Designfax weekly eMagazine

Subscribe Today!

Archives

View Archives

Partners

Manufacturing Center
Product Spotlight

Modern Applications News
Metalworking Ideas For
Today's Job Shops

Tooling and Production
Strategies for large
metalworking plants

Simplify pick and place with the THK PPR

THK's Pick-and-Place Robot PPR is a robot that can pick up delicate or minute workpieces such as electronic components and quickly and accurately transfer and assemble them to the base. In addition to the basic movements of raising, lowering, and rotating, various sensors (such as a force sensor), solenoid valves, and controller are all in one unit. The PPR is a process-optimized robot that can improve the production speed of the parts assembly processes and reduce work damage.
Learn more.

New ROBOMACHINE products and more from FANUC

FANUC America demonstrated the future of manufacturing at IMTS 2026 last week, showcasing how Physical AI-powered automation integrates advanced CNC, machining, and robotics to boost productivity and speed deployment. One highlight was the debut of the ROBODRILL DC Series machining centers -- including the high-speed D54CS and D74CS models -- alongside interactive demonstrations featuring collaborative robots, robotic welding, material joining, painting, and assembly technology.
See all the FANUC new tech featured at IMTS.

What is a stick-slip bi-phase positioning stage?

PI (Physik Instrumente) is expanding its Bi-Phase Inertia Drive (BIX) technology with new motor architectures for compact, high-precision nanopositioning applications. Based on the piezo stick-slip principle, BIX stages replace conventional single actuators with two synchronized multilayer piezo actuators. This compact design delivers precise, repeatable motion while maintaining piezo inertia self-locking.
Learn more about this technology.

Universal Robots unveils Gen 7 robot platform!

Redesigned from controller to tool flange, the new Gen 7 robot platform is out-of-the-box AI-ready, giving companies the modern software tools and next-level connectivity they need to confidently take AI from the lab into industrial operations. Gen 7 represents a unified system upgrade designed to make even the most demanding tasks and setups easier. See all the new features -- they are significant.
Read the full article.

Adaptor mount and hub options provide flexibility

Zero-Max's new CD Power-Series Flexible Shaft Couplings feature ISO Flange Adaptors matching ISO 9409-1 patterns on gear reducers and robotics. Eliminating custom transitions, this direct connection enhances torsional stiffness and positioning accuracy while saving space, weight, and inertia. Offering continuous torque up to 65,000 in.-lb and versatile hub options, these compact couplings deliver high power density.
Learn more.

Top-shelf motors: Completely revised maxon catalog

maxon has completely overhauled its 2026/2027 catalog, streamlining its portfolio to reduce complexity and improve navigation. The new structure features dedicated sections for business units -- Medical, Aerospace, Industrial Automation, Mobility -- and specialized fields like Robotics and Space. Key product highlights include new ECX PRIME and ECX FLAT motors, GSW planetary gearheads, and ESCON2/EPOS4 controllers.
Learn more and check it out.

Custom stators, rotors, and motor assemblies for low- to mid-volume applications

Arnold's Ramco Electric Motors is your single partner for custom motor components and complete assemblies. Ramco builds solutions for AC induction, switched reluctance, and brushless DC designs up to 200+ HP. Capabilities include custom stators, rotor-shaft assemblies, aluminum and copper casting, induction brazing, permanent magnet assembly, and precision rotor balancing.
Learn more.

Rotate robot arms more than 600 degrees

The unsupported twisterchain^® from igus eliminates the need for additional trough systems or guide plates in robotic applications, especially in palletizing. This results in a clean, efficient, and space-saving system architecture that delivers both technical and economic advantages. Thanks to its specialized design, it supports rotations of over 600 degrees.
Learn more.

Match the torque of rotary solenoids to your application

Magnetic Sensor Systems has launched the Made in USA R-10-200-CWM Series of clockwise rotary solenoids. Measuring 2.00 in. in diameter and 1.04 in. long with 18 different AWG options and a serrated front shaft end, these compact units optimize torque, current, and duty cycle. When power is removed, an integral return spring automatically returns the shaft to its home position. The shaft is supported by two high-precision radial ball bearings, providing smooth operation with no axial play. Applications include medical, security, and office equipment.
Learn more.

Planetary servo gear unit: New economy series

SEW-EURODRIVE has expanded its PxG planetary servo gear unit portfolio with the new PxG economy series, introducing the P1.G, P2.G, and P3.G performance classes. Designed for standard industrial automation applications like packaging and material handling, these cost-effective units feature peak torque ratings from 11 to 500 Nm and over 20,000 hours of service life, helping machine builders eliminate unnecessary over-specification.
Learn more.

Compact hexapod 6-DOF alignment system has overload protection

PI's compact H-811.I2HS hexapod delivers precise 6-DOF motion with patented overload protection, simplifying setup and operation in OEM applications. This built-in protection safeguards precision mechanics during installation and integration against accidental forces or improper handling. Furthermore, the hexapod mounts in any orientation, granting system designers exceptional flexibility for optical, photonics, microscopy, metrology, and automation systems.
Learn more.

What is STUDROLLER technology? Cross Roller Guides

NB SLIDE WAY cross roller guides use precision rollers to provide stable, non-recirculating linear motions in precision stages, inspection equipment, semiconductor manufacturing, and more. At the heart of all NB cross roller bearings is the STUDROLLER mechanism, which eliminates the cage-creep phenomenon that, over time, can create deviances in cross roller retainer performance. NB cross roller guides equipped with this system are more accurate and better performing than any other comparable products on the market today. High acceleration and faster cycle times are possible in any orientation.
View the video.

Ruggedized Nano servo drives for harsh environs

Copley Controls has released its R47 and R48 NanoPlus Micro Module servo drives. Designed for extreme environments and space-constrained applications, these rugged platforms operate from 9 to 180 VDC, delivering peak power up to 6.3 kW. Offering CANopen (R47) or EtherCAT (R48) communications, both feature STO SIL 3 safety and broad encoder support. Well suited for COTS military, nautical, aviation, oil refining, and vehicle-based systems.
Learn more.

Simplify AC motor control with the new OMRON M1 Inverter

The OMRON M1 Inverter simplifies machine design by unifying motion, safety, networking, and motor control into a single platform. Available in M1-STD, M1-ECT, and M1-EMP models, it controls IM and PM motors with high precision. Featuring SIL3 PLe STO safety and native EtherCAT, EtherNet/IP, or RS-485 communications, the M1 accelerates development within the Sysmac environment.
Learn more.

Flexible planetary gearheads: Quiet, extremely robust

FAULHABER GPT gearheads for miniature and micro motors deliver high power density, exceptional flexibility, and excellent cost efficiency. Designed for seamless integration with diverse motors and encoders, these compact planetary drives feature hardened stainless steel components that reliably withstand extreme torques and abrupt load changes. Offered in standard, low-noise, and high-torque variants, they ensure precise, durable performance across wide operating temperature ranges.
Learn more.

Continental supplies world's first turbocharger with aluminum turbine housing in cars

The global development trend toward turbocharging for gasoline engines is in full swing in a bid to provide smaller cubic capacity and lower fuel consumption while offering the same, if not better, performance. International automotive supplier Continental is supporting this trend and setting milestones with its pioneering and innovative turbocharger technology.

The first Continental turbocharger went into series production in a highly efficient, multi-award-winning 1.0l engine in 2011. The company is now adding another chapter to this success story with a technological world premier: Continental's powertrain developers have launched series production of the first car turbocharger with an aluminum turbine housing. Integration of the unit in the three-cylinder gasoline engine (1.5l of cubic capacity and 100 kW of power) for the standard MINI Hardtop has been ongoing since spring 2014.

"Aluminum in a turbocharger designed for cars is a real milestone," says Wolfgang Breuer, Head of the Engine Systems Business Unit of Continental's Powertrain Division. "With this lightweight material, we are saving nearly 30 percent of weight compared to a conventional turbocharger, while simultaneously reducing costs and achieving system benefits."

"It's not just the aluminum that makes the turbocharger special; it was also developed from being a typical add-on component to an integral part of the engine," says Udo Schwerdel, Head of Continental's Turbocharger Product Line, Engine Systems, Powertrain Division. "In order to meet the requirements placed on the unit and its integration in the cylinder head, we worked closely with the BMW Group starting from the simulation phase -- an indication of trust that we greatly appreciate."

Aluminum in the turbocharger = less weight, less fuel consumption
Full-load operation can be enough to make common turbocharger constructions with a steel housing glow red all over. However, the aluminum turbine housing keeps a cool head.

"The double-walled aluminum housing surrounds the hottest area with a cooling water jacket," says Schwerdel. The coolant flowing through this jacket ensures that the external housing surface does not get hotter than 120 C (248 F) and the internal temperature does not exceed 350 C (662 F), which Schwerdel explains has not one, but two benefits: "First, much less effort is required to protect neighboring components from the heat. Second, cooling of the exhaust flow reduces the thermal load on the catalytic converter, meaning it hardly ages at all."

At the same time, the dynamic response of the electric actuator at the wastegate ensures that the catalytic converter heats up quickly.

In keeping with the modular principle given by the customer, the turbocharger is tightly integrated in the engine (it is a fixed component of the exhaust manifold), but Continental turbochargers with a steel housing can also be attached to the same base engine using the interface on the cylinder head. The car manufacturer is using this option for high-performance engines as well as vehicles for export to hot countries. The bearing housing is cooled from inside the turbocharger for steel variants, while cooling from outside is sufficient for aluminum turbochargers.

In the MINI, 1.2 kg (2.6 lb) of weight is saved per aluminum turbocharger. Since reduced weight also means reduced fuel consumption, the lightweight material supports the fuel consumption and emission targets of the automotive industry. Despite the additional expenditure for the water cooling, aluminum turbochargers are also more affordable for automotive manufacturers.

"High-temperature-resistant materials such as nickel-base alloys drive up prices for turbochargers with steel housings," says Schwerdel, "whereas our aluminum alloy is a cost-effective material."

Source: Continental

Published September 2014

Rate this article