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June 03, 2025 | Volume 21 Issue 21 |
Manufacturing Center
Product Spotlight
Modern Applications News
Metalworking Ideas For
Today's Job Shops
Tooling and Production
Strategies for large
metalworking plants
As semicon-ductors and optical components become smaller and more sophisticated, the TZ Series of precision elevating tables from IKO International provides exceptional vertical positioning accuracy in a compact size. This unit features a unique wedge mechanism guided in the vertical direction by a pair of IKO C-Lube Super MX linear motion rolling guides arranged in parallel to achieve highly precise positioning with exceptional rigidity. An optional linear encoder provides full closed loop control to achieve positioning accuracy as high as 0.005 mm, with repeatability of +/-0.001 mm.
Learn more and get all the specs.
The COBOTTA PRO from DENSO Robotics is a lightweight, high-speed collaborative robot designed for communication between workers and robots while maximizing productivity. It delivers a blend of productivity and safety for both simple tasks and multi-step processes like assembly and inspection work. The 6-axis unit operates at speeds up to 2,500 mm per sec when no workers are near and slows or stops when people approach. Two models available: PRO 900 (max payload 6 kg) and PRO 1300 (max payload 12 kg). Many more functions and features.
Learn more.
New powerful, low-profile, pull-type clapper solenoids are available from Magnetic Sensor Systems (MSS). Applications include valve control, locks, starters, ventilators, clamping, sorting, appliances, tools, HVAC, brakes, clutches, switches, mixing, fire suppression systems, door controls, detent latches, and more. The S-16-264 Series of 17 Pull-Type Clapper Solenoids have ampere turns (windings) adjusted to meet the specific force and duty cycle requirements of your application. They provide up to 130 lb (578 N) of force.
Get all the specs for these solenoids and other options.
Bishop-Wisecarver provides a quick, very useful guide to help you evaluate the right drive strategy for your system: belt, screw, or chain-driven actuator. Each drive type has unique advantages and limitations, so evaluating all your options will help you find the most suitable actuator setup for your specific application needs.
Read the Bishop-Wisecarver blog.
PI, a global leader in precision motion control and nanoposi-tioning, now offers fast delivery of the L-511 linear micropositioning stage, which is designed for applications requiring minimum incremental motion down to 20 nm, drive forces up to 22 lb, and multi-axis configuration options. The L-511 can be combined to form XY or XYZ motion systems and integrated with rotary stages. A variety of drive and encoder options (stepper and servo motors, rotary, and linear encoders) enable ultra-fine sensitivity. Applications include: metrology, laser processing, semiconductors, biotech, optical alignment, and advanced automation.
Learn more and get all the specs.
According to the experts at Lin Engineering, there are two primary types of stepper motors to consider: permanent magnet (PM) and hybrid. But which is right for your application? Both types have their advantages and disadvantages, and the choice ultimately depends on your specific requirements.
Read this informative Lin Engineering article.
The new drylin WWP linear guide from igus features a PTFE-free locking carriage. Engineered from lubrication-free, high-performance polymers and aluminum, the guide offers a lightweight, hygienic, and low-maintenance alternative to complex mechanical and electronic adjustment systems. It is significantly more compact and lightweight than conventional recirculating ball-bearing systems. Applications include interior components in vehicles, aircraft, and furniture.
Learn more and get all the specs.
MAXXDRIVE industrial gear units from NORD DRIVE-SYSTEMS are an established drive solution for heavy-duty applications. In addition to conveying, lifting, and driving, they also play an important role in mixing and agitating systems. MAXXDRIVE units feature a compact, one-piece UNICASE housing that delivers long service life, easy maintenance, and quiet operation. Their robust design handles high axial and radial loads, achieves output torques up to 2,495,900 lb-in., and powers up to 8,075 hp.
Learn more.
According to PBC Linear, their new non-captive linear actuators are different from the more common external versions of lead screw-driven linear actuators because they allow the lead screw to completely pass through the motor. This fundamental difference offers advantages for designs that have limited space available or for engineers looking to shrink the overall size of their design package.
Read the full PBC Linear blog.
Güdel Inc. is highlighting new technologies at Automate 2025 booth #2418 that demonstrate its unmatched ability to solve automation engineering challenges. One is the Cobomover, a 7th-axis linear track purpose-built for collaborative and lightweight robots. Designed and manufactured in Switzerland, this unit extends the working range of robots up to 5 m, allowing them to operate multiple workstations and perform a variety of tasks without manual repositioning. Compatible with over 60 cobots and small traditional robots.
Learn more and get all the specs.
ThruSight-Focus is a high-performance, compact motion platform specifically engineered for applications requiring dual-side access to the sample or workpiece. It pairs ALIO's monolithic open-center XY stage -- known for its nanometer-level precision, crossed roller bearings, and direct linear drives -- with a novel Z-wedge mechanism that converts horizontal drive force into vertical motion via direct drive. This innovative architecture eliminates backlash, enhances servo responsiveness, and delivers fast, stable Z-axis movements -- all within a low-profile footprint.
Learn more.
Intelligent power management company Eaton launched a new differential engineered specifically for electric vehicles at Auto Shanghai 2025 in China. The innovative design addresses the unique challenges presented by EV propulsion systems, including shared low-viscosity oil environments, increased sensitivity to noise, and the demands of high and instant torque delivery.
Read the full article.
Applied Motion Products has introduced the MDX+ series, a family of low-voltage servo systems that integrate a servo drive, motor, and encoder into one package. This all-in-one drive is an ideal solution for manufacturers in logistics, AGV, medical, semiconductor, the solar industries, and many others.
Read the full article.
Universal Robots and Mobile Industrial Robots will debut new and AI-powered automation solutions across integrated industry workflows at Automate 2025 from May 12-15 in Detroit. This joint showcase from Teradyne Robotics companies will feature comprehensive automation solutions across Automotive, Electronics Manufacturing, and Logistics zones, highlighting the power of collaborative and mobile robotics.
Read the full article.
At Automate 2025, Olis will launch a remote automation monitoring, diagnostic, and error recovery app that turns Android smartphones and tablets into gateways for any automation cell -- without the need for additional hardware. The Olis app synchronizes real-time video with system logs, collecting diagnostic data on robots and PLCs to provide a complete picture when something goes wrong. Full setup takes less than five minutes (including a simple online purchase), making this app an efficient retrofit for legacy automation systems. Many more features, including screen sharing, alert setting, and customizable workflows.
Learn more.
By Caitlin Hayes, Cornell Chronicle
In 2021, Tompkins Consolidated Area Transit (TCAT) in Ithaca, NY, received a grant to procure seven all-electric buses and began a pilot program that didn't go as they'd hoped. In addition to issues with the manufacturers, the buses struggled in Ithaca's hilly terrain and were unreliable, with reduced range, in cold weather.
TCAT had already connected with Cornell University researchers to gain insights from the pilot, and now Cornell researchers have analyzed the buses' underperformance in the cold -- with implications for cities, schools, and other groups that are considering the electrification of their fleets, as well as operators, policymakers, and manufacturers.
In a study published May 27 in Transportation Research Part D, researchers analyzed two years of TCAT data and quantified the increased energy consumption of the pilot fleet, finding that the batteries on the electric buses consumed 48% more energy in cold weather (between -4 to 0 degrees Celsius, or around 25 to 32 degrees Fahrenheit) and nearly 27% more in a broader temperature range (-12 to 10 C, or 10 to 50 F).
The researchers also identify the operational culprits of the increased consumption and offer recommendations for improving the buses' functioning.
The study is the first to assess and analyze electric buses' performance in the northeastern United States, with an unprecedented dataset that covers significant distance -- more than 80,000 km (nearly 50,000 miles) -- at cold temperatures.
"We're benefiting from TCAT being a leader in this region, and it's a real privilege to have access to this data, so we can see the performance in real time," said senior author Max Zhang, the Irving Porter Church Professor of Engineering in Cornell Engineering and Provost's Fellow for Public Engagement. "One of the lessons we've learned is that these buses should be designed for the whole country, including states with colder climates. We've also found that they're different from conventional diesel buses, with different behaviors, which require different strategies to take advantage of this."
The researchers, including first author and doctoral student Jintao Gu, modeled how the buses would perform at optimal temperatures and compared that to the actual performance across more than 40 complex routes and schedules. They found that half of the increased consumption in cold weather comes from the batteries' need to heat themselves. That's because batteries in electric vehicles operate at an optimal temperature of around 75 F, and the colder the battery is when the bus starts, the more energy it takes to warm it. The other main culprit is the heating of the bus's cabin. With frequent stops, especially on urban routes in which the doors are opened and closed every few minutes, the batteries must work harder to heat the cabins.
"With an all-electric vehicle, the battery is the only onboard energy source," said Zhang, who is also a senior faculty fellow at the Cornell Atkinson Center for Sustainability. "Everything has to come from it."
The researchers also found that regenerative braking, whereby the battery recharges by capturing energy during braking, was also less efficient in cold weather. They said this is likely because the battery, which is about eight times the size of a standard electric vehicle battery, struggles to maintain an even temperature across its cells.
Short-term strategies to improve the batteries' function include storing the buses indoors when not in use, so the ambient temperature is warmer; charging the batteries when they're still warm; and limiting the length of time the bus doors are open at stops.
On a larger scale, Gu said the research points to the need for greater adjustments in, or assessments of, infrastructure to accommodate electric buses.
"You have to try to optimize the schedule of all of the buses and to consider the capability of your infrastructure -- how many charging stations you have, and if you have your own garage," he said. "You have to train the drivers, the dispatchers, and the service workers. I think from an operational and infrastructure perspective, there are a lot of messages here for future transit system planning."
Gu said the varied urban and rural routes and hilly terrain in Ithaca allowed the researchers to glean even more insights about the buses' performance, finding that the buses experienced a smaller increase in energy consumption on rural routes during cold weather compared to urban routes. That information might help planners strategically choose which routes to assign to electric buses in a mixed fleet.
The drastic increase in energy consumption was unexpected, Zhang said. "But any lessons are good lessons. This helps us learn as a society and do better."
The research is also an example of mutually beneficial collaboration between the Ithaca community and researchers at Cornell. Zhang's team has met repeatedly with TCAT officials as the research has progressed.
"We're learning each other's perspective, and we're sharing our insights," he said. "It's beautiful, right? Cornell researchers and TCAT, we're learning at the same time, we're learning through the data, through the collaboration."
Doctoral student Quanhuan Liao is a co-author.
Published June 2025