T
he Internet of Things per-
meates our lives daily,
changing the way we live
Vibration
by shifting how we con-
nect and communicate with people or
systems. The same holds true for the
Industrial Internet of Things (IIoT),
which offers similar benefits when used
Detection
to increase plant productivity and reli-
ability.
“For automation, control, and pro-
cess management, the industry has been
collecting data and using it to inform
actions for years,” said Kevin Clark, VP
the Canary in
of Fluke Accelix. “The ‘newness’ of the
IIoT is where the data can be stored—
such as in the cloud—how it is analyzed,
and then the capability to do something
the Mines for

[with] it.”
There are several maintenance strate-
gies associated with improving plant
performance, including preventive and
Manufacturing?
predictive maintenance (PM and PdM,
respectively). Condition monitoring—
part of predictive maintenance—uses
sensors and software to identify cur-
rent equipment state and performance
Keep excess vibration in check using IIoT-enabled abnormalities, such as increased vibra-
condition-monitoring sensors. tion, temperature, pressure, and more.
Vibration Detection
Market trends dictate technology do

more than simply provide measure-
ments. Devices that can connect to
online databases or third-party systems
accelerate the change in existing reliabil-
ity strategies. A truly connected frame-
work is required to meet the demands of
evolving facility environments.
A small pilot program is the best way
to start harnessing the power of IIoT
devices and can be mixed into existing
maintenance programs. Select a few
assets on which to install condition-
monitoring sensors, then scale the pro-
gram to meet the needs of the facility.
WHAT CAN VIBRATION SENSORS

DO?
IIoT-enabled, remote vibration sen-
sors upload asset measurements to
Connected reliability solutions such as Accelix track more than just vibration. With infra- cloud-based software in real-time.
red, power, temperature, electrical, and vibration data mapped to the asset inventory and Maintenance teams can use software to
trended over time, reliability and maintenance managers have the key indicators for asset view, track, and trend equipment per-
health on their screens always. formance.
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“We are looking for indications based most common problems with rotating severity. Alarms provide a safety net to
on known values of the machine when machines.” extreme conditional change, ensuring
it’s healthy and for deviations from that Using always-on vibration monitoring equipment never reaches the point of
norm, [indicating] machine condition sensors to screen for problems provides no return.
has changed from healthy to abnormal,” early warnings of equipment behavior
explained John Bernet, product applica- changes. Collected data allows users to CATCHING EQUIPMENT IN
tion specialist at Fluke. compare real-time events with historical THE ACT
When connected to software, vibra- information to determine machine fault “A lot of machines are more comput-
tion monitoring sensors:
• Provide around-the-clock asset

status
• Alert maintenance personnel to
potential equipment issues
• Record historical data useful in
identifying intermittent prob-
lems
“With vibration, we can see indi-

cations of faults 12 to 18 months in
advance, when there is still life left in
components,” Bernet said. “Condition
monitoring gives you some prewarning
and the ability to schedule corrective
repairs.”
Condition monitoring devices are
most effective when connected to com-
puterized maintenance management (∑∑∑∑∑∑∑∑∑N∑∑E∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑E∑∑∑∑∑∑∑∑∑∑Y∑∑∑∑∑∑∑∑∑∑
software (CMMS) or enterprise asset ∑SS∑∑∑∑∑∑∑∑∑∑∑∑T∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑
management (EAM) systems for data ∑∑∑∑∑∑∑∑∑∑∑∑∑7∑S∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑SS∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑
organization. CMMS/EAMs capture ∑S∑∑∑∑∑∑∑∑∑∑∑[∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑
and store aggregated data in one place.
Software trends and graphs the mea- *∑∑∑∑∑∑∑∑∑∑∑∑E∑∑∑∑∑∑∑∑∑∑∑∑∑N∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑
surements, so maintenance teams can ∑∑∑∑∑∑∑∑∑7∑S∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑E∑∑∑∑∑)$4∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑
make data-driven decisions. ∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑∑
WHY START WITH VIBRATION
SENSORS?
Change in vibration is a key indicator
of equipment health and often tops the
“why assets fail” list. Vibration comes
from rotating components, adjacent
machines, turbulent flows, foundations,
structural resonances, noise, and other
sources.
“Vibration analysis has been around
for 30 or 40 years, so the anomalies of
the four most common faults have all
been proven and well-documented…
The patterns are very easy to follow,”
Bernet said. “This makes vibration [an
ideal] technology to be able to find the
Vibration Detection
er-driven and they’re behind panels, and hoping the equipment anomaly shows not a cure-all. Elevated vibration levels
when you open the panel, the machine itself when the technician is pres- could indicate any number of problems.
shuts down,” Bernet said. “We can’t ent, wireless vibration sensors gather Best practices suggest using multiple
take a measurement then because the continuous data that can be viewed technologies to gain a comprehensive
machine shuts down.” remotely using connected software. view of asset health. Vibration monitor-
Additionally, problems might be Real-time, automatically uploaded data ing is just one way to identify equipment
intermittent and, therefore, difficult to points provide a different perspective. problems.
catch using manual routes. Rather than Viewing vibration data, however, is “Integration of data from multiple
sources allows for faster and better
maintenance decisions,” said Greg Perry,
CMRP, CRL, senior consultant for Fluke
Accelix.
WHAT’S IMPORTANT, WHAT’S NOT?

Implementation logistics should be
fleshed out before adding condition
monitoring. Each facility is different and
encounters its own unique problems
depending on machine usage and plant
environments. Implementing any main-
tenance program or strategy should be
made by individual operations, not as a
one-size-fits-all application.
Condition monitoring success sto-
ries mention the importance of review-
ing current facility maintenance status.
What’s working, what’s not, and how
will sensors help? Teams better under-
stand the path of an enhanced main-
tenance program when they assess the
current state.
Performing asset criticality analysis is
also a key to success. Once reprioritized,
many assets that may have seemed criti-
cal are found to merely be displaying
the most problems. Properly identifying
critical assets will help teams determine
where to place condition monitoring
sensors. Depending on the size of equip-
ment, more than one sensor may be
needed.
IIoT-ENHANCED SYSTEMS IMPROVE

SAFETY
When workers can access asset con-
dition data from their smart devices,
they aren’t working within hazardous
environments. The practice of removing
workers from dangerous environments
is a core element of safety and health
program best practices, known as Haz-
ard or Engineering Controls.

“
The flexibility of current and emerging
technology leaves no room for barriers.
“[Maintenance and reliability] professionals must
be able to collect asset and system measurements
however they want…This multisource information
can then be automatically stored for future study
and analysis.”
— Kevin Clark,VP of Fluke Accelix
“A lot of machines don’t have easy This multisource information can then
access—they’re up in a high place, or be automatically stored for future study
in an area where there’s temperature, and analysis...Interoperability is the key
steam, or caustic materials, or behind a to ensuring that plants and other facili-
panel,” Bernet said. ties have all the data they need in one
Deploying IIoT-enhanced condi- place.”
tion monitoring devices into existing The Industrial Revolution 4.0 (also
programs means that technicians can known as “Maintenance 4.0” and
check asset measurements from a safe “Industry 4.0”) will change the face of
distance. Furthermore, warnings from facility management and operation. The
alarms provide teams ample time to future of maintenance lies in using con-
get out to assets and into personal nected software and hardware to antici-
protective equipment before a failure pate problems.
occurs. As technologies evolve, machine
learning and artificial intelligence will
IT ALL ADDS UP further enhance maintenance decision
IIoT-enabled monitoring devices making, allowing teams to truly pre-
allow facilities to start maintain- dict impending problems. Implement-
ing equipment based on condition ing IIoT-enabled tools, sensors, and
rather than by a schedule. This pro- software is part of the path to predic-
cess is also known as condition-based tive maintenance and connected reli-
maintenance, or CBM. Adding condi- ability.
tion monitoring allows teams to gain To learn more about connected reli-
insight into equipment behaviors and ability, visit https://www.fluke.com/en-
health, empowering them to make us/products/condition-monitoring.
predictions and act before equipment
fails. ABOUT THE AUTHOR: As a lead product
Connected devices open the door to application specialist for Fluke Accelix, a
advanced maintenance connectivity. Fluke Corporation brand, Frederic Baud-
With the addition of each building block art focuses on the company’s process,
a well-constructed reliability strategy electrical, and mechanical product lines.
begins to form. He has 20 years of field service engineer-
“ The f lexibility of current and ing and preventive maintenance experi-
emerging technology leaves no room ence. He holds technical degrees in elec-
for barriers,” Clark continues. “[Main- trical and instrumentation engineering, is
tenance and reliability] professionals a Certified Materials & Resource Profes-
must be able to collect asset and system sional (CMRP), and has a thermography
measurements however they want... level I certificate.
Motion Control
DANIEL REPP and ROBERT SPADARZEWSKI | Lenze
Designing with
Motion Control
in Mind
What OEMs and design engineers need to know about motors, drives, and controllers.
W
hether design- functions. For a printing machine that to a largely linear process. Designing
ers are improv- relies on a specific set of winding appli- with motion control in mind, however,
ing a motion- cations, for example, designers would requires a mechatronics approach that
centric machine focus on the critical parts and develop includes developing the initial concepts,
or building a new one, it is essential they the rest of the machine in support of the determining the system topology and
begin with motion control in mind. core functions. machine approach, and selecting the
Then they can develop the design This sounds like Design Engineer- connection interface and software archi-
around the best way to get effective and ing 101, but with time-to-market pres- tecture.
efficient automation. sures and teams traditionally siloed into Here are some essential aspects of
Motion-based machines should be mechanical, electrical, and software motors, drives, controllers, and software
designed and built around their core departments, it’s easy for design to revert that engineers should consider from the
beginning of every machine design proj-
ect to reduce inefficiencies, errors, and
cost while making it possible for OEMs
to solve customer problems in less time.
THE DESIGN PROCESS

How and where parts move is typi-
cally where engineers spend most
of their engineering effort, especially
when developing innovative machines.
Although innovative builds are by far
the most time-consuming, they often
offer the biggest ROI, especially if teams
make use of the latest in virtual engi-
neering and modular designs.
The first step when develop-
ing a machine from scratch is to ask:
What are the critical functions of this
machine? It could be to make a machine
Motion-centric automation requires a collaborative effort between mechanical, electrical, that is easy-to-clean, low maintenance,
and software engineers. A process made much easier by carefully considering motion con- or highly accurate. Identify the tech-
trol needs early in the design process and digital engineering. nology that will deliver the required

function, performance, or vital functions. Consider
maintenance level. working with a motion-cen-
The more complex the tric automation supplier that
problem that needs to be can help define the critical
solved, the more difficult it details and determine the
will be to determine the most right approach.
Centralized, controller-based automation is best when you need

powerful, coordinated motion control.
Motion Control
Then ask: What are the machine’s standard functions? Stay- Today, virtual engineering lets teams design how machines
ing with the earlier printing machine example, the tension and will work using several parallel paths, thus dramatically short-
sensor controls used to unwind the material being printed on ening the developing cycle and the time-to-market. By creat-
are fairly standard. In fact, about 80% of a new machine’s tasks ing a digital twin (a virtual representation of the machine),
are variations on past machines’ tasks. each department can work on its own and develop parts and
Using modular hardware and code programming to handle controls concurrently with the rest of the team.
the engineering requirements for standard functions sig-
nificantly reduces the amount of design resources needed to
complete the project. It also uses time-proven functions, thus
increasing reliability and letting you focus on more complex
parts of the design.
Working with a motion control partner that can deliver
standard functions with modular hardware and software
means you can focus on the value-added features that distin-
guish your product from the competition’s.
In a typical design project, mechanical engineers build the
machine’s structure and its mechanical components; electri-
cal engineers add the electronics, including drives, wires,
and controls; and then software engineers write the code.
Every time there’s a mistake or problem, the project team has
to backtrack and correct it. So much time and energy in the
design process is spent re-doing design based on changes or Decentralized, drive-based automation is ideal when you need a
mistakes. Luckily, designing mechanics with CAD software more efficient or more compact motion control system and the criti-
and siloed planning and design are nearly things of the past. cal tasks can be performed independently
Pressure
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Wide range of design performance:
• Low pressure moisture-proof seals
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• Seal designs for high pressures to +10K psi (700 bar)
• Seal designs for all temperature ranges between -100ºC to 200ºC
• Hermetic designs for signal, power, high voltages or amperages,
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In-stock standard seals or custom designed seals for all quantities
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or visit our website with extensive product drawings at
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When considering whether controller- or drive-based automation is right, it’s important to
know it doesn’t have to be either-or. A smart, motion-centric design takes advantage of both
to create the right balance of power, coordination, efficiency, and space.
For An Angle Sensor That Works

Around Your Application…
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”ììàèòÖàòÃúúòú¤úÃÖ’Öòàé∞’úì
HIGH-QUALITY Motion Control
CONNECTOR
AND CABLE
A digital twin lets engineers quickly test various designs for
a machine as well as your machine technologies. For example,
SOLUTIONS perhaps a process requires material be fed into a machine feed

until the desired amount is collected and then the material
is cut; that means you must figure out a way to halt the feed
whenever the material needs to be cut. There are several ways
to handle that challenge, and all of them may affect how the
overall machine operates. Trying different remedies or relo-
cating components to see how it affects operations is simple
with a digital twin and leads to more efficient (and less) pro-
totyping.
Virtual engineering lets design teams all see how the entire
machine and its overlapping concepts work together to reach a
particular goal or goals.
SELECTING THE TOPOLOGY

Complex designs with several functions, more than one
axis of motion and multi-dimensional movement, and faster
output and throughput make system topology just as compli-
cated. Choosing between centralized, controller-based auto-
mation or decentralized, drive-based automation depends on
the machine being designed. What the machine does, both
its overall and local functions, affects whether you opt for
centralized or decentralized topology. Cabinet space, machine
size, ambient conditions, and even installation time also affect
this decision.
Centralized automation. The best way to get coordinated
motion control for complex machines is with controller-
based automation. Motion-control commands are usually
LEMO connectors are the forwarded to specific servo-inverters via a standardized
perfect choice for industrial real-time bus such as EtherCAT, and inverters drive all the
rugged applications in the motors.
most harsh environments. With controller-based automation, several motion axes can
be coordinated to perform a complex task. It is ideal topology
• Rugged if motion is at the heart of the machine and all parts must be
synchronized. For example, if it’s critical for each motion axis
• Compact to be in a specific place to get to properly position a robot arm,
• Lightweight you’ll likely choose controller-based automation.
Decentralized automation. With more compact machines
• Sealed and machine modules, decentralized motion control reduces
• Vibration Resistant or eliminates the load on machine controls. Instead, smaller
inverter drives assume decentralized control responsibilities,
• Cable Assembly Services an I/O system evaluates control signals, and a communication
• Many Sizes & Options bus such as EtherCAT forms an end-to-end network.
Decentralized automation is ideal when one portion of
the machine can take responsibility for completing a task
and doesn’t have to constantly report back to central control.
Instead, each portion of the machine performs quickly and
independently, only reporting back once its task is complete.
Because each device handles its own load in such an arrange-
ment, the overall machine can take advantage of more distrib-
LEMO USA, Inc. uted processing power.
800-444-5366 ® ®
[email protected] High Quality Connectors and Cables
Contact your local partner at www.lemo.com MARCH 2019 MACHINE DESIGN

D
ecentralized automation is ideal when one portion of the
machine can take responsibility for completing a task and
doesn’t have to constantly report back to central control. Instead, each
portion of the machine performs quickly and independently, only reporting
back once its task is complete.
Centralized and decentralized con-

trol. Although centralized automation
provides coordination and decentral-
ized provides more efficient distributed
processing power, a combination of
both is sometimes the best choice. The
final decision depends on overarching
requirements including goals related to:
• Cost/value
• Throughput
• Efficiency
• Reliability over time
• Safety specifications
The more complex the project, the

more important it is to have a motion
control engineering partner that can
give advice on the different aspects.
When the machine builder brings the
vision and the automation partner
brings the tools, that’s when you get the
best solution.
MACHINE NETWORKING
Establishing clean, future-proof
interconnectivity is also a key step in
designing with motion control in mind.
The communication protocol is just as
essential as where motors and drives are
located because it’s not just about the
what the components do—it’s also how
you connect it all.
A good design reduces the number of
wires and the distance they must go. For
example, a set of 10 to 15 wires going to a
remote terminal could be replaced with
an Ethernet cable using an industrial
communication protocol such as Ether-
CAT. Ethernet isn’t the only choice, but
whichever one you use, ensure you have
the right communication tools or buses,
so you can use common protocols. Pick-
Motion Control
alumacast.com
C
loud-networked plants analyze data
from different processes, different
production lines, and more to create more
complete representations of production process.
This lets them compare the overall equipment
effectiveness (OEE) of various production
facilities.
ing a good communication bus and hav- hardware, modular software improves
ing a plan for how everything will be laid the speed and efficiency of machine
out makes future expansions that much building.
easier. For example, say you are designing a
Focus on building a good design machine and want to add an extra step
inside the cabinet from the start. For between two phases. If you’re using
example, don’t put power supplies near modular software, you can simply add
electronic components that might be a component without reprograming or
affected by magnetic interference. Com- recoding. And, if you have six sections
ponent with high currents or frequencies all doing the same thing, you can write
can generate electrical noise in wires. code once and use it across all six sec-
So, keep high-voltage components away tions.
from low-voltage components for the Not only is designing more efficient
best operation. Additionally, find out with modular software, it also lets engi-
if your network is safety rated. If not, neers deliver the flexibility customers
PROTOTYPE and you’ll likely need hardwired redundant
safety connections so if one part fails, it
crave. For example, say the customer
wants a machine that runs different
LOW VOLUME detects its own failure and reacts. sized products, and the largest size
ALUMI UM and ZI C As the Industrial Internet of Things necessitates a change in how one sec-
(IIoT) takes hold, consider adding tion functions. With modular software,
CASTI GS advanced functions you or your custom- designers can simply change out the
Fast turnaround. ers may not quite be ready to use. Build-

ing the capabilities into the machine
section without affecting the rest of the
machine’s functions. This change could
Specialist in means it will be easier to upgrade that be automated to let the OEM, or even
thin wall and machine later. the customer, quickly switch between
machine functions. There’s nothing
complex geometries. SOFTWARE to reprogram because the module is
According to industry estimates, it already in the machine.
Expert guidance to won’t be long before OEMs will need to Machine builders can offer a stan-
ensure the success spend 50-60% of their machine develop- dard base machine with optional fea-
of your program.
ment time focused on software require- tures to meet each customer’s unique
ments. The evolution from a focus on requirements. Developing a portfolio
Call before your

mechanics to a focus on interface puts of mechanical, electrical, and software
smaller machine builders at a competi- modules makes it easier to quickly
design is finalized. tive disadvantage, but can also level the assemble configurable machines.
1.920.596.1988 playing field for companies willing to

adopt modular software and standard-
To get the most efficiency from mod-
ular software, however, it is essential to
ized, open protocols. follow industry standards, especially if
Sign up to receive How software is organized can you’re using more than one supplier. If
our prototype casting expand or limit what a machine can do the drive and sensor supplier aren’t fol-
tips for designers. now and into the future. Like modular lowing industry standards, then those
alumacast.com
Modular software not only improves the speed of individual machine design but can be
leveraged to deliver custom configured machines easier and faster. With modular software,
updating or reprogramming an existing machine for different functionality is simple.
components can’t talk to each other are growing in popularity. That trend
and all the modularity efficiencies are could raise the level of predictive main-
lost in figuring out how to connect the tenance and data-driven production
parts. and is the next major change in factory
Additionally, if your customer plans software; it starts with remote connec-
on connecting the data stream to a cloud tivity.
network, it’s essential any software is Cloud-networked plants analyze data
created using industry standard pro- from different processes, different pro-
tocols, so the machine can work with duction lines, and more to create more
other machines and interface with cloud complete representations of production
services. process. This lets them compare the
OPC UA and MQTT are the most overall equipment effectiveness (OEE)
common standard software architec- of various production facilities. Cutting-
tures. OPC UA enables near-real-time edge OEMs work with trusted auto-
communication between machines, mation partners to offer cloud-ready
controllers, the cloud, and other IT machines with modular Industry 4.0
devices, and is probably the closest to capabilities that can send out the data
a holistic communication infrastruc- end-users need.
ture you can get. MQTT is a more light- For machine builders, using motion
weight IIoT-messaging protocol that control automation and taking a holistic,
enables two applications to talk to each total-process approach to make custom-
other. It is often used in a single prod- ers’ plants or companies more efficient
uct—letting, for example, a sensor or a will be sure to win more business.
drive pull information from a product
and send it to the cloud. DANIEL REPP is an automation manager
and ROBERT SPADARZEWSKI is a se-
CLOUD CONNECTIVITY nior application engineer at Lenze Ameri-
Interconnected, closed-loop cas. They can be contacted with ques-
machines are still the majority, but tions at (800) 217-9100 or online (www.
factories fully networked to the cloud lenze.com/en-us/).
Industrial Automation
STEPHEN MRAZ| Senior Editor
Will Commercial
Cloud Providers
Increase the Cost of
Federal Data?
If federal agencies choose to save money by putting data (and lot of it) on commercial
services, will the cost of that data go up and its use decline?
F
ederal agencies generate or collect large volumes store it and make it available to users. Although agencies may
of data from such sources as earth-observing sat- have different strategies, these new partnerships could result
ellites, sensor networks, and genomics research. in user fees levied on downloads and analyses performed on
Much of that information is useful to commercial data while it remains in the cloud.
and academic institutions, which can usually access this pub- A researcher at the Georgia Institute of Technology who
licly generated data from agency servers at no charge. studies such data use, Mariel Borowitz, urges caution about
As the volume of data continues to expand, however, many the design of these commercial cloud partnerships and pos-
agencies are considering using commercial cloud services to sible imposition of user fees.

“Under the current system, free and open government data
is used by scientists to conduct research, by entrepreneurs to
create new businesses, and by citizens and other organizations
to promote government transparency,” says Borowitz. “If users
must pay fees to download or analyze data, it will decrease the
ability of users to access and work with data. Past experience
suggest that the effects of the decrease in data use could be
large both for individuals and society as a whole.”
Moving data to commercial cloud systems would likely
provide broader access and more efficient analysis options,
but she cautions those advantages could be offset by the cost,
particularly for organizations with small budgets.
“Agencies risk losing some of the benefits of this transition
by not budgeting for the costs associated with data downloads
and analysis,” Borowitz says. “Many who would be interested STAINLESS
in using the data may not be able to pay the associated fees.
Researchers, nonprofit organizations, and others who do not IS STANDARD
directly profit from the use of this data are most likely to be
affected.” Our rings provide the same ft and
Borowitz recently spent two years at NASA and watched function as stamped rings, but are
the development of systems that will increase data collection easier to assemble and remove with no
and debates about future data storage. She says she would like
special tools. Standard parts available in
to see the agencies that provide data continue to shoulder the
costs, up to some “reasonable level,” to ensure data continues stainless (302 & 316) and carbon steel.
to be readily available to all users. Standard or custom, we’ll provide you
As an alternative to commercial services, some agencies with the right ring, in the right material,
are considering developing their own, custom-built cloud for your application.
solutions. They will have to weigh the cost of benefits for the
different options. There will also be technical, organizational,
and policy issues to consider. Gear Assembly
Electrical Coupler
“Agencies are taking the issues of security and long-term
preservation of data seriously,” Borowitz adds. “When work-
ing with commercial providers, some are concerned about
getting ‘locked in’ to one provider, due to the costs of migrat-
ing data from one system to another. It is possible that costs
and capabilities could change over time. On the other hand,
commercial cloud providers have large workforces and
extensive infrastructure that let them provide services and
capabilities well beyond what any one agency would be able
to maintain.”
Borowitz notes that most agencies have not made final deci-
sions about cloud-based programs, so there should be enough
time to work through these issues.
“Most agencies that make data publicly available, par-
ticularly science agencies, are discussing and/or beginning to
transition to cloud systems,” she says. “However, these pro-
grams at agencies such as NSF, NIH, NASA, and NOAA, are
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A
petabyte is 1,024 terabytes, or a million gigabytes.
A gigabyte is 1,024 megabtyes. For scale, an average
photograph taken by a high-end cell phone camera can be in the
neighborhood of 10 megabytes. Laptop computers may be able to store
as much as a few terabytes of data.
to be provided and adjustments to the

programs to be made.”
The existence of fees to access gov-
ernment data is not without precedent,
but Borowitz argues past experience
suggests that user fees result in signifi-
cantly less use. Before Landsat data (sat-
ellite images of Earth) was made freely
available in 2008, no more than 25,000
images a year were purchased from
the collection. “Within a few years of
implementing the free and open data
policy, the government was distributing
250,000 images a month,” she says.
That suggests what cash-strapped
agencies are dealing with. The National
Oceanic and Atmospheric Administra-
tion, for example, houses more than
100 petabytes (PB) of data and gener-
ates more than 30 PB per year from sat-
ellites, radars, computer models, and
other sources. NASA projects its archive
will grow to 250 PB by 2025. And the
amount of genomic data at the National
Institutes of Health is growing exponen-
tially.
A petabyte is 1,024 terabytes, or a
million gigabytes. A gigabyte is 1,024
megabtyes. For scale, an average pho-
tograph taken by a high-end cell phone
camera can be in the neighborhood of
10 megabytes. Laptop computers may
be able to store as much as a few tera-
bytes of data.
Borowitz sees the transition to cloud
computing as both an opportunity and
a challenge for the future availability
of government data. “Decisions being
made right now about the structure of
these programs will significantly affect
researchers and society, so it is impor-
tant to raise awareness and increase
engagement on these issues.”

Book Review
JEFF KERNS | Technology Editor
Book Review:
Simplify Work
As new technology such as the IoT creates more complex systems, simplifying work
will take on greater value.
A
nyone who has ever often so does their complexity. Eventu- • Do we really need a coordinating
worked for a large ally, we end up spending more time on function between these groups?
company—or watched documenting, budgeting, and random • Do we need to report this fre-
parodies of doing so, meetings than actions associated with quently?
a la “The Office” or “Office Space”—is our actual job descriptions. • Do we need this many approvals?
aware of some of the ridiculousness that Now as we move into a faster-paced • Do I really need to attend that
can occur in the corporate world. Out- world with the IoT, some companies are meeting?
dated management practices, putting trying to pair yesterday’s business prac-
time into things that seem valueless, and tices with today’s technology. While this Employees in complex redundant sys-
poor communications all come to mind. might work, it isn’t taking full advantage tems can become frustrated and inun-
But while entertainment makes inef- of the technology’s capabilities. A new dated, which can further blur what is
ficiencies seem whimsical and funny, book by Jesse Newton, Simplify Work, important to the business or an individ-
in the real world companies are losing walks through some examples and ques- ual’s goals. This can make talent acquisi-
money, focus, and possibly business. tions to ask with the aim of discovering tion and retention difficult. If you are
As technology moves faster and IoT, a simpler way. hiring competent professionals, let them
Big Data, and Machine Learning con- According to the book, a good place do their job. Having to report to mul-
tinue to grow, the Keep it Simple Stupid to start is knowing how to ask the right tiple managers, being looped into e-mail
(K.I.S.S.) method will become increas- questions. Sometimes these might be chains that are unnecessary, or even
ingly important. As companies grow simple: dealing with IoT-associated technology
Book Review
that offers unnecessary noti-

fications can be distractions
from valuable work.
C omp anies t hat have
found success in simplic-
ity include Amazon, with
its simple platform base;
Apple, with its idea of keep-
ing teams small; and Elon
Musk’s entities, which open
communication and enable
any employee to go directly
to the person they need to
talk to without having to fol-
low the chain of command.
In all of these cases, extraneous unnecessary approvals and
distracting e-mails are limited.
Some other examples: Dassault’s 3D Experience Innovation
Lab in Wichita State University has collaborative rooms that
are designed to have no more than eight people. Festo started
a Bionics program where a small group of employees are given
all the resources they need to figure out how to build robotic
animals.
However, simplicity goes beyond small groups, resources,
and letting professionals be professionals. For example, Bosch
has ActiveCockpit, which acts as a digital whiteboard to make
sure anyone who misses meetings has access to it, and that
people who don’t need to attend can be easily sent any infor-
mation specific to them. This means you don’t have to attend
every meeting, but if you miss one that you should have been
at, you have access to the information.
In addition, many companies (such as Jabil) are designing
complex dashboards to organize the massive amount of data
being collected from the IoT into just the important informa-
tion and trends. It is important to reduce distractions and
notifications from your phone, e-mail, or meeting reminders,
which can easily can pile up.
If you are a minimalist working in a large complex
cooperation, don’t worry—you’re not crazy. Common sense
and simplifying things works well. Simplify Work starts right
off by laying out your gameplan:
• Get clear on the purpose

• Organize
• Reduce
This book can help you find ease in a complex company. But
even if you like complexity and meetings, you should also try
reading this book. You may be able to work less and accom-
plish more when you start asking the right questions. As new
technology such as the IoT progresses, simplicity will become
more valuable and offer competitive advantages.

247 Lynnfield Street, Peabody, MA 01 60 • 800. 21.3332 • www.HarmonicDrive.net
Harmonic Drive is a registered trademark of Harmonic Drive LLC. Valkyrie image courtesy of NASA.
Robotics
MARK HOWARD | Manager at EU Automation
Advancements in
ROBOTIC
SAFETY
Collaborative and traditional robots have
While physical safety guards are needed to separate humans from
safety limitations, but can you get the best
traditional robots, this safety precaution lets them operate at full
of both worlds? capacity without speed or weight restrictions.
H
ave you ever witnessed a robot malfunction implementing these limits, workers should not sustain injury
during a trade show demonstration? If so, you should the robot come into contact with them.
will understand the importance of robotic safety Due to these safety restrictions, collaborative robots are
equipment. Here, Mark Howard, manager at not currently an ideal replacement for all applications. These
industrial parts supplier EU Automation, examines the latest machines cannot deliver the same power and speeds as their
advancements in robotic safety and the future of safety on the industrial counterparts. So, how can manufacturers achieve
factory floor. greater collaboration on the factory floor, while still enjoying
Traditionally, industrial robots were confined to operate in the speed and efficiency of industrial robots?
robotic work cells—reinforced cages that physically separate
machines from the workspaces in which humans are present. BEYOND BASIC STANDARDS
However, many modern robots are better equipped with safety Before investing in any new automation, remaining compli-
features which reduce their threat to human workers. In fact, ant with the latest Occupational Safety and Health Adminis-
new collaborative models are specifically developed with this tration (OSHA) and American National Standards Institute
in mind. (ANSI) codes is the first step. However, manufacturers should
be prepared to go beyond basic safety standards to ensure the
COLLABORATIVE ROBOTS protection of their workers.
Sometimes referred to as cobots, collaborative robots are Power presses are a good example of why enhancing safety
marketed based on their ability to work alongside humans. on the shop floor is so important. These are some of the most
While these robots are still in their early phase—and are there- unforgiving machines in the factory, with the most common
fore significantly slower and less powerful than industrial injury cited as amputation, as recorded by the OSHA Safety
counterparts—the popularity of these machines demonstrates and Health Information Bulletin.
growing demand for robots that can operate outside of heavy- Meeting regulations is not only essential but can help to
duty caging. minimize the likelihood of these incidents. However, with
Cobots are developed based on the technical specifications new automation constantly being deployed on the shop floor,
defined by ISO/TS 15066, the international standard specifi- manufacturers should be prepared to increase their invest-
cally created for collaborative robots. Primarily, this standard ments in machine safety.
requires robots to demonstrate an ability to conduct a moni-
tored safe stop—a pause in operation if a human comes too ADVANCEMENTS IN SAFETY
close to the machine. Machinery will almost always be equipped with its own
Despite this requirement, physical contact between the safety features. However, there are ways to enhance the safety
robot and the worker can take place, providing the machine of machinery by integrating new technology. For instance,
meets power limitation requirements. According to ISO/TS a power press may be designed to cease operation should it
15066, the robot must be subject to maximum values and encounter a human body part. However, advanced motion
mechanical load limits and prove its ability to limit the maxi- sensors could be installed to ensure the machine stops before
mum permissible forces through drive dimensioning. By contacting the worker.

For particularly dangerous equipment, like power presses, alert device. Monitoring data in real-time, the PLC could auto-
safeguarding the entire perimeter of the machine is advised. matically raise an alarm based on whether the area has been
For instance, automated safety curtains, which can be locked compromised by a human worker. Automated software could
down during machine operation, will prevent humans from then automatically shut off power to the robots or slow them
accessing the hazardous area. Using this device, the machine down for safety, based on the proximity of the worker.
will not activate if the automated safety curtain is in the up When implemented on a larger scale, this web of sensors
position, removing the possibility of humans entering the area. and software could enable the smooth running of automated
Similarly, pressure sensitive mat guards and safety light production lines, while protecting the livelihoods of its work-
curtains can both be used to detect whether a worker has ers. In fact, with sensors to collect data from all areas of the
entered a specific area. Light curtains, for instance, generate facility, intelligent software could form a real-time digital
a safety stop signal based on movement. Using this method, it simulation of the factory—including the locations and behav-
is impossible for the machine to operate while a worker is in iors of all humans working within it.
harm’s way. Currently, manufacturers are required to strike a balance
While these safety automation methods are advantageous, between collaboration and performance. Should they require
they do not enable the collaborative environment desired on humans to work directly alongside robots in the factory, man-
some manufacturing floors. For this kind of environment to ufacturers have to compromise on the power and speeds of the
operate successfully, it requires a combination of intelligent safe- machine. Alternatively, if manufacturers opt for high power,
ty automation, software and—for the meantime at least—some these robots are still confined to heavy duty work cells, often
flexibility on the required power and force from machinery. bolstered by other safety automation, such as light curtains
and safety mats.
FUTURE FACTORIES Robots are designed to operate at intense power and meet
Consider this as an example. By collecting real-time data incredibly high speeds. Therefore, a malfunctioning machine
from light curtains and mat guards, a manufacturer could use can be potentially life-threatening. Robot safety cannot be
a programmable logic controller (PLC) to operate as a safety taken lightly.
POWER TRANSMISSION PROBLEMS?
WE HAVE AN ANSWER FOR THAT.

From synchronous belts and banded V-belts to specialty belts and sprockets
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3D Printing/CAD
JOHN O MILEWSKI | APEX3D LLC
11 MYTHS
About Additive
Manufacturing, Part 1
AM is surrounded by much hype, but are you getting the whole story?
F
ive years ago, Hod Lipson manufacturing and product design. I evolve, rebranded as Additive Manufac-
and Melba Kurman gave us bought and read the book and enjoyed turing (AM).
Fabricated: The New World it. I get that “no one wants to follow a AM of metal remains on a steady
of 3D Printing, 1 helping to small dream,” but as a process engineer march toward industry adoption, stan-
both create and ride a wave of enthusi- with a background in advanced materi- dardization, and certification for critical
asm for 3D printing. This enthusiasm, als, digital design, and manufacturing, I applications such as in aerospace and
combined with the infusion of U.S. gov- knew it was not that easy. medical devices. Some of the myths of
ernment funding and the expiration of Five years later, today, many of the the past have been dispelled as adop-
key patents, prompted many to buy a early 3D printer desktop units sit on tion by industry brings the technology
3D printer for the kids and make stock a shelf while some of those rising star to light. In other cases, the myths remain
investments in rising star companies. companies are struggling to regain mar- as potential users mentally map their
Along with their book, Lipson and ket value after the wild growth boom experience with 3D home printing into
Kurman gave us the 10 Principles of 3D and bust brought on by all the hype. the more formal AM fabrication of criti-
Printing as a roadmap into the future However, commercial 3D printing and cal components in a production envi-
to explain why 3D printing will disrupt rapid prototyping have continued to ronment.
1. These images show an injector as it looked immediately after it was removed from the selective laser-melting printer (1) and an injector
after inspection and polishing (r). (Credit: NASA/MSFC)

Borrowing heavily from the princi- internal structures, or varying wall click with a mouse in a CAD program
pals set forth by Lipson and Kurman, thicknesses can be significantly impact- can join multiple piece parts into a
my process engineering background, ed by complexity. Having said that, one single component that may then be 3D
and recent book research2, and with a
bit of tongue in cheek, here is my list
of 11 Myths About Additive Manufac-
turing.
MYTH 1: COMPLEXITY IS FREE.

AM complexity is not free. Much of
the cost of component complexity gets
pushed upstream to the design process
where finding or training skilled per-
sonnel to think and design outside the
box takes both time and money. Soft-
ware upgrades and add-ons such as
lattice generators and computer aided
engineering software may be required.
Downstream costs such as post-pro- 2. As power bed processes are currently the most used process for metal 3D printing, com-
cess finishing operations or inspection panies are starting to produce powders in mass in preparation when 3D printing expands
of components with complex shapes, deeper into prototyping, or production.
Powder
Metal (PM)
Advanced Technology
To Better Serve Industry
Our new mechanical-hydraulic powder
presses, Dorst and Osterwalder,
typically were used in the auto industry
only. SymmcoÕs customers now make use of its
technological innovations in the cost-effective production
of complex, multi-level PM parts at high production rates.
l More complex parts
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Addictive Manufacturing
printed. Materials engineers at NASA added complexity is made possible and grows with complexity. However, in AM
made the one-piece rocket engine injec- taken to a new level. you are not just changing the part mod-
tor in just 40 hours (Fig. 1) in a sophis- el—you are changing the build model
ticated 3D printing machine at NASA MYTH 2: VARIETY IS FREE. as well, and that may place additional
Marshall Space Flight Center’s advanced Parametric design software is great, restrictions upon the part orientation,
manufacturing facility.3 It took months but understanding the bounding con- support structures, and post-processing
to manufacture the same part by weld- ditions of design variations gets more operation such as heat treatment, finish
ing multiple parts. With AM, value- challenging with greater variety and machining, and inspection.
For critical-use components, stan-
dardized procedures, and certified
parts, re-qualification may be required
Precision Components for any deviation in design, material,

or process. Having said that, I am a big
See us at: fan of the concept of “one size fits one.” I
BIOMEDevice
Photo Etched Parts -
Design2Part - Boston, MA would like nothing better than custom-
Santa Clara, CA
fit earplugs, sneakers, and bike helmets,
• Intricate components as thin as .0005"
• Eliminates cost of hard tooling but not at 10X the cost where the cost of
• Eliminates burring and stress problems variety is passed down to me.
• Short lead times
• In-house forming, laminating and plating MYTH 3: NO ASSEMBLY REQUIRED.
• Prototype through production A reduced part count can save on
procurement, subcomponent fabrica-
Download
tion, tracking, assembly, touch labor,
Capabilities
Brochure and the bill of materials, as well as
shorten supply chains. Demonstration
examples made using AM have shown
Flex & Rigid-Flex Circuits
significant savings are possible. How-
• Medical, Aerospace and Telecom markets ever, even though AM machine capaci-
• Adhesiveless construction ties are increasing, many parts are larg-
• Selective plating of gold and tin er than what current AM systems can
• SMT and through hole component assembly produce, requiring two AM piece parts
• Package sizes down to 0201 and .4mm pitch to be fabricated, finished, and welded
• Microvia sizes down to .001" diameter together.
Fits and finishes remain critical, as do
Download
Flex Circuit consideration in-service maintenance
Design Guide and repair of components subject to
wear, failure, or other service life consid-
erations. A fully “assembled” design may
EMI/RFI Shielding impede powder removal, or access to
• Global supplier standard and custom products surfaces and features with critical post-
• Commercial and military markets processing or service/repair require-
• Over 100 finger stock gasket profiles ments.
• Shielded vents and filters
• Conductive foam and elastomer gaskets
MYTH 4: ZERO LEAD TIME.
• Board level shielding
I agree that reduced lead-time (not
Download zero) and reduced inventory are highly
Shielding attractive, as is the potential for local
Catalog fabrication by multiple service provid-
ers. These benefits are often possible for
models, prototypes, and non-critical
www.tech-etch.com components. However, as you move into
TECH-ETCH, INC., 45 Aldrin Road, Plymouth, MA 02360 ISO 9001 critical use and metal components, the
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changeover time between materials and the queue time for Sensors for Industrial
specialized post-processing operations may come into play.
Many larger service providers are dedicating machines to Applications?
specific materials and establishing specialized post-processing Our new VY2060 Stainless Steel and Brass Turbine
operations in-house, such as HIP or EDM (hot isostatic press- Flow Sensors provide accurate, and repeatable
ing or electrode discharge machining). Transportability of performance via sapphire bearings, stainless
3D designs between AM metal machines—e.g., getting the steel axles and intelligent engineering.
same part from a different machine, in a different location—
remains an issue when considering the benefit of multiple FEATURES
service providers. • High-quality
stainless steel
and brass
MYTH 5: UNLIMITED DESIGN SPACE. components
There are a large number of AM materials and processes. All • Compact,
have their limits. While the number of alloys suitable for AM versitile
design
metal processing is growing, the range of materials remains
• Measuring
small when compared with conventional processing. Cost and range from
availability of materials are primary design considerations, as 0.2 to 16 GPM
are limitations on the part size due to system build volume.
AM metal powder can cost twice that of wire feedstock, which Explore your options…contact us today!
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examples. You may not be constrained to a straight round Made in Germany…Quality by tradition
LOCKED INTO OLD TECHNOLOGY?
Addictive Manufacturing
passage or cooling channel designs, MYTH 6: ZERO SKILL nism, diagnosing and replacing a drive
but instead need to use a teardrop- or MANUFACTURING, REMOVING motor, troubleshooting a laser or elec-
diamond-shaped passage depending on HUMANS FROM THE LOOP. tron beam welding process, etc.). A
how the part is oriented relative to the If you have ever manufactured any- common myth of AM is there is only
build direction. Having said that, AM thing you know how many ways there one process to learn.
can enable the design and fabrication are for things to get screwed up and For better or worse, most automat-
of “impossible components,” those that the corrective action necessary (e.g., ed AM processes run without manual
cannot be made by any other process. responding to a clogged feeding mecha- intervention. Some have built-in feed-
back and real-time control; some have
data acquisition to flag off normal
conditions. Many AM machine lock
the users out from controlling or even
knowing many of the operating param-
eters due to intellectual property restric-
tions and do not allow intervention with
many of the parameters.
Touch labor expertise is required in
machine setup, process monitoring,
and post-processing. Support activi-
ties such as calibration and mainte-
nance will be just as critical on these
machines as with any other fabrication
process, and in some cases even more
so as you enter the material processing
space of lasers and electron beams. You
can expect zero skill AM to occur about
the same time as autonomous asteroid
• High accuracy and repeatability, with mining.
tolerances to ±0.00254mm. Surface fnish Part 2 continues with Myths 7 to 11
to 8 micro inches. Available uniform I.D. about 3D printing bringing compact
and O.D. Gold Plating or Cladding
portable manufacturing, precise digi-
• Slotting, faring and hole punching for
intricate designs with no additional tal replication being a one-step process,
handling and more. The true disruption and
• Braxton can deep draw most conventional transformation of manufacturing and
and exotic metals and alloys, plated or construction will occur in space where
unplated, to 57mm max length every aspect of current manufacturing
• Diameters can be as small as 0.215mm technology will be examined and re-
O.D. with a wall thickness as little as created, starting with a “clean slate” and
0.0127mm. Length to diameter ratios up We deep draw parts for a variety of
to 57:1 applications including electronic, a new dream.
communication, aerospace, medical and
more. Contact us today to learn how
our precision deep drawing process can REFERENCES
provide you with enhanced production 1. Fabricated: The New World of 3D Printing, Hod
effciencies and cost savings over Lipson, Melba Kurman, ISBN: 978-1-118-35063-8,
FREE traditional manufacturing methods. February 2013, https://www.wiley.com/en-us/Fab

ricated%3A+The+New+World+of+3D+Printing-
Designer’s p-9781118350638
Sample Kit To order, go to:
2. Additive Manufacturing of Metals From Funda-
www.braxtonmfg.com/kit mental Technology to Rocket Nozzles, Medical
or call 860-274-6781 Implants, and Custom Jewelry, John O. Milewski,
Springer Series in Materials Science 258, 2017, DOI
10.1007/978-3-319-58205-4 . https://www.springer.
ISO 9001:2008 com/us/book/9783319582047
Braxton Manufacturing Co., Inc. CERTIFIED
Watertown, CT 06795 • Tel: 860-274-6781 3. ÒRocket Engine Injector Manufactured With
3-D Printing Machine,Ó July 23, 2013, accessed
Braxton Manufacturing Co. of California, Inc. 12/12/2018, https://www.nasa.gov/exploration/sys-
Tustin, CA 92780 • Tel: 714-508-3570 tems/sls/multimedia/gallery/3d_printer_2.html
Visit our website: www.braxtonmfg.com

2019 Medical Design & Manufacturing West Conference Ad Index
(Continued from page 45)
ACE CONTROLS ...................................................23
AEROTECH INC.....................................................42
ALLIED ELECTRONICS.........................................33
ALTECH CORP ..............................................1,47, 49
ALUMA CAST INC. .................................................62
AMACOIL INC ........................................................14
APPLIED MOTION PRODUCTS ............................27
AURORA BEARING CO .........................................16
AUTOMATION24 INC. ..........................................IBC
AUTOMATIONDIRECT.COM ................................IFC
BANNER ENGINEERING CORP ...........................37
BRAXTON MANUFACTURING ..............................76
CAPLUGS...............................................................43
TE Connectivity offers virtual training for 3D printing anatomical models with CARLO GAVAZZI AUTOMATION COMPONENTS ..22
surgeons. Stratasys. CLIPPARD INSTRUMENT LAB INC.......................39
COMSOL INC .........................................................35
lated models and real-world controllers STRATASYS CONTITECH ...............................................71, 73, 75
DIGI-KEY ..................................................................5
for surgeons to hone their accuracy and 3D printing has opened the door for
DUER/CAROLINA COIL .........................................52
steady their hands. They simulation tool a more detailed type of medical analy- DURA-BELT ............................................................50
here was built in partnership with 3D sis. Taking information from x-rays and EAGLE STAINLESS TUBE CORP..........................53
Systems and Simbionix. CAT scans, digital modeling tools can EBM-PAPST ...........................................................10
help produce 3D-printed models of a EMERSON .............................................................15
EXAIR CORPORATION .........................................13
BIOMEDICAL INNOVATIONS patientÕs inner organs and bone structure
FABCO AIR, INC.....................................................20
IoT healthcare applications will for doctors to analyze. Above is a sam- HARMONIC DRIVE ................................................69
require massive data from patients to ple set of anatomical correct models 3D IGUS INC..................................................................3
help improve their medical treatments printed by Stratasys. The heart model, IMI PRECISION ENGINEERING............................79
and provide doctors with enough infor- for example, was printed on a J750 3D INTECH POWERCORE CORPORATION ..............59
JOB SHOP SHOWS, INC/THE EDWARD ...................
mation to advance patient care. Cus- printer and offers more than 360,000 col-
...............................................................BELLY BAND
tom wearable devices like the ones from ors, including realistic texture finishes. KNF NEUBERGER INC .........................................41
BioMedical Innovations adhere to the KWIK MARK, INC. ..................................................52
skin, with the ability to collect infor- 3D SYSTEMS LAPP USA ..............................................................21
mation from the patient and transmit The model below doesnÕt appear like LEMO USA INCORPORATED................................60
LIN ENGINEERING ................................................31
remotely. The sensors can adhere to the your normal human skeleton structure.
MASSA PRODUCTS ..............................................63
skin like tape or even via a temporary That is because it has been overlaid with MAXON MOTOR USA ............................................54
tattoo process. surgical guides for future operations. MICROMO ELECTRONICS ...................................34
The white guides located on the fore- MOLON MOTOR & COIL CORP. ............................55
arm, head, and leg are 3D printed and MW INDUSTRIES ..................................................26
NABEYA BI-TECH KAISHA....................................61
help surgeons know exactly where to cut
NB CORP ...............................................................17
when they are in the operating room. 3D NOVOTECHNIK......................................................59
printing technology allows surgeons to ONDRIVES US CORP ...........................................66
be more accurate and precise with their ORIENTAL MOTOR USA CORP ............................25
surgical procedures. PAVE TECHNOLOGY CO ......................................58
PHOENIX CONTACT..............................................29
PYRAMID INC ........................................................30
REELL PRECISION MANUFACTURING ..........50,75
ROLLON ...................................................................9
ROTOR CLIP CO ...............................................57, 68
SEW EURODRIVE .................................................BC
SIKA USA, INC. ......................................................75
SMALLEY STEEL RING CO ..................................65
SOLENOID SOLUTIONS, INC .................................6
SPIROL INTNL CORP..............................................8
SYMMCO INC ........................................................73
TADIRAN LITHIUM BATTERIES ............................19
TECH-ETCH INC....................................................74
THE LEE COMPANY ................................................7
BioMedical Innovations offers adhesive sen- 3D Systems offers complete human 3D print- TRIM-LOK INC .......................................................40
sors for patient monitoring. ing tools for surgery. XOMETRY ..............................................................28
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Goldense on R&D-Product Development
BRADFORD L. GOLDENSE | Contributing Technical Expert
The Powers
of Product Design
N
ot all designs are born equal. No one knows Product expertise. Some companies are known as being
this better than the Makers and managers smart and launching smart products. Apple, Toyota, Emer-
of small-mid firms competing against large son, John Deere, and Procter & Gamble have been examples
companies with big budgets, global chan- in their respective industries for decades. Never underesti-
nels, and purchasing clout across the supply chain. Technol- mate the lasting value of a strong brand and reputation for
ogy, media, and governments increasingly influence product delivering products ready to go and scale at their launch. If
success as well. Assuming your products get a fair hearing in you launch a product that is not ready to go and, worse, if the
the marketplace, are you known for impactful designs? news makes it to the media, the old adage applies: “It takes 10
Product design definitions. Quoting from IDSA’s (Indus- way-to-go’s to offset one aw-darn.”
trial Designers Society of America) list of industrial design Product reverence. Reverence is about speaking or show-
definitions, Charles Eames offers: “Design is a plan for arrang- ing a better way. It is usually companies that achieve reverent
ing elements in such a way as best to accomplish a particular status, but products may do so as well. Blackberries achieved
purpose.” Dieter Rams says: “Good design is making some- reverence, as has the iPhone. Few users switch. “Nothing runs
thing intelligible and memorable. Great design is making like a Deere” has kept farms and families loyal since 1837. In
something memorable and meaningful.” And James Dyson organization theory, reverence is the most powerful of the
adds: “Good design is about making a product or design five powers. If you are always showing a better way, you will
that serves a function better than anything else that has gone develop a loyal following to the manifestation of your ideas
before it. It’s about looking at everyday things with new eyes across product designs.
and working out how they can be made better.” Product personality. Most designers strive to evoke the
Product design powers. There are several types of power. emotions of their users and customers with their products. Is
Organization theory, for example offers five types: position the product fun to use or drive? Who didn’t love Elmo, or any
power, associative power, expert power, reverent power, and Porsche they ever sat in? Does the user interface flow off your
personality power. fingertips? Alexa, Assistant, and Siri are taking it the next step.
Product position. Here’s where giant distribution channels Is the display and its data immediately comprehensible in a
and company size disparities come into play. Some products are visually pleasing way? Dare I suggest Packman spawned the
launched in ideal positions to be perceived as desirable. Large gaming industry?
companies sometimes compete against themselves, and how Summary. Steve Jobs’ definition of industrial design on the
they position new models can have the same impact on a larger IDSA site gets at the wide-ranging subject of power. “Design
scale. One way to tip the scales in your favor is to win industry is the fundamental soul of a human-made creation that ends
awards. These peer competitions sort out the best from the rest. up expressing itself in successive outer layers of the product
Winning or placing boosts brand value on several levels and or service.” Reverence and expert power are at the top. They
may also result in increasing your stock price (MD, Nov ’18). assure interest in the outermost layers. If you see what you
Product association. Associating a product with environ- like, personality power makes you look more deeply. Position
mental sustainability affects design perception. One multi- and association power lag, noting that makers and small-to
year study found a company’s share of revenue from products medium-sized companies will argue that all products are not
rebranded as “sustainable” rose from 10% to 37% of total created equal.
revenues (CFO Magazine, Sep ’15). Associating products with
other winning products (yours or others) lifts a product’s BRADFORD L. GOLDENSE is founder and president of Gold-
design perception. If some marketeering smoke and mirrors ense Group Inc. (GGI; www.goldensegroupinc.com), a consult-
elevates the perception of a product design, why not? There ing, market research, and education firm focused on business
are many other ways products can be linked to concepts or and technology management strategies and practices for prod-
goods, or even people. uct creation, development, and commercialization.

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