Langenfeld, Germany: Next to sizing software as well as CAD data and simulations, ACE Stoßdämpfer GmbH now offers engineers data from digital twins for easier integration into virtual models. ACE is the first supplier of industrial shock absorbers to provide customers with Functional Mockup Units (FMUs). It offers the possibility to integrate physical models of a supplier product, in this case industrial shock absorbers, into the customer's own simulation models. This advantage is particularly evident with customized industrial dampers, as ACE is able to quickly provide prototypes as digital twins.

If customers want to use ACE's FMUs, they need simulation software that includes an FMI (Functional Mockup Interface). Common programs that integrate ACE's FMUs include Simulink and Adams.

Design engineers receive comprehensive data from ACE on all shock absorber types as digital twins so that they can test them virtually in the simulation model of their application.

Interested parties can find further information about ACE's digital services via the links https://www.acecontrols.co.uk/uk/sizing.html and https://ace-cad.de/

For information about simulations and digital twins, please contact ACE’s engineer Christian Junghans at c-junghans@ace-int.eu directly.

Trade Show Dates

Stabilus and Fabreeka

04. - 06.06.2024, Automotive Testing Expo, Stuttgart, Germany, Booth: 8424

Stabilus and ACE

18. - 19.09.2024, All About Automation, Chemnitz, Germany, Booth: pending

05. - 07.11.2024, FMB, Bad Salzuflen, Germany, Booth: pending

13. - 14.11.2024, Precisiebeurs, S'Hertogenbosch, Netherlands, Booth: pending

“Nothing is so good that it cannot be improved,” says Mark Fellinger of German film equipment specialist IDEA VISION GmbH. The company from Kolbermoor, Bavaria, develops, constructs and sells mechanical and electronic systems for the film industry. IDEA VISION has also specialized in stabilized camera platforms. “We rely on a mixture of German quality standards, maximum flexibility in use, easy handling and quick attachment to a wide variety of carrying platforms,” says Fellinger, describing the business. These properties can also be transferred to the work of ACE Stoßdämpfer GmbH from Langenfeld in Germany, which is one explanation for the cooperation between the two companies in the case of IDEA VISION’s Hybris Shock Absorber.

„Our Hybris Shock Absorbers are often used in very harsh environments. We were therefore looking for additional damping that would provide a soft stop at the end of the spring travel and maintain the camera's stable image." Image credits: IDEA VISION

The Problem: Reduce Vibrations and Hard Impact Shocks

The Hybris Shock Absorber system, which weighs 14 kg, is designed to stabilize the use of underslung and overhanging film cameras, gimbals or camera heads. Camera teams use it to compensate for shocks and vibrations that occur when filming while using cars, motorcycles or boats. An adjustable linear induction brake and a spring system ensure stable conditions when filming with Hybris Shock Absorbers. The sophisticated device can also be configured and controlled via an app and allows operation without contact. The braking and damping performance is extremely precise thanks to the magnetic eddy current principle and avoids direct mechanical stress on all components of the system and associated components. These may weigh between 1 kg and 40 kg and are dampened over a spring travel of 46 cm. Since the system is often used in harsh environments, such as uneven terrain, at sea and on race tracks, the designers were looking for additional damping. This was supposed to ensure gentle stops at the end of the spring travel to maintain stable images from the camera at all movements. Additionally, the damping element the designers were looking for had to limit the maximum suspension travel when camera teams want to create low tracking shots on bumpy terrain. Those were essential requirements in order to avoid the unwanted impact of the entire system.

Hybris Shock Absorber, the 14 kg stabilization system for camera movements from Idea Vision GmbH. Image credits: IDEA VISION

With Hybris Shock Absorber, camera professionals prevent jolting and shaking of images during action scenes, even on rough terrain. Picture credits: IDEA VISION

Hybris Shock Absorber supports film equipment weighing up to 40 kg and keeps shocks and vibrations away from it thanks to ACE's eddy current brake, spring and structural dampers. Picture credits: IDEA VISION

The Solution: Consulting and Tests Lead to Profile Dampers

Normally, ACE works closely with the customer to determine the appropriate damping solution based on design data. Many standard solutions can also be designed using the calculation and configuration tools on the ACE homepage: www.acecontrols.co.uk/uk/sizing.html. However, since equipment of different weights is used during filming and no two tracking shots are alike, Mark Fellinger sought personal contact with an ACE sales engineer. Hans-Jürgen Greindl, technician responsible for ACE Austria, visited him on site because his journey from the location in Linz, Austria, to Bavaria was the shortest. When an attempt with miniature shock absorbers was not completely satisfactory, Greindl switched to TUBUS profile dampers. The reversible dampers, called TUBUS because of their tube-like shape, are an alternative to hydraulically operated miniature and industrial shock absorbers when deceleration does not have to be linear and ultra-precise. Available from ACE in over 140 different versions, TUBUS shock absorbers are used to decelerate masses, especially under extreme operating conditions. From the variety of different dampers made from co-polyester elastomer, the partners decided on radial damping types. These have the advantage of a very long and soft braking process with progressive energy reduction at the end of the stroke, supporting the desired stable images. Available with strokes from 17 mm to 60 mm, the dampers can be easily integrated into existing constructions due to their compact design. They are able to absorb energy from 1.2 Nm/cycle to 146 Nm/cycle. After furnishing IDEA VISION with different samples, the TUBUS type TR83-50 proved to be the most suitable. Like all profile dampers supplied by ACE, they are maintenance-free and ready to install, hardly heat up and, therefore, ensure consistent damping. With a stroke of 50 mm, they provide additional safety for all camera movements and withstand individual loads with an energy capacity of up to 45 Nm/cycle.

A satisfied Mark Fellinger sees the rugged system and the motto "Nothing is so good that it cannot be improved" of IDEA VISION GmbH confirmed. Now, film enthusiasts and pros alike look forward to action scenes of films shot with the help of the improved Hybris Shock Absorber from Germany.

"After I saw the lightweight aluminum-titanium frames of the Hybris Shock Absorbers, it was clear that our TUBUS structural dampers could also be bolted to them quickly and easily for every turn, virtually made to measure." Picture credits: ACE

The structural dampers of the TUBUS TR family used by IDEA VISION are characterized by soft deceleration and energy absorption of up to 45 Nm/stroke with maximum strokes of 50 mm. Picture credits: ACE

The maintenance-free structural dampers of the TR series, which are ready for immediate installation thanks to the special screw supplied, are subjected to radial loads and decelerate very long and smoothly. Picture credits: ACE

Trade show dates

Stabilus and Fabreeka

04. - 06.06.2024, Automotive Testing Expo, Stuttgart, Germany, Booth: 8424

Stabilus and ACE

18. - 19.09.2024, All About Automation, Chemnitz, Germany, Booth: pending

05. - 07.11.2024, FMB, Bad Salzuflen, Germany, Booth: pending

13. - 14.11.2024, Precisiebeurs, S'Hertogenbosch, The Netherlands, Booth: pending

Recently, Arne Hankemeier, Julian Raimann and Tobias Ridder completed their training as state-certified technicians in the field of mechanical engineering at Felix-Fechenbach-Berufskolleg, a vocational college in Detmold, Germany. Volker Geise, responsible for educational management there, states that the proportion of practice-oriented work is very important in the mechanical engineering department at the technical college. Therefore, he welcomed right from the start that his three graduates wanted to work closely with nearby company MEYRA GmbH as part of their final thesis.

Julian Raimann, Arne Hankemeier und Tobias Ridder (from left to right), state-certified technicians in the field of mechanical engineering at Felix-Fechenbach-Berufskolleg, in front of their construction. Credit: Arne Hankemeier

As a member of internationally operating MEYRA Group from Kalldorf, Germany, the company is one of the leading manufacturers of high-quality wheelchairs and has also made a name for itself as a supplier of rehabilitation equipment. Following their claim “We move people”, MEYRA supports and motivates many people with disabilities around the world to achieve more mobility and independence. It is also constant exchange with those affected as well as with medical experts and those in therapy and care that enable MEYRA to develop practice-oriented products, last not least in close cooperation with medical supply retailers. This holistic, practical approach was very suitable for the learning group at the German college, although another connection existed: Tobias Ridder, one of the three young talents, was already working as a designer for custom-made products at MEYRA when he decided together with Arne Hankemeier and Julian Raimann to develop a professional drop test unit for wheelchairs as his final thesis at the college. With full support from his employer, they embarked on building a construction that is mainly intended to test the load capacity of MEYRA’s new wheelchair models.

Drop test unit for testing the stability of wheelchairs with controls in the foreground on the right and the pneumatically operated construction for engaging and disengaging the wheelchairs at the top. Credit: Felix-Fechenbach-Berufskolleg

The wheelchairs are latched, pneumatically lifted, unlatched and dropped, with the sensitive inner workings of this device being hydraulically dampened. Credit: Felix-Fechenbach-Berufskolleg

Requirement: High load capacity

The testing unit is designed in such a way that each wheelchair is loaded at first with the maximum permissible weight and then gets moved into the construction. Each model is then latched onto a gripper and raised using pneumatics and, after being latched, dropped from a previously defined height. To dampen the force of the lifting device's impact plate and to protect their whole structure the three technicians considered installing shock absorbers. This plan was backed by their goal that not only the stability of the wheelchairs should be proven, but the test device itself should also be as stable as possible and not have to be repaired after just a few cycles of use.

The impact plate itself must not impact, which is why four ACE miniature shock absorbers reliably and precisely reduce the mass forces to protect the overall structure. Credit: Felix-Fechenbach-Berufskolleg

In an interview the students said, they were familiar with one of the main advantages of hydraulic damping elements in that they work without rebound effects due to their linear characteristics. “Thanks to a presentation by ACE Stoßdämpfer GmbH, which we were able to join as part of our lessons, we knew that certain shock absorbers can not only solve the tasks of deceleration better in terms of their damping properties, but they also help ensure that testing is carried out more quietly than before, especially when comparing the damping tasks to the performance of steel springs or rubber buffers,” remembers Arne Hankemeier.

Since ACE offers tools for sizing on their homepage and since many other helpful services accompany the products, the students turned to ACE’s European headquarter in Langenfeld, Germany. To their delight the sales engineers not only confirmed the design data of the young engineers on the phone, they also sampled them with four miniature shock absorbers free of charge. This support of young engineers has been ACE's practice for years, as the company has experienced that sponsoring young academics and technical schools often result in innovative solutions and even new product series.

Problem solvers: Hydraulic damping elements

After the team received the four MC25EUM miniature shock absorbers from ACE everything happened very quickly: Due to their compact design the hydraulic components are predestined to be quickly integrated, also into already existing designs. Available in versions with and without diaphragm seal technology, the shock absorbers optimize a variety of machines by decelerating masses quickly and non-destructively. Customers can choose between adjustable and self-compensating versions. The latter were used in this case. The outer bodies of the miniature shock absorbers are produced from one solid piece of steel and are filled with temperature-stable special fluids. These hydraulic machine elements also come with integrated positive stops and are maintenance-free, having been developed and perfected by ACE, the technology and market leader for industrial shock absorbers for more than 60 years. The models used in this application provide a stroke of 6 mm and are suitable for energy capacities of 2.8 Nm per cycle.

Self-adjusting miniature shock absorbers from the MC5 to MC75 series made by ACE with thread sizes from M5x0.5 to M12x1 for the reduction of effective weights between 0.5 kg and 72 kg.

The teamwork of the three college graduates worked perfectly throughout the entire project. Tobias Ridder took over the design, while Arne Hankemeier and Julian Raimann were responsible for design and documentation. In the end, the integration of the four components sponsored by ACE was a small exercise, says Arne Hankemeier and draws this positive conclusion: “We were able to make the adjustment precisely using the continuous thread of the components and reliably hold it in the preset positions using the supplied lock nuts. These dampers really absorb the permissible load reliably, quietly and quickly and fulfill their purpose to the fullest extent. We have also noted very happily in our test series that quite a variety of large masses can be decelerated almost without any noise and certainly with no rebound within the small space of our construction.”

Trade fair dates

25.03. - 28.03.2024, Global Industries, Paris, France, Hall, Booth: 5C14

23.04. - 26.04.2024, Control Expo, Stuttgart, Germany, Hall, Booth: 5, 5203

'Solid support on every set' is the promise of quality from Egripment, a globally operating company, specializing in the technical equipment of film and TV teams and corresponding services. The studio technology specialists from the Netherlands underpin the mixture of high-tech and after sales services with a lifetime guarantee on their dollies and cranes. It is therefore not surprising that Egripment's solutions can be found at many shows and events, at indoor as well as at outdoor sets. For example, the company supplies tracks for both ground and hanging constructions and corresponding remote-controlled dollies, which are essential parts of the program for film and television productions at open-air, hall and studio shows or concerts and also for sporting events, including Olympic Games.

The Fast and the Furious

In addition to quality and support, Egripment offers another big plus: engineering know-how that is based on more than 40 years of practical work in the Industry. It results from daily contacts with cameramen, crews, operators and technicians who are working at a continually higher professional level. In conjunction with their field experience, Egripment pays a lot of attention to design and innovation. Together with on-going consultation, the company ensures that way that the products suit the needs of all film markets. The result is the development of a sophisticated series of Egripment cranes, dollies, remote camera heads and different tracking systems.

Rick Velthof, Egripment's global sales manager, explains: "In addition to high quality, our customers expect a high level of reliability from our solutions, which we document, for example, with lifetime guarantees." He illustrates the requirements placed on Egripment's constructions with this comparison: "While it was still possible to end tracking shots with electronically controlled stops and to secure the remote-controlled camera dolly on the track system in the end positions using rubber buffers not too long ago, today's speeds in studios or at sports broadcasts are too high for this type of security element. Another case in point is the resolution that can be achieved, which is already 8K." High technical features such as these require current studio and recording technology to be calibrated very precisely before use and to maintain the same high level of data quality throughout the production. Rick Velthof: "Under these conditions, hardly any production can afford to spend a lot of time recalibrating a camera and dolly that have crashed into the rubber buffers due to incorrect operation or a sudden power failure and then bounced back. To get this duo back in line with the rest of the equipment such as control monitors and the lighting system can last up to three days in individual cases."

Such unacceptable downtimes in the visual area are one aspect for more security demands, the audible part of film technology is another one, since braking movements of many servo motors and especially of rubber buffers are anything but silent and can disturb the sound engineers during their work. The greatest concern, however, is preventing even more costly damage if the dolly and camera are seriously damaged in a crash at the end of the track. "Our Generic Track System is a remote-controlled camera system weighing up to 80 kg, which is moved on a track width of 40 cm at a maximum speed of 3 m/s over a maximum length of 50 m and also makes curves possible. If there is a real crash at the end of such a path, the damage to the camera alone can add up to over 100,000 euros," reports Rick Velthof. In order to avoid this type of accident on the set, the Egripment team took a close look at the market for safety products in the field of linear technology and became aware of ACE Stoßdämpfer GmbH from Langenfeld in Germany, a specialist in industrial damping technology. On one hand, Egripment’s attention was triggered by the online presence and the wide range of motion control solutions at www.acecontrols.co.uk as well as on the site www.ace-ace.nl/ in Dutch. On the other hand, it is also due to the personal presence of the ACE sales team in the Netherlands.

Last Man Standing

As a globally operating developer and supplier of industrial shock absorbers, ACE Controls Inc., founded 60 years ago near Detroit, Michigan, USA, is not only the inventor of adjustable shock absorbers and still the current technology leader, but also an enterprise which has been part of the Stabilus Group since 2016. ACE Stoßdämpfer GmbH, the German based subsidiary for Europe, covers the market with distributors and also with a team of sales engineers. In this particular case, as with many other applications before, Ralf Küppers and Han Titulaer, as representatives of ACE in the BeNeLux countries, were literally the closest. Rick Velthof from Egripment: "In addition to the good impression we already had judging by ACE's Dutch homepage, Ralf Küppers was quick to react and willing to visit us at short notice, thus taking in the construction on site and offering us a perfectly fitting hydraulic damping solution.”

In Nederhorst den Berg in North Holland, which is in the immediate vicinity of Hilversum, internationally known for its television- and radio station, Ralf Küppers, thanks to the Egripment technicians, got to grips with their various track systems and dollies, as well as with the key data mentioned in terms of weight, speed and the route to be travelled on the track systems. "As a sports fan who had already seen modern remote-controlled cameras in use, for example in swimming competitions, I drove to Egripment with a rough idea of the performance of linear technology and the corresponding deceleration performance required. But in practice, in many TV stations, for example during game shows or live broadcasts with several fast-moving people or during concerts, the dollies reach speeds in excess of 50 km/h. This made me realize that in this case everything had to be smooth and noiseless in the event of an emergency stop – and also really fast." Accordingly, he used the design software from ACE, www.acecontrols.co.uk/uk/sizing/safety-products/online-calculation.html, entered the key data for mass, speed and distance and proposed the trial installation of two SCS33-25EU safety shock absorbers each at the end of the track construction erected for test purposes before. These hydraulic machine elements, which are designed purely for emergency stop tasks with a service life of up to 1,000 full load cycles, reliably provide their services in thousands of industrial applications, literally as the last man standing to protect linear constructions. They also serve as a kind of mechanical airbag for sensitive components such as sleds and the construction parts attached to them when they are accelerated on a track and, if worst comes to worst, need to be decelerated to 0 km/h immediately and without rebound effect, once hitting the end position. With laurels like these, Ralf Küppers felt confident that his company’s security forces that had already proven their qualities in countless emergencies and that are no strangers to gantries and conveyor systems, processing centers or assembly machines the world over, would also hold their ground when premiering in the film and television industry.

Silent Movie

Thanks to their compact design with a size of M33x1.5 and continuous threading, the security elements, each weighing 0.5 kg, can be quickly integrated into the construction and, with their dark, hardened steel outer bodies, look good in the anthracite-colored environment of film set devices. "In order to increase flexibility and adapt this emergency stop solution even better to customer-specific conditions on site, the SCS33-25EU dampers are mounted in universally adjustable clamping sleeves at Egripment. That way, they fulfill the function of stopping the dollies gently at the end of travel, and they also reduce damage and vibrations to a minimum. The specialty, however, about the universally adjustable clamping sleeves is that you can easily install intermediate stops when determining the track route and, in principle, infinitely long tracks can be secured," reports Ralf Küppers on the further course of the cooperation.

With a stroke of 23.2 mm, the self-adjusting safety dampers work with a regular energy absorption of up to 310 Nm per stroke in case of a dolly collision. This means that with the specified values of a maximum mass of 80 kg and a travel speed of 3 m/s in the event of an emergency stop, they consume 100 percent of the energy without rebound effects and emit the resulting heat to the environment via the steel outer body. Being more up-to-date for the requirements of modern film technology on the set thanks to the described main advantages for emergency stops, the hydraulic dampers offer another benefit over the previously used rubber buffers: They also exert less supporting forces on the tracks on impact, that is, when the accelerated masses hit the component. A bending of the track construction during the braking process was no longer found at Egripment after the installation of ACE’s solution.

The team around Rick Velthof has received good feedback from customers about the increased safety and additional possible uses of the hydraulic damping technology. It does not only show its strengths at full camera movement and maximum speeds of 0.5 m/s, but also convinces at the other end of the velocity range, in that the safety shock absorbers can be pushed through its stroke at a minimum of 0.02 m/s in creep speed. Under these conditions, the shock absorber provides minimal resistance to contacting masses, and there is no braking effect so that the team on the set can move the remotely operated dolly against the dampers almost in slow motion, ending the camera motion ultra-softly and very silently. With today's often automated technology and the high level of noise sensitivity in the studio, this is a further advantage compared to the dampers of the previous generation.

The Generic Track System is designed in such a way that the G-Track can be used as a base for many different applications and as the best base for fully computer controlled applications that allow control the dolly movements repeatedly and precisely, while it is also a perfect choice for fully automated applications. The G-Track system consists of a motorized dolly and can be configured with a telescopic column and a 2-axis camera head.

Egripment’s cranes, dollies and tracking systems are widely used in the film industry and now feature safety shock absorbers instead of buffers in end positions of tracks.

When using safety shock absorbers, the moving load, on impact, is smoothly stopped by a constant resisting force throughout the entire stroke. The moving load is decelerated with the lowest possible force in the shortest possible time, thus eliminating damaging force peaks and shock damage to machines and equipment.

The slim-line, high-performance safety shock absorbers are designed for emergency stop situations only, while their compact design in sizes M33x1.5 to M64x2 makes their integration into a wide variety of current applications very easy.

Tremor is defined as a rhythmic, involuntary oscillatory movement of a body part. Although everybody has tremors from time to time, for instance when nervous, this small degree of tremor is not enough to affect daily activities. Other pathologies, however, lead to disabling tremor. Essential tremor is the most common neurological movement disorder, affecting over 5.8% of the population over 65 years old. It is estimated that over 10 million people worldwide have Parkinson’s disease. Both disorders can lead to having severe difficulties in performing activities of daily living (ADL), such as eating and drinking.

Although tremors can sometimes be managed through pharmacotherapy or surgery, these treatments present drawbacks. Drugs have limited tremor reduction and have effect for half of the tremor population. Surgery can be a hazardous procedure for patients and efficacy of such treatment is likely to decrease over years. In this context, treatments that manage tremors by modifying limb biomechanics could provide a meaningful alternative solution. This is exactly the approach that STIL is pursuing with their medical device that stabilizes tremors.

A flash of inspiration

IJsbrand de Lange, CEO and founder of STIL, first came up with the idea for a biomechanical device in 2014, when he saw a promotional video by the Michael J. Fox Foundation about people with Parkinson’s disease. He recounts: "These tremors are involuntary shakes in the arm that arise when the muscles are repeatedly contracted and released. Though tremors are the symptom of a neurological disorder, the shaking hand is basically a ‘mechanical defect’. As a Bachelor of Mechanical Engineering, I looked at the problem through a mechanical lens. If a machine vibrates involuntarily, you can apply active or passive damping techniques, and the problem is solved. Why wouldn’t this work with a person? The idea stayed in my mind and while I was in Germany doing an internship at Festo’s Bionic Learning Network. I had a flash of inspiration that I wanted to work on for my graduation project.” For this Master’s thesis at the Delft University of Technology, he built a proof-of-principle experimental device that could replicate and suppress tremors. Though still in its infancy, this device proved that mechanical loading could be effectively used to suppress tremors.

First awards and subsidies, and then a dead end

This was the foundation from which STIL was established in 2017. After years of research and development, in collaboration with patients and doctors, the team developed a wearable device that suppresses tremors: the STIL orthosis. This medical device redirects biomechanical forces from the hand to the upper arm, using a kinematic structure with several artificial joints. First of all, this patented design still allows full range of motion in the arm. Added to that, each of these joints are integrated with specialized dampers, that resist the high-frequency oscillatory movement of tremor, but allow intentional movement. That is what makes the STIL orthosis unique in the world, allowing tremor patients to independently eat and drink again.

STIL soon found partners such as EIT Health, Rabobank, Reiner de Graaf Hospital and even the Dutch Brain Foundation to support the start-up. On the engineering side, several generations of the anti-tremor orthoses were developed that attracted publicity, winning several awards and collaborations on international level, such as an Eurostars project together with Fraunhofer IBMT. At the same time, behind the scenes, IJsbrand de Lange, Nicola Pambakian, the Chief Technology Officer of STIL, and their team were continuously improving the construction of their invention, developing their own components, partly with the help of CAD and 3D-printers, partly by sourcing available standard machine elements. The latter was the case when identifying the right item that needed to be integrated into the orthosis to help with the damping and controlling of hand and wrist motions.

Initially, STIL tried using off-the-shelf rotary dampers, but quickly noticed these components were not suited for their use case. Once Nicola Pambakian and the engineering team needed support for a customized damping solution, they hit a dead end. Looking for damper manufacturers online was the easy part. Finding a supplying partner who is willing to go the extra mile together with STIL is a different, ongoing story.

Thinking globally and acting locally

During their online research, STIL identified ACE Stoßdämpfer GmbH as a possible collaboration candidate. The company which is part of Stabilus, one of the world's leading providers of motion control solutions, offers a wide variety of standard components for damping and for vibration control as well as customer-specific engineering services. As another plus, ACE operates very closely with clients and prospects through a wide network of sales engineers and distributors working all over Europe. In the Benelux countries, for instance, ACE's experts Han Titulaer and Ralf Küppers have been working successfully with customers and distributors for more than a decade.

STIL soon leaned towards ACE's working style of thinking globally and acting locally, when Han Titulaer became the go-to person for professional advice and product samples. Since ACE is no stranger to mechanical vibration control and applications in the medical field, they could bring a lot of specific knowledge for the use case of the STIL orthosis. Initial prototypes were tested, which immediately yielded promising results when testing it with patients – a great start, for what turned out to become a long-term partnership.

"When you look at STIL’s requirements in terms of damping characteristics, sizing, but also life- time, there were no damping solutions on the market that fitted the bill", Han Titulaer explains, "and it gets even more difficult when you consider that it has to be incorporated into a device that patients wear every day." In a nutshell, STIL had very well identified the needs of the patients, and what the dampers should achieve, but had too little in-depth knowledge on how to turn this into a physical product. Therefore, their engineers asked Han Titulaer and the growing project team at ACE, led by managing director Dr. Peter Kremer and product manager Heiner Tapken, whether it would be possible to co-develop a revolutionary new damper for their medical device. ACE was willing to take on that challenge.

Going the extra mile

The wide spectrum of motion control products in ACE's selection and the company's willingness to develop custom products in conjunction with their partners, proved to be the winning combination. The collaboration was kicked off with defining user- and technical requirements, such as desired frequency behavior and axial loading forces. Moreover, for this specific application, zero backlash is allowed. Otherwise, the tremulous movement would not be properly absorbed by the damper, and would instead be lost in play. Such a feature is almost never achieved within off the shelf components. Last but not least, the damper had to provide significantly more cycles than a regular one.

The consulting team and engineers from ACE dove into the challenge and developed a new damper. Technical verification was done by ACE, and validation with the end-users was performed by STIL. In such an iterative collaboration, three generations of dampers were developed, until ACE hit the sweet spot. When the performance of the final generation was satisfactory, STIL gave the green light for a larger order. This batch was consequently used in STIL’s first clinical trial, which is planned to be finished by before the end of 2022. With positive results, this will allow the company to CE-mark this one-of-a-kind medical device. This is a feat, which would have not been possible without the support and persistence of ACE.

“It has been very exciting for ACE to be a part of this fantastic project. The young team around IJsbrand and Nicola has developed a very innovative product which will help many people in their daily life. We are really happy and proud that we could provide STIL with the damping solution they were looking for and we wish STIL a world-wide success”, Dr. Peter Kremer and Heiner Tapken state. A happy IJsbrand de Lange reflects on the cooperation: ‘Over the years, we collaborated with a lot of partners, but none have shown the commitment that ACE has put into our partnership. I was, and am still, very impressed with their flexibility, the quality of their service and the outstanding products they deliver.”

As we report, STIL is about to launch the anti-tremor orthosis on the Dutch healthcare market. Together with Stabilus, ACE's parent company, the wearable device will be presented on a broader stage for the first time at Medica 2022 in hall 14, booth D68 from November 14th to the 17th. The introduction of the orthosis for other European health markets is scheduled for 2024, with Germany as the pilot.

After years of development, STIL introduces the anti-tremor orthosis in action at Medica 2022 together with Stabilus and ACE in hall 14, booth D68 from November 14th to the 17th in Düsseldorf.

STIL B.V. is endorsed by the Dutch Brain Foundation for the development of the anti-tremor orthosis, a collaboration which enables the company to execute clinical testing.

ACE’s rotary dampers produce reliable damping performances by shearing thin silicon layers between the surfaces of a rotor and a stator.

Rotary dampers provided by ACE meet a variety of requirements. Customers can choose between a large range of geared, screw-fixed, long-life, compact, chemical-resistant and types with torque adjustment functions, all to make finding the desired product easy.

Upgrading a large luxury coach with inexpensive, small components — what sounds like a paradox was realized by a Dutch construction designer by equipping the auxiliary air compressors of his motor home with vibration absorbers from ACE as extras, thus ensuring a quieter environment inside when parked.

In times of the global Corona pandemic, mobile homes are more popular than ever. There are a wide variety of mobile options for individual travel. The most luxurious ones are coaches and Recreational Vehicles (RV) from various suppliers in the United States of America. The mobile homes in this sector have developed into mobile five-star hotels with elegant interiors, exclusive exteriors and powerful engines. Neither loudly humming air conditioning systems nor other technical systems operated by the power of compressors such as air suspension, door opening and closing systems or sanitary facilities fit into the picture. While driving, the additional background noise from these consumers is not quite as disturbing, especially since the compressor connected to the engine then provides the compressed air. However, once stopped, the travelers also want to have their peace and quiet in the truest sense of the word. In the present case, when parked and with the main engine shut off, two auxiliary compressors take on the task of ensuring a comfortable mobile living environment. In detail, the problem with the air supply system for the vehicle suspension, doors and toilets was the fastening of the respective compressors. Mounted in one of the technology and supply areas below the mobile home, they transmitted the vibrations to the body. This resulted in clearly noticeable and audible vibrations, which the owner did not want to tolerate, especially as the two smaller compressors run intermittently and at intervals of 15 to 30 minutes depending on air consumption, which proved to be intolerable, especially at night.

Work experience a plus

Peter van Dijk, successor of the founding generation and senior partner of the Dutch company Dijko Ovens B.V. from Tilburg, felt compelled to act. As a mechanical engineer and expert in the automation and electronic control of oven systems with integrated vacuum and deep-freezing for large bakeries, neither air conditioning nor pneumatic systems and compressors are a closed book for him. So he searched the Internet for industry proven components for isolating vibrations. After a few clicks, he came across the Dutch language version of ACE Stoßdämpfer GmbH’s website.

It struck him that the company from the Rhineland, in addition to products from the areas of Automation Control, Motion Control and Safety Products, also has a large number of solutions for Vibration Control in stock. This market segment is of increasing importance at ACE, since the strict requirements of employee protection, including noise pollution, can be met with vibration-isolating pads, rubber-metal isolators and low frequency pneumatic leveling mounts such as air springs. The field of vibration absorbers alone now consists of eleven different product families at ACE. Summarized under the collective term rubber-metal isolators, these components enable a wide range of applications. In doing so, they insulate disruptive shocks and vibrations from machines and engines to such an extent that working conditions for people and the environment improve significantly. For example, in the field of measurement technology, it is often only through their application that usable results come about. Whether it is leveling or robust machine feet, tube elements, vibration isolating connection elements or quick attachment elements, all ACE rubber-metal isolators can be used universally. They represent ideal solutions for most of the vibration isolation problems known in industrial applications. The additional bonus that the internationally renowned service from ACE also helps with individual projects is shown by the fact that the successful computing for making the air compressors of the mobile home less noisy was made possible by using ACE’s free calculation tool.

Finding a customized design within a few clicks

After considering all key data relevant to the respective construction, such as weight and support points, the sizing tool specially developed by ACE calculates the center of mass of the machine and thus the individual load on the support points, whereby eccentric loads can also be entered. The program employed is available online and is so intuitive to use that in many cases engineers and designers can find the ideal solution for vibration isolation in just a few steps, 24 hours a day. If desired, only fail-safe absorber types can be selected. However, the software not only determines which vibration absorbers best match the entered values, but also enables orders to be placed in the connected online shop. 

In the present case, the program suggested Bubble Mounts, specifically of the BM-50641 type. These inexpensive and efficient helpers achieve an insulation level of 95.65 percent under the given conditions and are designed especially for use under load in vertical compression loads. Being designed as low frequency vibration absorbers, the BM types reliably protect electronic and medical equipment, aircraft avionics and computers. As this case proves, they can also be used for effectively isolating small pumps and compressors. They are available in two low frequency vibration isolation versions while the five different available types withstand loads between 0.7 kg and 8.2 kg. Despite being small, all of them offer high-impact cushioning, which can be increased by the use of silicone. Their natural frequency with a nominal load of 8 Hz is so low that dangerous vibrations can be effectively eliminated in most cases. Like their siblings, the BM-50641 used here are easy to install and accept loads of 1.2 kg to 2.9 kg. 

Peter van Dijk looks back on the assembly process and the replacement of the components: “The original anti-vibration was done with ordinary cylindrical rubber spacers, measuring 15 mm in diameter and a height of 15 mm. This was very inefficient for the isolation of the compressors, and it transduced a lot of vibration. Just after replacing these original washers on the first compressor with ACE’s components, a difference was already noticeable and tangible, as my video also shows.” To distribute the load evenly, both compressors, weighing in at 7.3 kg each, are now mounted at all four respective points with the fitting components provided by ACE. The degree of insulation of 95.65 percent determined in theory now also ensures in practice that Peter van Dijk's coach meets the standards of a 5-star hotel when parked, and especially at night.

Especially when parked, travelers of coaches and RVs prefer to have some peace and quiet. Therefore, AC- and other technical systems for the air suspension as well as for the operation of doors and sanitary rooms should cause as little noise as possible, preferably at night

ACE’s sizing tool for machine foundation isolation is available around the clock for quick and easy input and precise configuration in Dutch and German language versions: www.ace-ace.nl/nl/berekeningen/trillingsdemper-berekening.html ACE also offers a free calculation service in English https://www.acecontrols.co.uk/uk/sizing/vibration-control/free-calculation-service.html

Vibration isolation leads to noise reduction in this particular case and many others

ACE's low frequency vibration absorbers of the BM type reliably protect electronic and medical equipment, aircraft avionics as well as computers and can also be used for isolating pumps and compressors

Download link to video

http://cms.plus-2.de/ftp/downloadFiles/ACE/With_and_without_ACE_Bubble_Mount_Air_Compressor_RV_Petervan_Dijk.MP4

Links to background information

www.dijko.com

https://www.dijko.com/about/

https://www.acecontrols.co.uk/uk/products/vibration-control/rubber-metal-isolators/bubble-mounts.html

https://www.ace-ace.nl/nl/producten/vibratietechniek/rubber-metaal-isolatoren/bubble-mounts.html

Picture Credits
Pictures 1 & 3: Peter van Dijk
Pictures 2 & 4: ACE Stoßdämpfer GmbH

 In 2016, Stabilus began to drive business with industrial customers by acquiring various brands. On one hand, these users, their constructions and designs benefit from the wide range of high-quality, high-performance components which the business unit Industrial can provide. On the other hand, they also benefit from the combined experience and innovative solutions of the development and sales teams, which are brought together under the direction of Stabilus, global market leader for gas springs, dampers and electromechanical drives.

Christian Kirchbaumer has 15 years of professional experience in various positions in international marketing and comes with the relevant experience of rebranding, brand positioning and digital marketing. Over the next months, he will shape the globally active marketing teams of the newly formed Stabilus business unit Industrial into a globally networked marketing unit, additionally supporting the planned expansion in Asia. Jürgen Roland, long-time managing director of ACE Stoßdämpfer GmbH and Vice President and Head of Stabilus Industrial, comments: “We will communicate our specialized brands and their benefits for industrial customers and at the same time bring them closer together under a uniform roof. Thus, the affiliation to the international market leader Stabilus becomes even more visible."

Christian Kirchbaumer, 'Head of Global Marketing' of the Stabilus business unit Industrial

Pinpoint Scientific Ltd. designs and manufactures a range of high-quality microbial environmental monitoring products for pharmaceutical clean rooms and other highly-controlled environments. “We are a technology-driven company and strongly believe in customer involvement throughout our development process to ensure our products meet their exact requirements. Our air and surface samplers were developed with the involvement of two or the largest pharmaceutical companies in the world,” states Gethin Jones, managing director of the globally operating enterprise which is based in Bridgend, Wales, near Cardiff in the UK. Asked about the qualities of the ImpactAir-140, he looks back at the development and says that the company thought it was about time the selection of 140 mm Slit-to-Agar air monitors was brought up to date. Since Pinpoint Scientific believes in developing only the best quality and performance products, ImpactAir has a whole list of advantages over the nearest competitors. The stainless steel construction does not shed particles, offers ultra low vibration and has a universal power supply with less than 50 Watt power consumption, while making operation easy with a large clear touch screen display and a remote control panel option. Fully validated to ISO 14698 for physical and biological efficiency, the system can be equipped with a range of accessories and still boasts only half the footprint and 4 kg less weight than its closest rival. Crucially, and unlike any other sampler of its kind, it has a built-in system that constantly monitors and adjusts the distance between the inlet and the agar surface, a factor which can cause significant performance variation in other samplers. In conclusion, users of ImpactAir work with higher sampling efficiency compared to the reference instruments and the nearest competitor, making it the new gold standard for monitoring and sampling in Class A through to D laboratory environments.

In order to make the daily work in clean-room environments of laboratories in the high-end food sector or medical technology, as well as in the pharmaceutical industry as easy as possible, the designers at Pinpoint Scientific have created a unique solution that has been thought through down to the smallest detail. During their search for high-quality components and while working on improving the operation of the lid with a quality solution for linear motion control the engineers contacted Applied Automation, one of ACE Fabreeka UK’s distributors. After considering all requirements and wishes, their field engineer recommended hydraulic dampers.

Hydraulic dampers filled with special oil for a special solution

Wyn Gordge, Area Manager for ACE Fabreeka UK, describes the initial situation: "We have often worked successfully with our distributor Applied Automation, and in this case study working together quickly led to the desired result for Pinpoint Scientific as well." The decisive point for the use of hydraulic dampers was the customer's request for the lid of the sampler to be opened without any significant effort. Without this requirement, industrial gas springs, which can be precisely adjusted to the desired opening and closing speed by means of a valve that are offered made of stainless steel by ACE, would have been suitable motion control components. However, hydraulic dampers were chosen since they provide a constant feed rate combined with easy adjustability and only have to be tapped lightly to trigger the opening process of the lid. Another plus is the fact that hydraulic dampers enable a gentle closing process with additional damping.

ACE and Applied Automation were able to demonstrate another strong case in point: known as competent development partners and valued for customer-specific solutions, also when initially supplying small quantities, the team achieved a masterpiece of hydraulics. Since the ImpactAir-140 microbial environmental monitoring products are mostly used in critical laboratory conditions and clean-rooms, the use of mineral oil as a damping medium in the cylindrical body of the brake was out of the question according to the specifications from Pinpoint Scientific. Due to this requirement and because of the sensitive areas of application, ACE chose to fill the dampers with a specially refined vegetable oil with a very similar viscosity and service life. In the course of the product design, the engineers at Pinpoint Scientific contributed stainless steel sleeves with which the outer bodies of the hydraulic dampers that are made of coated steel are covered. On the one hand the stainless steel covers enable better hygiene owing to strict clean room requirements and on the other hand the material of the sleeves matches the rest of the unit.

The ACE components featured in this case are HB15-50 type hydraulic dampers with outer body diameters of 15 mm and a stroke of 50 mm which makes them ideally suited to easily open the lid and to keep it at an opening angle of 60 degrees as desired. Coming with variable adjustment of the compressive and extension force between 20 N and 800 N, installing these hydraulic dampers is child's play with the adjustment segment on the piston. Due to their high quality and long service life, there are practically no limits regarding the wishes of customers such as Pinpoint Scientific with regard to the frequency of opening and closing high-end solutions such as ImpactAir-140. When not working in pharmaceutical clean rooms and other highly controlled environments, these top-quality components for precise motion control are primarily used in a wide variety of automotive or industrial constructions, but also in the electronics, furniture and leisure industries.

Pinpoint Scientific’s solution ImpactAir-140 is designed for continuous monitoring in high-grade areas, where in-process sampling of viable particles is often critical

The construction is made of 316L Stainless Steel with the hydraulic dampers for easy opening and closing of the lid covered by matching sleeves

Bodies made of coated steel in a slim gas spring design and piston rods with wear-resistant surface coating are distinctive features of ACE’s hydraulic dampers that offer users high quality and long service life along with easy adjustment achieved by turning the piston rod in its fully extended or fully compressed position

With outer body diameters between 12 mm and 70 mm and strokes ranging from 10 mm to 800 mm, the hydraulic dampers of the ACE product family HB can also be used as single or double acting brakes lending compression and extension forces from 20 N to 50,000 N to a wide variety of applications