Assembly

ASSEMBLY
JUNE 2017 www.assemblymag.com
Behind the
Scenes at
DeWALT
pg 30
New Cordless Tools 34
Force, Torque Sensors 38
Composites Assembly 42
Plastic Gears, Cams 46
Adhesives for Ammo 50
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ASSEMBLY
June 2017 Vol . 60, No . 6
66
COVER STORY

30 Behind the Scenes at DeWALT
DeWALT’s assembly plant in Charlotte, NC,
produces high-quality tools while beating overseas
competition.—John Sprovieri 36
FEATURES

34 Cordless Fastening Comes of Age
Engineers have more battery-powered options 46
available than ever.—Austin Weber

38 Force and Torque Sensors DEPARTMENTS
Advanced technologies increase the accuracy of force
Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
and torque sensors used in assembly and end-of-line Manufacturing and cybersecurity.—John Sprovieri
testing.—Jim Camillo
New & Noteworthy . . . . . . . . . . . . . . . . . . . 8

42 Assembling Thermoplastic Composites Rivet setters feature fast cycle times.—Austin Weber
Aerospace Assembly . . . . . . . . . . . . . . . . 10
Joining thermoplastic composites—either to each other
Flying cars blur fact and fiction.—Austin Weber
or to other materials—can be challenging.
—John Sprovieri Assembly Lines . . . . . . . . . . . . . . . . . . . . . 14
Reshoring activity outpaces offshoring.—Austin Weber

46 Plastic Parts Can Boost Machine Speed Assembly in Action . . . . . . . . . . . . . . . . . . 22
Robots rev up assembly at Maserati.—Jim Camillo
By upgrading gears, cam followers and other
components, engineers can improve machine speed by Integrated Showcase . . . . . . . . . . . . . . . . 58
15 to 20 percent.—Georg Bartosch In-depth profiles of the latest assembly technology.
Assembly Products . . . . . . . . . . . . . . . . . . 64

50 Ammunition Sealants and Bullet Pull Strength Grippers, indexers and other assembly products.
UV-curing ammunition sealants can make bullet Classified . . . . . . . . . . . . . . . . . . . . . . . . . . 70
pull strength more consistent and thereby improve Advertisers Index . . . . . . . . . . . . . . . . . . . . 71
performance and accuracy.—Drew Richards
Moser on Manufacturing . . . . . . . . . . . . . 72

54 Adhesives Aid Truck and Trailer Assembly Using TCO for selling vs. imports.—Harry Moser
High-strength adhesives and sealants can improve the NEXT MONTH

durability and appearance of trailers and truck bodies. State of the Profession Survey
—Bob Zweng Additive Manufacturing With Metal
Dispensing for Portable Electronics
Feeding and Driving Small Screws
Cover photo courtesy DeWALT
2 ASSEMBLY / June 2017 www.assemblymag.com

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ASSEMBLY
Online
Web Extras
38www.assemblymag.com
ERP System Provides Big Savings for Fan Manufacturer

Big Ass Solutions first made its mark selling massive ceiling fans for cooling factories and
warehouses. A powerful and effective enterprise resource planning system is essential
for running the company’s manufacturing operations. “It’s only a ceiling fan, but it’s a very
complex product,” says Bill Nall, chief information officer at Big Ass Solutions. “You can’t
manage that level of complexity without having a tight ERP system.”
Airbus Ramps Up Automation
Airbus plans to dramatically boost output of its most popular airplane, the A320, over the next few years. That kind
of production volume, which would be unprecedented in the commercial aerospace industry, will require automated
assembly lines. ASSEMBLY recently interviewed an Airbus executive to learn about the company’s “FuturAssy”
automation strategy.
Web Blogs
Handheld Servo Press Tops Lineup of New Press Technologies
at ASSEMBLY Show
A handheld servo press from Promess Inc. was one of many new technologies on display
at the 2016 ASSEMBLY Show. More than a dozen press suppliers exhibited the latest in
hydraulic, pneumatic and electric technologies.
Lasers, Hot Plates, Ultrasonics Among New Technologies for Joining Plastic Parts
Dukane Corp. unveiled a new technology for laser welding clear-on-clear plastic parts at the 2016 ASSEMBLY Show.
Dukane was one of more than a dozen suppliers of plastics assembly technology exhibiting at the 2016 show. Here are
just a few examples of what you could have seen on the show floor.
New Technology Ensures Error-Proof Fastening
The 2016 ASSEMBLY Show was dominated by suppliers of fasteners and fastening tools. From automatic
screwdriving systems to cordless tools to intelligent riveting tools, here is a roundup of the new fastening tools that
were seen on the show floor.
Assembly White Papers

New Sensors Optimize Performance of Robotics and Motion Control
Recent years have witnessed major new developments in sensors for handling, assembly
and robotics. Engineers are no longer confined to sensor choices from the past, with
components becoming more powerful, compact and universal. Today, sensors are
integrated directly with the actuator, making setup comparatively easy.
Assembly TV
New Assembly Robots Displayed at Automate Show
The 2017 Automate show just wrapped up in Chicago. More than 400 suppliers displayed the latest
in robotics, machine vision and motion control. Robots of all shapes and sizes were the main attraction
at the event. In this news video, chief editor John Sprovieri reports on the latest assembly technologies
from the show.
Assembly Webinars
Driving Innovation—3D Printing in the Medical Device Industry
Amid challenges such as rising costs, an aging population and payer-focused outcomes, 3D
printing can help medical device companies seeking an edge in innovation, manufacturing
and sales. In this webinar, you’ll learn how produce customized tools and devices to fit
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Cybersecurity
O
n May 12, hackers launched a “ransomware” cyberat- TOM ESPOSITO
Publisher
tack that would eventually infect 300,000 machines espositot@bnpmedia.com
in 150 countries over a three-day period.
BILL DEYOE
The ransomware, known as WannaCry, locked Associate Publisher
computers and blocked access to files. Victims were deyoew@bnpmedia.com
ordered to pay a $300 ransom to regain their data. The JOHN SPROVIERI
countries most affected by the ransomware were Russia, Editor
sprovierij@bnpmedia.com
Taiwan, Ukraine and India, but the attack also hit U.S.
companies, notably FedEx. Victims included universities, AUSTIN WEBER
Senior Editor
oil companies, telecom providers and train systems. webera@bnpmedia.com
The virus hit computers running older versions of JIM CAMILLO
Microsoft software that had not been recently updated. Senior Editor
Microsoft released patches in April and again during the attack to fix a camilloj@bnpmedia.com
vulnerability that allowed the worm to spread across networks. Computers at MIKE ROBINSON
manufacturers and hospitals, which can be hard to patch without disrupting Art Director
robinsonm@bnpmedia.com
operations, were particularly vulnerable. Indeed, the cyberattack slowed or
ROXY MATACHE
stopped production at five assembly plants run by Renault-Nissan, including the Marketing Manager
automaker’s huge factory in Sunderland, UK. matacher@bnpmedia.com
By May 15, the attack had largely been stanched. Renault-Nissan is the only LISA THEUT
carmaker to have reported problems stemming from the attack, but who’s to Production Manager
say Ford, GM or Toyota won’t be next? Cyberattacks on factories are the new theutl@bnpmedia.com
normal today, and the WannaCry attack is only the latest. In 2008, for example, a CAROLYN PERUCCA
Buyers Guide Project Leader
uranium enrichment facility in Iran was disrupted by a computer worm, Stuxnet, peruccac@bnpmedia.com
allegedly developed by a U.S. intelligence agency. In 2014, a blast furnace in
LISA VERIDIANO
Germany was damaged after malware infected the steelmaker’s production Trade Show Coordinator
management system and disabled control systems. In December 2015, a veridianol@bnpmedia.com
cyberattack on a power station in West Ukraine cut electricity to 80,000 homes. JILL L. DEVRIES
Sadly, the problem will get worse as manufacturers invest in the Industrial Internet Corporate Reprint
of Things and so-called “smart,” or “connected,” factories. Market research firm IHS devriesj@bnpmedia.com
forecasts that the number of “things” (machines other than computers) connected to NIKKI SMITH
the Internet will grow from 15.4 billion devices in 2015 to 75.4 billion in 2025. Online Development Director
That trend represents a tremendous opportunity to increase efficiency, but it ERIN MYGAL
could also leave manufacturers vulnerable to cyberattacks. And, it’s not just their Directory Development Manager
computer systems manufacturers have to worry about.
A recent study by cybersecurity firm Trend Micro Inc. and Polytechnic
CORPORATE DIRECTORS
University of Milan, Italy, concluded that robots are vulnerable to cyberattack.
The researchers found that the much of the software running robots is outdated; Publishing John R. Schrei
is based on vulnerable operating systems and libraries; is reliant on obsolete Corporate Strategy Rita M. Foumia
or cryptographic libraries; and has weak authentication systems with default, Creative Michael T. Powell
unchangeable credentials. Additionally, the researchers found tens of thousands Events Scott Wolters
of industrial devices—including robots—residing on public IP addresses that Finance Lisa L. Paulus
could be exploited by hackers. Information Technology Scott Krywko
Human Resources Marlene J. Witthoft
The researchers further demonstrated that hackers could alter a robot
Production Vincent M. Miconi
controller’s parameters; tamper with the robot’s calibration parameters; tamper Clear Seas Research Beth A. Surowiec
with the production logic; and prevent operators from discovering any problems.
How good is your cybersecurity? Are your operating systems up to date? Is
your data backed up and secure? Check now or start learning about bitcoin.
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Collaborative Robot Is Easy to Deploy

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Wireless Device Detects Small Water Leaks
The RFM5126 Moisture Intrusion Portal System uses battery-free,
wireless sensors to detect in-vehicle water leaks caused by incorrect
assembly. It electronically identifies small leaks with less cost and less
labor than conventional manual inspection methods that require gloves
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RFMicron Inc.
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Laser Projection System Aids Assemblers

The ASSEMBLY-PRO laser projection system is designed for use on
high-mix, low-volume assembly lines. A laser projector mounted above
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assembly steps and shows the position of key items such as drill holes,
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www.assemblymag.com June 2017 / ASSE M B LY 9

AEROSPACE ASSEMBLY
Flying Cars Blur

Fact and Fiction
F
BY AUSTIN WEBER or decades, many people have fantasized think of the concept of flying cars, and what
about flying cars and roadworthy aircraft. the desirable parameters are for such a novel
SENIOR EDITOR While several successful prototypes have approach to mobility.”
WEBERA@BNPMEDIA.COM been built in the past, the idea has never Sivak and his colleagues discovered that
gotten off the ground. But, that may more than 60 percent of respondents are “very
finally be about to change. concerned” with the overall safety of flying cars,
In the past few months, flying car technology and with their performance in congested airspace
has attracted widespread attention. Articles have and poor weather.
appeared in a number of credible publications, “Despite these concerns, most Americans
including The Economist, The New York Times would still ultimately like to use flying cars,” says
and USA Today. Sivak. “About three-fourths of the respondents
Engineers in cited shorter travel time as the main reason,
China, France, while less than 10 percent said fewer crashes,
Germany, Holland, better fuel economy or lower emissions were the
Israel, Japan, Slo- most likely benefits of [the vehicles].”
vakia, the United While numerous hurdles remain, one of the
States and else- biggest debates is over which type of design will
where are currently win out. Some folks believe cars should sprout
working on a vari- wings, while others think a brand new type of
ety of cutting-edge aircraft is the way to go.
designs that show Engineers at companies such as AeroMobil,
potential. Carplane and Terrafugia are developing flying
Even big-name cars that feature foldable wings and rear-
players from both mounted pusher props. Meanwhile, engineers
the automotive and at startups such as Cartivator, Lilium and Urban
aerospace sectors, Aeronautics are focusing on alternative designs
such as Airbus and that rely on electric jet engines, lift fans or tilt
Toyota, are pouring rotors for vertical takeoff and landing (VTOL).
Flying car technology money into R&D efforts. In fact, Toyota hopes However, building a practical flying car is
continues to fascinate the to deploy a fleet of vehicles in time for the 2020 easier said than done. It’s extremely difficult to
general public, but frustrate Olympics in Tokyo. create a car that can fly or a plane that can drive
engineers. Illustration Despite considerable concern about liability on public roads.
courtesy AeroMobil and safety, two-thirds of Americans say they “Most designs end up being either
would like to ride in or operate their own inefficient cars or inefficient airplanes,” says
airborne vehicle. A recent study conducted by the Hans Weber, president of TECOP International
University of Michigan Transportation Research Inc., an aerospace consulting firm. “Weight and
Institute (UMTRI) claims that 41 percent of handling issues are huge challenges confronting
respondents are “very interested” in riding in a engineers. But, designs with electric propulsion
flying car. systems that enable VTOL appear to hold the
“Until recently, flying cars have existed most promise.”
primarily in the realm of science fiction, although According to Weber, it will be at least several
patents for such vehicles extend to the early years more years before viable flying cars exist. When
of aviation,” says Michael Sivak, a research they do hit the market, he believes manufacturers
professor at UMTRI. “However, there has been will adapt more production processes from the
a rapid increase in interest in flying cars from aerospace industry than the automotive sector.
companies ranging from large, international “In order to fly, all components and materials
manufacturers to a variety of startups. will have to be certified by the FAA,” explains
“Major technological, traffic-control and Weber. “So, assembly lines will probably closely
licensing issues still need to be addressed,” resemble what’s typically found in aircraft
warns Sivak. “A big unknown is what consumers factories.” A

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Assembly Lines
Inventions
New facilities
Mergers
NASA Explores is a logical extension of in-space
Reshoring Activity In-Space Assembly manufacturing, following recent
success printing plastic parts on
Outpaces Offshoring HOUSTON—Engineers
NASA hope to take manufacturing
at the space station.
“We’ve already seen the ben-
to new heights. The space agency efits of on-demand manufacturing
is currently soliciting proposals for tools and replacement parts
for the development of a first-gen- on the station,” said Crusan. “We
eration, in-space, multi-material want to increase the number of
fabrication laboratory, or FabLab, materials we can use to manufac-
for space missions. ture items on-demand in space and
“The FabLab development path improve overall manufacturing ef-
will be implemented in three phas- ficiencies, as well.”
es, with the objective of the final Crusan believes that in-space
phase to demonstrate a commer- manufacturing ultimately should
cially developed FabLab on the become an end-to-end process
International Space Station,” says capable of recycling feedstock, as
For the first time in decades, more manufacturing jobs are
Jason Crusan, director of NASA’s
returning to the United States than are going offshore.
Advanced Exploration Systems
KILDEER, IL—For the first time in decades, more manufacturing Division and Space Technology
jobs are returning to the United States than are going offshore. Mission Directorate (STMD).
According to the Reshoring Initiative, new U.S. manufacturing jobs “This solicitation seeks re-
attributed to reshoring and foreign direct investment (FDI) totaled sponses only to Phase A, in which
77,000 in 2016. That’s a 10 percent increase over 2015, and it private industry partners will pro-
exceeded the rate of offshoring by about 27,000 jobs. duce ground-based prototypes
This trend contrasts with the period from 2000 to 2003, when the with a measurable ability to ma- This science sample container
United States lost approximately 220,000 manufacturing jobs per ture into flight demonstrations was the first made-in-space
year to offshoring. on the space station within three object to be printed with
“The tide has turned,” claims Harry Moser, president of the Re- years,” adds Crusan. two plastic parts: a lid and a
shoring Initiative. “The numbers demonstrate that reshoring and According to Crusan, FabLab container.
FDI are important contributing factors to the country’s rebounding
manufacturing sector.
“The overall trend was up from 2015, due to anticipation of
NLRB Tops List of Burdensome Agencies
Regulatory reform has emerged as one of the Trump administration’s
potential policy changes that will make the United States more top priorities. In this month’s Web poll, we asked what agency has the
competitive, continued rising wages overseas, and increased use of most impact on your manufacturing operation. Nearly half of you say
total cost of ownership for sourcing decisions,” explains Moser. it’s the NLRB.
Proximity to customers was the leading factor for reshoring,
followed by government incentives, skilled workforce availability NLRB 44%
and ecosystem synergies. The Southeast and Texas remain the top
regions for reshoring and FDI, with the Midwest in second place OSHA 28%
due to its strong industrial base.
Transportation equipment remained the strongest industry, 17%
FTC
accounting for nearly 40 percent of total jobs returned. Plastics,
rubber and furniture saw the largest increases in industry ranking.
The Reshoring Initiative is currently participating in Return One EPA 11%
Million Jobs, a group recently created to raise $20 million to bring
1 million manufacturing jobs to the U.S. from offshore. To learn What's your opinion?
more, click www.returnomj.com or www.reshorenow.org. Visit www.assemblymag.com to answer this month's poll.

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Assembly Lines
well as harvesting it from extrater- mechanisms such as this one,” hollow die, creating
restrial sources. adds Reuter. “This solicitation a tube.
For FabLab Phase A, NASA has great potential for developing Compared to the
is requesting ground prototypes meaningful applications for space traditional extru-
designed to be compatible with missions, as well as direct terres- sion press method
the space station and capable of trial commercial infusion.” in which a metal
remote-controlled operations from is forced through a
Earth to manufacture multi-mate- die at a consistent
rial components, including met- speed and tem-
als. Phase A selectees will have
LIFT to Investigate perature, the new
A new R&D initiative is using friction stir
18 months to deliver a prototype, Auto Frame process is expected extrusion processing technology to manufacture
after which NASA will determine Weight Reduction to drastically re- lightweight automotive frames.
which, if any, partners will con- duce the mass and
tinue to Phase B. DETROIT—Lightweight Inno- weight of automotive frames. mercial and military transporta-
“Having an integrated capabil- vations For Tomorrow (LIFT) has “Friction stir welding tech- tion industry,” claims Taub, a for-
ity for on-demand manufacturing launched an R&D initiative to use nology allows the formation of mer engineer at Ford Motor Co.
and repair of components and sys- friction stir extrusion processing enhanced tubular structures with and General Motors. “By reducing
tems during space missions will technology to manufacture light- higher strength and ductility, the weight and cost of materials
be integral for sustainable explo- weight automotive frames. which enable mass reduction of used in auto frame production,
ration missions,” says Jim Reuter, Based on friction stir welding hydroformed vehicle structures by land-based vehicles will be able to
deputy associate administrator for principles, in which the rotation of eliminating weld flanges, reducing operate more efficiently.
STMD Programs. a tool generates heat and softens wall thickness and forming tubes “In two phases, the project
“This is a rapidly evolving, dis- the workpiece to create a weld, with more efficient profiles,” says aims to demonstrate that friction
ruptive area in which NASA wants friction stir extrusion technol- Alan Taub, chief technology offi- stir extruded tubing has improved
to continue working with industry ogy includes a rotating rod, which cer at LIFT. corrosion-resistant properties
and academia to develop these stirs the material in a container “The results of this project will over conventionally extruded tub-
technologies through collaborative and forces it between the rod and have a major impact on the coming, and that friction stir extruded
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applications, these
mau and MTI. Other research fully integrated
partners include Oak Ridge Na- systems offer
tional Laboratory, Southwest Re- absolute control
search Institute, the University of and real time
Michigan, the University of Notre feedback.
Dame, Ohio State University
and the University of Tennessee-
Knoxville. Flush self-pierce riveting is an
The project is expected to be effective way to join two pieces
completed by the end of next year. of metal.
welding, [break-stem] riveting and

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SCHUNK Receives feature is that the rivets are flush
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here. Henrik Schunk, managing
ABB and IBM
partner of SCHUNK, received the Partner to Develop
award from German Chancellor AI Technology
Angela Merkel. SCHUNK
received the award for its Co-act AUBURN HILLS, MI—ABB
Gripper JK1, the world’s first and International Business Ma-
intelligent gripping module for chines Corp. (IBM) have formed
human-robot collaboration. a strategic partnership that com-
bines ABB Ability with IBM Wat-
son Internet of Things cognitive SCHMIDT TorquePresses
capabilities. The initiative will fo-
Orbitform and cus on factory floor and smart grid
Reach working speeds
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AKH Form Riveting applications. reduce cycle times.
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provide absolute SCHMIDT® Presses can be supplied
and AKH Inc. have created a stra- tions combined with IBM’s exper- with controls that meet the
tegic business alliance. Orbitform tise in artificial intelligence and stroke measurement
highest global safety standards.
to compensate for any
will now produce FSPR Assembly machine learning,” says Ulrich These ergonomic press control
tolerance variations systems are completely redundant
Machines for installing the AKH Spiesshofer, CEO of ABB. “To- including any thermal electronically and pneumatically.
FAS-NER, a flush, self-piercing gether, IBM and ABB will create expansion of ram. They are designed to ensure
rivet created by AKH in 1981. powerful solutions for customers workers’ safety, which will reduce
“Highlights of this new sys- to benefit from the fourth indus- workman’s compensation claims.
tem include self-piercing, and trial revolution.
flush-mounted rivets that can be “This [initiative] marks the
prepainted and can join dissimi- next level of industrial technol- Let us work with you to find the
lar metals with multiple layers up ogy, moving beyond current con- right press for your assembly
to 0.36-inch,” says Phil Sponsler, nected systems that simply gather application. Contact us today.
president of Orbitform. “[Our goal data, to industrial operations and
is] to streamline the process in a machines that use data to sense, Call 1-800-959-1218 25 YEARS
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Assembly Lines
Products developed by ABB Watson’s real-time cognitive in- from ISO 9001-2008 to the new Video Game
and IBM will help manufacturers sights directly to the shop floor ISO 9001-2015 standard. The Simulates Auto
tackle some of their biggest chal- in combination with ABB’s in- transition includes several updates Assembly Lines
lenges, such as improving quality dustrial automation technology, to the Mountz quality manage-
control, reducing downtime, and companies will be better equipped ment system. LONDON—Simulation games
increasing the speed and yield of to increase the volume flowing “[Our] quality team spent the last allow people to immerse them-
assembly lines. through their production lines, year providing organizational guid- selves within fantasy worlds and
“These solutions will move be- while improving accuracy and ance for updating our quality man- assume occupations such as ath-
yond current connected systems consistency,” claims Ginni Rom- agement system to the new stan- letes, farmers, pirates or soldiers.
that simply gather data to cogni- etty, president and CEO of IBM. dard,” says Brad Mountz, president Now, they can also become an
tive industrial machines that use “As parts flow through the man- and CEO. “This ISO certification is auto assembly plant manager.
data to understand, sense, reason ufacturing process, the solution a testament to our ongoing commit- Positech Games recently devel-
and take actions supporting indus- will alert the manufacturer to criti- ment to continuous improvement oped a PC-based strategy game
trial workers to help eliminate in- cal faults not visible to the human with our quality processes.” called Production Line. It requires
efficient processes and redundant eye in the quality of assembly,” The ISO 9001 standard helps players to run a small, but growing
tasks,” Spiesshofer points out. adds Rometty. “This will enable organizations demonstrate that car company.
For example, ABB and IBM will fast intervention from quality con- they can offer products and servic- “The objective is to grow your
leverage Watson’s artificial intelli- trol experts [and] easier identifica- es of consistently good quality to business while at the same time
gence to help find defects via real- tion of defects.” their customers. The revised stan- perfecting the [assembly line]
time production images that are dard ensures that quality manage- layout and production process for
captured through an ABB system ment for any organization is now making cars, in order to bring the
and then analyzed using IBM Wat- completely integrated and aligned sale price for your cars as low as
son IoT for Manufacturing. Previ-
Mountz Certifies with all business strategies within possible and thus available to the
ously, these inspections were done to ISO 9001:2015 an organization. mass market,” says Cliff Harris,
manually, which was often a slow SAN JOSE, CA—Mountz Inc., To achieve certification, Mountz director of Positech Games.
and error-prone process. a leading supplier of torque and partnered with TUV SUD America “The mechanics of the game
“By bringing the power of fastening products, has migrated Inc., an independent third party. are unusual in that the player is
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productivity and prof-
itability,” says Kevin
Mauger, president and
Accuracy.
former sole owner of
NCC. “We expect the
ESOP to increase the
Speed.
retirement security of
our employee own-
A new simulation game lets players operate
ers, particularly if we
Durability.
an automotive assembly plant.
continue on the growth
not striving to make the product path we have enjoyed the last sev-
bigger, but to constantly subdivide eral years.
the production process to squeeze “Our company is built on the The Q2 Series sets the standard
every possible optimization, and positive culture and energy of
making each stage of the produc- our team creating an environment for assembly tool ergonomics while
tion line as simple, fast and effi- that supports a positive customer delivering repeatable performance
cient as possible,” adds Harris. experience with the speed and
The key to the game is to stra- agility required to compete in today in and day out across a full
tegically arrange workstations and day’s market,” adds Mauger. “The range of screwdrivers, nutrunners
break down each of the tasks of ESOP will give our employees a
car production into smaller and financial interest in the continued and drills.
more efficient stages. Players have growth and success of the busi-
to manage production processes ness, creating even more of a
Performance:
such as engine and chassis as- team effort and vested interest in Powerful & Fast
sembly lines, in addition to a body supporting our customers than we
shop and a paint shop. They also have today.” Flexibility:
have to tackle a wide variety of 3 air inlet options
bottlenecks.
As part of his research, Harris Ergonomics:
visited Ford Motor Co. plants in
Most Robots Are Compact and lightweight
Detroit. He claims he was inspired Vulnerable to
to create the game after reading a Hacking
copy of Henry Ford’s autobiogra-
phy, My Life and Work. TOKYO—Most industrial ro-
To learn more about the game, bots are vulnerable to hacking,
click www.positech.co.uk/produc- claims a recent study conducted
tionline. by Trend Micro Inc. “Rogue Ro-
bots: Testing the Limits of an In-
dustrial Robot’s Security” dem-
onstrates how easily robots can be
Glide-Line Is Now compromised in a factory.
Employee-Owned The report is based on tests
SOUDERTON, PA—The par- conducted by Trend Micro’s For-
ent company of Glide-Line, NCC ward-Looking Threat Research
Automated Systems, recently team and the Polytechnic Univer-
formed an employee stock owner- sity of Milan. They used an ABB
ship plan (ESOP). In the transac- IRB140 robot in a laboratory set- featuring an egg-shaped
tion, ownership sold a significant ting that simulated production en-
housing design for natural fit and
interest to a newly created em- vironments.
ployee stock ownership trust that “Robots are everywhere,” says maximum operator comfort
allows current and future employ- Jon Clay, senior global market-
ees to gain a beneficial ownership ing manager at Trend Micro. “We
interest in the company without need these systems to support In-
any personal cash investment. dustry 4.0, a new wave of innova-
Learn more at
“In light of the challenges fac- tion based around automation and IRTOOLS.COM/Q2
ing American workers, an ESOP smart factories that could trans-
is an excellent way in which to as- form society in a way similar to
sure the continuation of our world- the very first steam engines in the
class team of valued employees, late 18th century.
and enhance our company’s “[However], as these systems

Assembly Lines
systems and librar- M Memory corruption. M Altering the controller’s pa-

ies like Linux 2.6,” M Missing code signing. rameters (the attacker alters the
adds Clay. “[Ro- M Naive cryptography. control system so the robot moves
bots] sometimes M Poor run-time isolation. unexpectedly or inaccurately, at
rely on obsolete M Unsecured network and the attacker’s will).
or broken crypto- command injection. M Tampering with calibration
graphic libraries, M Weak authentication. parameters (the attacker changes
and feature poor “By combining these vulner- the calibration to make the robot
authentication with abilities, we show how an attacker move unexpectedly or inaccurate-
default, unchange- can implement robot-specific at- ly, at the attacker’s will).
able credentials.” tacks ranging from violating safe- M Tampering with the produc-
Most industrial robots are vulnerable to hacking, Industrial ro- ty requirements up to stealthily tion logic (the attacker manipu-
but manufacturers can take steps to prevent bots that are manipulating [assembly lines],” lates the program executed by the
against it.
reachable directly says Clay. “Due to the architectur- robot to introduce defects in the
get smarter and more intercon- via the Internet, to allow for real commonalities of most modern workpiece).
nected, [they become more vul- mote monitoring and mainte- industrial robots and the existence M Altering the user-perceived
nerable to cyberattack],” warns nance, are extremely vulnerable. of strict standards, the [machine] robot state (the attacker manipu-
Clay. “Web services allow exter- According to Trend Micro’s re- chosen for our case study is repre- lates the status information so the
nal software or devices to ‘speak’ port, the United States leads the sentative of a large class of indus- operator is not aware of the true
with their robot controller via world in having the largest volume trial robots. status of the robot).
HTTP requests, while new appli- of machines exposed in this way. “We were able to determine five M Altering the robot state (the
cation program interfaces allow The report includes a case study classes of attacks that are possible attacker manipulates the true robot
humans to control robots through demonstrating exactly how a cy- once an attacker is able to exploit status so the operator loses control
smartphone apps. berattack on a typical industrial any of the several weaknesses that or can get injured).
“This is compounded by out- robot could be achieved. Threats we found in industrial robot architec- To learn more about the robot
dated software powering many sys- that manufacturers should guard tures and implementations,” claims security study, click www.trend-
tems, based on vulnerable operating against include: Clay. Those scenarios include: micro.com.
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Assembly in Action
More Than 80 Robots

Rev Up Assembly
at Maserati
W
hen one thinks of Italy, models in a continuous flow.
several things immediately Workers at the start of the line manu-
come to mind. There’s wine ally weld and bond three areas of the
and pasta, world-class soc- vehicle using high-strength steel and
cer and gondoliers singing die-cast aluminum parts, and semi-
in Venice. Another thing structural adhesive. These areas are
that symbolizes Italy is Maserati, the the front framework (where the engine
manufacturer of technologically ad- and all related mechanical components
vanced sports cars. Founded in 1914, are mounted), central floor (front seats,
the company operates tunnel) and back framework (back
plants or sales offices in seats, trunk).
more than 40 countries
around the world.
Maserati cars—both The automated section of the
old and new—are famous
for their luxury design, assembly line features 86 robots.
sporty lines and aggres-
sive engines. The Quattro- Next, the vehicle is moved to the au-
porte and Ghibli are two tomated section featuring 86 robots.
of the company’s newer There, the robots perform spot welding
and most popular models. while inserting subcomponents (brake
Both are manufactured at hoses, underbody parts, wiring) and
Officine Maserati in Grug- closing elements (side and top clamp
liasco, near Turin, which brackets, rivets, Tucker studs). They also
reopened in January 2013 precisely fold the flanges of the metal
after being closed for six sheets where needed (roller hemming).
A total of 86 robots perform welding, part years. The facility is also known as the After this, the chassis is moved down
handling, riveting and other tasks on the Giovanni Agnelli Plant, having been the line to where the body is added in
sheet metal assembly line at Maserati’s
plant in Grugliasco, Italy. Photo courtesy
named after the company’s chairman parallel. The skeleton, or internal part
Comau SpA from 1966 to 1996. of the side, is fastened first, followed by
Current plant manager Alberto Filip- outer skin. Painting and final assembly
pini says the facility produces 150 are performed soon afterward.
vehicles per day (over two shifts) and Of the 86 robots used at the plant,
50,000 vehicles per year. Flexibil-
ity on the sheet metal assembly
line is essential to maintaining
this high rate of production.
The line is programmed to au-
tomatically determine whether
the piece is for the Quattroporte
or Ghibli, notes Filippini. This
For reprints of any is important because the two ve-
Assembly in Action article, hicle bodies differ substantially in
Maserati relies predominantly on Comau robots
please contact Jill L. DeVries terms of chassis length and related because they offer quick head changes, a large
at devriesj@bnpmedia.com components. The line is flexible working area and high-precision movement.
or 248-244-1726. enough to produce one or both Photo courtesy Comau SpA

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Assembly in Action
82 are articulated and multiaxis mod- VGVs Deliver Parts to

els made by Comau SpA. Novara says
Maserati likes Comau robots because
Appliance Assembly Line
they offer quick head changes, a large
working area, and high-precision
movement when handling parts or
I f Ohio ever needs a catch phrase to
promote its manufacturing success,
“five out of eight is great” would be ap-
performing tasks, such as spreading propriate. The reason is because Ohio
adhesive. The robots also feature a is home to five of Whirlpool Corp.’s
hollow wrist design that reduces foot- eight U.S. assembly plants. Those five
print by housing the welding-gun, factories are located in the Ohio cities
air-flow and all other cables inside of Clyde, Findlay, Greenville, Mari- At Whirlpool Corp.’s manufacturing plant
in Clyde, OH, more than 50 vision-guided
the robot arm. on and Ottawa.
vehicles safely and efficiently bring parts to
Overall, each Quattroporte and Encompassing 2.4 million square feet, workers on the assembly line. Photo courtesy
Ghibli vehicle receives 4,785 welds, the Clyde plant is the largest washing Seegrid Corp.
190 rivets and 243 arc-welded studs. machine factory in the world. More than
More than 1,000 welds are made prior 3,000 workers there produce 20,000 one assembly line. Since then, the com-
to the sheet metal assembly line, com- washers per day (over three shifts), five pany has installed more than 50 VGVs
pared to 3,702 welds made on the line. days a week. On average, one machine throughout the huge plant.
Of these, 1,025 welds are done by hand rolls down the line every four seconds. “For any manufacturer in the United
and 2,677 by robots. The car also re- A few years ago, plant management States, there is an overall labor short-
quires about 79 meters of adhesive: 13 looked into ways to increase worker age, especially for skilled positions,”
applied manually and 66 by robot. safety by lessening the use of fork- explains Jim Keppler, integrated supply
For more information on articulated lifts. They purchased a vision-guided chain vice president at Whirlpool. “The
and multiaxis robots, call 248-353- vehicle (VGV) made by Seegrid Corp. VGVs have let us move more than 150
8888 or visit www.comau.com/eng. and had it move parts to workers along people into value-added positions from
drive in
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To Be Precise.

needs change, any facility staff mem- dispatching for material transport.
ber can modify the VGV’s route. Besides parts-to-line delivery, the
Operators can use Seegrid Supervi- vehicles can be used for long hauls,
sor software for real-time monitoring staging and sortation, replenishment,
and status updates, and to manage and kitting and picking, trash removal and
control intersections. The software can cross docking.
also be integrated with external devices For more information on vision-
or existing software systems for VGV guided vehicles, call 412-379-4500 or
notifications, customized operation and visit www.seegrid.com.
Several vision-guided pallet trucks and tow
tractors are available, all of which operate
in automatic or manual mode for maximum
flexibility. Photo courtesy Seegrid Corp.
those involving mundane work.”

Keppler says Whirlpool especially
SMALLER. LIGHTER.
SMARTER.
likes that the vehicles eliminate the
problems of absenteeism and worker
turnover, while improving worker safe-
ty and ensuring consistent delivery of
parts to the line. In addition, the VGVs
are easier to program than traditional
automated guided vehicles (AGVs) that
use lasers or follow wires, magnets or
tapes on the floor.
“This evolution in AGVs lets us [eas-
ily] reconfigure the vehicles [for] new ADVANCED
ERGONOMICS
routes and assembly line locations
within our facility,” notes Keppler. “It’s
so easy that even a guy like me can do
it. During one of my visits to the Clyde ONLY 6-3/8” IN LENGTH
plant, the [managers] actually had me
ONLY 2.4 LBS. WITH BATTERY
program one of the units.”
Seegrid offers an extensive line of
VGV pallet trucks and tow tractors, all
of which operate in automatic or man- 6-STAGE
ual mode for maximum flexibility. Tow
tractors can be coupled with trailers, PROGRAMMABLE
carts or dollies. Pallet trucks transport PRECISION FASTENING
palletized goods. • Spindle Direction by Time
Each vehicle is “trained” by an opera- or Rotation
tor, who walks or drives the VGV along • Speed Management by Time
the desired route. During training, the or Rotation
vehicle captures images of the facility • Finishing Strategy
and builds a three-dimensional map of
its surroundings. Once training is com- ALSO FEATURES PREVENTATIVE
MAINTENANCE SCHEDULING
plete, the operator enters the desired
route on the keypad and then loads the
VGV with goods, either directly on the
vehicle or onto carts or trailers.
The VGV then follows its three-di-
mensional map to safely and efficiently To learn more, call 800-867-8265 (ext. 3121) for
requesting further contact or how to acquire trials.
navigate through the facility and inte-
grate flawlessly with the rest of the op- makitaassemblytools.com
eration. When workflow and business

Assembly in Action
AGCO Smooths out its propelled crop sprayer: the Challenger

RoGator 600 series.
Equipment Design Process “What we heard from large-scale
C rop sprayers play a vital role in pro-

fessional farm management. Farm-
ers and farming contractors rely on
farmers and contractors all over Europe
was that a smooth ride was essential to
spray performance. Speed and boom
this equipment to evenly apply exact reach [were also important],” explains
amounts of nutrients and protectants Joris Hiddema, engineering manager
on hundreds of acres on demand—al- for sprayers at AGCO. “We realized that
though it’s not as easy as it sounds. just touching-up our old design wouldn’t LMS Virtual.Lab Motion modeling software
Chemicals are pumped from large work. We needed an unconventional de- simulates full-motion behavior of complex
tanks to tiny nozzles along wide booms sign approach.” mechatronic systems. Graphic courtesy
that span across multiple rows of crops. The Challenger RoGator travels up to Siemens PLM Software
The tanks can hold thousands of liters 30 kilometers per hour and has a boom tion of the boom suspension, as well as
of fluid, and the booms can be many length of 36 meters. It features a boom all vehicle dynamics. This was critical
meters in length. In addition, opera- suspension system with an all-steel central for boom stability.”
tors must maneuver sharp turns at the frame and cantilevered truss beams made The LMS Engineering (LMSE) team
end of crop rows, where big bumps can of tubular aluminum to save weight. extracted the dimensions and mass of the
cause fatigue cracks in the equipment, “We worked with the learning man- boom arms, the central frame and pen-
and a small bounce may result in un- agement system (LMS) experts from dulum suspension. Next, they used LMS
even or spotty spray. Siemens PLM Software to tune each Virtual.Lab Motion (VLM) software to
Netherlands-based AGCO Corp. has spring-damper pair for ideal handling create a multibody model of the frame
been manufacturing crop sprayers for of extreme horizontal, vertical and yaw and pendulum. The team later created a
decades. In 2014, company engineers boom movements,” explains Hiddema. finite element model of the boom arms
decided to redesign AGCO’s latest self- “The project required detailed evalua- and performed a modal analysis.
PRECISION You built your reputation on precision and that means calibration
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compact size and simplicity allows use on the assembly line or in the
calibration lab and a unique washer design with almost no friction
more accurately simulates clamp load. The included, easy-to-use
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Upgrade to a system that’s as precise as you are.

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business, from materials and de- drive (FEAD) belts at its dynamom-
sign, to assembly, performance eter lab in Dearborn, MI, to make sure
and customer service. Quite of- they conform to the SAE J2432-2012
ten, these same companies are standard (Performance Testing of PK
equally committed to meeting Section V-Ribbed Belts). This standard
the highest industry standards in provides accessory drive belt testing
one or more of these areas. methods and includes test configura-
The Challenger RoGator 600 series crop sprayer has a
Ford Motor Co., for example, tions, pulley diameters, power loads
boom length of 36 meters. Photo courtesy AGCO Corp.
regularly tests front end accessory and guidance for interpreting test data.
“We needed to consider vibrations
from the tractor, so the entire vehicle was
Elevating Worker Platforms

modeled, including independent wheel
suspensions, the steering system, the
cabin and all the joints: spherical, revo-
lute and cylindrical ones,” says Hiddema.
“Mass and inertial properties were cal-
culated from CAD data. Tires were rep-
resented in a VLM model to determine
tire-induced vibrations. Pendulum sus-
pension kinematics were checked for po-
tential interference such as joint lockups.”
LMSE also performed a multi-body
VLM simulation to check the boom
response at various speeds and maneu-
vers. This simulation provided the right
information to fine-tune the dampers
and springs, and properly position the
components.
To accurately build the sprayer proto-
type, performance traits were measured
using LMS SCADAS Mobile hardware
for data acquisition and LMS Test.
Lab software for data analysis. All hor- Improve Productivity and Worker Safety
izontal, vertical and yaw displacements Elevating Worker Platforms from Southworth provide
convenient access to large or elevated structures allowing
closely matched those predicted with workers to perform assembly, maintenance or stock picking
multi-body dynamics simulation. operations faster, safer and easier. They eliminate the
AGCO was also happy to learn that risks and hassles commonly associated with ladders and
LMSE significantly reduced the coeffi- scaffolding and provide the speed, flexibility and security
of a powered variable height platform to create a more
cient of variation (CV) of the sprayer’s productive work environment.
distribution pattern to about 5 percent.
A few more advantages include:
This rating is based on a system from
Instant height adjustability
the Germany-based Julius Kühn Insti- Platforms accommodate multiple workers
tute, which regards a CV of 15 to 20 as Tools travel up and down with workers
acceptable and below 10 as exceptional. Decks can be equipped with slide-out extensions, bridges,
For more information on LMS ramps, power supplies, tool fixtures, custom surfaces, etc.
software, call 800-498-5351 or visit Fixed, hinged or retractable safety gates and handrails
www.plm.automation.siemens.com. Every application is different, so our engineering department
works closely with customers to satisfy their unique
application requirements.
Visit www.SouthworthProducts.com/platforms
Ford Takes a Stand for
Better Belt Testing
W orld-class manufacturers maintain 1-800-743-1000
high standards in every facet of their www.SouthworthProducts.com making work faster, safer, and easier since 1890

Assembly in Action
A few years ago, Ford had SAKOR misalignment. Through misalignment

Technologies Inc. develop a custom belt and tilt to the pulleys—two major
noise test stand to increase the automak- contributors to engine belt noise—the
er’s testing flexibility. Ford needed a stand stand helps Ford engineers test new
that handles belts of any length or width, rubber formulations, fibrous materials
and offers alignment accuracy with full and pulley-and-belt shapes designed to
control of temperature and belt tension. minimize belt chirping under several
Along with these functional capabili- environmental conditions.
ties, the stand has a high-speed AC dy- “The stand is versatile enough to adapt
namometer that precisely simulates the to further noise test development,” ex-
torque pulses from engine firing with- plains Willis, who leads SAE’s belt drive
out the fuel, cooling and fire-suppres- (automotive) systems committee. “It
sion systems necessary for fired-engine [helps] Ford continue to provide high-
testing. It also features a thermal cham- quality product to its customers.”
ber and a water mist system that mimic SAKOR makes three types of AC Ford Motor Co. tests front end accessory drive
belts with this custom belt noise test stand.
a wide range of environmental condi- dynamometers. The four-quadrant Ac- Photo courtesy SAKOR Technologies Inc.
tions known to have a major effect on cuDyne series includes 5-kilowatt to
belt noise performance. 3-megawatt models used for testing comply with engine testing procedures
Scott Willis, FEAD technical spe- active (engines, electric motors) and required by emission standards con-
cialist at Ford, is impressed with the passive (transmissions, generators, al- tained in 40 CFR Part 1065.
stand’s flexibility. Besides allowing ternators) components. Its MicroDyne SAKOR has designed and built test
Ford engineers to test in accordance units are designed for testing small mo- instrumentation systems for other man-
with the SAE specification, the stand tors and components with 100 watts to ufacturers besides automotive OEMs.
performs aging and durability test- 5 kilowatts of power. Small engine dy- For more information, call 517-332-
ing, and creates axial and angular belt namometers help engine manufacturers 7256 or visit www.sakor.com.
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ASSEMBLY Assembly Plant Tour
Behind the Scenes

at DEWALT
N
otice to the highly skilled pneumatic screwdriver suspended from
DEWALT’s assembly plant in workers at DEWALT’s a tool balancer, I install the screws
Charlotte, NC, produces high- assembly plant in Charlotte,
NC: Your jobs are safe.
in a crisscross pattern to ensure even
tightening.
quality tools while beating Well, they’re safe from So far, so good. I swap places with
dilettante journalists, anyway. the worker next to me. Then, I lay the
overseas competition. During a recent visit to this bright, tool on its side and install eight screws
open, state-of-the-art factory, I took to hold the two halves of the body
a turn on the line assembling one of together. Perhaps with a few more days
DEWALT’s hottest products, the (or weeks) of practice, I might be as
20-volt MAX XR three-speed quick as the pros on the line.
cordless drill and screwdriver, Screws tightened, it was time to
which is powered by a brushless program the tool.
motor and a 5 amp-hour lithium- Many power tools are driven by
ion battery. brushed motors, which are commutated
The tool is assembled manu- mechanically. As the rotor turns, pairs
ally. I began in the middle of a of commutator bars contact the brushes
nine-person line consisting of a in succession, connecting electrical
series of workstations arranged power sequentially to different sets of
end-to-end in a U-shaped cell. armature windings, which keeps the
Each workstation has uprights rotor turning. The main drawback of
featuring task lights, parts bins, these motors is that the brushes wear out
tool balancers, visual assem- and must be replaced.
bly aids, and other equipment. DEWALT’s next-gen cordless tools
Everything is within easy reach. are driven by brushless motors. In a
Behind the workstations, flow brushless motor, the magnets are on
racks equipped with casters keep the rotor, and the windings are wrapped
workers supplied with parts and around poles on the stator. Instead of
subassemblies. brushes and a commutator bar, the
The tool is passed from windings are switched on and off
worker to worker in a clever sequentially by solid-state electronics.
The Charlotte plant makes a variety of 18- and fixture made from a soft plastic. The Besides needing less maintenance,
20-volt cordless tools, including reciprocating fixture is designed to securely hold the brushless motors are smaller, lighter
saws. Photo courtesy DEWALT
tool vertically or horizontally. When the and more efficient than brushed motors.
tool is fully assembled and ready for But, those electronics need to be
For information on how to obtain testing, the empty fixture is placed on programmed. So, at the next station, I
reprints/e-prints of this article, an inclined roller conveyor, which takes plug the tool into an electronic fixture.
please contact Jill L. DeVries it back to the start of the line. At the press of a button, a computer
at devriesj@bnpmedia.com When I get the tool, it’s pointing up. downloads a program for running the
or 248-244-1726. My first task is to install four screws to motor and other functions. When that’s
attach the metal housing (containing done, I plug the tool into a series of
 By John Sprovieri the transmission, chuck and torque automated test stands, which check the
Editor in Chief adjustment collar) to the main body function of the electronics, motor and
sprovierij@bnpmedia.com of the tool. Using a slim, push-to-start transmission. Every tool gets tested.
When the tool passes muster, I tools assembled in Charlotte. Local
move to the labeling station, and suppliers also provide Charlotte with
it’s here where I run afoul of Tony parts. (Since not every part is made
Segura, team lead for DEWALT’s in this country, DEWALT tools are
premium brushless tool lines. My designated “Made in the USA with
task is to apply seven adhesive- Global Materials.”)
backed labels to various locations on “We want to localize as many of
the tool. For example, on the left side the components as possible, wherever
of the tool, just below the DEWALT it makes financial sense,” says Craig
name, there’s a small rectangular Zielinski, director of manufacturing
recess where I must apply a label with for global tools and storage at Stanley
the name of the tool. It seemed easy Black & Decker Inc., the parent
enough, but my label was, perhaps, company of DEWALT.
not as straight as it could have been. In addition to the cordless drill
“No, that’s not good,” says Segura, and driver, the Charlotte plant makes
checking my work. He peels off my a variety of other 18- and 20-volt
shamefully crooked label and applies cordless tools, including hammer
a new one. drills, impact wrenches, reciprocating
As I apply the remaining labels, saws and flashlights. The factory also
Segura keeps an eye on me the way makes the brushed and brushless
an owl might watch a mouse. When I A worker uses a pneumatic screwdriver to install motors that go into the tools. The
finish, Segura places the tool in a cus- screws in a cordless impact wrench. Photo courtesy facility opened in October 2013, and
tom error-proofing fixture equipped DEWALT on Feb. 20, 2017, the plant produced
with various sensors that automatical- Jackson, TN. Those seven plants output its 10 millionth tool.
ly check for the presence of all seven more than 90 million products in 2016, “DEWALT has significantly
labels. I was beginning to feel bad about an almost 50 percent increase from the increased its production of tools made
my label-application abilities, until I 62 million individual products output in the U.S. with global materials,”
learn that every tool DEWALT makes in 2015. says Frank Mannarino, president of
goes through the same check. Besides tools, some of those U.S. DEWALT Global Power Tools and
It may have been “just” a label, but, plants also make many of the parts, such Equipment. “We have worked hard to
of course, it’s a part seen by the user as metal gears, that go into the cordless drive greater productivity and efficiency
every time he picks up the tool. Any- at our manufacturing facilities. …
thing less than perfection in some- We are a global brand proud to have
thing so simple and obvious as a label been founded in the United States and
might lead the consumer to question proud to continue to manufacture in
the quality of the rest of the product. the United States.”
That sort of attention to detail and It wasn’t always that way. Before
quality is emblematic of how things the Charlotte facility opened,
are done at DEWALT’s Charlotte DEWALT was assembling many
assembly plant and, indeed, of its tools in Mexico and China.
throughout the entire company. Then, about a decade ago, the com-
pany shifted strategies, opting to
Made in the USA produce tools close to where they
For carpenters, woodworkers, will be sold. Such a strategy offers
auto mechanics and other numerous advantages. Logistics are
tradespeople, DEWALT power tools simpler, transport costs are lower,
are synonymous with quality and and there is less risk of an interrup-
durability. What’s just as important, tion to supply. And from a market-
for some, is that those tools are made ing perspective, consumers prefer
right here in the U.S. products that are completely or par-
Besides Charlotte, DEWALT tially made in the U.S. to ones made
operates factories in New Britain, overseas.
CT; Greenfield, IN; Hampstead, MD; DEWALT makes all the brushed and brushless motors “Ultimately, our goal is to manu-
Shelbyville, KY; Cheraw, SC; and that go into its tools. Photo courtesy DEWALT facture as close to our end-users as
Assembly Plant Tour
possible,” says Zielinski, who’s Nimble Manufacturing
been with the company since The Charlotte plant has
1998. “We are doing the same evolved considerably over the
types of localization activities to years. It started off manufacturing
service our customers in other 21 high-volume cordless SKUs.
regions of the world. Since then, the factory’s SKU
“Think of the responsiveness count has tripled thanks to
to our customers,” he adds. “We new product introductions
are producing tools inside the and additional products being
largest distribution center in our “localized.”
network. Tools can literally be Covering 1.2 million square
in stock, ready to pick out of our feet, the factory literally lies
DC, within minutes of coming across the border between North
off the assembly line. Inventory Cordless tools are mostly assembled manually. Lines consist of and South Carolina. (A sign
levels can be minimized vs. the a series of workstations arranged end-to-end in a U-shaped cell. over the entrance to DEWALT’s
five to six weeks [of inventory] Photo courtesy DEWALT distribution center reads,
you would see [if the tools were] “Welcome to South Carolina.”)
coming from China. Zielinski recalls. “We have a long The factory employs some 500 people
“Whatever the DC ships today, I history of continuous improvement and runs seven days a week.
want to be making tomorrow.” and productivity tied to our Stanley U-shaped assembly cells—each
Reshoring wasn’t easy. “Bringing Fulfilment System. While [the plant dedicated to a specific tool family—
products back from a low-cost labor initially increased the company’s labor line the perimeter of the factory. In the
market to a higher-cost labor market costs], we have made great strides middle are automated assembly systems
is always a challenge, but we had to minimize that increase. There for making brushed and brushless
tremendous support from upper are actually tools being produced in motors. Lean manufacturing principles
management to start up the Charlotte Charlotte now that are cheaper than our guided the layout for efficient inflow
manufacturing facility back in 2013,” cost out of China.” of parts and outflow of finished goods.

“We had a kaizen event before we loading and unloading tools into test is more than 20 years old and still going
ever placed a machine,” says Zielinski. equipment. strong.) That sort of longevity doesn’t
Engineers used cardboard cutouts, 5S The latter is a work in progress, but come by accident.
projects and value-stream mapping to Zielinski sees potential in the technol- “The secret to durability goes back to
determine the ideal layout. ogy. Loading and unloading “is not understanding your end-users and how
While most tasks at the plant are how you want to be using your skilled they use the tools, and then working
manual, DEWALT deploys automation workforce,” he says. “I want my opera- with our design group to create a very
wherever it makes sense. tors doing value-adding tasks, like sol- robust design and very tight control
“We are always looking for more dering.” of our manufacturing processes,” says
productive ways to manufacture our Zielinski is particularly proud of the Zielinski. “We do an extensive amount of
tools, and that goes across our entire brushless motor line, which was installed conformance testing at all our facilities
network of U.S. plants,” says Zielins- less than two years ago and requires just to ensure that we do not drift from our
ki. “We continue to evolve, especially two people to operate. The compact, fully original design specifications.”
the way we are using technology in automated line can wind and assemble The Charlotte factory has two labs
the manufacturing process, whether four different motors. The tooling needed dedicated to reliability testing. One is
it is using tablets for documentation to assemble each motor variant is stored geared to application-based reliability
control and work instructions [or] right on the machine, so changeover can testing. In this lab, technicians simply
monitoring our processes through a be accomplished quickly. use and abuse tools just how consumers
connected [overall equipment effec- DEWALT had been importing the would. A reciprocating saw makes cut
tiveness] system. Technology is motors, but the new line nixed that. after cut in a thick beam. An impact tool
changing rapidly, and we want to be “It reduced our lead time for brushless tightens one lag bolt after another.
on the forefront of that to remain motors from six weeks to 12 feet,” he The other lab takes a more scientific
competitive.” says. approach. Tools are secured in custom
Indeed, DEWALT is experimenting fixtures that run them constantly or cycle
with 3D printing to make fixtures Reliability Testing them on and off for hours. Sophisticated
and tooling; automatic cells to install DEWALT tools are known for their electronics monitor how each tool is
screws; and collaborative robots for durability. (My DEWALT cordless drill holding up to the abuse. A
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ASSEMBLY Power Tools
Cordless Fastening
Comes of Age
T
he popularity of cordless tools Cutting the Cord
Engineers have more battery- on the assembly line continues Cordless tools are now quieter
powered options available to grow. Battery-operated
devices allow assemblers to
and more economically viable than
many alternatives, such as traditional
than ever. more easily work on platforms air tools. Today’s devices are more
or inside car interiors, tractor durable and much cheaper to operate
cabs, aircraft wings and other on assembly lines. According to some
tight spaces. estimates, they can save up to 95
Cordless tools also improve percent in energy costs compared to
safety and increase quality. There air tools.
are no air hoses and electrical “There’s still a need for traditional,
cords to trip workers or scratch pneumatic tools, but we see a lot of
paint jobs. That’s why they’re manufacturers moving toward quieter
the fastest-growing segment of plants,” says Eric Dees, director of
the power tool market. global assembly tools at Ingersoll Rand.
Battery-powered fastening “Some of them are committing to full
tools have been around since battery platforms.
they were first invented for use “It’s primarily due to the intan-
by NASA astronauts 50 years gible costs around safety,” explains
ago. Although they quickly Dees. “Insurance costs can be lower
found a niche with homeowners when there’s a reduced risk of trip
and contractors, assembly line hazards and a reduced need for ear
applications have been more protection.”
limited. “The torque capabilities of cordless
But, that’s starting to change. tools have increased and maximum
Assemblers in many industries, speeds now match air tools,” claims
especially automotive, aerospace John Bradford, senior sales engineer at
and off-highway equipment, Bosch Production Tools. “This was a
are cutting the cord. And, in big sticking point for many engineers
some cutting-edge plants, only in the past.
cordless tools are allowed. “Trying to convince their operators
State-of-the-art cordless tools store data, Batteries now last longer, weigh that using a slower tool that did not
identify errors, validate production and support less, cost less and recharge quicker. have an air hose attached was a good
troubleshooting. Photo courtesy Ingersoll Rand
In addition, the torque capabilities thing was sometimes difficult,” says
of cordless tools have increased and Bradford. “Engineers today would
For information on how to obtain maximum speeds now match many air like as many of their assembly tools as
reprints/e-prints of this article, tools. possible to be cordless.”
please contact Jill L. DeVries The latest generation of cordless Operator safety and ergonomics
at devriesj@bnpmedia.com fastening tool technology boasts more are important cordless tool benefits
or 248-244-1726. accurate torque, repeatability and that appeal to many manufacturing
dependability than ever. In addition, engineers.
 By Austin Weber wireless traceability and network “They don’t want cords on the factory
Senior Editor integration is now the rule rather than floor,” says Anthony Zimmerman,
webera@bnpmedia.com the exception. global product manager for cordless
tools at Apex Tool Group LLC. been eager to adopt battery-
“In fact, some companies powered fastening tools,” he
now specify that if a battery- points out. “Another industry
powered tool will do the job, it that’s hungry for cordless
must be selected over a corded options is aerospace.”
alternative.” Traditionally, cordless tools
Sometimes, age can be a were primarily used for non-
factor in the appeal of cordless safety critical automotive appli-
tools. cations, such as attaching door
“The younger generation trim and instrument panels. But,
seems to embrace new tech- that’s quickly changing.
nology,” notes Russ Hughes, “OEMs and suppliers are now
threaded fastening technology Cordless tools are now quieter and more economically viable than willing to use cordless tools for
marketing manager at Desout- many alternatives. Photo courtesy Desoutter Industrial Tools applications that would have
ter Industrial Tools. “[Some been performed with a DC tool
engineers who] have been around lon- manufacturers to invest in the devices. in the past,” says Dees. “This includes
ger just need more time to prove it out “Engineers now see the advantages powertrain, in addition to air bags, brakes
and accept the change. Others will of cordless tools for assembly and steering systems.”
always underestimate a cordless tool’s applications,” says John Olson, power “Cordless tools are now used for all
capability.” tool group manager at Panasonic Eco kinds of joints,” adds Manoj Malhotra,
Desoutter’s newest cordless pro- Solutions Co. North America. “The global marketing manager for the power
duction tool is the BLRT, a trans- drawbacks cordless tools had 10 years tools group at Apex Tool Group LLC.
ducerized pulse tool. The lightweight ago have now been overcome. There “The only limitation is torque.
device features high speed, no torque is a definite change in attitude in the “The torque threshold for most
reaction and a clear OLED display. industry, and many engineers now see cordless tools is now around 105
Its currently only in use at three auto cordless tools as being the future of newton-meters,” notes Malhotra. “In
plants, but the tool will be formally assembly.” the past, engineers typically specified
launched at the ASSEMBLY Show in According to Olson, automotive either electric or pneumatic tools for
late October. assembly plants that may have had 100 any fastening application that required a
According to Hughes, the new or less cordless tools a decade ago now torque of 50 newton-meters or higher.”
battery-powered tool was designed have more than 1,000. Today’s offerings are much faster
with operator ergonomics in mind. “Many agricultural and construction and more durable than what was
“Unlike other pulse tools, we don’t use equipment manufacturers have also available just a few years ago. Back
a hydraulic pulse mechanism,” he then, cordless tools often had
points out. “We just use a robust brushed motors, analog switches
gear set to do all the pulsing. We and nickel-cadmium or nickel-
also use lightweight materials, metal hydride batteries with
such as aluminum, composites limited charge cycles.
and titanium. “Cordless tools were fairly
“In addition, new algorithms high maintenance and lacked the
are always being developed to speed, durability and run times to
help reduce operator injuries and keep up with modern takt times,”
fatigue,” says Hughes. “We have says Olson. “And, there were few
one built into all our products, wireless traceability systems.
including cordless tools. We call “In the past, manufacturers
this ERGO stop. It reduces the viewed cordless assembly tools as
affect the operator feels when high-maintenance items,” Olson
the tool shuts off. We gradually points out. “They would often go
release the tool to prevent reaction through a lot of brush motors and
to the operator.” switches, making them expensive
As cordless technology has to own and operate.
evolved, tool suppliers have been The latest generation of cordless fastening tools is more accurate, “Many of the earlier cordless
able to improve their products. repeatable and dependable than ever. Photo courtesy Panasonic tools used direct-drive motors,
That’s made it easier to convince Eco Solutions Co. North America which ran slower,” adds Olson.
Power Tools
“They couldn’t keep up with the tion and connecting the tools to
pace of their air-tool counterparts.” a Panasonic assembly qualifier,
batch counting and line control
New Technology can be incorporated to prevent
State-of-the-art cordless tools defects from moving down the
feature brushless motors and high- assembly line.
capacity lithium-ion batteries for The pistol-grip tools feature
higher durability. advanced error-proofing
Working in conjunction with capability via an enable
Toyota Motor Co., Panasonic and disable feature. At each
engineers developed pulse tools workstation, they receive a signal
that feature hybrid switches, to turn on, which enables the
resulting in almost no mechanical operator to only install a certain
failures. number of fasteners. After they
For instance, the company’s are installed, the tool is disabled
EYFGB Series of cordless to prevent errors or defects.
clutch tools use a hybrid switch “That tool can’t be used
that allows the higher current Operator safety and ergonomics are important cordless tool at another workstation on the
benefits that appeal to many manufacturing engineers.
draw of the motor and brake to Photo courtesy DEPRAG Inc. assembly line or elsewhere in the
be controlled by a separate cir- factory,” says Olson. “We can do
cuit, bypassing the switch altogether. are the EYFNA1PR and EYFPA1JR that to an individual tool or an entire
Because the hybrid switches have mechanical pulse tools. “They are [the group of tools.”
only 0.5 amp going through them, only] cordless tools in their torque range To prevent loose or under-torqued
compared to 25 or 30 amps in con- that have no reaction and advanced error fasteners, a CPU monitors the output
ventional switches, the contacts last proofing with networking capability,” torque of the tool. If the torque falls
much longer. claims Olson. below the selected value due to battery
Panasonic’s newest product offerings By utilizing wireless communica- power, the CPU automatically adjusts
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the tool to deliver the correct power, In fact, some 2 ampere-hour batteries production tools,” notes Morgan.
which makes the tool very accurate and are now the same size and weight of “With the latest generation of
repeatable. 1 or 1.5 ampere batteries of just a few batteries, we’re able to run longer at
“As the operator runs the tool, the years ago. higher torques,” says Ingersoll Rand’s
CPU monitors the battery level and Despite those advances, some Dees. “And, as the battery begins to lose
when the battery no longer has enough engineers still need to be convinced its charge, you no longer see dramatic
power to reach the required torque, the about the benefits of cordless tools. drops in performance.”
CPU automatically shuts down the tool “There is definitely a learning Last month, Ingersoll Rand
to prevent under-torqued fasteners,” curve that needs to be overcome,” says unveiled its QXN line of cordless
explains Olson. Cecil Morgan, applications engineer at tools, including pistol grips and right-
Although Panasonic only offers DEPRAG Inc. “In the past, battery tools angle wrenches.
pistol-grip tools, it’s currently in the had a bad reputation, which was mainly “The simple, cost-effective tools
process of developing a line of right- because of the battery life and the time provide programmable torque control,
angle tools, which are popular for it took to recharge. traceability and gang count capabilities
applications that require reach or easier “[To address that], we package that ordinary clutch tools can’t,”
access to tight places. each of our cordless tools with one claims Dees. “They store data, identify
charger and two batteries each, so that errors, validate production and support
Better Batteries there is hopefully always one battery troubleshooting.
Battery technology has also fully charged and the other battery is “The QXN tools can be programmed
improved in recent years. For instance, charging,” adds Morgan. “We have also to achieve specific torque, gang counts
energy density of lithium-ion batteries reduced the recharge time to below 40 and degree of rotation right down to
has increased, which allows longer run minutes for a full charge. detecting cross-threads and stripped
times without increasing the size or “Longer battery life and quicker fasteners,” adds Dees. “They employ
weight of the power pack. charging are important in all cordless closed-loop transducers to provide the
New battery chemistries allow tools, but we see the importance of accu- highest level of traceability and ensure
faster charge times and more charge racy, flexibility, documentation, analysis that the tool is delivering the specific
cycles during the life of the batteries. and traceability as the future of cordless torque required.” A
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ASSEMBLY Sensors
Force and
Torque Sensors
R
obots are increasingly being surface and formed into a complex
Advanced technologies made to mirror humans. orientation.
increase the accuracy of force The best example of this is
the dual-armed robot—such
Tests like this one, as well as a
wide range of assembly processes,
and torque sensors used in as ABB’s YuMi and Rethink cannot be properly performed without
Robotics’ Baxter—designed torque and force sensors. Thankfully
product assembly and end-of- specifically to work closely with people for manufactures, the advanced
on the assembly line. technologies of these devices ensure
line testing. Another example is the compliantly reliability and accuracy in every
engineered ECCERobot, which mimics application, whether it’s tightening a
the inner structures and mechanisms of a fastener, installing a valve or verifying
human being. The robot was developed operation of electronic switches.
by the Robot Studio based in Divonne-
Les-Bains, France. Simple Devices
In 2015, Studio engineers decided Sensors are simple, straightforward
to measure the tensile and compression devices that, in essence, serve as
forces exerted on the robot’s hands, arms various human senses within automated
and shoulders while it is lifting objects. equipment. They are used in assembly
They selected FUTEK’s LSB200 force and end-of-line testing operations to
sensor for the experiment because of detect the presence, position, orientation
its small size (0.75-inch wide and 0.25- or movement of an object. After the
inch thick) and high accuracy. The sensor initially measures a physical
engineers positioned more than 60 of quantity, an external signal conditioner
the sensors along each forearm and converts the data into an electrical
below each shoulder. energy measurement so it can be read
The LSB200’s size and accuracy by a person or instrument.
make it a good fit for various Force sensors monitor the rate of
assembly applications as well, notes change, and the relative change, in force
Richard Walker, senior engineering between two surfaces. The sensors may
director at FUTEK Advanced Sensor be bolted or magnet-mounted within the
The 8400V series of bearingless digital torque Technology Inc. Another benefit is assembly or testing equipment, or onto
transducers are accurate to within ±0.027 its 1,000 percent overload rating, the part tooling.
percent of full scale and offer torque capacity which enables the sensor to withstand Torque sensors measure and record
from 28 to 11,000 newton-meters. incidental loads up to 10 times its the rotational force on various rotating
Photo courtesy S. Himmelstein and Co.
calibrated range. systems. Some torque sensors only
For information on how to obtain One medical device manufacturer measure static torque, while others
reprints/e-prints of this article, operates a catheter test stand equipped are able to handle static and dynamic
please contact Jill L. DeVries with a different FUTEK force sensor (in process) torque. The sensors are
at devriesj@bnpmedia.com (LSB210 load) and its TRH605 hex- installed between test pieces and their
or 248-244-1726. drive rotary torque sensor. Paired mounting plates, and either sit on a
with a USB output kit, and test and pedestal or “float” in the driveline.
 By Jim Camillo measurement software, the sensors All sensors are analog or digital.
Senior Editor measure the track force and torque of a Analog sensors have an output that
camilloj@bnpmedia.com catheter as it’s pushed along the stand’s falls within a certain range, whereas
digital sensors output a range the performance of brake pedals, air
of values that must increase bags, seats, pumps and speed control
in steps. Most models are mechanisms. Torque sensors test
directly wired to a PLC or power train components, suspen-
data acquisition system, sion systems and engine horsepower
although some suppliers also to improve fuel efficiency. Rotary
offer telemetry-transmission torque sensors are used for strain
sensors that wirelessly measurement, testing the clutch,
transmit data to receiving gearboxes and dynamic torque with-
equipment. in the engine. Tveter says his com-
The predominant mea- pany’s torque transducers are used
suring technologies of force for auditing to verify that fasteners
and torque sensors are strain are tightened to the correct torque.
gauge and the piezoelectric. A Kistler’s 9217-A piezoelectric
strain gauge consists of a thin force sensor is used for assembly
wire or foil arranged in a grid and testing by different types of
and bonded to a thin backing. Torque sensors are installed between test pieces and their manufacturers. Shaped like a bolt,
The gauge is mounted to the mounting plates. Graphic courtesy FUTEK Advanced Sensor the sensor measures quasistatic and
sensor so that the conductors Technology Inc. dynamic tensile and compression
are aligned in the direction of Application Driven forces of 1 or more millinewtons
the stress. When a force is applied to a “Application is everything when on robots and automatic assembly
structure, its length changes. Strain is it comes to picking a force or torque machines. Force is introduced via an
the ratio of this change in dimension to sensor,” says Walker. “A robotic M3 tapped hole at the front.
the structure’s original dimension. assembly application, for example, may The sensor offers high resolution,
In contrast, piezoelectric sensors need an advanced multi-axis sensor three calibrated measuring ranges
compress asymmetrical, elastic crystals that is low-profile enough to fit in (±5, ±50 and ±500 newtons) and a
to produce voltage. The amount of end-of-arm tooling or a gripper. But, dynamic range of 1-to-100,000. Its
voltage is directly proportional to the a manual testing process might only preloaded measuring element provides
amount of force. Because piezoelectric- require a simple sensor to pass or fail high rigidity and a higher tolerance to
based sensors have a wider measuring an assembly based on its weight, which bending moments. The sensor body
range, they are better able to measure indicates whether or not the assembly has an M10x1 millimeter pitch external
dynamic loads than static ones. contains all of the required parts.” thread and a sealed connector.
Kistler Instrument Group makes Automotive manufacturers rely on Aerospace manufacturers frequently
piezoelectric strain sensors for indirect force and torque sensors to perform use force sensors or strain gauges during
force measurements. Jim Macy, senior high-volume assembly and testing on fatigue analysis research to determine
manufacturing specialist at Kistler, a daily basis. Standard assembly work wing and fuselage strength. Minda says
says these sensors are often used includes press-fitting bearings, seating these companies apply enough vertical
in applications with less-stringent valves and installing switches and force against the wing, and lateral
measurement requirements. buttons. force against the fuselage, until each
The sensors are mounted to a nearby Mark Minda, business development component either cracks or fails.
C-frame or column rather than directly and account manager at HBM Inc., says NASA and its subcontractors rely
on the part tooling or fixturing. This the company’s force sensors and torque on force sensors to measure burn rate
approach saves time and money and transducers are used in automation, during rocket booster testing. Walker
allows for easy retrofitting. These sen- assembly and R&D applications. points out that the Mars Curiosity rover
sors also provide overload protection Steven Tveter, vice president at S. has been using two FUTEK custom
and the ability to measure very large Himmelstein and Co., says several cryogenic force sensors since landing
forces because the structure absorbs automotive customers use force on the red planet on Aug. 6, 2012.
the entire force. To enable a successful transducers to verify proper bearing “One sensor operates within the
indirect measurement, particular atten- installation. Another process that force rover’s drilling arm and monitors the
tion must be paid to the selection of sensors monitor is the pinching of high- drill bit’s force as it pierces into alien
the sensor measurement location. The pressure enclosures in automotive parts ground, and the surface’s push back
strain at the structure’s measuring point during resistance welding. force level,” explains Walker. “The
must be proportional to the force appli- On the testing side, OEMs and Tier other is a multiaxial load and torque
cation point. 1 suppliers use force sensors to verify sensor responsible for the maneuvers
Sensors
of the main robotic drilling arm. Tveter, sensors are up to 10
This sensor makes sure the arm times more accurate than just a
never applies too much force, decade ago. Back then a sensor
causing the turret system to could achieve ±0.1 percent of full
break off.” scale; today, it is capable of ±0.01
Makers of white goods, medi- percent.
cal devices and consumer elec- Proper calibration is essential
tronics benefit from force and to maintaining this level of accu-
torque sensors, as well. Such sen- racy. Tveter says that all of Him-
sors are integrated into assembly melstein’s sensors are calibrated
and testing equipment for appli- in an ISO 17025-certified lab
ance doors, hinges and parts to ensure high-accuracy perfor-
that get pressed, says Walker, mance from day one, along with
adding that more-accurate sen- full traceability.
sors are a big reason why white Shaped like a bolt, the 9217-A piezoelectric force sensor HBM’s calibration labs are cer-
goods manufacturers continue to measures quasistatic and dynamic tensile and compression
tified by the German government
forces of 1 or more millinewtons on robots and automatic
increase their in-process testing. assembly machines. Photo courtesy Kistler Instrument Group (PTB), and tests there show the
Macy says that appliance and company’s T12HP torque trans-
automotive companies often use force ation of switches and buttons, while ducer to be one of the most accurate in
sensors to verify different assembly rotary torque sensors help when testing the world, with a non-linearity at ±0.007
processes. small electric motors. percent of full scale. Introduced earlier
Medical-equipment companies this year, the transducer has a Spanning
that resistance-weld dialysis machines Recent Developments feature that allows users to run detailed
sometimes use force sensors to verify Force and torque sensor technology analyses of any partial measurement
proper pinching of high-pressure enclo- has evolved significantly in four areas range from the full scale range.
sures. As for consumer electronics, this century: accuracy, size, adaptability Minda says the transducer is
force sensors confirm the proper oper- and housing materials. According to available with nominal (rated) torques
Integrate deep drilling into

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ranging from 100 newton-meters to 10 piezoelectric crystals, to offer sensing it popular among automotive and aero-
kilonewton-meters. Its measurement solutions that feature smaller sensors space manufacturers for assembly and
flange directly installs in the drivetrain with high sensitivity and precision. Sen- testing.
and is maintenance free. CAN, sors are also getting thinner to more The easy-to-install devices have a
Profibus, EtherCAT, and Profinet easily fit in areas with limited space and 3-kilohertz dynamic response, high
interfaces ensure easy integration of stackup requirements. overrange (300 percent) and overload
the transducer with different test stand Regarding adaptability, some (200 or 400 percent), and are immune
concepts. In addition, it is temperature suppliers offer dual-range sensors to clamping and other extraneous loads.
compensated to 0.005 error percent per that allow manufacturers to easily Users can select from 10 units of torque
10 degrees Kelvin of change. switch between a high and low range measurement without having to reca-
Like many of the products they of measurement. Dual-range torque librate the transducer. Dual-range con-
measure, sensors continue to get sensors accurately measure peak and figurations are available.
smaller. Walker says that some torque operating torque. Traditionally, sensor housings have
sensors are as small as a half-dollar Torque sensors that use frequency been made of either steel or anodized
coin, with ranges from 1 in-oz to modulation (FM) technology experi- aluminum. For the past several years,
10,000 in-lb. FUTEK has been able to ence minimal wear, even in continu- however, suppliers have offered models
shrink the size of its sensors by hand ous-use applications. The torque signal with stainless steel housings. Some
soldering various contacts instead of is transmitted from the rotating shaft sensor components are ceramic coated
hard wiring them, and using integrated without contact, and processed as an for insulation and wear resistance.
circuits to eliminate wiring errors and analog signal. “Today’s strain-gauge-based trans-
increase repeatability. All 10 bearingless digital torque ducers are excellent compared to prod-
Another technology that allows for transducers in Himmelstein’s 84000V ucts made decades ago,” concludes
a more compact sensor measurement series come with FM and analog out- Minda. “However, end users must still
solution is micro-electromechanical puts, and are accurate to within ±0.027 be careful to use the transducers prop-
systems or MEMS. Macy says Kis- percent of full scale. Tveter says the erly. There are many factors related to
tler utilizes advancements in this tech- series’ wide range of torque capacity measurement uncertainty other than the
nology, in conjunction with advanced (28 to 11,000 newton-meters) makes transducer itself.” A
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ASSEMBLY Lightweighting
Assembling Thermoplastic
Composites
P
Joining thermoplastic lastics and polymer composites
are essential to a wide range of
much amplitude can crack or weaken
distal areas of the parts.
composites—either to each safety and performance parts
in cars today. In fact, the use of
Part design is another issue. When
welding plastics that contain fillers, it’s
other or to other materials— plastic and polymer composites a good idea to increase the amount of
in light vehicles has increased material at the joint interface. “Usually,
can be challenging. from less than 20 pounds per vehicle you need more weld surface with a
in 1960 to 334 pounds per car in 2015. filled material than you would with a
A material such as nylon 66 with virgin material,” says Barton.
33 percent glass fiber Whenever possible, engineers would
reinforcement is used prefer to use ultrasonics to weld plastic
in myriad automotive parts, due to its speed and economy.
assemblies, including “We weld filled plastics all the time,”
manifolds, engine says Sophie Morneau, Emerson global
covers, carbon canisters, director of application development at
engine mounts, shift Branson Ultrasonics. “In fact, 10 to 20
levers and radiator tanks. percent filler can actually help ultra-
Unfortunately, the sonic welding by making the material
fillers that add strength, stiffer, which helps transmit vibration to
stiffness and heat resis- the weld joint. The softer the material,
tance to plastic parts the more it will absorb vibration.”
give engineers extra On the other hand, too much filler
The new FLOWpoint Delta PT screw combines things to think about when planning the can adversely affect the weld. “If you
the attributes of two proven fastener designs, assembly process. have too much fiber, you won’t have
the Delta PT screw for plastics assembly and
good mixing of the plastic at the weld
the FDS flow-drilling screw for sheet-metal
assembly. Photo courtesy Semblex Corp. Plastic Welding interface, so achieving a hermetic seal
There are lots of technologies for can be an issue,” explains Morneau.
welding plastic parts: ultrasonics, “With filler content above 30 percent,
vibration, spin, hot-plate, infrared you may start to see issues.”
and laser. They all can join plastics Another consideration is that fillers,
reinforced with glass fibers, talc, mica especially glass fiber, can be abrasive.
or other fillers. Which method to use Ultrasonic horns may need a protective
depends on the plastic; the type and coating to prevent premature wear.
For information on how to obtain amount of filler; the size and shape of the When parts are too big, too complex
reprints/e-prints of this article, parts; and the application requirements. or too tough for ultrasonic welding,
please contact Jill L. DeVries Regardless of process, filled other processes come to the fore. One of
at devriesj@bnpmedia.com materials typically need “more time, those is vibration welding. In fact, some
or 248-244-1726. more pressure and more energy,” evidence suggests that the vibrations
says Jason Barton, national sales and might help intertwine the fibers at the
marketing manager at Dukane Corp. weld interface and thereby increase
“Semicrystalline materials tend to need joint strength.
By John Sprovieri quite a bit more.” When using vibration welding to
Editor in Chief That can be an issue when using join filled materials, the weld bead—the
sprovierij@bnpmedia.com ultrasonic or vibration welding. Too area of the part that gets melted during
the process—should be wider and The fastener’s multi-angled
taller than normal, advises Kevin thread profile and cored recess
Buckley, Emerson technical appli- maximize engagement with the
cations manager at Branson Ultra- plastic. Fasteners with a flat root
sonics. “If the walls of the part are 2 can cause material to jam, which
millimeters thick, you should make can concentrate stress in the plastic
the weld bead 2.5 millimeters,” he and lead to cracking. The cored root
says. “If it’s equal to the wall thick- eliminates stress concentrations and
ness, you can expect 90 percent of The best option for fastening plastic containing glass, provides nearly 100-percent flank
talc or other filler is typically a thread-forming screw,
the parent material strength.” engagement.
like the Delta PT. Photo courtesy Semblex Corp.
Flash containment is critical The head of the Delta PT has
when vibration welding filled a large bearing surface, which
materials. “With vibration welding, distributes pressure over a wide
the material that gets displaced from area of the boss. It also enhances
the joint has very little residual joint stability by reducing creep
heat,” says Buckley. “When you and increasing break-loose torque.
add fillers, that flash cools off even The increased minor diameter and
faster. So, you might have to oversize Threaded inserts are another option for fastening large cross sectional area of the
thermoplastic composites. However, the recommended
the volume of the flash trap area.” hole size may have to be increased, depending on the Delta PT boost torsional and tensile
Sometimes, welding processes filler content of the material. Photo courtesy SPIROL strength, so the fastener can be
can be used in conjunction with each International Corp. used in thermoset and glass-filled
other. For example, infrared emitters thermoplastic materials.
can be used to preheat filled materials “With some exceptions, the best option Regardless of what type of fastener
prior to vibration welding. for fastening plastic containing glass, they use for plastic, engineers are well-
“It’s slower than conventional talc or other filler is typically a thread- advised to put the brakes on driver
vibration welding, but it’s faster than forming screw. speed.
hot-plate welding,” says Barton. “It also “It’s not what the material is made “With any fastener for plastic, it’s
reduces flash and particulate generation of, but how stiff it is. Stiffness will important that you do not install it at
and creates a stronger bond.” give you an indication of how tolerant too high a speed,” warns Tripp. “You
Laser welding is another option for the material will be to thread forming. don’t want to generate heat, which will
joining filled materials—as long as Once you get above a flexural modulus soften the plastic and reduce the drive-
the laser doesn’t have to travel too far of 1.4 million to 1.6 million psi, you’re to-strip ratio.”
through the transmissive part. “If you’re looking at thread-cutting screws.”
welding a nylon part with 30 percent One of the most common thread- Threaded Inserts
glass, that laser is going to bounce off forming screws for plastics is the Delta Threaded inserts are another option
some of those fibers,” says Buckley. PT, which was developed by German for fastening thermoplastic composites.
“Weld times are going to be longer, and fastener manufacturer EJOT and With inserts, parts can be safely and
you’re going to have to increase the licensed to a number of North American securely fastened using bolts, which
light intensity.” producers, including Semblex. The means they can also be easily disas-
screw is used in a variety of automotive sembled over and over again. When
Threaded Fasteners applications involving both filled and fastening with screws driven directly
If the plastic parts must be unfilled plastics, including headlamp into plastic, there is a risk of creating
disassembled, engineers have little casings, motor covers, intake manifolds crossed or stripped threads every time
choice but to use threaded fasteners and throttle valves. the parts are rejoined.
for assembly. Fortunately, numerous The flank geometry of the Delta PT An additional benefit is high
screws have been designed specifically screw reduces radial stress on the boss. load-carrying capability. “Inserts are
for fastening plastics, and the presence The flank starts with a 30-degree angle generally twice the diameter of a screw,
of glass fibers or other fillers isn’t much that quickly backs off into a 20-degree which increases the shear surface
of an issue. angle. This permits unimpeded flow of fourfold,” says Christie L. Jones, market
“Fastening glass-filled thermo- the plastic during installation. development manager at SPIROL
plastics is pretty cut-and-dried,” says “The threads gently move the International Corp.
Terry Tripp, strategic account manager plastic…into the root of the thread, The considerations for specifying
and engineering product specialist at which allows you to get high amounts and installing threaded inserts in
fastener manufacturer Semblex Corp. of flank contact,” explains Tripp. thermoplastic composites are similar to
Lightweighting
tapping inserts driven into a hole like a temperature will also affect cycle time.”
screw. Other inserts are installed with a Hole size is another consideration.
heated tool or an ultrasonic tool. Which If the plastic contains glass or mineral
to choose depends on the material. fillers, the recommended hole size
For example, self-tapping inserts are may have to be increased. “Our rule of
available in thread-forming or thread- thumb is that if the filler content is equal
cutting versions, depending on the to or greater than 15 percent, increase
ductility of the plastic. Thread-forming the size of the hole by 0.003 inch. If the
versions are best for ductile plastics, filler content is equal to or greater than
says Jones. Their coarse threads prevent 35 percent, increase the size of the hole
reaming out the hole. Thread-cutting by 0.006 inch.”
versions are better for brittle materials. Other general considerations that
If the insert will be installed with can affect the performance of a threaded
heat or ultrasonics, a big consideration insert are the configuration of the hole
is the heat deflection temperature of (straight vs. tapered), the wall thickness,
the plastic. “You want to be able to and whether the holes are molded or
Ultrasonic welders are more than capable of install the insert without heating the drilled.
welding filled plastic. In fact, 10 to 20 percent plastic so much that you end up with
filler can actually help the process by making
the material stiffer. Photo courtesy Branson
flash spewing out of the hole,” explains Best of Both Worlds
Ultrasonics Jones. “On the other hand, you don’t Due to its high strength and low
want to heat the plastic so little that weight, carbon fiber-reinforced plastic
those for homogeneous thermoplastics. you end up cold-pressing the insert. (CFRP) is increasingly being used in
There are many types of insert. Some The goal is to maximize the displaced aerospace, automotive and sporting
are installed during molding. Others plastic within the knurls, grooves and goods applications.
are pressed in. Expansion inserts are undercuts of the insert. Until recently, engineers had three
pressed into the plastic and expand “The size of the insert and how options to use threaded fasteners in
when the mating screw is installed. Self- quickly the plastic reaches the softening conjunction with CFRP. They could

embed studs or nuts in the material says Eric Breidenbaugh, FDS product forming, screwdriving and tightening.
during layup; they could bond studs or line manager for Semblex, which is The initial driver speed is approxi-
nuts to the material after curing; or they licensed to produce the new fastener. mately 2,000 rpm, compared with 5,000
could drill holes in the material and use “The FLOWpoint Delta PT has to 8,000 rpm for a flow-drilling screw
conventional nuts, bolts, break-stem more threads per inch, which works in aluminum. “You want to get good
rivets or rivet nuts. better when you’re dealing with thin forming, but you don’t want to burn
Now, EJOT has just introduced materials.” the plastic or tear the material up,” says
another option: the FLOWpoint Delta The fastener is designed to join Breidenbaugh.
PT screw. This fastener combines the CFRP to aluminum or steel. The CFRP Axial pressure is also lower. Whereas
attributes of two of EJOT’s proven could be the top material or the bottom. a flow-drilling screw might be installed
fastener designs, the Delta PT screw The CFRP must be a minimum thick- with 2,000 newtons of downward
for plastics assembly and the FDS flow- ness of 2 to 4 millimeters, depending force, the FLOWpoint Delta PT screw
drilling screw for sheet-metal assembly. on the material. The metal sheet must is installed with 300 to 800 newtons of
The FLOWpoint Delta PT is a be a minimum thickness of 1 to 2 mil- force.
self-piercing and self-tapping screw limeters. “With anything less than that, “There’s so much variation with
that penetrates both the clamped and you just won’t get good thread engage- CFRP, every application needs to be
mating material without a pilot hole. ment,” says Breidenbaugh. tested,” cautions Breidenbaugh. “There
The thread geometry of the Delta PT The FLOWpoint Delta PT is are no standard guidelines yet.”
screw was modified slightly to form installed like a flow-drilling screw, The FLOWpoint Delta PT screw can
a strong female thread in CFRP that with a combination of axial pressure be produced with most common internal
permits disassembly and reassembly of and high rotational speed. The fas- and external drive recesses and head
the screw. Similarly, the tip of the FDS tener penetrates the layers, extrudes geometries. It is available in stainless
screw was changed to permit better a short boss, forms its own threads, steel, steel, aluminum. One challenge
penetration of CFRP. and applies clamping force between with installing fasteners in CFRP is
“CFRP is typically a thin material. the sheets. The installation process galvanic corrosion, so engineers should
You don’t have big, long bosses with has six distinct steps: heating, pen- carefully choose the fastener material,
lots of room for thread engagement,” etration, extrusion forming, thread plating and coating. A
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ASSEMBLY Motion Control
Plastic Parts Can Boost

Machine Speed
W
hen it comes to the or linear actuators—engineers can
By upgrading gears, cam economics of assembly typically improve the speed of a machine
followers, track rollers and machines, faster is always
better. Every minute that
by 15 to 20 percent or more. In one case,
we were even able to double the output
other components, engineers it runs, a fast machine of a caplet making machine.
produces more goods—and While it’s easy to overlook the
can improve the speed of a more profits—than an otherwise similar contribution of individual machine
slow machine. So why don’t you simply components to line speeds, upgrading
machine by 15 to 20 percent crank up the speed on your existing these components doesn’t require the
assembly lines or design faster, new huge capital expenditures associated
or more. machines? with infrastructure upgrades.
The answer is that speed, for all its Not every cam follower, track
economic advantages, roller or gear lends itself to speed.
has some steep costs Engineers will need to pick components
from an engineering per- that reduce mass without sacrificing
spective. Faster assembly strength. Engineers will also want
lines typically suffer from components that can resist abrasive wear
resonance and vibration without requiring excessive lubrication
problems. These fast schedules.
machines tend to operate
close to the critical speed Polymers Are Faster
of gears and other mov- One of the defining characteristics
ing components, and they of fast, advanced machines is that they
may have more violent tend to incorporate components made
reciprocating movements partially or entirely from high-tech
as well. As a result, they polymers. When properly designed and
experience more wear made from the right material, polymer
and need more aggressive machine components weigh far less
Featuring polymer-bearing surfaces with metal maintenance and lubrication schedules. than comparable metal components.
shafts and precision ball bearings, these cam What’s more, the technologies that For example, our cam followers, which
followers weigh about 40 percent less than all-
can boost line speed do not come cheap. combine a polymer-bearing surface with
metal cam followers of the same size.
Photo courtesy Intech Corp. Faster lines typically require higher- metal shafts and precision ball bearings,
bandwidth controls, as well as larger weigh about 40 percent less than all-
For information on how to obtain motors, actuators and gearboxes. The metal cam followers of the same size.
reprints/e-prints of this article, machine frame will likely have to be The weight savings reduces inertia,
please contact Jill L. DeVries beefed up as well. While these infra- which, combined with low rolling
at devriesj@bnpmedia.com structure upgrades may well pay for resistance, allows for more efficient
or 248-244-1726. themselves if line speeds improve prof- high-speed operation. The same logic
itability, they also require a significant and weight savings applies to gears and
amount of engineering effort. track rollers too.
 By Georg Bartosch There is, however, a simpler way High-speed machines with all-
President to improve line speeds. By upgrading metal components require continuous
Intech Corp. motion components—such as cam lubrication that’s most often provided
Closter, NJ followers, track rollers, gears, cams by central lubrication systems, oil-filled
gearboxes or oil spray. An interruption has a combination of physical and
of lubrication, like when a nozzle in mechanical properties that makes it
a central lubrication system clogs, uniquely well-suited for use in motion
usually leads to catastrophic failure components, particularly at high
and downtime. Polymer machine speeds. These properties include:
components can solve the lubrication M Stability and strength. Power-Core
and wear problems and reduce the maintains its tensile properties and
amount maintenance associated with dimensional stability in persistent hu-
all-metal systems. Wear—and the midity or even total immersion. By
resulting need to constantly provide contrast, most engineering polymers
lubrication—slows down high- absorb moisture. These hygroscopic
speed machines. Grease or oil can polymers can weaken by up to 50 per-
also contaminate the machine’s final cent and no longer carry their design
product. loads. Or, they can swell by 3 percent
The best polymer motion or more, making them incompatible
components are made from self- with any mating components.
lubricating materials, so they eliminate M No lubrication required. Power-
the need for lubrication. They also Core parts have self-lubricating prop-
resist various wear mechanisms— erties and smooth machined surfaces,
such as corrosive wear and galling— so they eliminate the need for lubrica- Used for painting cars, Intech’s Power-Core robotic
that affect metal machine components. tion—and associated viscous drag. arm provides electrical insulation for paint charged
The result is that polymer components M Vibration damping. Like many with 100,000 volts. Photo courtesy Intech Corp.
maintain smooth bearing surfaces over plastics, Power-Core offers inher-
a long lifecycle. ent damping capabilities that metals
Keep in mind, though, that not all won’t provide. Unlike many plastics,
engineering polymers will perform Power-Core’s damping capabilities
equally in machine components. Some reach their maximum point close to
polymers lack the required tensile typical operating temperatures of
properties. Others can’t meet the high-speed assembly lines. The damp-
requirements for thermal, chemical ing capabilities of plastics let polymer
or moisture resistance. Moisture, in motion components reduce noise and
particular, can be a problem, since vibration as line speeds increase.
it’s ubiquitous in many manufacturing
locations. It will cause most Plastics Have Limits
engineering polymers to lose tensile There’s a good reason metals still
properties or change dimensions. make up the majority of highly loaded
Making sure that polymer machine gears, cam followers, track rollers
components have the right properties and similar components. In these
for the job is an essential ingredient applications, even a well-designed
for success. At Intech, we’ve found plastic part of equal size may not offer With an outside diameter of 19 inches, this 2.5-
that a variety of polymers can make enough structural strength to meet the inch wide spur gear is the main drive of a diaper-
good motion components as long as application requirements. making machine. Photo courtesy Intech Corp.
the properties are carefully matched to While polymers and other compos-
the application requirements. Acetal, ite materials don’t have the tensile or
a go-to engineering polymer for gears compressive strength of metals, there
and other motion components, can are many applications where metal
work well in many applications. We components are not used to their full
use it ourselves all the time. But, to load capacity. These applications are
really push the performance envelope, where polymers shine. They’re light-
engineers will need to consider other weight, which means lower inertia,
polymers. kinetic energy and forces. They also By upgrading motion components—such as these
Our choice for the most demanding have self-lubricating characteristics, track rollers—engineers can improve the speed
motion applications is Power-Core, which reduces or eliminates lubri- of a machine by 15 to 20 percent or more. Photo
a material based on butadiene. It cation and wear. Lightweight, low- courtesy Intech Corp.

Motion Control
casting plastic bearing surfaces over replaces may not carry the load.
structural steel or aluminum elements. When designing for higher speeds,
For example, we can apply polymer- you’ll often need to meet the require-
bearing surfaces over high-speed roller ments of larger component sizes. As
ball bearings, which is a natural fit long as there’s enough room, you can
for applications slowed down by the design a component to carry the load
greased needle bearings used in most by increasing the width or outside diam-
metal cam followers. We also employ eter, for example.
metal shafts and gear hubs. Of course, gear tooth mesh and cam
These hybrid systems require some follower tire designs also play a crucial
extra design attention. Using advanced role. The design process requires close
stress analysis, we can determine the cooperation with the engineers in charge
right ratio of plastic to metal. A well- of designing the equipment.
designed component will take the best One recent example involved the arm
of what each material has to offer— of a painting robot. To carry the pay-
A hybrid approach to machine components structural strength from the metal, such load and evenly distribute the stresses
lets engineers get the best of both worlds—the as using metal core for safe gear attach- throughout its 1,000-millimeter length,
lightweight of plastics and the high-strength of
ment to a metal shaft, and beneficial we changed the original 100 by 100
metals. This gear set features plastic bearing
surfaces over structural steel or aluminum surface properties from the polymer. millimeter square aluminum tube cross-
elements. Photo courtesy Intech Corp. section to a tapered shape with a 260
Analyze and Redesign by 150 millimeter cross section at the
friction components also help to reduce To calculate forces and simulate the wide end. The purpose of the change to
drive power requirements and energy stresses in lightweight polymer com- plastic material was to provide electri-
cost. ponents, it pays to understand the load cal insulation to the robotic arm in an
To get the best of both worlds, characteristics of the entire system, bear- electrostatic paint process.
we often take a hybrid approach that ing in mind that a plastic component Another example is a 19-inch OD
uses plastics and metals together— the same size as the metal component it anti-backlash Power-Core gear in
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a diaper-making machine. This gear Finally, and most importantly, metal springs, simplifying design. Most impor-
must withstand the forces associated motion components have no damping tantly, they don’t wear the cam surface,
with an e-stop, which is equivalent to capabilities. As a result, the production preventing costly downtime.
the full torque of a 10-hp motor for line may be unable to provide faster Making gears out of maintenance-
30 milliseconds, plus the shock load operation due to problems with shock, free polymers—which can be up to
of the machine’s gear train mass. Our vibration and noise. seven times lighter than metal—elimi-
calculations showed that if we increased With these limitations of metals nates vibration common to compara-
the gear width from 2 to 2.5 inches, the in mind, here are two examples bly sized all-metal gear systems. This
gear would carry this high emergency that illustrate how plastic motion increases both speed and machine
load. The increase in width was possible components helped increase the speed output. In the case of a caplet-making
because the application had enough of assembly lines. machine, we replaced a heavy 3.5 inch-
room on the drive end of the machine to Metal cam followers, as well as the wide cast iron gear with an outside
accommodate the thicker gear. cams or rails they’re running on, are diameter of 17 inches and weighing
subject to metal-on-metal wear. Over- about 170 pounds, with a Power-Core
Maximizing Speed greased needle bearings in metal cam gear containing a metal hub that weighs
Whether you have a new or existing followers can lead to skidding and extra less than 40 pounds. This increased the
production line, it turns out that metal wear. Cam followers on high-speed machine output from 400 to 800 caplets
motion components can impose speed machines are often pressed against the per minute.
limitations in several ways. First, metal cam with heavy spring loads to prevent The customer came to us with the
components can limit motion systems skidding. High spring loads only accel- request to eliminate grease in its caplet
by virtue of their sheer mass—heavier erate wear on both the cam and cam production line and ended up with
components have more inertia, lower follower. Fitted with lubricated-for-life a machine that produced double the
critical speed, and require more force ball bearings, polymer cam followers output of prevailing industry standards.
to accelerate. In addition, metal com- eliminate the need for lubrication of both Polymer components often produce
ponents require lubrication, and worn the bearing and the cam surface. And, unexpected benefits.
components must be replaced, which when properly designed, they maintain For more information, call 877-218-
often causes prolonged downtimes. full contact with the cam without any 2650 or visit www.intechpower.com. A
PACKAGING AUTOMOTIVE ASSEMBLY PHARMACEUTICAL
THE LEADING
CAM INDEXER
The state-of-the-art compact design of the WEISS TC
Standard Cam Indexer means no external gearbox is
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currently over a decade of proven operations across
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ASSEMBLY Adhesive Bonding
Ammunition Sealants
and Bullet Pull Strength
B
ullet pull strength is the force interaction between the bullet and the
UV-curing external necessary to separate a bullet case mouth. Several things can affect
ammunition sealants can from the cartridge casing.
This force can vary, depending
bullet pull strength, including:
M The relationship between the bullet
make bullet pull strength on the type and size of the diameter and the case mouth diameter.
ammunition. It can even vary M The hardness of the case or the
more consistent and thereby from cartridge to cartridge within the material finish on the inner walls of the
same type and caliber. UV-curing case mouth.
improve performance and external ammunition sealants can make M The bullet material.
bullet pull strength more consistent M The presence or absence of a metal
accuracy. and thereby improve performance and jacket.
accuracy. M The sealant used, such as inner-
Repeatability is mouth bitumen.
core to a user’s expe- M The mouth crimp.
rience with ammuni- Traditionally, the primary method
tion. The last thing to control bullet pull strength has been
you want when fir- to physically alter the casing and bul-
ing a gun is a sur- let to adjust the fit. For example, the
prise, and ballistics case mouth can be crimped. Crimp-
engineers work tire- ing is done to set the minimum force
lessly to produce needed to extract the bullet. Crimping
reliable ammunition also serves to lock the case mouth
that will perform the inside the bullet cannelure. This sys-
same way time and tem works to protect against both
time again. The con- crimp jump and bullet setback, which
sistency of ammuni- is particularly important for ammu-
tion is typically mea- nition used in automatic weapons.
sured by analyzing Without crimping, the bullet might
External ammunition sealants are applied with the “tightness” of a shot grouping fired be pushed inside the case during
noncontact precision jet valves to the joint line under specified conditions. The pattern mechanical feeding. This can result
of the cartridge case mouth and bullet.
is judged by measuring the distance in a higher pressure shot, which may
Photo courtesy Hernon Manufacturing Inc.
between the most disparate impacts. be a severe problem during firing.
Anything that can bring the shots into a
For information on how to obtain more concise pattern proves an increase An Alternative to Crimping
reprints/e-prints of this article, in precision. Ammunition sealants were originally
please contact Jill L. DeVries Bullet pull strength is one of the developed to protect cartridges against
at devriesj@bnpmedia.com many factors that affect ammunition water and other contaminants. Histori-
or 248-244-1726. performance in such a test. If the pull cally, sealants have been asphalt-based
strengths vary or are inconsistent (bitumen) and were heavily dosed with
around the circumference of the bullet, solvent to keep the mixture’s viscosity
 By Drew Richards that variation will often translate into low during application. Once applied,
Marketing Coordinator irregular trajectories and impacts for the sealant would need time to become
Hernon Manufacturing Inc. projectiles. tack-free as the solvent evaporated.
Sanford, FL Bullet pull strength is a result of the This evaporation of solvents resulted
in toxic fumes that were associated with crimping. The
potentially harmful to goal is to produce an assembly
the environment and to with more consistent bullet
process engineers. pull strength.
Hernon developed However, unsuppressed
UV-curing sealants and crimping is necessary for most
ammunition sealing sys- ammunition types and uses.
tems to modernize this External ammunition sealants
process. Our external mask the variables associated
ammunition sealants are with crimping, reducing their
100 percent active with consequences and creating
no solvents. This elimi- more consistent bullet pull
nates toxic fumes and strengths.
allows sealing systems Because of its low viscosi-
to process ammunition ty and wicking properties, the
continuously, creating external ammunition sealant
efficiency gains over is distributed evenly around
batch processing meth- the cartridge case mouth and
ods. base of the projectile. This
External ammunition sealants are available with a range of tested pull
While first developed strengths. Which to choose depends on the bullet, the gun, accuracy even distribution results in
to protect against water requirements, and other factors. Source: Hernon Manufacturing Inc. uniform bullet pull strength
and other contaminants, and a stable release and flight
it was later realized that the sealants settings, cannelure depth, cannelure pattern for the bullet. This claim is
could be used to alter bullet pull style, and other factors. evidenced by comparing the stan-
strength. Using external ammunition Because of these variables, it is dard deviation of bullet pull strength
sealant, pull strength is set by common to suppress the mouth crimp for sealed and unsealed cartridges.
bonding the projectile to the casing. for match-grade or sniper-grade Results for sealed rounds have a lower
Because sealants adhere to the casing ammunition, since those cartridges standard deviation. A lower stan-
and projectile with a defined shear are usually not fired with automatic dard deviation of bullet pull strength
strength, ammunition manufacturers weapons. Suppressing the mouth translates into more consistent bullet
can essentially select the pull strength crimp reduces the complexity of the velocities, a more reliable trajectory
needed to separate the projectile from the cartridge, avoiding potential issues for each bullet, and ultimately a tight-
casing. If manufacturers er (more precise) grouping
would rather just seal on the target.
the cartridge without External ammunition seal-
otherwise changing ants can maximize bullet pull
the properties of the strength at almost 300 pounds.
assembly, they can use As bullet pull strength increas-
a sealant that does not es, so does the pressure inside
measurably alter bullet the ammunition casing prior to
pull strength. the bullet firing. This may be a
Using an external positive or a negative for bal-
sealant to set bullet pull listics engineers, depending
strength can significant- on what they want to achieve.
ly improve ammunition As a result, ammunition seal-
performance compared ants are available with a range
with crimping. How? of tested pull strengths.
Crimping a cartridge Of course, many factors
adds variables that can can affect the performance of
make bullet pull strength ammunition, and individual
inconsistent. The con- results may vary based upon
sistency and efficacy of New technology has put automated sealing, curing and inspection systems the manufacturer and cartridge
the crimp is influenced within reach of any ammunition manufacturer. Photo courtesy Hernon model. How an ammunition
by tool wear, machine Manufacturing Inc. sealant is dispensed and cured
Adhesive Bonding
can also influence results. Changes without ever leaving the assembly
in how much sealant is applied to line.
the cartridge, the wavelength of Originally, the cost of automated
ultraviolet (UV) light used to cure the ammunition sealing systems may
sealant, and the length and intensity of have only made business sense for
light exposure can all lead to variation the largest ammunition manufactur-
in bond strength. Each cartridge type ers. However, new smaller models
should be tested individually to have brought automated sealing, cur-
determine the exact effects. ing and inspection equipment within
reach of any manufacturer. Improve-
Dispensing and Curing Sealants ments in design have reduced
External ammunition sealants machine complexity and even the
are applied with noncontact preci- software and interface has become
sion jet valves to the joint line of more intuitive.
the cartridge case mouth and bul- For more information, call 407-
let. They can also be applied to 322-4000 or visit www.hernon-
the primer cap. They are specially ammosealing.com. A
formulated to exhibit very low vis-
cosity and to wick around the case
mouth and primer, resulting in a Bullet pull strength is one of the many factors that ASSEMBLY ONLINE
smooth, consistent distribution of affect the performance of ammunition. Photo courtesy For more information on adhesive bonding,
sealant. The sealants are then cured Hernon Manufacturing Inc. visit www.assemblymag.com to read these
in place using an array of UV LED articles:
curing lights. cure. Further subsurface curing occurs  Dispensing: Sweating Bullets.
When exposed to UV light at the anaerobically. After UV curing is  Adhesive-Based Process Seals Logos Onto
right wavelength and intensity, the completed, ammunition can be handled, Bullets.
sealants only need a few seconds to tested, packaged and shipped in minutes  Best Practices for UV-Cure Adhesives.
Cam Indexer
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REGISTER FOR FREE TODAY
OCTOBER 24 – 26, 2017

DONALD E. STEPHENS CONVENTION CENTER
ROSEMONT, IL
EXHIBIT HALL EXPRESSWAY

The ASSEMBLY Show’s expansive exhibit hall is a city center complete
with experiences, tons of activities and things to do.
DRIVER’S EDUCATION:
Learning Theater presentations right on the exhibit floor.
REST AREAS:
Lounge areas for you to rest, relax,
network, and recharge your phone
and yourself!
GET BEHIND THE WHEEL:

With nearly 300 exhibiting companies you’ll be able to
test-drive new assembly technologies and equipment.
Don’t miss out on the expansive expo hall featuring the latest
assembly solutions, technologies and equipment that you can
interact with hands-on in large booths with working machinery.
Register for FREE today at TheASSEMBLYShow.com!
ASSEMBLY Adhesive Bonding
Adhesives Aid Truck and

Trailer Assembly
T
he main objective for trailer bodies, leading to sleeker, more
High-strength adhesives and manufacturers of commercial innovative designs.
M Improved throughput. Structural ad-
sealants can improve the transportation equipment is to
profitability build high-quality hesives allow manufacturers to bond
durability and appearance products. One way to meet and seal in one step, which shortens
this objective is to assemble the assembly line layout. With fewer
of trailers and truck bodies, trailers and truck bodies with advanced fasteners to install or joints to weld,
structural adhesives and seam sealers. manufacturers can produce more trucks
while enhancing throughput. High-strength adhesives and sealants and trailers with the same number of
can improve the longevity personnel.
and durability of trailers
and truck bodies, while Structural Adhesive Chemistries
enhancing throughput Structural adhesive chemistries
and takt times. include acrylics, urethanes and epoxies.
Using adhesives and Acrylics are one of the strongest
sealants in truck and adhesives (shear strength of more than
trailer assembly offers 3,000 psi) and require only minimal
many benefits: surface preparation. Urethanes are also
M Better structural in- strong (shear strength of more than
tegrity. Structural ad- 2,000 psi) and flexible. Some can also
hesives eliminate stress be sanded. Epoxy adhesives work well
concentrations, diminish in both high and low temperatures and
squeaks and rattles, and exhibit similar shear strengths compared
improve fatigue perfor- with urethane products.
Seam sealers are available in one- and two- mance. Closure-panel and body-panel Adhesives can be used to bond metal
component formulations. The photo depicts a bonding have been trusted applications to metal, plastic to metal, and plastic to
seam sealer being applied to a rear body panel.
in the automotive market for more than plastic.
Photo courtesy Lord Corp.
30 years. Metal-to-metal bonding is limited
M Noise, vibration and harshness to nonstructural applications. Metal-
(NVH) improvements. Liquid-applied bonding products are available in acrylic,
sound deadeners (LASDs) dampen vi- epoxy and urethane formulations.
bration, rattles and noise in floor pan- Curing times run the gamut from slow
els, underbodies and cabins. Sealants to medium to fast. Fast-set adhesives
For information on how to obtain also provide a quieter ride by eliminat- cure to handling strength in 45 to 60
reprints/e-prints of this article, ing air gaps that can lead to wind noise. minutes. Medium-set formulas cure to
please contact Jill L. DeVries M Corrosion protection. Sealants are handling strength in 90 to 120 minutes.
at devriesj@bnpmedia.com especially formulated to prevent car Plastic-to-metal and plastic-to-
or 248-244-1726. parts from corroding. plastic adhesives offer the ability to
M Nicer appearance. Transportation securely bond dissimilar materials.
companies want truck and trailer These adhesives are available as
 By Bob Zweng bodies with a high-end appearance. urethanes and epoxies, in fast-set and
Central Regional Sales Manager Adhesives and sealants allow engineers slow-set cure times.
LORD Corp. to reduce the number of welds and Acrylic, methyl methacrylate
Cary, NC fasteners needed to assemble truck and adhesives are a great choice for metal-
to-metal bonding, including aluminum, cold-rolled steel, galvanized
steel and stainless steel. These adhesives also bond well to many
types of composites and allow for cross-bonding of bare metals to
composites.
A major advantage of acrylics is that they bond to metals and
composites with minimal surface preparation. They cure rapidly,
produce high-strength bonds, and resist extreme environmental
conditions. Some disadvantages include the odor of unmixed material,
as well as difficulty bonding to porous substrates, such as wood, paper
and concrete.
Two-component urethanes are ideal for bonding thermoplastics,
thermoset plastics, painted metals and porous substrates. These are
adhesives are economical and easy to dispense from bulk supplies.
Two-component urethanes are flexible and have excellent weathering
performance. However, urethanes cure slower than acrylics and do not
bond well to bare metals.
Epoxies are an older, general-purpose adhesive chemistry. They
bond a wide range of substrates, including metals, plastics and stone.
Epoxies form high-strength bonds; have a high degree of environ-
mental and chemical resistance; and can be exposed to temperatures
exceeding 400 F. Conversely, this chemistry is often rigid and brittle.
It also cures more slowly than acrylics and urethanes.
Adhesives work best when parts are designed for shear or
compression loads. Adhesives perform less favorably under peel or
tension loads. Overlap joints should be approximately 1 inch wide for
best results. Fusor 108B is a two-part structural acrylic adhesive for
Understanding the open time of the adhesive and the time to bonding aluminum and steel. It can be used for panel
bonding, weld bonding and rivet bonding. Photo courtesy Lord
reach handling strength is important to building a process. Ambient Corp.
temperature can affect open time and handling strength. Adhesives will
cure slower in colder environments, and they will set up faster when the
temperature is warmer. Proper fixturing is critical to building quality
parts. The fixtures must securely hold parts until sufficient handling
strength has been reached.
Initially, assemblers typically dispense adhesives using handheld
cartridges. Once proficiencies and higher volumes are realized, it may
be beneficial to use meter-mix-dispense systems along with automation
to provide pinpoint accuracy, save on material costs, and reduce waste.
Adhesive manufacturers can provide information on what type of
dispensing systems work best for specific adhesive materials.
Manufacturing With Seam Sealers

Seam sealers seal flanges and joints to prevent water leaks and
corrosion. A variety of chemistries are available, including urethanes,
epoxies or MS polymers (silyl-modified polyethers). They are offered
in one- and two-component formulations. Two-component sealers will
cure through a chemical reaction; one-component sealers cure through
a moisture reaction. One-component sealers will set in one hour and
fully cure in approximately 72 hours. Two-component sealers set up
quickly in 5 to 15 minutes and are fully cured in 24 hours. Older sealers
cured through evaporation of solvents.
Certain one-component sealers, such as windshield urethane,
will not attain a strong bond directly to metal. For metal-to-metal A major advantage of acrylics is that they bond to metals and
applications, use direct-to-metal sealers for the best results and to composites with minimal surface preparation. Photo courtesy
prevent corrosion. Lord Corp.

Adhesive Bonding
Finally, there are LASDs. These seam
sealers are applied to a panel to add
mass, stiffen the metal, or create an
insulting layer. LASDs can be applied
with a trowel or spray gun.
A controlled-flow seam sealer
is ideal for use on sloped surfaces,
roof channels, drip rails, and truck-
bed floor seams. The formula is easy
to dispense in a smooth bead. Self-
leveling seam sealers are used mainly
on roof-ditch areas, but can also be
used on core supports, aprons, truck
seams and roof-deck quarter panels.
This sealer self-levels within the
applied area. Sprayable sealers are
applied to trunk floors and wheelhouse
areas to provide a textured surface.
They can also be used as a stone-guard
coating for rocker panels and the lower
Lord 406 is a two-part, structural acrylic adhesive for bonding metals and thermoplastics.
Glass beads mixed into the adhesive ensure a uniform thickness to the bond line. portions of exterior body skins. With
Photo courtesy Lord Corp. an atomized pneumatic spray gun, the
operator can control the thickness and
There are three common methods of through sealer. The sealer is applied in texture of the sealer.
using seam sealers. One is to apply the the joint between panels. The panels are For more information adhesives and
sealer over the joint to cosmetically hide then joined via resistance spot welding sealants, call 877-ASK-LORD or visit
it or seal it. Another option is a weld- or mechanical fasteners, such as rivets. www.lord.com. A
Torque Tools You Trust
1-847-455-8677
customerservice@srtorque.com
www.srtorque.com
ACCURATE. RELIABLE. DURABLE. TOOLS YOU TRUST.

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Tooling for Your Riveting Dispense For Automobiles Riveting Technology
Machines?
Orbitform is known for designing, Flexible Automation, Inc. created an The new RIVSET® HDX meets the
manufacturing and building great riveting efficient and reliable primer applicator requirements for material mixes when
machines and systems, but did you know for automative glass. The material joining ultra-high-strength steels. The
we can also supply all the spare parts and dispense system utilizes two Fanuc fastener geometry has been optimized
tooling your machine needs? Additionally, M-10iA/6L six-axis robots to apply and the rivet hardness adapted.
we can provide perishable tooling for non- primer on both sides of right- and left- Böllhoff can realize consistent joints
Orbitform branded machines. Contact hand automotive glass panels. The using materials of tensile strengths
our SP&T team for all your tooling needs. system has been fast and reliable for +1,600 MPa.
All parts and tooling are manufactured automated dispense.
in-house, in Jackson, Michigan.
Flexible Automation
Orbitform (810) 742-8540 Böllhoff, Inc.
1600 Executive Dr. sales@FlexAutoInc.com 820 Kirts Blvd Suite 500
Jackson, MI 49203 www.FAIMachines.com Troy, MI 48084
(517) 787-9447 (248) 709-4757
www.Orbitform.com www.bollhoff-usa.com
New TorquePress Delivers Compact Design An Industry First: Cleco®

Ultimate Ram with More Torque TULMan™ Air Tool Management
Positioning Accuracy
SCHMIDT Technology
recently introduced
the electric-controlled
TorquePress 520 with
complete process
monitoring capabilities
and a maximum force
of 4,500 lbs. Much
faster than a conven- The Cleco TULMan, an electronic
tional servo press, its DESTACO’s CAMCO Servo Positioner tripometer and odometer for small
torque motor can reach GTB Series Rotary Tables are the lightest, pneumatic power tools, allows tool
working speeds in most compact, high accuracy servo performance checks and preventative
milliseconds thereby positioners available. The GTB units are maintenance to be implemented based
significantly reducing lubricated for life, and available in four on tool usage. Easy to install, this
cycle times. Direct drive sizes. universal device can be used anywhere
and a built-in ram sen- air is flowing between 5cfm and 20cfm.
sor guarantee absolute n Superior accuracy and zero backlash
stroke measurement, thereby compensat- n 34% Lower in height Cleco Production Tools
ing for any tolerance variations including n 64% lower in weight Lexington, SC
the thermal expansion of the ram. n Delivers 1.4 times more torque. (800) 845-5629
techservices@apextoolgroup.com
SCHMIDT Technology DESTACO www.ClecoTools.com/TULMan
(800) 959-1218 888-DESTACO (337-8226)
info@schmidtpresses.com www.destaco.com
www.schmidtpresses.com

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INTEGRATED SHOWCASE
5000 Series Electric SharpVue Inspection System: Kistler maXYmos NC for Process
and Pneumatic Grippers Futuristic, Innovative, Easy To Use Control and Evaluation
S h a r p Vu e
Inspection
S y s t e m
combines
advanced
d i g i t a l
microscope
technology
Available in 2-jaw and 3-jaw variants with comfort
from 3mm to 45mm stroke per jaw. and ease of The Kistler maXYmos NC controls, monitors,
These robust grippers provide 30 million use. View crystal clear 1080p images evaluates and documents your joining and
cycles maintenance free and are IP64 on your HD monitor, reducing eye strain press-fit processes through an intuitive and
out of the box with IP67 optional. Class and neck fatigue associated with frequent user friendly interface. Integrated sequence
leading gripping forces and moments use of traditional microscopes. Includes controller, 128 independent part programs
make them suitable for the most imaging and measurement software. and powerful evaluation tools are at your
challenging applications and the toughest Magnification: Up to 30x optical and fingertips via the optional color touch
environments. up to 300x digital. To learn more visit screen. Integration and connecting to your
aventools.com assembly machine is made simple through
Zimmer Group US, Inc. the on-board standard fieldbus interfaces.
1095 6th Street Ct SE Aven Inc
Hickory, NC 28602 4330 Varsity Drive Kistler Instrument Corporation
(828) 855-9722 Ann Arbor, MI 48108 30280 Hudson Drive
Sales.us@zimmer-group.com (734) -973-0099 Novi, MI 48377
www.zimmer-group.com Fax: (734) 973-0097 (248) 668-6900
info@aventools.com sales.us@kistler.com
aventools.com www.kistler.com
Pneumatic Crimp Tools from DMC Precise & Accurate Dispense SANKYO Automation Inc. “To be
Pump from Techcon Systems the Chosen Automation Partner”
Sankyo has provided the world’s man-

The DMC Pneumatic Crimp tools are ufacturers with a variety of products
trouble-free, dependable, compact, and Techcon Systems’ new TS8100 series designed to increase productivity. We
light-weight. This allows them to be used PC Pump is a continuously volumetric are committed to the creation of new
easily as hand tools, as well as high dispensing pump designed to dispense products that will benefit our customers
production bench tools. The bench mount wide range of fluids, from low viscosity using our previous experience and our
will allow the tool to be secured at virtually coating to high viscosity greases. passion for “Monozukuri”, the art, science,
any angle for individual comfort, thereby Unaffected by fluctuation in material craftsmanship and continuous improve-
minimizing operator fatigue. viscosity or material pressure, the TS8100 ments as it applies to manufacturing.
PC Pump is able to produce dispensing
Daniels Manufacturing Corp. repeatability of +/- 1%. Sankyo Automation, Inc
526 Thorpe Road 10655 State Route 47, Sidney, OH 45365
Orlando, FL 32824 USA Techcon Systems (937) 498-4901
(407) 855-6161 10800 Valley View Street Fax: (937) 498-9403
Fax: (407) 855-6884 Cypress, CA 90630 sales@sankyoamerica.com
www.dmctools.com (714) 230-2398 www.sankyoamerica.com
cla@techconsystems.com
www.techconsystems.com

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INTEGRATED SHOWCASE
Your RTM Solution for Configure Your Pneumatic Best in Class Tool Changers
Carbon Fiber Infusion Products in 60 Seconds!
The Patriot
Innovator Injection
System combines
highly accurate
mixing technology
and unique control
panel to be your
RTM and injection
solution. Designed
for a variety of
materials from NEW Product Configurator generates
carbon fiber to polyester, this versatile everything from one location (even a smart
system is equipped with user friendly, fully phone!): Specific Part Numbers • Prices • IPR’s TK Series Tool Changers are best
pneumatic automated controls, directing Lead Times • CAD Files • Seal & Repair in class for the automotive, aerospace &
the number of strokes during injections Kit Part No’s with Prices • Accessories general manufacturing industries. They
and recirculation to make your processes • Attachments • Mounting Hardware feature almost 3X the Moment Load &
easier and more efficient. • Switches and Sensors and much more! Locking Force than the competition, offer
Try it out the Best Repeatability in the Industry, and
fits any robot model.
Fabco-Air, Inc.
3716 N.E. 49th Ave. IPR Robotics
Gainesville, FL 32609 (248) 591-3880
service@fabco-air.com techsales@iprrobotics.com
(865) 686-5670 www.fabco-air.com http://www.iprrobotics.com
info@mvpind.com
www.MVPind.com
Durability - DuPas Eliminate Vibration In Your Gorbel’s Lifting Solutions

Hydraulic Impluse Tools Production Environment Deliver Better Results
Vi b r a t i o n a n d Choosing the right
Shock decrease material-handling
product quality, solution can yield
interfere with positive results that go
testing and damage beyond your plant floor.
equipment. ACE Gorbel lifting solutions
Vibration Mounts are the right choice.
and PAD material Our dependable,
eliminate harmful ergonomically-
vibration. Cost designed cranes,
The DuPas TDIS Series Hydraulic Impulse effective and jibs, hoists and intelligent lift equipment
Tool offers comfort, speed & efficiency customizable, our proven products can raise your performance by lowering
incorporated into the ergonomic, durable will boost production, help quality and assembly and loading cycle times, not to
design. With up to 450 NM capacity, the reduce maintenance. Easy to install with mention downtime due to maintenance
stability & accuracy of the shut-off system no moving parts or fluids, ACE will help issues and operator injuries.
coupled with a double chamber motor is you calm your environment. Our app can The result: higher customer satisfaction,
assurance that your process is repeatable measure low-frequency vibration and safety ratings, and profit potential. Learn
with a robust tool. select products. more and download our free ebook at
gorbel/elevate.com.
TorqTec ACE Controls, Inc.
100 Jeffrey Way, Suite D 23435 Industrial Park Drive Gorbel, Inc.
Youngsville, NC 27596 Farmington Hills, MI 48335 600 Fishers Run
(919) 561-5536 (800) 521-3320 Fishers, NY 14453
info@torqtec.net shocks@acecontrols.com (800) 821-0086
www.torqtec.net www.acecontrols.com info@gorbel.com
www.gorbel.com

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INTEGRATED SHOWCASE
Does Your Robot Need to Press? “Feed While You Drive” ELP Electric Linear Module
Technology
The “Feed While You
D r i v e ” t e ch n o l o g y
incorporates a swivel
screw feed arm directly
into the automated
screwdrivers feed head.
This method eliminates Easily adjusted in two steps: the end
time spent waiting for positions are mechanically adjusted
the next fastener to with a screw, the speed of extension
travel from the feed and retraction is adjusted using rotary
The Integrated B ack Stop line system and reduces the switches. No shock absorber adjustment
incorporates Promess’ E MAP cycle time by an average of 2-3 seconds. is necessary because the brake process
technology with a lighter weight is automatically regulated. The ELP has
housing and hardened end cap making Contact us to learn how WEBER a long service life and low maintenance
this package ideal for any and all robotic technologies can help increase your cycles.
application needs. Like the EMAP production capacity.
this package stills includes force and
position feedback.
Weber Screwdriving Systems Inc.
Mooresville, NC 28117
(704) 360-5820 SCHUNK
www.weberusa.com 211 Kitty Hawk Dr.
Promess Inc Morrisville, NC 27560
(810) 229-9334 (919) 572-2705
promess@promessinc.com www.us.schunk.com
www.promessinc.com
Integrated Thermal Customized Modular Precision

Machine Vision Systems Handling Systems
We’re dedicated to solving today’s Afag Automation provides world-class

industrial thermal process and control handling systems in both pneumatic and
issues with an engineered and scientific electric versions. These systems are
approach. With integrated machine vision created specifically to fit your applications
systems utilizing FLIR thermal imaging and have exacting standards. Built
technology and our background in from a modular component base, the
process automation, we deliver cutting- reconfigurable systems have a two year,
edge process validation technology, or 40 million-stroke warranty and are
strong quality assurance and significant assembled and tested in the USA.
ROI through scrap reduction.
Afag Automation
Emitted Energy Corp. 820 Fesslers Parkway Suite 210
(513) 752-9999 Nashville, TN 37210
sales@emittedenergy.com (615) 730-7515
www.emittedenergy.com Nashville@afag.com
www.afag.com/en

Products
Marking Machine
Servo-Positioning Rotary Tables The Model 66 marking machine prints up to 250
Although compact and lightweight, GTB ser- characters per minute on two lines of rubber type in a
vo-positioning rotary tables feature a roller- maximum marking area of 0.75-inch square. It holds
gear drive engineered to deliver high torque a 0.5-ounce bottle of ink, but comes with three large
and motion flexibility. Each model in the refill bottles and 25 prefilled small bottles (in any color
specified by the customer). The machine weighs only
13 ounces and requires 20 psi of air pressure to operate.
Also included are 10 high-density dots (marking head
only), 50 ink media pads, three rubber-type holders
and three rubber cushions. Optional marking heads are
0.125, 0.1875, 0.25, 0.375, 0.5 and 0.625 inch.
Sprinter Marking Inc.
www.sprintermarking.com
740-453-1000
series (GTB40, GTB63, GTB80, GTB100) Benchtop Robotic Dispenser

is durable enough to meet the demanding The dispense head on the EZ Series dispenser controls all X-Y-Z
payload requirements of various industrial motion of the valve and syringe, eliminating the need for an external
applications. The tables mount vertically and PC or control box. This design enables the dispenser to be used as
horizontally, contain a lifetime of lubricant a stand-alone workcell or mounted on conveyors or indexing dials.
(eliminating maintenance) and can support a The unit dispenses material at a maximum speed of more than 20
wide range of off-the-shelf servomotors for fps. Motion paths are defined by typing commands, importing CAD
optimum performance. They also feature a files or using the advanced jog and teach functions. The dispenser
direct motor coupling that prevents backlash. allows connectivity through RS-232, network and dual USB ports,
An optional gear reducer is available for appli- with additional I/O and logic ports provided to streamline integration.
cations that require increased torque. Hundreds of patterns are stored on the included CF memory card.
Destaco, a Dover Co. Dispense Works Inc.
www.destaco.com www.dispenseworks.com
866-726-3599 815-363-3524
Femtosecond-Laser Etching ERP Software

Developed jointly with LightFab GmbH, With Epicor ERP 10.1 software, manufacturers can
selective laser etching (SLE) uses a femtosec- automatically create and customize projects in real
ond ultra short pulse (USP) laser to precisely time and receive a report update every 5 minutes. The
software’s Service Connect feature enables workers
to quickly move a wide range of information in and
out of the ERP platform. Another function, Business
Activity Queries, lets users format a report with
dozens of queries so they quickly find the right information. The configurator feature integrates
a complex set of calculations to ensure accurate and competitive pricing. Once an order is com-
pleted, packaging slips are automatically created to streamline shipping.
Epicor Software Corp.
www.epicor.com
800-999-1809
etch 3D structures in hard, brittle and trans-

parent materials like quartz and fused silica. EOAT Treats Metal, Composite Parts
The process involves creating a pattern in The ROBOTsander turns any robot into a collabora-
these materials with the USP (pulse length of tive one that performs various types of surface prepa-
less than 1 nanosecond) and then chemically ration on metal and composite materials. Specific
treating the pattern to significantly enhance processes include grinding, polishing, deburring,
its sharpness. Current applications include the sanding and carbon fiber reinforced polymer activa-
electronics and medical industries, and micro- tion for automotive, aerospace, appliance, off-high-
fluidics, a technology that includes manufac- way and outdoor power equipment products. Ideal for
turing microminiaturized devices containing large volume and large area production, the end-of-
chambers and tunnels through which fluids arm tooling provides data recording, process diagnosis and optimization, predictive maintenance
flow or are confined. and remote product support, as well as spare parts and user time management.
PhotoMachining Inc. SUHNER Industrial Products Corp.
www.photomachining.com www.suhner.com
603-882-9944 706-235-8046

Scanner Protects Workers
From Mobile Equipment
AGVs, forklifts, robots and moving machines
SPLIT RIVETER TOOL BACKPACKS
equipped with the SE2L safety laser scanner
can quickly detect the presence of objects or
people and avoid them. The compact scanner
provides a standard 270-degree arc of protec-

tion at a distance up to 20 meters. This protec-
tion area can be configured into any pattern. Ergonomic Reduces weight of tool
Standard capabilities include master-slave by up to 70%
functionality, which allows one scanner to act Increases User
as master and communicate with up to three Mobility Comfortable
others, and dual zone protection, enabling one
scanner to scan two adjacent zones simultane- Reduces User
Increases Productivity Fatigue
ously and independently. Different patterns
can be applied on the fly by sending com-
mands via an Ethernet port, or by configuring
the encoder input to react to changes in speed.
IDEC Corp.
www.idec.com/se2l
800-262-4332
PNEUMATIC. ELECTRIC.
THE GRIPPER.
State-of-the-art
steel on steel
linear guides
Multi-Mode Leak Detectors + Extraordinary precision
TitanTest M-Series detectors use wet (oil- + Corrosion resistance
sealed rotary vane) or dry pumping technol- + IP protection IP64/IP67
+ 30 million cycles maintenance free
ogy to detect leaks of hydrogen, helium-4
(nonradioactive isotope) and helium-3 (light + The GPP5000 / GEP5000 Series
nonradioactive isotope) in less than 0.5 sec-
THE KNOW-HOW FACTORY
ond. It provides two test modes: vacuum
(gross, fine, ultra) and sniffing. The mini-
mum detectable helium leak rate in ultra
mode is less than 5 x 10-12 atmosphere cc
per second. Cycle time and reject limits are
easily programmable. Standard accessories
include a helium spray probe gun and sniffer www.zimmer-group.com

Products
probe. Optional accessories are a mobile cart, defense. Users can import IPC-2581 files into
wired and wireless remote control, and high- the software to create a new project or define

capacity external vacuum pumps. a new circuit card within an existing project.
LACO Technologies They can also use the part modeling module
www.lacotech.com to enable and disable finite element analysis
 801-486-1004
Fast Mechatronic Gripper

modeling for any specific part. Another capa-
bility is lead modeling, whereby engineers can
use multiple elements, as needed, to model
 Recently added to the EGP series, the EGP

25 Speed electric gripper features a reduced
lead feet and shoulders.
DfR Solutions
internal gear ratio that lets it open or close in www.dfrsolutions.com
0.03 second for quick picking and placing of 301-474-0607
small parts (0.05 kilogram or less). The grip-
per weighs 110 grams and has a grip force Level Loader With Turntable
The PalletPal Roll-On loader features a plat-
form for loading and unloading pallets (up
to 2,500 pounds) using a hand pallet truck. A
built-in turntable rotates the load so it can be
handled from the side nearest the worker. The
platform measures 44 by 48 inches, accepts a
variety of pallet sizes, and hydraulically lowers
to the floor or raises to a height of 30 inches.


 of 13 newtons with a 3-millimeter stroke per
finger. It features a durable-aluminum hous-
ing, maintenance-free servomotors and a junc-
tion roller guide that produce high dynamics As goods are loaded, the platform is lowered
and energy efficiency. The gripper also takes so that each succeeding tier of goods is loaded
screws on the side or at the base for increased at the same height. When pallets are unloaded,
design flexibility. It fulfills protection class the platform starts at its lowest height and is
IP30 and accepts the sensor systems used in progressively raised so each tier of goods is
the company’s MPG-plus gripper series. removed at the same height. Raising and low-
SCHUNK Inc. ering is controlled by a pushbutton pendant or
www.schunk.com foot switch. Toe protection is provided on all
919-572-2818 working sides.
Southworth Products Corp.
Software Predicts www.southworthproducts.com
Semiconductor Wear Life 207-878-0700
Sherlock 5.2 design software analyzes, grades
and certifies the expected reliability of prod- Hot-Melt Feed System
ucts in rugged environments at the circuit card With the InvisiPac feed system, hot-melt adhe-
assembly level. Based on Physics of Failure sives are reliably delivered without stickiness
or glue clumping—resulting in more uptime

science, the software is used by electronics
manufacturers that serve high-performance
industries like aerospace, automotive and
and production. The system automatically
feeds pellets from the adhesive bin into a fully
enclosed chicklet feed hopper, which keeps
material free of dust and contaminants. Pel-
lets are fed to within 4 inches of the bottom of
the hopper. An internal shaker with vibrating Transducerized Pulse Tool
arms prevents adhesive build up and clumps,
and reduces air consumption that is needed
for external shakers. The system requires 40 Bring your assembly process
to 100 pounds psi of vacuum air pressure and to the next level.
installs easily, due to a push-to-connect airline
and quick-disconnect vacuum hose.
Graco Advanced Fluid Dispense • Light Weight
www.invisipac.com • Reaction Free
800-746-1334 • Re-hit Detection
• Minimal Maintenance
Belt-Conveyor Oven
Manufacturers can use the Number 897 belt-
• No CO² Emissions
conveyor oven to preheat trays of parts up to
350 F prior to potting operations. A photo
cell automatically stops the belt when parts
reach the unload position. The oven features Contact your Desoutter representative today for a demonstration.
a carbon steel conveyor belt that is 30 inches
wide and 1 inch high, has a variable-drive
0.25-hp motor and moves 1.4 to 27 inches per Desoutter Industrial Tools | 1815 Clubhouse Rd. - Rock Hill, SC 29730
Phone: (877) 224-7377 | Email: desoutter.na@desouttertools.com
eShowroom Assistant www.desouttertools.com
minute. Along with a large workspace (36 by

¨
120 by 15 inches), the oven has a 4-foot-long
belt loading zone, Incoloy-sheathed tubular By Aries Engineering Company, Inc.
elements that produce 30 kilowatts of heat and
a 10-foot-long heat zone with recirculated air- Speed,
flow down to the parts. There are three control-
lers (indicating temperature, excess tempera- Precision,
ture, SCR power) and an airflow safety switch.
The Grieve Corp. Power
www.grievecorp.com H-Frame
847-546-8225 HyperPress
• H-Frame and C-Frame Presses available in
Manual Tool Changer Un-Guided, 2-Post and 4-Post Guided Assemblies
The Millibar Manual tool changer has electri-
• Exceptionally Low Profile CGB Presses available
cal and pneumatic pass-throughs that allow in 1-30 Tons
for fast and easy integration with UR3, UR5
and UR10 robots to increase their productiv- • HyperPierce Equalizing Units are ideal for
CGB-Frame Piercing, Riveting, Marking, Clinching, Staking
ity. Dual 6-millimeter fittings easily plumb and Assembly Applications
compressed air to open and close pneumatic
• Optional HyperView-Press available for Active
grippers, vacuum foam grippers and suction Cycle Quality Control on all HyperPress designs
Equalizing Unit
All HyperPress Assemblies can
be modified to fit your application
Proudly Made in the USA.
Aries Engineering Company

Servo Actuators, Hydra-Pneumatic Cylinders, Presses and Joining Systems
C-Frame
Ph. 734.529.8855 • www.hypercyl.com • Fax 734.529.8844

Products
cups; drive integral Venturi vacuum pumps; or to access any data from across the production ensures careful handling of fragile parts for
monitor levels of vacuum switches and sensors line; and select up to 10 part features (scalar assembly and measurement applications.
mounted at the robot base. The tool changer attributes) to compare their data and create an SMAC Corp.
weighs just 0.7 kilogram and is low profile (35 Advanced Trend report. www.smac-mca.com/new-product
millimeters high) to fit into confined spaces Sciemetric Instruments Inc. 760-929-7575
and maximize payload. Its extended-length www.sciemetric.com
finger catch minimizes opening and clos- 877-931-9200 Ultrasonic Tube Welding
ing forces while keeping end-of-arm tooling In a single operation, the US-3020TS por-
securely locked in place. Programmable Micro Gripper table gun ultrasonically welds copper and
Universal Robots USA Inc. Besides being very light (about 30 grams), aluminum tubing and trims it to length. The
www.universal-robots.com the electric MGR5 micro gripper features two machine handles tubing up to 0.9-millimeter
844-462-6268 independently controlled fingers that precisely thick and 2 to 12 millimeters in diameter, a
handle high volumes of fragile, small and asym- size commonly used in air conditioning and
Manufacturing Analytics Software metric parts. The gripper offers programmable refrigeration systems, as well as capillary and
Sciemetric Studio SE software enables manu- force down to 5 grams and real-time feedback bulb temperature sensors. Standard features
facturers to easily review, report on, compare (via built-in sensors) to verify proper pickup, include a state-of-the-art weld head, a control-
and analyze part data to determine the cause of a ler and a 17-inch LCD visual interface. The
production problem and improve assembly line gun produces consistent welds at a rapid cycle
yield. SE complements LT software, the initial rate of 20 welds per minute, and its tooling can
installment of the company’s Studio suite that be changed out in less than 3 minutes. In addi-
lets manufacturing engineers analyze complex
part data for small groups of production and
test stations. With SE, companies can visualize
waveforms and images from machine vision
systems; connect to a QualityWorX database
orientation and placement. It has a 10-mil-

limeter stroke (5 millimeters per axis), a peak
force of 1.7 newtons at 1.5 amps and a standard
encoder resolution of 5 microns (1 micron
is optional). The gripper’s Soft-Land feature
THE TRUSTED SOURCE FOR NEW MOBILITY INFORMATION
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www.AutonomousVehicleTech.com/ASMB
tion, the gun requires low maintenance and Typical output torques range from 60 to 800 is 1 watt at 365 nanometers or 2 watts at 385,
comes with a no-leak-tube guarantee—even newton-meters. Compact and quiet, the gear- 395 and 405 nanometers. The FE400 performs
on tubes contaminated with oil. boxes have an efficiency of up to 96 percent, full curing, while the other two series enable
Tech-Sonic Inc. feature corrosion-resistant aluminum housings edge curing with analog control.
www.tech-sonic.us and pluggable connections, and require no Phoseon Technology
614-792-3117 maintenance. www.phoseon.com
ABM Drives Inc. 503-439-6446
Angular Gearboxes www.abm-drives.com
Each of this company’s two-stage, 90-degree 513-576-1300 Grippers Remove
gearboxes are customized and come fully Shaft-Mounted Items
assembled with geared motors, an integrat- LED Curing Lamps SG-Series Sync Grip pullers feature simul-
ed motor controller and a flexible interface. The FireEdge family of air-cooled UV LED taneously engaging jaws that safely remove
Their design enables manufacturers to meet lamps quickly cure adhesives, coatings and shaft-mounted bearings, bushings, gears,
a wide range of electrical and mechanical inks. Series FE400 offers emitting window sleeves, wheels and sprockets. The device’s
drive parameters when installing them in con- sizes of 80, 120, 160, 180 and 240 by 10 mil-
veyors, vertical storage or material-handling limeters, with a peak irradiance of 4 watts per
systems. The motor controller mounts directly centimeter square at 365 nanometers or 8 watts
on the motor or is installed in an electric panel. at 395 nanometers. The FE300 lamps have a
window size of 75 or 110 by 10 millimeters,
with an irradiance of 3 watts at 365 nanometers
or 5 watts at 385, 395 and 405 nanometers.
Models in the FE200 series have the same
window size as the FE300, but the irradiance
Pre-Mixed & Frozen Resins

Eliminate weighing & mixing materials!
Reliable & convenient - simply thaw & dispense.

Air-free, filled syringes 55cc & smaller.
Available for epoxies, silicones, urethanes & polysulfides.
1-866-322-8322 kitpackers.com ISO9001:2008 certified

Products
three-jaw configuration evens load distribution, while its threaded

spindle and jaw indexes provide adjustable reach. Mechanical and
THE TRUSTED SOURCE FOR NEW MOBILITY INFORMATION hydraulic series are available. The former have a capacity of 1 to 20
tons, a maximum reach of 4.1 to 23.6 inches, and a spread range 4.3
Welcome to the world of to 26.8 inches. Hydraulic pullers have a capacity of 14 to 50 tons, a
Sign up today for Autonomous Vehicle Technology. reach of 12.6 to 27.6 inches, and a range of 13.8 to 38.6 inches, with
10,000 psi maximum operating pressure. They come with detachable
hydraulic cylinders, and a gauge assembly and hose that monitors
applied pulling forces.
Enerpac
www.enerpac.com/en-us
800-558-0530
Cable Tie Tool

The GTS-E cable tie hand
tool features an ergonomic
design that increases produc-
tivity and reduces the risk of
repetitive motion injuries.
Handle force is 15 percent
lower than comparable tools.
An improved cable tie cut-off
mechanism reduces impact
Autonomous Vehicle Technology provides solutions to real-world challenges facing its subscribers,
combining print and digital products. Stay up to speed by reserving your first print edition. Unlock a
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Advertisers Index
Apex Tool Group ......................................................................www.apexpowertools.com ......................................... 800-845-5629 ........................................ 41
Aries Engineering Co. .......................................................................... www.hypercyl.com ..........................................734-529-8855 .........................................67
The ASSEMBLY Show ......................................................www.theassemblyshow.com .................................................................................................12, 13, 53
ATC Automation ........................................................................ www.automationtool.com ..........................................931-528-5417 ....................................... BC
ATI Industrial Automation............................................................................ www.ati-ia.com .......................................... 919-772-0115 ........................................... 5
BalTec Corp. ......................................................................... www.balteccorporation.com ...........................................724-873-5757 ........................................ 36
Banner Engineering ........................................................... www.bannerengineering.com .......................................... 888-373-6767 ........................................ 15
Canon ..........................................................................................www.usa.canon.com/smv ......................................... 408-468-5819 ........................................ 66
Comau ........................................................................................................ www.comau.com ............................................................................................................... 69
DEPRAG Inc. ..................................................................................... www.depragusa.com .......................................800-4-DEPRAG ......................................IBC
Design Tool .................................................................................... www.designtoolinc.com ......................................... 800-948-1038 ........................................ 16
Desoutter Industrial Tools......................................................... www.desouttertools.com ......................................... 888-298-2905 .........................................67
DESTACO ...............................................................................................www.destaco.com ........................................ 888-DESTACO ........................................ 28
DeWAL .........................................................................................................www.dewal.com ......................................... 800-366-8356 ........................................... 7
Ellsworth Adhesives ............................................................................ www.ellsworth.com ......................................... 800-888-0698 ................................. 18, 48
Gage Bilt Inc. ..........................................................................................www.gagebilt.com ......................................... 586-226-1500 ........................................ 65
Hernon Manufacturing .....................................................................www.hernonmfg.com ......................................... 800-681-0004 ........................................... 9
Ingersoll Rand ............................................................... www.ingersollrandproducts.com ..........................................704-655-4000 ....................................... 19
Janome Industrial Equipment USA Inc........................................... www.janome-ie.com ...........................................847-357-8870 .........................................37
Kistler North America (Kistler Instrument Corp.) ................................ www.kistler.com ......................................... 248-668-6900 ........................................ 20
KitPackers ............................................................................................ www.kitpackers.com ........................................ 866-322-8322 ........................................ 69
Komax Wire ..........................................................................................www.komaxusa.com .....................................888-GO-KOMAX ........................................ 33
Magnatag Visible Systems............................................................... www.magnatag.com ......................................... 800-624-4154 ........................................ 45
Makita USA Inc................................................................www.makitaassemblytools.com ..........................................800-4-MAKITA ........................................ 25
Orbitform ............................................................................................... www.orbitform.com ...........................................517-787-9447 ........................................... 1
Panasonic ...........................................................www.us.panasonic.com/assemblytools ..........................................201-392-4193 ........................................ 26
PennEngineering .....................................................................................www.pemnet.com ..........................................800-230-4736 ........................................ 23
ProLine .....................................................................................................www.1proline.com ..........................................800-739-9067 ........................................... 8
Promess ............................................................................................ www.promessinc.com ..........................................810-229-9334 .......................................IFC
Sankyo ......................................................................................... www.sankyoamerica.com ..........................................937-498-4901 ........................................ 52
Schleuniger Inc. ..........................................................................www.schleuniger-na.com ..........................................603-668-8117 ........................................ 24
Schmidt Technology ................................................................www.schmidtpresses.com ......................................... 800-959-1218 .........................................17
Schunk Inc. ................................................................................................www.schunk.com ..........................................800-772-4865 ........................................... 3
Sciemetric ............................................................................................www.sciemetric.com .......................................... 877-931-9200 ........................................ 21
Sealant Equipment & Engineering Inc............................. www.sealantequipment.com ......................................... 734-459-8600 ........................................... 9
Southworth Products ......................................................www.southworthproducts.com .......................................... 800-743-1000 .........................................27
SPIROL.........................................................................................................www.spirol.com .......................................... 860-774-8571 ........................................... 8
Sturtevant Richmont ............................................................................. www.srtorque.com .......................................... 800-877-1347 ........................................ 56
Suhner Industrial Products Corp.......................................................... www.suhner.com ......................................... 706-235-8046 ........................................ 40
Taiwan International Fastener Show 2018..................... www.fastenertaiwan.com.tw ..........................................212-904-1677 ........................................ 29
Tohnichi .................................................................................................... www.tohnichi.com ..........................................847-947-8560 ........................................ 44
WEBER Screwdriving Systems Inc. ..........................................www.weberusa.com ..........................................914-962-5775 ........................................ 32
Weiss North America ............................................................................www.weissna.com ........................................ 888-WEISSNA ........................................ 49
Zimmer Group ..............................................................................www.zimmer-group.com ............................................................................................................... 65
This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.
®
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Moser
on MANUFACTURING
Harry Moser
President, The Reshoring Initiative
Using TCO for

Selling vs. Imports
vice president of sales reported, lean, green, compliance and qual-
U
se the Total Cost of Own-
ership Estimator (TCO) “We used the TCO calculator from ity champions should all support
to make a strong case the Reshoring Initiative. This tool domestic sourcing. The line man-
when selling against framed the costs and risks of both agement should be receptive to
offshore competitors! options and was a crucial piece to ideas to improve turns and from-
Sixty percent of compa- our winning strategy.” stock availability while reducing
nies make sourcing decisions based We suggest asking about off- warranty and travel costs.
on rudimentary metrics, such as shore-sourced products that are Many U.S. OEMs have out-
wage rate, ex-works price or landed causing the customer problems, sourced design, build and pack-
cost, often resulting in a 15 to 30 such as late deliveries, poor qual- aging of complex products, such
percent understatement of actual ity, intellectual property theft, as major appliances, to Chinese
offshoring costs. The TCO Estima- excess inventory, lost orders and contract manufacturers. They will
tor is a free online tool that helps want to find similar support from
companies account for all relevant
factors—overhead, balance sheet,
A U.S. contract manufacturer U.S. suppliers. Broaden your val-
ue-added offerings.
risks, corporate strategy and other
external and internal business con-
used TCO to win a $60 Email us at info@reshorenow.
org if you need help with reshor-
siderations—to determine the true million order. ing or TCO. We’d also love to
total cost of a part or assembly. hear about your success reshor-
When you find yourself com- travel costs. Push hardest especial- ing and selling against imports.
peting with a lower-priced off- ly when there has been a very pub- Our mission is to help you and
shore product, we suggest offering lic problem with offshore deliver- your customers re-evaluate off-
to help the customer compare the ies, like the West Coast dock strike shoring vs. domestic sourcing and
TCO of your offer vs. the lower- or natural disasters. Ask about make the right decisions. If you
priced offshore offer. If the buyer your customer’s plans to prepare use TCO, some of those decisions
resists, gather whatever informa- for President Trump’s drive to will favor reshoring.
tion you can from other contacts bring back manufacturing jobs. Buyers often ask a salesman,
at the company, do TCO from the Show your prospect that its com- “Can you match the Chinese
customer’s perspective, and re- petitors are reshoring. More than price?” Your response should be,
view the results with the buyer. It 1,000 companies have already suc- “Probably not, but let’s see if I can
is best to be conservative and un- cessfully brought the manufacture offer you a lower total cost that
derstate the hidden costs. of parts or products back to the U.S. increases your profitability.” A
Here is a real world example of from offshore. The Reshoring Initia-
a company that used TCO to sell tive website provides a slide file of Editor’s note: Harry Moser is the
against imports. Electronics man- 400 reshoring cases, a case studies president of the Reshoring Initiative.
ufacturing services provider Mo- file, and a library (with an advanced His column will appear every other
rey Corp. was pursuing a $60 mil- search function) where you can find month, alternating with Austin We-
lion contract ($15 million per year a collection of real-world success ber’s “On Campus.” Has your com-
for four years) vs. a lower-priced stories. You may have to overcome pany reshored production? Are you
Asian competitor. With the help senior management’s directives that thinking about it? We’d like to hear
of the Reshoring Initiative, Morey X percent of products must be off- of your success or help you achieve
used the TCO Estimator to show shored, but what a great opportunity it. With your approval, we would
the customer that although Mo- to meet senior management. love to report on your successes or
rey’s price was higher, the TCO Work with natural allies within opportunities in future issues. Con-
was lower. Tony Woodall, Morey’s your customer’s company. The tact harry.moser@reshorenow.org.
DEPRAG Position Kontroll Stand
delivers the ultimate in process reliability.
Combining the precision of automated processes with the flexibility of human operation,
DEPRAG PKS assembly is optimized for use in all types of environments. Coupled with
DEPRAG EC Screwdrivers, or as a component within an innovative DEPRAG Intelligent
Manual Workstation, PKS provides intuitive programming, adaptable guidance hardware,
and flexible software to deliver reliable control and sequencing. See the DEPRAG difference
in your products with PKS.
Find out more at depragusa.com • 800.4.DEPRAG

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