www.designworldonline.

com
August 2024

INSIDE:
MOTION CONTROL
Avoiding common
issues when tuning
an inverter to an
electric motor
PAG E 1 8

AUTOMATED WAREHOUSE Cracking down on

sustainable
Mitigate cybersecurity
risk in the automated
warehouse
PAG E 2 5

THE ROBOT REPORT

RealTime Robotics
collaborates on motion
planning with Mitsubishi
Electric
propulsion PAG E 1 0

PAG E 4 1

ALSO INSIDE:

AEROSPACE & DEFENSE

SUPPLEMENT
PAG ES 59 - 6 2

cover concepts DW 08-2024 final.indd 1 7/31/24 3:21 PM

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| AT16USA |

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altech – DW 08-24.indd 2 7/29/24 9:18 AM
altech – DW 08-24.indd 3 7/29/24 9:18 AM
 NEW! Insights
4 AXIS SERVO from

2.25” Inflation, the economy,

China, and Canada
One of my favorite speakers at industry conferences is Alan Beaulieu of
ITR Outlook; he regularly presents to groups like the National Fluid Power
Association and Power Transmission Distributors Association. ITR’s angle is
strictly on policy, economics, and demographic trends, not politics. That’s not
to say that he doesn’t sometimes anger folks in the audience on both sides
of the spectrum, but I appreciate him staying out of the mudslinging and just
talking data.
Earlier this year, Beaulieu spoke to the NFPA, and some of his comments
are worth keeping in mind over the next few years. Here are four areas
to watch.

• 2019 was part of what he calls the “great before,” ... and you’re never
going to see something like it again. We are now simply living with
inflation. While inflation is decreasing, commodity prices have declined
- brushed or bldc motors — but other input costs have not. He also said that if you want to buy
- 5 amps per axis a business, make sure to do it by 2025. After 2025, he explained that
interest rates will likely go up for the rest of the decade.
- 16 analog inputs • Much of the U.S.’s position on the China/Taiwan situation has to do
- 16 on/off drivers with the fact that Taiwan produces a lot of the military’s chips. China
- home and limit in attacking Taiwan would almost necessitate a military response at this
point. But if Taiwan falls after 2027, when some of the chip situation is
- live tech support
solved, Beaulieu thinks the State Department may feel we won’t have to
- made in the USA do anything about it.
• For those who say that we “can’t know” about the coming Great
Depression (which Beaulieu has long predicted for the 2030s, based on
See the demographic trends and Baby Boomers retiring en masse), his response
EZQUAD SERVO is, “It’s math. It will be global, and you can’t hide from it.” Beaulieu said
states that will be hit most severely include New Jersey, California,
in action! Connecticut, and Illinois. Pennsylvania, he noted, has almost as high
a percentage of Boomers as Florida, which does not bode well for its
financial future.
• Because of immigration and its proximity to the U.S., Canada will win in
WWW.ALLMOTION.COM the long haul. He suggested that future personal investment in Canada
could be smart, including bonds, as their banking system is more
resilient and less prone to political machinations. DW

(510) 471-4000
Paul J. Heney - VP, Editorial Director
30097 Ahern Avenue pheney@wtwhmedia.com
Union City, CA 94587 On X (formerly Twitter) @wtwh_paulheney
Te c h n i c a l S u p p o r t
(408) 460-1345

4 August 2024 www.designworldonline.com DESIGN WORLD

insights – DW 08-2024 v3 final.indd 4 7/29/24 9:13 AM

 Remote I/O

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banner engineering – DW 09-24.indd 5 7/31/24 7:51 AM

 Contents 8 • 2024 • VOL 19 NO 8 • DESIGNWORLDONLINE.COM

DEPARTMENTS
04 Insights

10 Design For Industry

14 Design Notes

63 Ad Index

10
64 Technical Thinking

SUPPLEMENTS

| StockStudio, Adobe Stock

ON THE COVER
AUGUST 2024
theautomatedwarehouse.com
Cracking down on
sustainable propulsion
A Supplement to Design World
A Supplement to Design World • August 2024 www.therobotreport.com

A new onboard ammonia cracking system produces zero

carbon emissions at the point of use.

A NEW KIND OF
COLLABORATION
IN THE REALTIME ROBOTICS COLLABORATES ON
WAREHOUSE
Inside:
PAGE 26

A new kind of collaboration in the warehouse .................................. 26

Mitigate cybersecurity risk in the automated warehouse ............30
Preparing the warehouse automation plan .........................................34
MOTIONWITHPLANNING
PAGE 42

MITSUBISHI ELECTRIC
Inside:
RealTime Robotics Collaborates on motion planning with Mitsubishi Electric ...................................42
Stanford researcher discusses UMI gripper and diffusion AI models .................................................. 50
Siemens introduces high-inertia 1FK7-HI servo motors ..............................................................................54

PAG E S 2 5 - 3 9 PAG E S 4 1 - 5 8

AUGUST 2024
11
FEATURES
18
how
MOTION CONTROL
AI-at-the-edge
enables decision superiority
on today’s battlefield Avoiding common issues when tuning an interverter to
an electric motor
Page 60

A little knowledge of some key factors and potential issues can

PAG E S 5 9 - 6 2 help smooth the process of tuning an inverter to an electric motor.

22 LINEAR MOTION
Hybrid steppers in linear actuators
Sometimes called motorized screws, NEMA-stepper linear
actuators leverage how step motors rotate a preset discrete
amount for every pulse of electrical power into their windings ... a
22 characteristic useful for axes in fine load positioning.

6 August 2024 www.designworldonline.com DESIGN WORLD

table of contents - DW 08-2024 v1.indd 6 7/31/24 8:21 AM

240710_AutoMotion_DW_US.indd
digikey – DW 08-24.indd 5 1 7/8/24 11:54
7/29/24 9:19 AM
 DESIGN WORLD
NOW ONLINE! EDITORIAL
FOLLOW THE WHOLE TEAM @DESIGNWORLD

Director, Audience FINANCE

Development
VP, Editorial Director Bruce Sprague Controller
Paul J. Heney bsprague@wtwhmedia.com Brian Korsberg
pheney@wtwhmedia.com bkorsberg@wtwhmedia.com
@wtwh_paulheney WEB DEV / DIGITAL
OPERATIONS Accounts Receivable Specialist
Managing Editor Jamila Milton
Mike Santora Web Development Manager jmilton@wtwhmedia.com
msantora@wtwhmedia.com B. David Miyares
@dw_mikesantora dmiyares@wtwhmedia.com
@wtwh_webdave VIDEO SERVICES
Executive Editor
Lisa Eitel Senior Digital Media Videographer
leitel@wtwhmedia.com Manager Cole Kistler
@dw_lisaeitel Patrick Curran cole@wtwhmedia.com

Help us honor the Senior Editor

pcurran@wtwhmedia.com
@wtwhseopatrick PRODUCTION SERVICES

companies that have Miles Budimir

mbudimir@wtwhmedia.com Front End Developer Customer Service Manager

provided the most

@dw_motion Melissa Annand Stephanie Hulett
mannand@wtwhmedia.com shulett@wtwhmedia.com

leadership in engineering
Senior Editor
Mary Gannon Software Engineer Customer Service
mgannon@wtwhmedia.com David Bozentka Representative
@dw_marygannon dbozentka@wtwhmedia.com Tracy Powers
It has been a fascinating decade Senior Editor DIGITAL MARKETING
tpowers@wtwhmedia.com

for all businesses, including Rachael Pasini Customer Service

rpasini@wtwhmedia.com VP, Digital Marketing Representative
manufacturers. We’ve seen the @WTWH_Rachael Virginia Goulding JoAnn Martin
difficult supply chain issues vgoulding@wtwhmedia.com jmartin@wtwhmedia.com
Associate Editor @wtwh_virginia
brought on by the worldwide Heather Hall Customer Service
pandemic, along with a shortage hhall@wtwhmedia.com Digital Marketing Manager Representative
@wtwh_heathhall Taylor Meade Renee Massey-Linston
of qualified workers and the tmeade@wtwhmedia.com renee@wtwhmedia.com
@WTWH_Taylor
strong reshoring trends in many
CREATIVE SERVICES Customer Service
industries. If nothing else, this Digital Marketing Coordinator Representative
Meagan Konvalin Trinidy Longgood
helps to show how resilient VP, Creative Director
mkonvalin@wtwhmedia.com tlonggood@wtwhmedia.com
Matthew Claney
manufacturers can be. mclaney@wtwhmedia.com
Webinar Coordinator
@wtwh_designer Digital Production Manager
Emira Wininger
Reggie Hall
These companies represent the Art Director
ewininger@wtwhmedia.com
rhall@wtwhmedia.com
best and brightest, and they reflect Allison Washko
Webinar Coordinator
awashko@wtwhmedia.com Digital Production Specialist
the continued vision, integrity, Dan Santarelli
Nicole Johnson
dsantarelli@wtwhmedia.com
njohnson@wtwhmedia.com
and creativity of their design (and
EVENTS
manufacturing) engineers. Digital Design Manager
Events Manager Samantha King
Jen Osborne sking@wtwhmedia.com
We think they deserve recognition josborne@wtwhmedia.com
from you, too. Vote online for one @wtwh_jen Marketing Graphic Designer
Hannah Bragg
or more of the companies listed Events Manager hbragg@wtwhmedia.com
through October. Brittany Belko
bbelko@wtwhmedia.com Digital Production Specialist
2023 2023 2023 Elise Ondak
Event Marketing Specialist eondak@wtwhmedia.com
SILVER
NATIONAL
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BRONZE
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AWARD AWARD AWARD
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VOTE
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Medical Design
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staff page - DW 08-2024 v1.indd 8 7/18/24 2:47 PM

 MICRO SOLUTIONS
FOR BIG INNOVATIONS®

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Accumold®, Micro-Mold® are registered trademarks of Accu-Mold LLC. All rights reserved. ISO 9001, ISO 14001, ISO 13485

accumold – DW 09-24.indd 5 7/31/24 7:59 AM

 Design For Industry
OFFSHORE

Cracking down on
sustainable propulsion
Though hydrogen is in demand letter. This document guides the early power packs will be deployed in two
for offshore energy applications, adoption and efficient implementation 20-ft containers, each containing
transporting and storing H2 remains of new technologies to confirm they 400 kW of electrical power and
challenging. Ammonia (NH3) is an can fulfill their intended functions ventilation, and safety systems. This
alternative hydrogen carrier gaining and performance requirements. This integrated solution will enable the vessel
attention for maritime propulsion. process addresses regulatory gaps in to operate with zero carbon emissions.
Shipping companies such as North technology adoption, offering insights Additionally, MSB and Amogy
Sea Container Line (NCL) in Norway and assessing technology maturity levels recently completed a feasibility study
and Mitsubishi Shipbuilding (MSB) are and associated risks. of onboard hydrogen production and
exploring a new onboard ammonia “Amogy’s new technology represents use with Amogy’s ammonia-cracking
cracking system to produce cleaner the rapid development of innovation technology and the Mitsubishi Ammonia
power. around alternative fuels for maritime Supply and Safety System (MAmmoSS).
Amogy, headquartered in Brooklyn, use. Cracking ammonia to produce The two companies completed the
New York, has developed an innovative hydrogen for fuel cells has the potential studies to confirm the feasibility of two
ammonia-to-electrical power system that to accelerate the energy transition in collaborative concept designs: a power
splits, or “cracks,” liquid ammonia into its the maritime industry, supporting global train combining ammonia cracking
base elements, hydrogen and nitrogen. decarbonization goals,” said Patrick and hydrogen fuel cells for ships and
The system then funnels the hydrogen Ryan, SVP and CTO of ABS, in a press a hydrogen supply facility to supply
into a fuel cell, creating clean electricity release. hydrogen as a pilot fuel to an ammonia
to power the ship. Unlike traditional NCL intends to embark on a pilot fuel engine. With this collaboration,
combustion engines, the technology project by installing Amogy’s ammonia- the companies aim to address the
produces zero carbon emissions at the to-electric power system on a new International Maritime Organization’s
point of use. 300 twenty-foot equivalent unit (TEU) new net zero greenhouse gas emissions
As a milestone on its path to broader container ship to be delivered early in target by or around 2050. DW
industry adoption, the American Bureau 2026. The system will feature four
of Shipping (ABS) presented Amogy with 200- kW modules, providing 800 kW
Amogy • amogy.co
a New Technology Qualification (NTQ) of clean energy capacity. The 200-kW
| StockStudio, Adobe Stock

10 August 2024 www.designworldonline.com DESIGN WORLD

design for industry - DW 08-2024 v4 final.indd 10 7/29/24 9:17 AM

 Design For Industry
L A B O R AT O R Y AU T O M AT I O N
POWER TRANSMISSION
RETAINING DEVICES &
maintenance & assembly tools
Automation BEARLOK SHOELOK BEARLOK Shrink Disc

meets integration
Automation is necessary for today’s dynamic and uncertain
market. Thus, more organizations seek flexible solutions
that afford efficient, sustainable operations. ABB Robotics
launched the OmniCore intelligent automation platform on
a scalable, modular control architecture to support a wide BEARHUG CLAMPNUT TANGENTLOK

range of functions and applications.

The platform can deliver robot path accuracy at levels
less than 0.6 mm with multiple robots running up to
1,600 mm per second, operating up to 25% faster and
consuming up to 20% less energy than the previous ABB
controller. Organizations can design, operate, maintain, and
optimize operations with over 1,000 hardware and software
options, including Absolute Accuracy, PickMaster Twin, PRECISION NUTS & WASHERS
INCH and METRIC THREADS
ADAPTER SLEEVE ASSEMBLIES

external axis and vision systems, and fieldbuses. LEFT HANDED as well as
RIGHT -HANDED
“Through our development of advanced mechatronics,
Materials of:
AI, and vision systems, our robots are more accessible, CARBON, ALLOY and
capable, flexible, and mobile than ever. But increasingly, HARDENED ALLOY
STEELS
they must also work seamlessly together, with us and each Materials of:
other, to take on more tasks in more places,” said Sami Atiya, ALLUMINUM and
president of ABB’s Robotics & Discrete Automation business, CORROSION RESISTANT
STEEL
in a press release. “This is why we are launching OmniCore,
a unique, single-control architecture — one platform and one NUTS & WASHERS HARDENED TONGUE WASHERS SPLIT COLLAR

language that integrates our complete range of hardware

and software.”
Omnicore replaces ABB Robotics' IRC5 controller,
which will be phased out in June 2026. ABB will continue
to support its customers using IRC5 with spare parts and
services through the
robot's remaining
lifetime. DW ABB Robotics RETHREADING DIES ADJUSTABLE SPANNER WRENCH BEARING ASSEMBLY SOCKET
www.go.abb/robotics

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HI
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US
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abundantly and delivers quickly the best quality and largest array of
adjustable, heavy thrust bearing, and torque load carrying retaining
devices for bearing, power transmission and other industrial assemblies;
and specialized tools for their careful assembly.
Visit our website–whittet-higgins.com–to peruse the many possibilities
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design for industry - DW 08-2024 v4 final.indd 11 7/29/24 9:17 AM

 Design For Industry
M AT E R I A L H A N D L I N G

MILLIONS Compact linear

of Springs tracks deliver
precise positioning
IN STOCK AND READY TO SHIP!
Space utilization is a key principle in material handling
systems, requiring machine builders to select more compact
Compression Springs components for automation technologies. Actuonix Motion
Devices recently launched its new T16-R series linear
Extension Springs track servo, a variant of its T16 track actuator line and the
Torsion Springs company's most powerful linear track servo. Designed for
applications where side load is essential and mounting
Die Springs space is limited, the T16-R provides engineers and
designers with a versatile and efficient solution. Its compact
Wire Forms form factor and advanced functionality make it suitable
for various applications, from robotics and automation to
MADE IN USA
1-800-424-0500 custom motion projects.
The new linear track allows for highly accurate and
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SINCE 1939 repeatable movements with 100 mm, 200 mm, and
300 mm stroke lengths. It has three gear ratio options and a
maximum force of 67 lb. With its small footprint, the T16-R is
suitable for projects with
tight space constraints,
POWER TRANSMISSION-PART CONVEYING offering a high- Actuonix

PYRATHANE® BELTS
performance solution with www.actuonix.com
a compact footprint. DW

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LINE SHAFT CONVEYOR BELTS - Original Equipment and Connectable
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12 August 2024 DESIGN WORLD

2024pyramid_3.625x4.625.indd 1 12/7/2023 2:56:56 PM

design for industry - DW 08-2024 v4 final.indd 12 7/29/24 9:17 AM

 Design For Industry
ENERGY

Microgrids need big battery storage

Microgrids are localized energy systems that can operate encompasses inverters, batteries, cooling systems,
independently or in conjunction with the main power grid. transformers, safety features, and controls.
They often incorporate renewable energy sources and Two connection-ready BESS options are available: a small,
battery energy storage systems (BESS) to create a more hybrid 7-ft NEMA 3R enclosure that is ac and dc coupled,
sustainable and resilient energy supply. As part of a microgrid and a medium 20-ft NEMA 3R enclosure that is ac coupled.
system, BESS captures and accumulates energy from The family sizes range from 60 kW to 2 MW in 2-h and 4-h
different sources and stores it in rechargeable batteries for configurations.
later use. The stored energy from a BESS can be discharged to
Schneider Electric announced a new BESS engineered supply power to office, industrial, and commercial facilities
as part of its EcoStruxure Microgrid Flex system. Comprised or electric vehicles. The system also offers bidirectional
of a battery system, battery management system, power connectivity to the grid, providing the flexibility to operate as
conversion system, and controller, BESS has been tested either grid-connected or off-grid. With the capacity to store
and validated to work as an integral component of the energy for immediate access during outages, BESS can
standardized microgrid system and fully integrated into deliver up to 2 MW of power when needed. The solution is
the software suite, which includes EcoStruxure Microgrid certified to the UL9540
Operation and EcoStruxure Microgrid Advisor. standard with a fire
The all-in-one enclosure incorporates pre-integrated safety system aligned Schneider Electric
components, and multiple BESS units can function in with the latest NFPA 855 www.se.com
parallel as a unified entity. This comprehensive integration standards. DW

DESIGN WORLD www.designworldonline.com August 2024 13

design for industry - DW 08-2024 v4 final.indd 13 7/29/24 9:17 AM

 Design Notes
EDITED BY MIKE SANTORA

Brick machine supplier embraces the

benefits of new bushings
A South African manufacturer and supplier of
concrete brick-making machines has started using
Vesconite Hilube linear bushings as spare parts for
its manual/electric brick-making machines and as
standard components in its range of manual brick-
making machines.
The Vesconite Hilube wear-resistant self-lubricating
bushings are installed on the shafts on which the
tamper guide system moves to compress the concrete
aggregate to produce bricks.
Vesconite Hilube has become a standard feature
in the manually operated brick-making machines
produced by the company. These machines cater
to entrepreneurs and startup companies requiring
low-output production, where reliability and ease of
maintenance are paramount. Each hand-operated
machine, known as an egg layer, incorporates
eight Vesconite Hilube bushings, ensuring optimal
performance and longevity.
Vesconite Hilube bushings are also offered as
replacement bushings for the manual/electric brick-
making machines that the brick-machine company
sources from elsewhere. Supplied with steel bushings
initially, the company offers Vesconite Hilube
bushings as replacements, recognizing their superior
performance, longevity, and good availability. These
machines, equipped with 16 Vesconite Hilube linear
bushings, cater to higher production demands.
The decision to adopt Vesconite Hilube bushings
stems from their many advantages.
Foremost among these is the simplicity of
installation and replacement. Traditional steel bushings
supplied with manual/electric machines are prone
to breakage, particularly during removal. Vesconite
Hilube bushings have streamlined maintenance
Top: The Vesconite Hilube wear-
procedures because of their ease of installation and
resistant self-lubricating bushings
removal. They also minimize downtime since they are
are installed on the shafts on
fit-for-purpose and include holes for the screws that
which the tamper guide system
attach the bushings to the blocks that are placed on
moves to compress the concrete
the four shafts on which the tamper guide system
aggregate to produce bricks.
is located.
Moreover, these bushings demonstrate
Left: The hand-operated brick
remarkable resistance to wear and tear, a crucial
machines that use eight Vesconite
requirement for brick-making machines exposed to
Hilube bushings.
harsh environments in which cement and dust are

14 August 2024 www.designworldonline.com DESIGN WORLD

design notes - DW 08-2024 v4 final.indd 14 7/29/24 9:28 AM

 Abracadabra!
Accessory Power Strips
& Jumper Cords—
1-Week Lead-Times

Interpower® Accessory Power

Strips (APS) are perfect for
multiple IEC 60320 jumper
cords for smooth integration.
The transition from steel bushings to Vesconite
Country-specific cord can be
Hilube has also mitigated the issue of terminated with an IEC 60320
accelerated wear on shafts caused by metal- connector such as a C13 or
on-metal friction. C19 to mate with a C14 or C19
outlet in the APS. Now you can
found. Operators are encouraged Vesconite Bearings, the supplier of plug IEC 60320 jumper cord
to clean the machines before and the bushings, has been ongoing for sets into the APS to power
after shifts, but where this does not several years, facilitating continuous multiple devices—the jumper
occur, maintenance challenges are improvement in bushing design and cord sets contain IEC 60320
increased and are more effectively performance. With each iteration, the plug connectors on one end
managed where Vesconite Hilube bushings have become increasingly and IEC 60320 connectors on
the other.
bushings are in place. snug on the shaft, promising further
The transition from steel bushings machine efficiency and reliability
to Vesconite Hilube has also enhancements.
mitigated the issue of accelerated The brick-making machine
wear on shafts caused by metal- supplier acknowledges the varying
on-metal friction. In the past, this degrees of wear experienced on
wear and tear necessitated shaft their clients' machines, depending on
replacements, incurring additional usage and maintenance practices. ®

costs and operational disruptions. However, the company reports

With Vesconite Hilube in place, no bushing-related issues since ®

the brick-making machine supplier Vesconite Hilube bushings were

anticipates improving the durability of introduced. DW Toll-Free Phone: (800) 662-2290
both bushings and shafts, translating E-mail: info@interpower.com
into long-term cost savings and Business Hours:
enhanced operational efficiency. 7 a.m.–5 p.m. CST
Vesconite Bearings
Collaboration between the
brick-making machine supplier and
vesconite.com Order Online!
www.interpower.com

DESIGN WORLD www.designworldonline.com August 2024 15

design notes - DW 08-2024 v4 final.indd 15 7/29/24 9:28 AM

 Design Notes
BY EMMA WOOD • GLOBAL PRODUCT MANAGER FOR NON-ULTRASONIC TECHNOLOGIES • EMERSON

What is quasi-simultaneous
laser welding?
Laser plastic welding continues to heat at the interface between the two trace a beam of laser energy along
grow in popularity worldwide because it parts that melts the plastic. Then, with the contours of the weld joint in a
provides a unique range of capabilities the help of controlled compressive continuous, closed loop. The heating
and benefits: gentle and vibration-free force, the softened part surfaces are effect on the plastic is very rapid but not
joining, particle-free cleanliness and brought together, and the weld is simultaneous, hence the name “quasi-
precision fluid paths, strong bonds with completed. Laser welds are clean and simultaneous.”
hermetic seals, exceptional aesthetic particle-free, with hermetic seals and an While simultaneous laser welding
appearance, and the versatility to bond excellent aesthetic appearance. is well-suited to high-volume,
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16 August 2024 www.designworldonline.com DESIGN WORLD

design notes - DW 08-2024 v4 final.indd 16 7/29/24 9:28 AM

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DESIGN WORLD www.designworldonline.com August 2024 17

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 Motion Control

t AVOIDING COMMON
ISSUES WHEN TUNING AN
s INVERTER TO AN ELECTRIC
MOTOR
A little knowledge of some key factors and potential
issues can help smooth the process of tuning an
inverter to an electric motor.

PATRICK BERKNER, SYSTEMS APPLICATION ENGINEER

JONAH LEASON, ELECTRIFICATION PRODUCT MANAGER
KAMAL T. WOLLY, SENIOR SYSTEMS ENGINEER
PARKER HANNIFIN

WITH more companies attempting

to electrify their equipment,
a common challenge is properly tuning
Control modes are key tools in
optimizing the tuning process for a
specific application and represent the
an inverter to an electric motor. To method used by the inverter to correct
save time and create efficiency in a performance error of the electric
this transition, it’s important to give motor. The appropriate control mode
proper consideration to a number of chosen is based on the motor type
factors when tuning an inverter to an required for either a traction or work
electric motor. These include control function. Other contributing factors
modes and limit functions, knowing include the specific application use and
the different types of tuning (current, the machine’s architecture. Here’s a
velocity/speed loops, voltage), being review of some of the more common
familiar with some common tuning control modes.
issues associated with the power
source and/or mechanics, and how Speed control
tuning is evolving into automation. In an ePump application, the control
mode would most likely be speed or
Control modes velocity mode. This means the input
When looking into purchasing an command will control the motor speed.
electric motor and inverter system, A motor’s speed control mode
many parameters must be investigated, provides a narrow window of The heart of Parker’s electrified
portfolio includes PMAC electric motors
including the required system control acceptable speed, affecting the paired with mobile inverters optimized
mode. rotational speed of the motor, and for efficiency and functional safety.

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 it’s also an efficient method to manage
motor output.
In speed control mode, the speed
loop’s proportional and integral (PI)
controls adjust the motor’s torque
demand, ensuring the measured motor
speed matches the commanded speed.
The controller first calculates a speed
error (speed demand minus speed
feedback), which is then fed to the speed
loop PI regulator.

Torque control
A vehicle traction operation usually
involves torque mode. Similar to how
an automobile operates, pressing the The graph shows the optimal
accelerator applies torque to the wheels. current loop tuning result with
The more the accelerator is pressed, a 2 msec rise time.
the more torque is applied, making
the vehicle go faster. Releasing the
accelerator makes the vehicle coast.
In “Torque Control” mode, the speed
loop’s PI regulator is inactive. However,
when stopping the inverter while in In the graph, speed loop
“Torque Control” mode, the inverter tuning is shown, with the Kp
automatically switches to “Speed and Ki parameters adjusted to
Control” mode and ramps the motor to minimize over/undershoot of
zero speed. velocity feedback.
“Torque Control” mode often has
a speed limiter feature which reduces
the torque limit to zero if the motor
speed exceeds the set speed limit. This
prevents motor acceleration beyond
these speeds.
It’s highly recommended to set the
control limit to ensure the torque does
not exceed any system component’s
torque limits.

Vdc control mode

If the system must generate electrical
power, then Vdc control mode is A positive torque demand for a required for either a traction or work
selected. In applications that require positive motor speed controls the flow function. Other contributing factors
“Vdc Voltage Control” mode, the electric of energy from the inverter dc link include the specific application use
motor is driven from an engine (such as to the externally powered devices, and the machine’s architecture.
an internal combustion engine), which thus reducing the dc link voltage. A
provides mechanical energy to the negative torque demand for a positive Limit functions
electric motor controlled by the inverter. motor speed will control energy Limit functions are a series of
In “Vdc Voltage Control” mode, into the inverter dc link from the functional blocks for motors and drives
the inverter automatically controls the motor (regenerating operation), thus that work together to provide a final
motor’s torque demand to ensure that increasing the dc link voltage. current/torque limit at the motor’s
the measured Vdc bus voltage (feedback) The appropriate control mode output. In addition to these functional
matches the Vdc voltage demand. chosen is based on the motor type blocks, current and torque limits

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 Motion Control

are internal protection methods with

user-settable limits. Current and torque
limiting is used to protect the inverter,
motor, and the system components.
There are two types of current limits:

Nominal voltage current limit

In an electric motor, the current limiting
is derived first before being converted
into a torque limit. Current limiting
commonly occurs automatically to Block diagram
protect the inverter and motor. of a typical
control loop
Current limits are based on the
showing the
temperature of the inverter, output command
switching frequency, output electrical inputs and
frequency, and the rated device feedback loops.
current. The output of this function is
the maximum amount of continuous make an optimally tuned velocity loop Tuning the velocity loop consists of
current that the inverter can produce at impossible. adjusting the Kp and Ki to reduce any
any moment in time. It may be read as For systems that are run in torque speed overshoot upon the release of
a diagnostic if the commanded motor control, with no speed limit, it’s only pump press and any speed decrease
output is not attainable due to inverter necessary to tune the current loop. due to the rapid application of
device limitations. In this scenario, be careful the motor hydraulic pressure.
does not run to its maximum possible With velocity loop tuning, Kp is used
DC voltage current limit motor speed, resulting in a run-away to reduce the over- and undershoot of
DC voltage current limit and motor condition. Finally, when tuning a the motor velocity, and Ki is used to
temperature current limits are traction system with a speed limit, a reduce the amount of time it takes to
configurable by the user and controlled tuned velocity loop is required. recover from a velocity under- or over-
to a performance band defined within shoot condition.
the system hardware capability. The Current loop tuning When the Kp and Ki parameters
battery management system can To adjust the current loop in most are optimally set, any external forces
limit available current as well, as it is inverters, there are two parameters, applied to the motor will have little, if
responsible for providing available Kp, the proportional term and Ki, the any, change in velocity.
output current and input current integral term. As an example, with
(during regeneration). These limits can Parker’s GVI Inverter, Kp is used to Common tuning issues
also restrict the input/output current adjust the rise time of the waveform’s Common tuning issues associated
if either the dc voltage or the motor initial segment and Ki is used to adjust with tuning servo systems are typically
temperature are outside the operation the rise time of the second half of the associated with two main areas; the
limits set at system commissioning. waveform. The rise time signifies the power source and mechanics.
The current limiting’s output is an time it takes for the current to go from Frequent power source issues
important diagnostic, as the primary the inverter to the motor windings in include:
controller in any system will need to 2 msec.
know what the inverter is capable of at The ideal scenario is to adjust the • Not having a sufficient energy
any point in time. Finally, the primary Kpand Ki terms to achieve a current source
controller also needs to be aware if any rise time of 2 to 3 msec. This is • The battery management system
factors have resulted in a limitation of achieved by starting the Kp and Ki with (BMS) limiting the available
available performance. some initial values and then adjusting current, resulting in lower motor
to reach the ideal rise time. current or speed
Servo system tuning • Insufficient battery system
A servo system typically consists of Velocity/speed loop tuning voltage, resulting in limited motor
both a current and velocity loop. In this While tuning the velocity loop, the speed
system, the current loop must be tuned goal is to keep the motor velocity • Insufficient instantaneous reaction
first, followed by the velocity loop. In consistent and independent of the time of the dc power supply
fact, a poorly tuned current loop can shaft loading. relative to load spikes

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 Some common mechanical issues
include:

• Shaft loading awareness for the

different types of loop tuning
• Current loop tuning does not
require loads to be removed
• Velocity loop tuning should be
loaded for optimal results
• Compliance in the load train (chains,
gears, belts etc.) resulting in instability,
unnecessary vibrations and variations
in speed and torque signals
• Identifying differences in system
response times to reach an optimally
dampened loop
• Under-dampened loop in a
velocity mode can cause slow
oscillations “porposing”
• Over-dampened loop is rigid
with noticeable oscillations
or overshoot where the loop
appears unstable

The future of tuning

It’s likely that the days of manual tuning
demonstrated above are nearing the end.
Electric motor and inverter manufacturers
are creating the next generation of
FOR WHATEVER YOU’RE MAKING,

WE’LL DO
inverters that can automatically tune an
inverter to an electric motor. It’s now
possible to simply select the motor part

OUR PART.
number and the motor parameters, limits,
and tuning are loaded into the inverter for
the speed and current loop settings.
This level of optimization can save
valuable time and increase the efficiency of
an electrified system significantly such that PRECISION STAMPINGS, WASHERS,
it outperforms a traditional diesel system SPACERS & SHIMS. For over 100 years,
and, potentially, a motor and inverter from a nearly every industry across the globe
combination of suppliers. has trusted Boker’s to provide quality
Due to the complexity of modifying components, world-class service and
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performance expectations. DW (800) -WASHERS bokers.com

Parker Hannifin
parker.com

DESIGN WORLD August 2024 21

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 Linear Motion

Hybrid steppers
Lisa Eitel • Executive Editor

in linear actuators
Stepper motors are
commonly used
in linear motion applications for their
has alternating north and south poles
parallel to the rotor shaft. These motors
are also called can-stack or tin-can
step, or microstepping modes for higher
resolution. Permanent magnet stepper
motors have higher torque capabilities
precise positioning capabilities and motors because their stators consist of than variable reluctance types we’re
good holding torque. Though the basic two coils contained in soft iron housings about to cover, but at limited speeds
operating principle is the same for all (so-called cans) with teeth on the … so they’re best for applications that
stepper motors, there are differences inside that interact with the rotor. Refer require low to moderate torque at low
in operation and performance between to linearmotiontips.com for a deeper speeds.
the three primary types — permanent dive on linear actuators based on this
magnet, variable reluctance, and hybrid. stepper-motor type. Variable reluctance stepper motors
Permanent-magnet steppers typically Variable reluctance stepper motors have
Permanent magnet stepper motors have a step angle of 3.6° (100 steps the simplest construction out of all three
Permanent magnet stepper motors per revolution) although models are stepper-motor types. They include a
have a permanent magnet rotor that available with 1.8° step angles. These nonmagnetic toothed rotor made of soft
is axially magnetized — meaning it motors can operate in full-step, half- iron as well as a wound electromagnetic

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 stator. Because the rotor is not magnetized, there’s no therefore produce higher torque than permanent magnet or
attraction between the rotor and stator when the windings variable reluctance designs. Hybrid stepper motors can also
aren’t energized — so variable reluctance motors don’t achieve step angles as small as 0.72° in full-step mode and
produce detent torque. operate at higher speeds than other designs.
Their dynamic torque production is relatively low, Although proprietary designs and production methods
but variable reluctance stepper motors have less torque let manufacturers optimize the torque output (as well as step
dropoff at higher motor speeds. That means for moderate accuracy and speed characteristics) of their hybrid stepper
to high-speed applications, they are often a better choice motors, torque production is still closely tied to the frame size
than permanent-magnet designs. One caveat: Variable of the motor.
reluctance stepper motors are notoriously noisy, so are Stepper motors generally adhere to the NEMA ICS 16-
unsuitable for applications for which quiet operation is a 2001 standard for frame sizes, which specifies mounting
design objective. dimensions such as flange size and bolt circle diameter.
However, one dimension not covered by the NEMA standard
Hybrid stepper motors is motor length. And this flexibility in motor length for a given
Many NEMA stepper linear actuators have at their core frame size provides manufacturers with another option
hybrid stepper motors. These electromechanical linear for increasing the torque production of a particular NEMA
devices leverage the way in which hybrid stepper motors size stepper motor — by creating motors with longer stack
impart simple and efficient operation. lengths. For example, double- and triple-stack stepper motors
A combination of permanent magnet and variable are now common offerings from several manufacturers.
reluctance designs, hybrid stepper motors have a Double and triple-stack hybrid stepper motors simply have
permanent-magnet toothed rotor made from two multiple rotors and stators, stacked end-to-end. With multiple
sections or cups that are opposite in polarity — with rotor and stator sections, the motor can produce more torque
teeth arrays that are radially offset from each other. The without the need to increase the frame size. Only the length
electromagnetic stator is also toothed. The rotor teeth of the motor increases. (Note that a few manufacturers also
help guide the magnetic flux to preferred locations in the produce quad-stack stepper motors.)
air gap … and that in turn improves their holding, dynamic, However, in double- and triple-stack (and quad-stack)
and detent torque when compared to those of permanent stepper motor designs, torque falls off faster as speed
magnet and variable reluctance stepper-motor types. Longer lasting Belts, HEHT Split Spools -- no regrind wide_Layout 1 8/22/2023 6:05 PM
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Double and triple-stack hybrid stepper motors

Of the three primary stepper motor designs — permanent
magnet, variable reluctance, and hybrid — hybrid stepper
motors are arguably the most popular in industrial
applications. Hybrid stepper motors are constructed with
a rotor made of two sections or cups with a permanent
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linear mc feature - DW 08-2024 v3 final.indd 23 7/29/24 9:35 AM

 Linear Motion

increases than it does in single-stack helps reduce or avoid resonance and Note that NEMA stepper-based linear
designs. This is because the added oscillations. actuators from some manufacturers are
rotor and stator sections also increase specifically designed for power density
the motor’s inductance. And higher How hybrid motor version affects — with motor features to yield up to
inductance means the electrical time linear-actuator choice 50% more force (and better precision)
constant of the motor — the amount of Specifying a hybrid-stepper linear than comparable linear actuators from
time it takes the current in the windings actuator includes steps generally competitors. That’s especially useful in
to reach 63% of its maximum value applicable to any motor-driven screw- laboratory and medical equipment or
— is also increased. When a stepper based actuator. First, the design designs that are intended to be portable.
motor operates at high speeds, a high engineer should define required force, In some cases, a given series of
electrical time constant means there travel, and stroke speed for the axis one particular linear actuator can also
isn’t enough time for the current (and, in question — along with its target life sport stepper motors of one frame size
therefore, torque) to reach its maximum in stroke cycles. (Typical peak linear but various stack lengths to provide a
value at each motor step, resulting in a force ratings for NEMA stepper linear variety of holding torque capabilities
torque drop-off as speed increases. actuators range from 180 to 1,800 N.) … and higher linear force for longer
Another way to increase the torque Design values and supplier references stacks. Some linear-actuator suppliers
from a stepper motor without increasing yield rated force and predicted loss of even offer stepper motor options having
the NEMA frame size is to use a gearbox power beyond a given stroke count. different winding arrangements to satisfy
with the motor. The addition of a Required power in Watts or Joule/sec specialty linear-speed requirements. DW
gearbox increases the torque delivered depends on stroke length multiplied
from the motor to the load — and can by force divided by time allotted per
also provide better inertia matching stroke. In some instances, manufacturer-
between the motor and the load. Plus supplied performance charts can Linear Motion Tips
when connected to a gearbox, the motor help engineers more quickly identify linearmotiontips.com
can operate at higher speeds … which actuators meeting all the design criteria.

TWO TYPES OF LINEAR STEPPER MOTORS

LINEAR ACTUATOR BASED ON A
TAXONOMY A LOT LIKE THAT OF ROTARY STEPPER MOTORS
HYBRID STEPPER MOTOR

PHASE COIL

VARIABLE-RELUCTANCE
LINEAR STEPPER MOTOR

Linear actuators built around HYBRID LINEAR STEPPER MOTOR

hybrid stepper motors should not
be confused with hybrid stepper
linear motors or the pre-integrated
linear components (complete
MAGNET
with encoder feedback for servo PLATEN
operation) sometimes referred to
as hybrid stepper actuators.

ENCODER + MOTOR

HYBRID STEPPER LINEAR

POSITION CURRENT
ACTUATION CAN ALSO REFER TO A
COMMAND
TRAJECTORY LOOP CONTROL
CLOSED-LOOP STEPPER CONTROL
DRIVE

ACTUAL POSITION

24 August 2024 www.designworldonline.com DESIGN WORLD

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 AUGUST 2024
theautomatedwarehouse.com

A Supplement to Design World

A NEW KIND OF
COLLABORATION
IN THE

WAREHOUSE
Inside:
PAGE 26

A new kind of collaboration in the warehouse ................................... 26

Mitigate cybersecurity risk in the automated warehouse .............30
Preparing the warehouse automation plan ..........................................34

automated warehouse cover - DW 08-2024 v2 final.indd 56 7/22/24 1:37 PM

 AUTOMATED WAREHOUSE

k
to c
eS
ob
| Ad
UMass Amherst
designs a multi-
robot team that
shares situational
awareness.

A new kind of collaboration

in the warehouse BY STEPHANIE NEIL • EXECUTIVE EDITOR

The capabilities of collaborative

robots, commonly referred to
as “cobots,” could soon expand beyond
Agency (DARPA) Director’s Fellowship
and a U.S. National Science Foundation
Career Award, is led by Hao Zhang,
two main areas – group introspection
and cooperative competition, dubbed
“coopetition.”
direct human-robot interaction to include associate professor in the UMass Group introspection would allow
heterogeneous robots intelligently Amherst Manning College of Information robots in a team to be aware of all their
coordinating and interacting with each and Computer Sciences and director other team members, so they have a
other. of the Human-Centered Robotics Lab. shared situational awareness of the
New research from the University Zhang’s research on “autonomous group overall team’s capabilities. To accomplish
of Massachusetts Amherst is proving introspective learning and coopetition that, Zhang is modeling robots in a team
robots can be programmed to create for cross-capability multi-robot as a graph to enable group awareness,
their own teams and voluntarily wait adaptation,” uses lessons from the social and using conditional models that
for their teammates to execute a set of psychology of humans to help teams identify backup robots with similar
dependent tasks. This new multi-team of robots with different capabilities capabilities to replace failed teammates.
robot collaboration has the potential to work together and adapt to complex They are solving the competition
improve manufacturing and warehouse situations. aspect by simultaneously modeling
productivity. When Zhang was awarded the cooperation at the team level and
The research, funded by the U.S. DARPA prize last year to improve robot competition at the individual level.
Defense Advanced Research Projects teamwork, he was already focusing on Cooperation tackles tasks that are

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 THE INDUSTRY’S MOST
COMPREHENSIVE AMR FLEET
Autonomously transport materials up to 4,200 lb with the industry’s most
comprehensive autonomous mobile robots and fleet management software.

$1.5M 6x 11 month
saved in the first year throughput increase customer payback period
at an aerospace facility at a CPG facility at an automotive facility

www.ottomotors.com

rockwell – AW 08-24.indd 5 7/29/24 9:43 AM

 AUTOMATED WAREHOUSE

infeasible for individual robots to solve,

while competition encourages each
“There’s a long history
robot to perform better and adapt faster. of debate on whether we
Multi-robot mix and match
want to build a single,
In a warehouse setting there may be powerful humanoid robot
many different types of robots and
payload capacities: fixed in place robotic that can do all the jobs, or
arms, mobile automated guided vehicles we have a team of robots
(AGVs), heavy-lifting palletizers, etc.
The challenge, however, is coordinating that can collaborate”
a diverse set of robots for a common
purpose. with a graph attention transformer
“There’s a long history of debate network (GATN) that computes rewards
on whether we want to build a single, for scheduling tasks to robots. LVWS
powerful humanoid robot that can do all includes nodes (robots) and edges
the jobs, or we have a team of robots (communication, relationships, or spatial
that can collaborate,” stated Zhang. positions).
“Robots have big tasks, just like humans. According to the multi-robot research,
For example, [if] they have a large box collaborative scheduling is formulated
that cannot be carried by a single robot, as a bipartite matching problem where
the scenario will need multiple robots to robots are assigned to tasks. These
collaboratively work on that.” tasks are put into a GATN that integrates
The other behavior is voluntary graph attention networks to encode the
waiting. “We want the robot to be able to local graph structure and transformers to
actively wait because, if they just choose encode contextual information.
a greedy solution to always perform The resulting outputs are
smaller tasks that are immediately embeddings for each node, as well as
available, sometimes the bigger task will global embedding for each graph which
never be executed,” Zhang explains. are used to compute a reward matrix
As a solution, Zhang created a used to perform bipartite matching.
learning-based approach for scheduling To test their LVWS approach, the
robots called learning for voluntary research team gave six robots 18 tasks
waiting and subteaming (LVWS) coupled in a computer simulation and compared

Group introspection and cooperative

competition enables multi-robot teams
to collaborate. | UMass Amherst

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 Hao Zhang Williard Jose

their LVWS approach to four other Jose responds by describing this

methods. In this computer model, scenario: There are three robots — two
there is a known, perfect solution for that can lift four pounds each and one
completing the scenario in the fastest that can lift 10 pounds. One of the small
amount of time. The researchers ran the robots is busy with a different task and
different models through the simulation there is a seven-pound box that needs to
and calculated how much worse be moved.
each method was compared to this “Instead of that big robot performing
perfect solution, a measure known as that task, it would be more beneficial
suboptimality. for the small robot to wait for the other
The comparison methods ranged small robot and then they do that big
from 11.8% to 23% suboptimal. The new task together because that bigger robot’s
LVWS method was 0.8% suboptimal. resource is better suited to do a different
“So, the solution is close to the best large task,” Jose explained.
possible or theoretical solution,” said Zhang hopes this work will aid
Williard Jose, an author on the paper and the progress of developing teams of
a doctoral student in computer science at heterogeneous robots, particularly as it
the Human-Centered Robotics Lab, in a relates to the scalability of large industry
statement. environments that require specialized
The team has also demonstrated this tasks. AW
method running on real-world robots.

Worth the wait

A common question the research team
has received is, “How does making a
robot wait make the whole team faster?”

Scan the QR code to watch a demonstration of the LVWS

method in a manufacturing assembly case study run in a
Gazebo simulation or visit:
www.youtube.com/watch?v=zslbOXQXtSI

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 AUTOMATED WAREHOUSE

Mitigate
cybersecurity
risk
in the
automated
warehouse
How to recognize threats, track critical data, and train employees.
BY STEPHANIE NEIL • EXECUTIVE EDITOR

The warehouse is integral to the

manufacturing supply chain.
As such, with cybersecurity threats on
McKinsey has identified three
cybersecurity trends that represent the
biggest threat now and in the future:
With these trends in mind, it’s
important to understand how to
mitigate risks.
the rise, there’s an urgent need to adopt • On-demand access to ubiquitous data To get a better understanding
best practices that will ensure that the and information platforms. Recent of the actions needed to protect
warehouse doesn’t become the weakest shifts toward mobile platforms and the automated warehouse, Locus
link in the supply chain. remote work require high-speed Robotics outlined some best practices.
As more automation makes its way access to ubiquitous, large data The company makes autonomous
into warehouses and more assets are sets. This dependency exacerbates mobile robots (AMR) for fulfillment.
integrated, there is a pressing need the threat of a breach. And since In June, it received the 2024
to safeguard the digital and physical organizations collect more data about Fortress Cybersecurity Award in
infrastructure. This is especially urgent their customers, such a breach could the Compliance category from the
since cybercriminals are crafty and be costly. Business Intelligence Group.
could use an opening in a warehouse as • Hackers are increasingly using artificial Locus specified three areas of
a backdoor into a partner’s network. intelligence to launch sophisticated importance: understanding the threats,
For example, in February 2023, attacks. Attackers using advanced capturing the data, and training the
Applied Materials, a semiconductor tools such as AI, automation, and workforce.
technology supplier, was reportedly the machine learning could cut the end-to-
victim of a cybersecurity incident that end life cycle of an attack from weeks Bad actors vs. bad decisions
originated from a ransomware attack on to days or even hours. Cybercrime is growing and is
one of its suppliers. That incident cost • The growing regulatory landscape descending upon unsuspecting
Applied Materials $250 million in its and continued gaps in resources, businesses from all directions. There
second quarter that year. knowledge, and talent. Many are nation-state adversaries that pose
No warehouse or fulfillment center organizations don’t have enough a national security risk in the form of
wants to be a catalyst for cyber cybersecurity expertise. The shortfall advanced persistent threat activity
catastrophe. Yet, staying safe is not is growing as regulators increase (APT) aimed at targeted and prolonged
easy, as malicious actors are finding their monitoring of cybersecurity in network intrusion. There is malware,
new ways to infiltrate organizations. corporations. phishing, and ransomware, which are

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 Solutions for
Automation and
Robotics

the most common forms of attacks on However, other threats are already
business, and, as seen in the Applied penetrating the plant and warehouse.
Materials example, can be costly. “Artificial intelligence, I think, is a big
And then there are the employees security risk,” Khalil said.
who make mistakes – such as plugging The cybersecurity risks
a virus-infected USB drive into a system. associated with generative artificial
Or simply taking a call from the wrong intelligence (GenAI) in warehouses
person. The data breach at MGM can be broadly categorized into data
Resorts in September 2023 that shut breaches, system vulnerabilities, and
down electronic payments and casino compliance challenges. | Pneumatic | Mechatronic
machines was initiated by a hacker While GenAI may boost Grippers Grippers
group impersonating the IT staff, gaining productivity and enhance decision-
access to systems via a call to an making, its integration into robotics
employee. and other systems exposes
Fouad Khalil, senior director for new potential attack vectors for
enterprise security, risk, and compliance cybercriminals.
at Locus Robotics, is a member of a “The data that powers GenAI
| Robotic Quick | Inductive
group called InfraGard, a national non- — often sensitive and proprietary
Change Systems Coupling
profit organization that has formed a — can become a target,” said Khalil. Systems
partnership between the Federal Bureau “Moreover, the interconnected
of Investigation and the private sector nature of modern warehouses means
to educate and share information on a breach in one area can have
security threats and risks. As an InfraGard cascading effects throughout the
member, he has access to timely insight entire operation.”
on threats to critical infrastructure, To that end, the cybersecurity
Learn more today.
providing the knowledge and resources risks associated with this technology 847-215-0591
to not only protect Locus Robotics, but should be considered and steps smw-electronics.com
also its customers. taken to mitigate risk. (see sidebar).

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 AUTOMATED WAREHOUSE

Follow the data

While GenAI uses data, robots
generate it. To secure that data
throughout the warehouse, it has to
be tracked.
“When you follow the data,
you understand where it is stored,
how it is transmitted, how it is
processed, and you have sufficient
controls over those data elements
Intelligent Pallet Systems to make sure that it’s protected,”
Khalil said. “And if it’s not protected,

Built For Capacity, Speed, & Accuracy then [you have to figure out] what
action you can take to mitigate
the risk.”
One way to mitigate the risk
is to create a barrier, which is
what Locus Robotics does with
its secure tunnel of encrypted
data used to share information.
But constant infrastructure
changes in a warehouse can
affect the environment. Adding
a network node or allowing an
OEM access into the network, for
example, could open the door to
unauthorized network access.
“It sounds simple, but it's a lot
of complexity that comes into play,”
said Khalil.
While Locus Robotics builds
AMRs, they are just one piece
of the solution. According to the
Wilmington, Mass.-based company,
it has designed its navigation
software with measures to protect
customers’ proprietary data.
“It's a one-stop shop/black-
box secure solution that gets
deployed to a warehouse that
offers the cloud reporting, the on-
premises reporting, the robotics,
services, operational efficiencies,
connectivity for the network, and
everything else that comes into
play to make it effective and more
productive,” Khalil explained. “That
black-box approach is what we
deliver, and security comes through
www.dornerconveyors.com that entire lifecycle, from start
to end.”

32 DESIGN WORLD

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 Awareness must be raised for awareness training is a critical part
security of keeping the warehouse safe from
Khalil emphasized that security is cyber threats. “Especially given the
Solutions for
everyone’s responsibility – from the fact that employees are your front line Automation and
robot provider to the management of defense, they must be always kept Robotics
team to the engineers and the up to date on all things security,” Khalil
operators in the warehouse. With said.
all these different people in the mix, And it's not just about training Our innovative automation
education is imperative. your employees to be cybersecurity- systems will help you
“The first challenge that you find aware, but also training everyone in maximize productivity,
in our industry is awareness and the partner ecosystem. To ensure a reliability and profitability.
acceptance that there is a risk,” he safe environment in the warehouse
– Process automation
said, noting the shared responsibility and beyond, the entire supply chain
model is important to understand. needs to embrace cybersecurity best – Mechatronic drives
“Every time we deploy our solution to practices. AW – Reduced CO2 footprint
a warehouse, we are accepting the
– Reduced energy consumption
risks that they're experiencing.”
Shared responsibility should be Locus Robotics
reflected throughout the ranks of locusrobotics.com
an organization, as well. Security

Mitigate Your Cybersecurity Risks

According to Locus Robotics’ Fouad Khalil, the cybersecurity challenges

of integrating GenAI into warehouse operations are significant, but not
insurmountable. Here are some ways to safeguard warehouse operations:
• Conduct a comprehensive risk assessment: Begin with a thorough
assessment of the cybersecurity risks associated with implementing
generative AI. Understand where vulnerabilities may exist and how | Inductive | Digitized
they can be exploited. Coupling Systems Workholding
• Use robust data-protection measures: Implement state-of-the-art Energy + Signals Hybrid / Electric
encryption, access controls, and data anonymization techniques to
protect sensitive information from unauthorized access.
• Regularly update systems and manage patches: Keep all systems,
including AI algorithms and connected devices, updated with the
latest security patches to close any vulnerabilities that could be
exploited by attackers.
| Sensor | PLC Safety +
• Train employees: Educate your workforce about the potential
cybersecurity risks and best practices for preventing breaches. A well- Systems Hardware
Components
informed team is your first line of defense against cyber threats.
• Have an incident-response plan: Develop a comprehensive incident
response plan that outlines steps to be taken in the event of a
cybersecurity breach. This should include procedures for containing
the breach, assessing the damage, and communicating with
stakeholders.
• Collaborate with AI vendors: Work closely with your GenAI
vendors to ensure they adhere to rigorous cybersecurity standards.
Understand their data handling and storage practices, and ensure Learn more today.
847-215-0591
they align with your security requirements.
smw-electronics.com

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 AUTOMATED WAREHOUSE

Preparing the
warehouse
BY CHRIS VAVRA • SENIOR EDITOR

automation plan
Consider this five-step strategy for a successful
move away from manual processes.

The warehouse industry has

transformed from its dire
state 20 years ago, to an exciting era
promise significant benefits, reflecting
continuous industry evolution.
Christoph Buchmann, sales
which are fueling the growing trend
toward automation and data exchange
in technology and processes.
driven by Industry 4.0. Automation, director at Movu Robotics, outlined Automation offers great potential
fueled by efficiency, drives global a five-step process for successful for manufacturers, Buchmann said
growth, especially in the United States. automation adoption. The steps during his presentation, “Mastering
However, newcomers to robotics need include change management, a robust the Path to Automation: A Roadmap
a solid warehouse automation plan, process review, software design for Successful Implementation” at
according to Movu Robotics, a maker emphasizing IT integration, hardware Modex in Atlanta earlier this year. “If
of shuttle systems and autonomous considerations, and meticulous you’re not thinking about automation
mobile robots (AMRs). implementation with worker training now, you should start,” he said.
Five current trends, including for long-term success.
e-commerce growth and workforce The warehouse industry was in a Five trends to consider in a
challenges, are driving warehouse terrible state 20 years ago, according warehouse automation plan
adoption of automation. Upcoming to Buchmann. Today, he said, it’s a Buchmann said five things are driving
trends like actionable data and very exciting time, thanks to the rise the acceleration of warehouse
robotics-as-a-service (RaaS) also of Industry 4.0 and other concepts, automation:

THE 5 PHASES OF TRANSITION

Movu Robotics presented

steps to a successful
warehouse automation
plan. | Chris Vavra,
WTWH Media

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 “The one thing you can Solutions for
expect is the unexpected” Automation and
Robotics
1. Greater efficiency and model to use robotics for their
profitability. It’s more cost- short-term needs rather than Non-contact transmission of
effective than ever to implement making the long-term investment both power and data offers
automation. right now.
2. Workforce development 5. Safety and sustainability. – Safe and fast data
changes. The worker shortage Keeping workers and facilities communication via
remains a major challenge for safer has always been a priority, Ethernet Signals (Profinet,
employers. but now companies are trying to Ethernet IP, etc.)
3. Rising cost of real estate. reduce energy costs. – High energy transmission
Rather than build new facilities, (up to 400 Watts)
companies are trying to make Five steps to moving from a manual
more of what they have. to an automated process – Totally wear and
4. E-commerce growth. The Buchmann said there are many maintenance free
COVID-19 pandemic was among benefits automation can bring, such
the factors forcing changes as better efficiency and throughput, F180
Inductive
in consumer behavior and higher profitability, better safety, and Coupler
expectations for faster order improved accuracy. However, he
fulfillment. acknowledged that it isn’t as easy as
5. Food supply. The food and pushing a button.
beverage industry has been Buchmann described a five-
using automation even more to step process to transition from a
match consumer demand and manual process to an automated
keep costs down. one. The entire transition requires a
culture change, he said, and taking
While these trends are fueling ownership and trusting in your
automation’s growth now, Buchmann partners and employees is key.
| Inductive | Linear
said five more trends are coming that Management might approve,
Coupling Systems Positioning
will have just as big an impact: but the workers are the ones who (Energy + Signals) Systems
1. Actionable data. There is will make a deployment happen,
more data than ever, and the Buchmann added. It’s critical that the
technology has evolved to where plan be flexible throughout the entire
companies can take advantage. process.
2. Accelerating technology. “The one thing you can expect is
Advances in machinery, software, the unexpected,” he said. | USP-Ultrasonic | PLC Safety +

and now artificial intelligence are Positioning Hardware

Measuring Components
continuing. 1. Change management System
3. Entry-level automation. Putting people, particularly those who
Buchmann said automation will be most affected, in a leadership
was big and complex 20 years role is critical. Buchmann said people
ago. That has changed. Now, are naturally reluctant to change,
robots are more scalable, more and they need to be persuaded. He
affordable, and less complicated. said doing this with a heavy hand
4. RaaS. Robotic fleets have grown and making people feel bad about
Learn more today.
in manufacturing facilities and what they’re doing wrong right off the 847-215-0591
small-to-midsize enterprises bat will shut down the conversation smw-electronics.com
(SMEs) are turning to the service before it even begins.

DESIGN WORLD www.designworldonline.com August 2024 35

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 AUTOMATED WAREHOUSE

WHAT’S DRIVING THIS ACCELERATION?

Five current and future trends

are driving automation growth in Gathering the right data requires an transition designed to achieve?” he said.
warehouse facilities. in-depth data analysis of the information It’s also worth looking at an alternative
| Chris Vavra, WTWH Media most important to the operation and analysis and determining what is the
creating models that illustrate a full view cost or risk of not automating.
of the four walls within an operation. From there, the plan can move
He said the trick is to encourage It can also help uncover the nuances forward with a business case that
them by highlighting what they’re that make each corporation unique and provides a thorough and detailed
doing well and lowering their provide a foundation to build success, roadmap for success.
emotional barriers to new ideas. said Buchmann.
“You’ll be surprised how quickly He recommended that companies 3. Software design
they’ll buy in,” Buchmann said. follow these three steps during the Buchmann said companies should
“Workers want to shine.” process review and design: not underestimate the importance
By building on those small wins Assess current operations. Conduct of IT integration because the most
and having them own the new a thorough analysis of warehouse common reason for failed automation
processes and technology, it’ll be processes, workflows, and technologies implementations is lack of it.
easy to get buy-in on the ground and consider future needs. It’s a little more complicated
floor, which is where change Set clear objectives. Define specific because warehouse software can have
management starts. goals for warehouse automation and overlapping functions and no fixed
2. Process review and design establish key performance indicators function divisions. That means each IT
Buchmann said developing a strong (KPIs) and targets to measure the landscape of a warehouse is different.
plan is critical because it needs to implementation’s success. Companies need to find the right
improve upon what is already being Educate yourself. Buchmann said set of functions to successfully fulfill
implemented. Having the right data is people involved in the project should operational needs.
critical to success, and any potential engage with vendors and technology Getting the automated interface
solution is only as good as the data experts as well as evaluate the latest right and using a digital twin, which is
that goes into the design. Developing automation technologies to find an emulation and virtual replica of a
an automation plan on bad data or a successful examples. real-life system, also can help as a tool
bad process is only going to lead to a It’s important to answer key questions to drive improvements in warehouse
bad automated process, he said. such as “What is the automation productivity and efficiency.

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 4. Hardware design
There are many types of automation equipment used in warehouse
facilities. The four most common are:
1. Mobile robots
2. Automated storage and retrieval systems (ASRS)
3. Conveyor and sortation systems
4. Stationary and collaborative robots.

Buchmann explained that there are many operational needs and

priorities to consider, such as whether the facility should be semi-
automated or fully “lights out.” It’s also worth asking about operational
redundancy, adaptability, and scalability during the process.
Whatever the case, a thorough analysis is a must because
mismatched technologies lead to inefficiencies.

5. Implementation and support

Low Friction Polymers
Now the real physical work starts, said Buchmann. The good news is Heat Sealing Tapes
everything is all set because KPIs were already established. Masking Tapes
The commissioning and implementation process should cover
the fundamentals, such as testing everything at all levels and doing
Release Fabrics
performance tests beforehand. Worker training is also critical for a Silicone Rubber
warehouse automation plan to be successfully executed.
It won’t be a perfect process and it shouldn’t be, but the issues will Types of Products
be minor, Buchmann said, as long as people know how to react. “Minor • PTFE made
problems can cause downtime if you’re not trained for them,” he said. with Teflon®
People are at the heart of the process, and companies that realize
Fluoropolymers
and value their workers’ potential and take the time to develop a strong
process will come out ahead in the automation race. It’s one they can’t • Kapton® Polyimide
afford to lose as it becomes more than a “nice to have,” like it was 20 • PEEK
years ago. Now, a warehouse automation plan is a necessity. AW • Nylon® 6/6
• ULTEM® PEI
Christoph Buchmann, • Mylar®
sales director at Movu • PVDF
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how to adopt warehouse • UHMW
automation in Atlanta. |
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 ADVERTORIAL

Unleashing Efficiency: The Dynamic

Duo of Conveyors and Robotics in
Modern Warehousing
In the dynamic landscape of modern into existing conveyor systems. With a time inventory checks. Conveyors
warehousing, the integration of robust design, increased weight rating, efficiently transport these robotic
conveyors and robotics has emerged extended widths, and a low-profile platforms, enabling swift and accurate
as a game-changer, revolutionizing aluminum frame, the 2700 series is updates to inventory levels. This
how facilities meet goals of throughput ideal for applications that require both synergy ensures that warehouses
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Looking Forward: The Future of
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Robotics, equipped with advanced ensure unparalleled quality control evolve, the integration of conveyors
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Dorner conveyors specifically act systems, Conveyors contribute accurate, and responsive supply chain
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(AMRs) and robotic arms have processes. Robots navigate the
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38 August 2024 www.designworldonline.com DESIGN WORLD

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 ADVERTORIAL

The Data Driven Warehouse

How real-time data collected at every touch point smooths out operations
Emerging technologies are revolutionizing What is lacking in today’s supply chain With data and AI/ML, digital twins can
supply planning, enhancing supply chain strategies? continuously evaluate supply chains and
efficiency, agility, and resiliency. Real-time Supply planning today involves technology, networks, informing businesses in an
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• Business disruptions and market and efficiency by learning from both
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DESIGN WORLD www.designworldonline.com August 2024 39

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parvalux – DW 01-24.indd 5 7/31/24 2:39 PM
 A Supplement to Design World • August 2024 www.therobotreport.com

REALTIME ROBOTICS COLLABORATES ON

MOTIONWITHPLANNING
PAGE 42

MITSUBISHI ELECTRIC
Inside:
RealTime Robotics Collaborates on motion planning with Mitsubishi Electric ....................................42
Stanford researcher discusses UMI gripper and diffusion AI models ................................................... 50
Siemens introduces high-inertia 1FK7-HI servo motors ...............................................................................54

cover - RR 08-2024 v1.indd 111 7/22/24 1:35 PM

 Realtime Robotics
demonstrates a multi-
robot workcell during
Mitsubishi Electric’s visit.
| Eugene Demaitre

Realtime Robotics collaborates on

MOTION PLANNING with Mitsubishi Electric

EUGENE DEMAITRE • EDITORIAL DIRECTOR • ROBOTICS

BOSTON — As factories and

warehouses look to
automate more of their operations, they
Robotics (RTR). “We’re planning with
Mitsubishi Electric to put our motion
planner into its CNC controller.”
Mitsubishi, that was able to optimize
motion as desired in seconds.
“Mitsubishi Electric is a multi-
need confidence that multiple robots The company recently received business conglomerate, a technology
can conduct complex tasks repeatedly, strategic investment from Mitsubishi leader, and one of the leading suppliers
reliably, and safely. Realtime Robotics Electric Corp. as part of its ongoing of factory automation products
has developed hardware-agnostic Series B round. Realtime Robotics said worldwide,” said Dr. Toshie Takeuchi,
software to run and coordinate industrial it plans to use the funding to continue executive officer and group president
workcells smoothly without error or scaling and refining its motion-planning for factory automation systems at
collision. optimization and runtime systems. Mitsubishi. “I see this partnership as
“The lack of coordination on the In June, a high-ranking delegation the perfect point where experience
fly is a key reason why we don’t see from Mitsubishi Electric Co. (MELCO) meets innovation to create value for our
multiple robots in many applications visited Realtime Robotics to celebrate customers, stakeholders, and society.”
today — even in machine tending, the companies’ collaboration. RTR She and Howard answered the
where multiple arms could be useful,” demonstrated a workcell with four robot following questions from The Robot
said Peter Howard, CEO of Realtime arms from different vendors, including Report:

42 August 2024 www.therobotreport.com THE ROBOT REPORT

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 Mitsubishi Electric, Realtime
Robotics integrate technologies

How is Realtime Robotics’ motion-

optimization software unique? How
will it help Mitsubishi Electric’s
customers?

Takeuchi: Realtime Robotics’ software

is unique in many ways. It starts with
the ability to do collision-free motion
planning. From there, the motion
planning in single robot cells as well as
multirobot cells can be automatically
optimized for cycle time. MELCO’s Dr. Takeuchi changes
Our customers will benefit by optimization parameters during
optimizing cycle time to improve RTR demonstration by Kevin
production efficiency and reducing the Carlin, chief commercial officer.
| Realtime Robotics
amount of engineering efforts required
for equipment design.
plan, enabling hundreds of thousands technology into our 3D simulator to
Howard: Typically, to provide access of motions in a couple of hours. It’s like significantly improve equipment and
for multiple tools at once, you need an Google Maps for industrial robots. system design.
interlocked sequence, which loses time. Our plan is to incorporate this
According to the IFR [which recognized Does Mitsubishi have a timeframe technology into our FA control
the company for its “choreography” in mind for integrating Realtime’s systems, including PLCs and CNCs,
tool], up to 70% of the cost of a robot is technology into its controls for and this integration is currently under
in programming it. factory automation (FA)? When will development and testing, with a launch
With RapidPlan, we automatically they be available? expected soon.
tune for fixed applications, saving time.
Our cloud service can consume files Takeuchi: We are starting by integrating Howard: We’re currently validating
and send back an optimized motion RTR’s motion-planning and optimization and characterizing for remote

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 optimization with customers. We’re
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In the demo cell, you couldn’t easily
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Mitsubishi Electric recently launched

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Realtime Robotics CEO Peter Howard Takeuchi: Yes, they are. Our robots
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 Howard: For example, Sony uses increasing throughput and optimizing could plan for the motion of both the
Mitsubishi robots to manufacture floor space. AMR [autonomous mobile robot] and
2-cm parts, and we can get down to By implementing collision-free the arm.
submillimeter accuracy if it’s a known motion planning, we help our customers
object with a CAD file. reduce the potential for collisions, Mitsubishi strengthens partnership
Cobots are fine for larger objects thereby reducing losses and improving
and voxels, but users must still conduct overall performance. Do you expect that the addition of
safety assessments. a member to Realtime Robotics’
Howard: It’s all about shortening cycle board of directors will help it jointly
RTR optimizes motion for multiple times and avoiding collisions. In Europe, plan future products with Mitsubishi
applications energy efficiency is increasingly a Electric?
What sorts of applications or use priority, and in Japan, floor space is at
cases do Mitsubishi and Realtime a premium, but throughput is still the Takeuchi: Yes. Since our initial
expect to benefit from closer most important. investment in Realtime Robotics,
coordination among robots? Our mission is to make automation we have both benefited from this
simpler to program. For customers like partnership. We look forward to
Takeuchi: Our interaction with and Mitsubishi, Toyota, and Siemens, the integrating the Realtime Robotics
understanding from customers suggest hardware has to be industrial-grade, and technology into our portfolio of
that almost all manufacturing sites so does the software. We talk to all the products to continue enhancing our
are continuously in need of increasing OEMs and have close relationships with next-gen products with advanced
production, efficiency, profitability, and the major robot suppliers. features and scalability.
sustainability. This is ideal for uses cases such
With our collaboration, we can as gluing, deburring, welding and Howard: RTR has been working with
reduce the robots’ cycle time, hence assembly. RapidSense can also be Mitsubishi since 2018, so it’s our longest
increasing efficiency. Multi-robot helpful in mixed-case palletizing. For customer and partner. We have other
applications can collaborate seamlessly, mobile manipulation, RTR’s software investors, but our relationship with
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 Stanford researcher discusses

UMI GRIPPER AND

DIFFUSION AI MODELS MIKE OITZMAN • SENIOR EDITOR

The Robot Report recently spoke

with Ph.D. student Cheng
Chi about his research at Stanford
University and recent publications
about using diffusion AI models for
robotics applications. He also discussed
the recent universal manipulation
interface, or UMI gripper, project,
which demonstrates the capabilities of Stanford researcher
diffusion model robotics. Cheng Chi. | Huy Ha
The UMI gripper was part of his
Ph.D. thesis work, and he has open-
sourced the gripper design and all of The Universal
the code so that others can continue to Manipulation
help evolve the AI diffusion policy work. Interface
demonstrates
AI innovation accelerates diffusion models for
robotics.
| Cheng Chi,
How did you get your start in
Stanford University
robotics?
I worked in the robotics industry for
a while, starting at the autonomous DALL-E 2 came out, and that’s also them, but there are also other robotics
vehicle company Nuro, where I was when Stable Diffusion came out. research projects that are also starting
doing localization and mapping. I realized the specific ways which to work.
And then I applied for my Ph.D. diffusion models could be formulated
program and ended up with my to solve a couple of really big A lot has changed in the past
advisor Shuran Song. We were both at problems for robotics, in terms of few years. Is artificial intelligence
Columbia University when I started my end-to-end learning and in the actual innovation accelerating?
Ph.D., and then last year, she moved representation for robotics. Yes, exactly. I experienced it firsthand
to Stanford to become full-time faculty, So, I wrote one of the first papers in academia. Imitation learning was
and I moved [to Stanford] with her. that brought the diffusion model into the dumbest thing possible you could
For my Ph.D. research, I started as robotics, which is called diffusion do for machine learning with robotics.
a classical robotics researcher, and I policy. That’s my paper for my previous It’s like, you teleoperate the robot to
started working with machine learning, project before the UMI project. And I collect data, the data is paired with
specifically for perception. Then in think that’s the foundation of why the images, and the corresponding actions.
early 2022, diffusion models started to UMI gripper works. There’s a paradigm In class, we’re taught that people
work for image generation, that’s when shift happening, my project was one of proved that in this paradigm of

50 August 2024 www.therobotreport.com THE ROBOT REPORT

robot report section - DW 08-2024 v6 final.indd 50 7/29/24 9:56 AM

 The first diffusion
policy research Automate with a
Competitive Edge
at Columbia was
to push a T into
position on a table.
| Cheng Chi

imitation learning or behavior, cloning

doesn’t work. People proved that errors
grow exponentially. And that’s why you
need reinforcement learning and all the
other methods that can address these
limitations.
But fortunately, I wasn’t paying too much
attention in class. So I just went to the lab
and tried it, and it worked surprisingly well.
I wrote the code, I applied the diffusion
model to this and for my first task; it just
worked. I said, “That’s too easy. That’s not
worth a paper.”
I kept adding more tasks like online
benchmarks, trying to break the algorithm
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 When I tried to perturb the system, it
just kept pushing it back to its original
place.
And so that paper got published,
and I think that’s my proudest work, Two UR cobots
I made the paper open-source, and equipped with
I open-sourced all the code because UMI grippers
the results were so good, I was demonstrate the
worried that people were not going folding of a shirt.
| Cheng Chi
to believe it. As it turned out, it’s not
a coincidence, and other people can
reproduce my results and also get But with this paradigm, I can pump That’s my expectation of how this will
very good performance. out a new task in a few days. It’s a really evolve.
I realized that now there’s a big difference. That’s also the moment I But simultaneously, there’s a
paradigm shift. Before [this UMI realized that the key trend is that it’s all problem here. I think the robotics
Gripper research], I needed to about data now. I realized after training industry was tailored toward the
engineer a separate perception more tasks, that my code hadn’t been assumption that robots are precise,
system, planning system, and then changed for a few months. repeatable, and predictable. But they’re
a control system. But now I can The only thing that changed was the not adaptable. So the entire robotics
combine all of them with a single data, and whenever the robot doesn’t industry is geared towards vertical
neural network. work, it’s not the code, it’s the data. end-use cases optimized for these
The most important thing is that So when I just add more data, it works properties.
it’s agnostic to tasks. With the same better. Whereas robots powered by AI
robot, I can just collect a different And that prompted me to think will have different sets of properties,
data set and train a model with a that we are into this paradigm of other and they won’t be good at being
different data set, and it will just do AI fields as well. For example, large precise. They won’t be good at being
the different tasks. language models and vision models reliable, they won’t be good at being
Obviously, collecting the data set started with a small data regime in repeatable. But they will be good at
part is painful, as I need to do it 100 2015, but now with a huge amount of generalizing to unseen environments.
to 300 times for one environment internet data, it works like magic. So you need to find specific use cases
to get it to work. But in actuality, it’s The algorithm doesn’t change that where it’s okay if you fail maybe 0.1% of
maybe one afternoon’s worth of work. much. The only thing that changed is the time.
Compared to tuning a sim-to-real the scale of training, and maybe the
transfer algorithm takes me a few size of the models, and makes me feel Safety versus generalization
months, so this is a big improvement. like maybe robotics is about to enter
that that regime soon. Robots in industry must be safe
UMI Gripper training ‘all about 100% of the time. What do you think
the data’ Can these different AI models be the solution is to this requirement?
stacked like Lego building blocks to I think if you want to deploy robots
When you’re training the system build more sophisticated systems? in use cases where safety is critical,
for the UMI Gripper, you’re just I believe in big models, but I think they you either need to have a classical
using the vision feedback and might not be the same thing as you system or a shell that protects the AI
nothing else? imagine, like Lego blocks. I suspect system so that it guarantees that when
Just the cameras and the end effector that the way you build AI for robotics something bad happens, at least there’s
pose of the robot — that’s it. We had will be that you take whatever tasks you a worst-case scenario to make sure
two cameras: one side camera that want to do, you collect a whole bunch that something bad doesn’t actually
was mounted onto the table, and the of data for the task, run that through happen.
other one on the wrist. a model, and then you get something Or you design the hardware such
That was the original algorithm you can use. that the hardware is [inherently] safe.
at the time, and I could change If you have a whole bunch of these Hardware is simple. Industrial robots
to another task and use the same different types of data sets, you can for example don’t rely that much on
algorithm, and it would just work. This combine them, to train an even bigger perception. They have expensive
was a big, big difference. Previously, model. You can call that a foundation motors, gearboxes, and harmonic
we could only afford one or two tasks model, and you can adapt it to drives to make a really precise and very
per paper because it was so time- whatever use case. You’re using data, stiff mechanism. RR
consuming to set up a new task. not building blocks, and not code.

52 August 2024 www.therobotreport.com THE ROBOT REPORT

robot report section - DW 08-2024 v6 final.indd 52 7/29/24 9:56 AM

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 Siemens introduces high-inertia

1FK7-HI SERVO MOTORS THE ROBOT REPORT STAFF

Siemens Industry is expanding its

1FK7 servomotor family,
with the introduction of a new high-
encoders, as well as 18 color options.
A mechanical decoupler between
the motor and encoder shaft protects
plug-n-play operation when paired to
the Sinamics S drive platform.
All servomotors in this new line
inertia style. The higher rotor inertia of the encoder from mechanical vibrations, are also configured to interface with
this design makes the control response providing a long service life. Siemens Sinumerik CNC technology
of the new 1FK7-HI servomotors robust In cases where the encoder needs to for machine tool applications and the
and suitable for high- and variable-load be exchanged, the device automatically motion controller Simotion for general
inertia applications. aligns the encoder signal to the rotor motion control use.
Siemens said these self-cooled 1FK7- pole position, enabling feedbacks to Selecting the proper motor to suit
HI servomotors provide stall torque in be changed in the field in less than five the application is facilitated by the
the 3 Nm to 20 Nm range. They are minutes. Siemens Sizer toolbox and compatible
offered in IP64 or IP65 with IP67 flange These new Siemens 1FK7-HI 3D CAD model-generating CAD-
degree of protection, with selectable servomotors also feature the unique Creator package. RR
options for plain or keyed shaft, holding Drive-Cliq serial bus and electronic
brake, 22-bit incremental or absolute nameplate recognition, allowing virtual

The 1FK-Hi servo motors

are designed for variable-
load inertia applications.
| Siemens

54 August 2024 www.therobotreport.com THE ROBOT REPORT

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Final tousa
send.indd 1 12/5/23 10:02
8:13 AM
canon – RR 08-24.indd 5 7/29/24 AM
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 AUGUST 2024

how
AI-at-the-edge
enables decision superiority
on today’s battlefield
Page 60

cover – AD DW 08-2024 v1.indd 47 7/22/24 1:33 PM

 The CJADC2
Aerospace/Defense concept creates
a secure, unified
command and
control network
across all defense
branches and among
allied partners.
| Source TK

how By Timothy Stewart

AI-at-the-edge
enables decision superiority
on today’s battlefield
Thanks to recent technological advances,
militaries can co-locate sensors and
ruggedized, AI-powered supercomputers in tiny
spaces across big networks ­— and acquire the
information advantage they crave.

In October 2020, the U.S. Army and

U.S. Air Force announced the
Combined Joint All-Domain Command
While this definition captures what
CJADC2 aims to achieve, it says little
about how to achieve it. However, some
destined for those who can best
leverage and secure information to
make the best decision in the shortest
and Control (CJADC2) Implementation lessons learned in recent conflicts have time. Military conflicts in the 21st
Plan, a unified effort to provide strategic been integrated with this data-driven century will continue to use this strategy
advantage in large-scale, multidomain warfighting concept. at an accelerated pace, thanks to
battles. Deemed a warfighting necessity advances in AI and data processing.
by the U.S. Department of Defense, Growing Use of Digitized Information Objectives such as lowering the
the CJADC2 framework helps inform CJADC2 uses artificial intelligence cognitive load of soldiers and decision-
modern warfare initiatives by better (AI), machine learning (ML), decision makers and decreasing the response
managing data volume and complexity. autonomy, and other advanced time to gain an advantage represent
This initiative is designed to give U.S. capabilities to better connect just some of the requirements, risks and
military personnel a tactical advantage sensors with shooters (e.g., soldiers, technical challenges being addressed.
and provide the same across and within tanks, UAVs) and reduce the time
allied and partner nations, promoting it takes to bring lethal and non- The Importance of Shared
a more collaborative and effective lethal effects against an adversary to Intelligence
multinational defense strategy. influence multidomain operations. Advances in telecommunications,
CJADC2 aims to create a Not surprisingly, AI-based, compact sensors, processing power, and
multinational framework for integrated supercomputers designed to manage weapons, along with the growing utility
command and control that enables a growing amount of data and inputs of space and cyberspace as operational
military forces to sense, make sense, are increasingly used in military domains, have fundamentally shifted
and act, in the DoD’s words, “at all and defense operations. By using the character of command and control
levels and phases of war, across all this compact, rugged computing in warfare. Data is the new strategic
domains, and with partners, to deliver technology incorporated directly into asset that is employed enterprise-wide
information advantage at the speed today’s defense platforms, military in multidomain operations to achieve a
of relevance.” In other words, it gives operations gain better intelligence, holistic approach.
them decision superiority: the ability faster, which leads to more successful The benefits of networked
to assimilate, analyze, and respond outcomes. communication include:
to information acquired from the Throughout history, decision • Streamlining of large data transfers
battlespace more rapidly than an superiority has always been crucial to from sensors to mission computer
adversary. winning or losing battles, with success • Improved system response time

60 August 2024 www.designworldonline.com DESIGN WORLD

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 • Reduced wiring complexity Ukraine over the Siverskyi Donets River adapt to changing circumstances and
increases system reliability, highlighted many challenges and risks take advantage of opportunities as they
availability, maintainability associated with this complex operation arise.
• Improved upgradeability and and identified potential technical Deploying AI algorithms on devices
scalability solutions using AI/ML and other critical physically close to the data source
technologies. — an approach known as “AI at the
One iteration of CJADC2 focuses edge” (AIAE) – allows decisions to
on creating a global targeting system Information Flow Improves Risk be made with minimal latency and
that can enable combatants to locate, Analysis provides flexibility in a rapidly changing
target, and engage the enemy, then Since most future breaching operations environment. For example, connecting
asses the results — a critical process will likely be conducted using sensors directly to the AIAE unit will
known as the kill chain. Another unmanned or optionally manned greatly reduce latency between the
looks at how CJADC2 can assist systems, large amounts of data must be observe and orient steps in the
with achieving decision superiority secured and transmitted across tactical OODA Loop.
to maneuver forces to positions of networks to synchronize reconnaissance It is the same for significantly
advantage to prevent an adversary from and security, logistics, and other reduced latency between the orient
meeting their objectives. This iteration warfighting functions. and decide steps because there’s no
has recently been analyzed in manned At the macro level, CJADC2 need to send out large amounts of data
and unmanned ground systems in land involves gathering massive quantities for additional decision-making steps
operations. of data through a broad range of to a distant node and then wait for the
distributed sensors and processing it decision to be sent back. Sending the
AI in Ground Operations into actionable information. The system resulting “act” command from the AIAE
One of the most complex ground- is stitched together with a robust set of unit reduces latency for the decide-act
based maneuvers is a wet-gap communication links that allocate the steps for the same reasons.
crossing. However, there are distinct correct information across the network
logistical challenges in planning and to enable organizations to achieve Higher Processing Power Gives
executing these critical operations. enhanced effects in their specific areas Systems More Computation
When successfully executed, a wet-gap of responsibility. A dominant commercial-off-the-shelf
crossing operation can provide one The OODA Loop, a well-known solution for AIAE processing is a
of the most valuable assets in war — and accepted decision-making model, general-purpose graphics processing
speed — to seize the initiative, prevent describes a four-step process for unit (GPGPU). They can handle
enemy reconnaissance, and exploit executing combat operations: Observe, large amounts of data in parallel —
success. Executing a safe and efficient Orient, Decide, Act. Developed by U.S. much faster than traditional central
wet-gap crossing allows friendly forces Air Force Col. John Boyd, it emphasizes processing units (CPUs) — thereby
to set the necessary conditions for the importance of speed and agility accelerating a wide range of AI
further success. in decision-making and action-taking applications.
A recent analysis of a failed wet-gap to complete the loop as quickly and Modules in the NVIDIA Jetson
crossing by Russian forces in eastern efficiently as possible so that you can family combine AI-capable GPGPUs

“AI at the
edge” can
accelerate
the OODA
Loop used
in military
operations.
| Source TK

DESIGN WORLD www.designworldonline.com August 2024 61

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 Aerospace/Defense

with multicore CPUs to create a tightly its low power consumption

coupled, high-performance, low- and maximum weight
power supercomputer that supports of 1.3 lbs., it’s a suitable
AI processing and decision-making candidate for AIAE
applications software. applications from
For example, the NVIDIA Jetson the perspectives of
Xavier NX module provides six trillion performance and SWaP:
floating point operations per second size, weight, and power.
(TFLOPS) performance with a maximum
power of 15 watts. This performance Other Considerations of AI in
is comparable to that of a several Military Operations
hundred-watt workstation with a AIAE’s numerous benefits, such as The A179 Lightning is a compact,
processor and GPU cards. reduced latency and increased security, AI-powered supercomputer that can
This type of computing architecture also present some technological process vast amounts of sensor data
can process and apply AI algorithms challenges, including limited at the edge of networked military
for more than 20 high-definition video processing power and storage as well hardware. | Aitech
inputs with 1040p resolution at a rate as energy efficiency.
of 30 frames per second — enough Using rugged AI supercomputing AI-capable systems are protected from
bandwidth to run AI applications for modules addresses many of these cyber and spoofing attacks, securing
a system of multiple high-definition challenges, but there are also concerns shared information in several ways.
cameras. For defense operations, of data transfer and security. These include reducing the amount of
the high processing capabilities of Time-sensitive networking (TSN) is data shared across tactical networks,
the NVIDIA architecture enable AIAE a communication protocol that ensures simplifying data distribution efforts,
processing, thanks to the compact critical information reaches decision- reducing system latency, improving
supercomputers embedded within the makers without delay by transmitting data redundancy at the sensors, and
military platform. real-time data with high precision eliminating interoperability issues
A ruggedized supercomputer with and reliability. It also facilitates the between systems since all use the same
an NVIDIA Jetson Xavier NX module collection, aggregation, and analysis communications protocols and data
can be as small as 4 x 2.3 x 3.9-in. With of this real-time data, empowering messaging structures.
decision-makers with Leveraging AI/ML and advanced
accurate, up-to-date algorithmic warfare systems provides a

Brushless Motors
information. significant decision-making advantage.
TSN synchronizes Rugged, compact supercomputers can
devices and systems help manage the influx of data that
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networks to improved intelligence in military
ensure that data operations.
from multiple Every system and program should
sources is aligned mandate sensor data sharing and
and consistent. interoperability. This data-sharing
This provides a construct can create secured
holistic view of battlespace awareness, in which actions
the operational in one part of the single, integrated,
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62 August 2024 DESIGN WORLD

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 SALES

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LEADERSHIP TEAM

Publisher
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ad index - DW 08-2024 v1.indd 63 8/2/24 4:23 PM

 Technical Thinking
By Mark Jones

Rare cases of technology decline

The norm is technology just gets hours. It is questionable advice and just gone. Just 10 blue links on a white
better. Cars are better. The feeler the latest example of software getting background. It was revolutionary.
gauges I used to adjust the valves in worse. The brilliant Cory Doctorow Google search is very different today.
my first car still reside in the upper gave it a name: enshitification. It so My search now begins with paid ads
right drawer of my toolbox. I haven’t captures the times, the American and YouTube videos, a property owned
adjusted valves in decades. Same for Dialect Society made it the word of the by Google. I have to page down twice
my grease gun. There isn’t a grease year for 2023. to get below the trash. The poor results
zerk on my current car. Oil lasts 10,000 Enshitification certainly isn’t from SGE just add distraction.
miles, three times that of my first car. unique to Google, but Google’s The enshitification of the Flint Water
I’m carrying more computing power importance makes its degradation System was driven by cost cutting.
and better connectivity in my pocket particularly alarming. Water is critical Ineptitude did the rest as ignorance
than existed in the entire Chemistry infrastructure and so is Google Search. drove bad decisions. The enshitification
Department when I started graduate 90% of all search is Google, “Critical of Google is also driven by money.
school. Computers have gotten better. Infrastructure are those assets, As Doctorow notes, in enshitification
Plastics better. Paints better. Toilets systems, and networks that provide of services, the user is forgotten
better. It is hard to find a technology functions necessary for our way of in the quest for more profit. It is a
area that isn’t better now than 20 years life,” is a definition that surely includes conscious effort. Google knows they
ago. (The Flint Water Crisis, which Google Search. It is the definition are enshitifying. Appending udm=14 to
I’ve written about several times, was offered by the U.S. Cybersecurity any search is a switch that turns back
mercifully one of the rare examples of and Infrastructure Agency (CISA). the clock. It transports back in time to
technology devolution, where working CISA doesn’t directly name Google. provide Google Search the way it used
technology was rendered inoperable.) The vague use of “necessary for life” to be. Enshitification can be undone
Software stands out. There are encompasses Google Search. It is hard because it was done on purpose.
many cases where it is getting worse. to imagine a day without search and Undo’s don’t happen often in life
The report about AI advice for kidney Google is search. It fits the CISA critical but are a feature of software. It is
stones caught my attention. Asking infrastructure definition. what separates Flint, a real-world
Google’s new AI-enhanced search, the Search was crappy until Larry Page enshitification, from the enshitification
Google Search Generative Experience, and Sergey Brin developed PageRank. of Google search, a software issue.
Google SGE, how to pass kidney stones It was genius. The algorithm and the There was no undo for the water, no
quickly offers the advice of drinking simplicity of the results were amazing. undo for ineptitude. DW
at least two quarts of urine every 24 The clutter plaguing other search was
| Thaspol, Adobe Stock

64 August 2024 www.designworldonline.com DESIGN WORLD

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 Repeatable
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