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| July 23, 2024 | Volume 20 Issue 28 |
Manufacturing Center
Product Spotlight
Modern Applications News
Metalworking Ideas For
Today's Job Shops
Tooling and Production
Strategies for large
metalworking plants
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Deliveries are getting faster than ever in the United States, but the quicker movement of goods is undercutting the country's climate progress.
In a new study published July 18 in the journal Nature Energy, a University of Colorado at Boulder (CU Boulder) researcher and his collaborator estimate that federal regulations aimed at enhancing heavy-duty trucks' energy efficiency could be as much as 20% less effective than policymakers initially anticipated.
That's because the regulations make trucking cheaper. As a result, more shippers will likely switch from using less energy-intensive rail transportation to using more energy-intensive trucks to ship goods.
"We were surprised to see how big of an impact the change in shipping decisions has on our energy use," said Jonathan Hughes, the paper's corresponding author and professor in the Department of Economics at CU Boulder. "Increasing vehicles' energy efficiency is very costly for truck makers, so it's important to know how much benefit we can get realistically from these costly regulations."
The rebound effect
In economics, increased consumption due to improved efficiency and reduced costs is known as the rebound effect.
For example, if using an air conditioner consumes much more electricity than using a fan, many people will stick to the fan. However, when air conditioners become more efficient and cooling becomes cheaper, more people will switch to air conditioners. This behavior change would increase overall energy consumption.
Hughes and his collaborators wanted to study the extent of the rebound effect in the freight sector.
"When we think about the challenges in energy and climate change issues, freight transportation is a big, important sector that hasn't received enough attention," Hughes said.
The freight sector, which includes transportation of goods by truck, train, ship, and airplane, represents approximately 10% of total U.S. energy consumption. Freight movement contributes to 27% of the country's greenhouse gas (GHG) emissions from the transportation sector, which is the largest source of emissions in the United States.
The majority of emissions from the freight sector come from trucking, which saw a 76% increase in GHG emissions since 1990.
In a bid to reduce emissions and avoid the worse consequences of climate change, the U.S. Environmental Protection Agency (EPA) has rolled out a series of regulations to improve heavy-duty vehicles' energy efficiency since 2011. These rules require newly manufactured trucks to achieve better mileage using less fuel and emit less GHG.
In March, the EPA announced the strictest-ever fuel economy standards, aiming to prevent 1 billion metric tons of GHG emissions by 2055.
However, while these regulations make trucks more energy efficient, they also make trucking cheaper by reducing fuel costs. As a result, many shippers may opt to transport their goods by truck instead of rail, because trucks can reach destinations faster, allowing for quicker product sales. The authors note that trucks consume significantly more fuel than rail to transport the same amount of goods over the same distance.
Unintended consequence
Hughes and his collaborator, James Bushnell of University of California at Davis, used newly released data on goods movement from the U.S. Census Bureau to estimate the rebound effect in the freight sector. Using a computer simulation, they calculated the amount of energy saved if the EPA regulations increased new trucks' fuel efficiency by 5%, which is roughly what the standard is today.
Under this scenario, the team found the regulations had the potential to save 674 million gallons of gas per year. However, when they factored in the increased share of goods forecasted to be shipped by truck due to the rebound effect, the regulations would only save 497 million gallons of fuel -- still a significant amount, but 26% less than previously estimated.
Some industries, such as the chemical, animal feed, alcohol, and petroleum industries, are particularly sensitive to reductions in fuel costs and would likely experience the largest rebound effect, Hughes said.
Accounting for all modes of freight transportation, the team estimated the rebound effect in the freight sector would reduce the total fuel savings from federal regulations by 20%.
"We show that if we make transportation much more efficient, either through increasing energy efficiency or automation that reduces labor costs, we will likely wind up consuming more energy than we thought we would," said Hughes.
While the paper focused on the freight sector, Hughes added a similar rebound effect could also exist in the retail sector, which includes businesses like Amazon.
"These regulations that help reduce transportation costs certainly benefit consumers, because we can now purchase things at lower prices. But we show that these rules can be somewhat counterproductive in terms of achieving our climate change and energy goals," Hughes said.
Hughes said making fuel pricier and transportation more expensive through programs like taxing carbon emissions would be a more effective way to reduce energy use in transportation. Those types of policies, however, tend to be very difficult to garner political support, he added.
"This study shows we should get a more complete picture of the impacts these regulations might have, so we don't end up adopting policies that lead to unintended negative effects," he said.
Source: University of Colorado at Boulder
Published July 2024