Design 14 February 2013

February 14, 2013A Penton Media Publication

Tune in to EngineeringTV.com

HOW TO DEAL WITH WATER

HAMMER,

page 54

NICE THREADS: BASICS OF METAL

INSERTS,page 66

LUBRICATION FOR LIFE, page 72

New developments in 3D printing

page 46

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FEATURES

Water hammer can affect most any fluid system with rapidly changing flows.

FLUID POWER

Water hammer (or steam hammer) is a violent flow transient in piping named for the loud banging it generates. It can affect almost any fluid system that experiences rapidly changing flows, including power-plant piping, water-supply systems, pumped storage facilities, oil pipelines, and hydraulic and general fluid-handling lines.

Water hammer is not just a nuisance. It can rupture or collapse pipes, uproot anchors, and cause other calamities associated with excessive pipe movement. Proper design and operation prevent such destruction.

Pressure wavesTo design piping systems that stand up to the forces that water hammer gen-

erates, engineers first need to recognize pressure-wave propagation in pipes. This includes both the size and swiftness of the pressure surge, and how pres-sure waves affect pipe.

Suddenly closing a gate or valve builds up pressure by Δp that propagates up-stream at the speed of sound. The pressure wave is reflected at the reservoir or junction and travels back to the gate, changing pressure in the pipe by –Δp. The wave reflects off the closed gate, turns into a negative pressure wave and travels toward the reservoir for a second round trip. The pressure wave decays in two to three cycles.

Engineers can determine the magnitude of the pressure surge by considering a layer of fluid adjacent to the gate (as shown in the Control volume illustration). As the gate closes to block flow, the resulting boundary forces on the control volume accelerate the fluid mass inside.

Violent flow transients

can destroy piping.

Here’s a look at the

causes, and how to

head off problems.

Authored by:

Moo-Zung LeeWest Hills, Calif.

Edited by Kenneth J. [email protected]

Key points:• Water hammer can affect most any fluid

system with rapidly changing flows.

• It can rupture or collapse pipes, uproot or damage supports, and break connections to equipment.

• Solutions include well-designed restraints, slowing valve openings, and eliminating entrapped air.

Resources:Moo-Zung Lee has a BSME from the National Taiwan Univ., MSME from the Univ. of Houston, and a Ph.D. from New York State Univ. at Stony Brook. He has nearly 40 years experience in power-plant construction and dynamic and stress analyses of nuclear-power-plant piping and aerospace and defense systems.

Taming

WATERHAMMER

FEBRUARY 14, 2013MACHINE DESIGN.com54

INSTRUMENTATION

Authored by:

Jim Schwartz, National Instruments Corp.Austin, Tex.Edited by Leland [email protected]

Key points• Consider the complete systembefore testing begins.

• Account for hardware, software, data storage and processing, and the testing environment when developing a test system.

National Instruments Inc., Austin, Tex., www.ni.com

More on this case study, http://sine.ni.com/cs/app/

doc/p/id/cs-14909

ITM, Milford, Ohio, www.un-yah.com/

Tips for

largemachinerytestsystems Visualizing test data

When testing large cranes under potentially dangerous loading conditions, the ability to visualize and

interpret the data in real time can prevent failures and make things less risky for personnel. This application

employed a structural test environment called iTestSystem from ITM that included capabilities to

process the data during acquisition.

Data storage and post-processing Test systems for compliance with safety standards

must output data in a standard file format. Because ITM collected data in a standard file format, Manitowoc engineers could analyze data and verify test results

using existing in-house software.

Electromagnetic interference

Noise sources like TV and radio stations can affect

measurements, necessitating data filters to ensure accuracy. For example,

the NI CompactDAQ data acquisition platform from

National Instruments includes integrated signal

conditioning such as filtering, amplification, and excitation.

Quarter bridge measurements

Instrumentation options are limitless. You need to

chose hardware that can be optimized for the application.

ITM engineers used NI C Series modules with the

NI CompactDAQ platform. Each module includes

built-in bridge completion, excitation, amplification, and filtering required for making

quarter bridge strain gage measurements.

Shielding from the elements Most large equipment won’t fit in a test lab. It’s usually exposed to the elements. Each piece of

instrumentation should sit in rugged, sealed enclosures. In ITM’s case, Nema 4X enclosures

protected instruments.

Safety standards Engineers at ITM had to pay close attention to

SAE J987, which outlines the methods for testing static loads on a lattice boom crane. This let them

supply Manitowoc with the test results to show compliance. SAE J987 dictates this particular test,

but nearly every large piece of machinery has certain standards and codes.

Instrumentation and documentation The safety standard usually includes the required instrumentation accuracy, calibration procedures, and documentation steps for the final report. But different manufacturers may have more detailed or stringent requirements. Failure to understand

them can cost hours of test time

Choice of strain gage Strain gages have nearly

unlimited variations based on qualities such as size,

sensitivity, material temperature coefficients, temperature ranges,

and measurement axis. Pay attention to the strain gage properties and the material it mounts on. Here, 32 strain gages mount to each lattice

section along the entire length of the boom, according to the

methods described in SAE J987. Measurements of buckling stresses in the crane boom

lattices came from single-axis 350-Ω strain gages used in a

quarter bridge configuration. In total, ITM used 144 strain gages along the length of the boom.

Lead wire resistance and shunt calibration A strain measurement is essentially a resistance

measurement, so lead wire resistance can cause offsets.

Quarter-bridge measurements are inherently sensitive to the resistance of wiring between the sensor and measurement device. So long wire runs on

off-highway equipment are a problem. A method called shunt calibration can quantify the lead

wire resistance and nullify this effect, either in software as data is acquired or in post-processing.

What to look out for when

sensors get widely dispersed

over big machines.

With data acquisition projects, the costs of delays are often high. That’s particularly true for heavy machinery like cranes, mining shovels, and excavators. Examples come from obstacles commonly faced by engineers measuring strain along the length of a 300-ft crane boom made by Manitowoc Cranes. Mark Yeager and Tim Carlier, test engineers for Integrated Test and Measurement (ITM), a service provider (employed by Manitowoc Cranes) specializing in challenging test applications, took these measurements over several weeks. MD

FEBRUARY 14, 2013MACHINE DESIGN.com64 FEBRUARY 14, 2013 MACHINE DESIGN.com 65

VOLUME 85ISSUE 2

FEBRUARY 14, 2013

Access our Reader Service Web site to quickly find and request information on the

products and services found in the pages of MACHINE DESIGN.www.machinedesign.com/rsc

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The changing face of 3D printing

Technology once deemed too expensive for

wide use has infiltrated manufacturing and

even become a hit with consumers.

Taming water hammer

Violent flow transients can destroy

piping. Here’s a look at the causes, and

how to head off problems.

Tips for large

machinery test systems

An example shows how to configure

data-acquisition instrumentation

when sensors are widely dispersed

and subject to the outdoors

environment.

Putting inserts in plastic

parts: Ultrasonic or heat?

Threaded inserts can be placed in

thermoplastic parts using heat or

ultrasonics. Here are the advantages

and disadvantages of each.

Motion-Control

Technology Guide

Reliability and lubrication

VFDs: Boosting efficiency in hoisting applications

Practical protection of motion designs and workers

Baggage-scanning system minimizes lost luggage


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RS# 103

DEPARTMENTS

EDITORIAL

Secret to achieving goals: Don’t try too hard

EDITORIAL STAFF

LETTERS

SCANNING FOR IDEAS

Rifle lets sniper set new record

Torque limiter protects machinery

REPORTER’S NOTEBOOK

LOOKING BACK

COMMENTARY

Acquihire: When companies have more money than brains

SENSOR SENSE

Pulse-ranging technology

TAVENNER ON SAFETY

Rolling equipment, fractured feet

VANTAGE POINT

Meeting and beating new-product cost targets —Julie Driscoll

ORR ON ENGINEERING

The nature of design

SOFTWARE REVIEW

Direct modeler builds a better fuel tank

PRODUCT SPOTLIGHT

Mechanical slides, drives, & gears

PRODUCTS

DATA FILES

BUSINESS INDEX

AD INDEX

CLASSIFIEDS

BUSINESS STAFF

BACKTALK

For customized article reprints and permissions please contact: Wright’s Media, 877-652-5295, or email at [email protected].

Editorial content is indexed in the Applied Science Technology Index, the Engineering Index, SciSearch and Research Alert. Microfilm copies available from National Archive Publishing Company (NAPC), 300 N. Zeeb Rd., P.O. Box 998, Ann Arbor, MI 48106-0998, Ph: 734-302-6500 or 800-420-NAPC (6272), extension 6578.

Permission to photocopy is granted for users registered with the Copyright Clearance Center (CCC) Inc. to photocopy any article, with the exception of those for which separate ownership is indicated on the first page of the article, provided that the base fee of $1.25 per copy of the article, plus $.60 per page is paid to CCC, 222 Rosewood Dr., Danvers, MA 01923 (Code No. 0024-9114/13 $1.25 + .60).

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Printed in U.S.A., Copyright © 2013. Penton Media, Inc. All rights reserved. MACHINE DESIGN (ISSN 0024-9114) is published semimonthly except for a single issue in January, February, April, June, July, August, and October by Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66212.

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Kep-O-seal

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Free 76-page catalog and technical assistance

Controls micrositeHeidenhain has launched a microsite on its TNC

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Relays and controlsThe Littelfuse Technical Center lets users download

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Littelfuse.com/RelaysControls.

The Model X from TeslaAt this year’s North American International Auto

Show, Editor Leland Teschler talks to a Tesla

Motors product planner about the new Model X.

The electric car blends a minivan and SEV and has

unique “falcon” wing doors that swing up and out

of the way. With optional all-wheel drive, the Model

X sports 0 to 60-mph acceleration in under 5 sec.

Get a preview at www.engineeringtv.com/video/

The-Model-X-Complete-with-Falco;Only-Engineering-

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RS# 106

EDITORIAL

Secret to achieving goals: Don’t try too hard

Spring is in the air, and to many people, that means it’s time to pursue a national pastime. No, not baseball: evaluating last year’s employee per-formance goals and setting new ones.

I don’t know what the process looks like in your company, but at mine, it often involves going back to last year’s performance reviews and changing goals that were obsolete two weeks after they were writ-ten. Managers then write in another set of goals that pretty much reflect what their employees actually accomplished last year.

I used to stress out over whether changing goals after the fact this way defeated the purpose of the whole exercise. But that was before I became aware of an increasing body of research showing that pursuing business goals too relentlessly can be counterproductive. Among those who have come to this conclusion is Chris Kayes, a George Washington University professor of management science. Specifically, Kayes noticed problems cropping up when organizations set big, audacious goals for themselves, a tactic frequently advocated by management consultants. Evidence often emerged that the goal was either wildly out of reach or just unwise. But instead of abandoning the whole idea, some organiza-tions would pour even more effort into it. This redoubling of exertion oftentimes resulted in plans going farther off track.

Interestingly, Kayes thinks a lot of these ill-advised escapades hap-pen because the people involved find it easier to continue investing in a strategy that isn’t working than to change course. The goal, he explains, can become part of their identity. Uncertainty about the goal then no longer merely threatens their plans, it threatens them as individuals. Sticking to the plan makes them feel better by giving them a sense of certainty about the future, even as evidence mounts that they’ve got the wrong plan.

Another management consultant who finds fault with conventional ideas about goal setting is Stephen Shapiro, author of books such as, Goal-free Living, and a speaker at TEDx conferences. Shapiro once commissioned a survey that found 41% of the respondents weren’t any happier after achieving goals they’d set for themselves. It also revealed 18% claimed goals had destroyed a friendship, a marriage, or another significant relationship. Another 36% claimed adding goals on their to-do list made them worry more, though over half of them had a goal of reducing the amount of stress in their lives.

Shapiro now tells companies that they can get more out of their employees by getting rid of goals. Instead, he says, it’s better to have a broad sense of direction but without a precise vision for the future.

Similar themes emerge from the work of University of Virginia busi-ness research professor Saras D. Sarasvathy. She questioned successful entrepreneurs about the best way of bringing a new product to market. They largely pooh-poohed the idea of devising a business plan with a lot of specific goals. Better to just go out and try things, they said. You’ll find you what your immediate goals should be as you go along.

Which pretty much explains why we generally figure out annual em-ployee goals only in hindsight.

— Leland Teschler, Editor

RS# 107

FEBRUARY 14, 2013

M i c r o h y d r a u l i c s .M a c r o c a p a b i l i t i e s .

Lee ShuttleValve. Shownactual size.Designed toisolate thenormal fromthe emergencyhydraulic sys-tem. So small,it fits rightinto the headof an actuator.

W e s t b r o o k • G e r r a r d s C r o s s • P a r i s • F r a n k f u r t • M i l a n

So much reliability and performance, in so little space.Creating high-performance flow control on a micro scale has beenThe Lee Company’s exclusive focus for more than 50 years. And it’s been a successful mission, as evidenced by thousands of applied Lee Microhydraulics designs – ranging from less than 0.10 in. to 1.00 in.in diameter, and 0.1 to 68 grams, for operating pressures to 8,000 psi.

But small size and light weight are just the beginning.There’salso absolute reliability built into every Lee component through100% testing and inspection. Zero defects. It’s a production benchmarkthat has enabled Lee to meet demanding application needs in allsorts of industries. Aerospace, medical instrumentation, automotive,machine tools and oil drilling, to name a few.

The innovative problem solvers.We don’t just satisfy requirements.We also solve problems –whether by simple modification, or ground-zero design engineering.The Lee Company is the world’s most capable and proven source for hydraulic-component innovation. And we’ve documented thisclaim in extensive detail with the Lee Technical Hydraulic Handbook.An invaluable reference, the Lee handbook contains essential dataon the entire Microhydraulics product line, which includes:

Lee Shuttle Valves. Detented, spring-biased, inverse,loose ball and zero leak shuttle valves from 50-700 Lohms.

Lee Safety Screens. Best protection for critical system elements. 75 to 500 micron hole size. Pressures to 7,500 psid.

Lee Pri. Pressure relief valves in insert form.50 to 400 Lohm capacity. 20 to 5,400 psid cracking pressures.

Lee Directional Flow Control. 40 to 20,000 Lohms in metered direction. 12 to 470 Lohms in free-flow direction.

Lee Restrictors. Single and multi-orifice restrictors.200 to 2.2 million Lohms.

Lee Plugs. The best way to seal drilled holes to 32,000 psi.No O-rings, threads or sealants required.

Lee Cheks. All-metal and zero-leak check valves.4 to 400 Lohms.

Essential reading for designers ofhydraulic systems.Send for your free copy.

The Lee Company2 Pettipaug Rd,Westbrook CT 06498-0424860-399-6281 Fax: 860-399-22701-800-LEE PLUGwww.TheLeeCo.com

Innovation in miniature.

RS# 108

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Spring Applied Brakes

EDITORIAL STAFF

1300 E. 9th St. Cleveland, OH 44114-1503

EDITORLeland E. Teschler

[email protected]

MANAGING EDITORKenneth J. Korane

[email protected]

SENIOR EDITORSElisabeth Eitel

[email protected]

Leslie [email protected]

Stephen J. [email protected]

ASSOCIATE EDITORSLindsey Frick

[email protected] J. Repas, Jr.

[email protected]

INDUSTRY COVERAGE:

AUTOMOTIVE, PACKAGING, MEDICAL

Stephen J. Mraz

CAD/CAM, MANUFACTURING Leslie Gordon

ELECTRICAL, ELECTRONICS Robert J. Repas, Jr.

FASTENING & JOINING, MATERIALSLindsey Frick

FLUID POWERKenneth J. Korane

MECHANICAL

Elisabeth EitelLindsey Frick

Kenneth J. Korane

EDITORIAL PRODUCTION Denise Greco

Editorial Production Manager

Randall L. RubenkingArt Director

RS# 110

RS# 109


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RS# 111

LETTERS

looking for those trained employ-ees, dry your eyes and try spend-ing a little bit of your millions to train a few people for yourselves.

Richard Distel

Snow clones?

I read the article, “Rethinking the Snowmobile” (Nov. 20), and noticed that the Snow Runner is similar to the Snow Hawk which has been around since 2002. The asking price

Companies crying crocodile tearsYour editorial is just another tearful plea by companies for more low-cost yet fully trained employees (“More Green cards, More H-1B Visas,” Nov. 6). If they want em-ployees trained beyond the ability to read, speak, think, and perform math, I suggest they train those employees themselves.

Over the years that I ran a tool-and-die company, we routinely trained apprentices at a ratio of one for every eight journeymen. It was a four-year program and included almost 1,000 hr of class time, paid at straight time, but wages rose as the apprenticeship progressed. The apprentice paid tuition but got it back as a lump-sum reward after graduation. Un-fortunately, these new journey-men then went to the bottom of the seniority list and got laid off first and soon, due to the cyclical nature of the automotive trade. Most of them quickly found an-other job. About half returned and several stayed with us over the years, several rising to managerial positions in our company.

I guess we trained them too well. Many went on to manage-ment or engineering jobs at the big three (gasp — on only a four-year apprenticeship after high school). The goal was that any graduate apprentice, left alone in the shop with a part print and a wood model (or later a math model and a computer) would be able to design, build, and tryout dies for a sheet-metal part — from a bracket to a quarter panel. We were a small company, but we did okay in competition with the Henry Ford Trade School and the GM Technical Institute. Those in-stitutions are also gone now, of course. No need to train people if we can get them trained to our specifications at public expense from state universities either here or in China, India, or Korea.

Hey, Microsoft, while you’re

for the SR-125 ($5,550) is compara-ble to a Ski-Doo MX Z Sport ($6,549), which seems like a better deal.

Jim Smouse

Yes , our Snow Runner and the

Snow Hawk are both single-ski ve-

hicles, but that ’s where the simi-

larity ends. Look at the design re-

quirements we set out and met in

the development process — com-

pletely different than the Snow

Hawk or traditional snowmobiles.

Shortage? What shortage?Several readers commented on Leland Teschler’s recent blog entry (“Not So Bad : Manufacturing Skills Gap is Local, Not National,” Oct. 16). It mentioned a study that indicated machinists and welders were in short sup-ply in only five of the top 50 manufacturing cities in the U. S. Readers, all manufac-turers, disagreed.

Tulsa, Okla., may not be one of the top five manufacturing centers, but we manufacture a lot of the equipment used in oil and natural-gas production and refining. There are billboards, roadside signs, and even a sign in a local BBQ restaurant put up by local companies looking for CNC machinists with at least three years of experience with starting pay of a minimum of $25/hr. Skilled welders start at $18 to $20/hr, plus overtime. That is good money in this region with some of the lowest housing costs and gasoline prices in the country.

Don Allen

This is the biggest load of nonsense I’ve read in a long time. Manu-facturers, including me, have a completely different experience with trying to hire and retain good machinists and manufacturing people.

Chis Reeve

I think the study’s analysis is severely flawed. In our area in central Min-nesota, we have serious skill gaps in many areas, especially for welders and skilled machinists. A large effort is being expended in our area to address the skill gaps and train workers.

Lester Engel

Their statistics don’t match the on-the-ground experience among manufacturers I’m networking with in the Los Angeles area. It’s a bo-gus study.

William Pratt


RS# 112

We designed the AGR series motorized rotary stages to provide significantimprovements in speed, load capacity and long-term positioning performance overprevious generations of worm-gear-drive stages. The AGR series incorporates duallarge diameter pre-loaded angular contact bearings optimally separated to provideexcellent error motion specifications, as well as best possible load handling capability.The large clear aperture (sizes from 50 mm to 200 mm) allows the AGR series toaddress applications requiring a through-hole fixturing.

Contact our Application Engineers today for more information on the AGR series orany of our other superior direct-drive and worm-drive rotary stages.

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LETTERSLETTERS TO THE EDITOR

Please include your name, address, and daytime phone number. Letters may be edited for brevity and to focus on essential points.

Mail: Letters, MACHINE DESIGN, 1300 E. 9th St., Cleveland, OH 44114-1503, Fax: 216-621-8469

E-mail, Editorial: [email protected]

Such projects are worth funding early on for addition to our scien-tific knowledge-base. However, failing to honestly identify further development projects as impracti-cal nonstarters illustrates what is wrong with how our government decides where and how to spend our money.Selfish researchers, bent on

making a name for themselves, or on creat ing a fasc inat ing open-ended career-length proj-ect, should not be permitted so much influence over the decision-makers. Objective experts should have majority influence, not the pioneering expert or the ignorant politicians.

Mike Netbith

and fossil fuel to make this fuel (“Navy Tries Turning Seawater into Fuel,” Nov. 20,). There are many bet-ter ways to reach this objective.

Al Nabhani

First off, you do not catalytically combine CO

2 and H

2 to get hydro-

carbons without a lot of energy input. Second, there is no free hy-drogen in seawater. Any hydrogen would have to come from breaking down water molecules, a process which requires more energy than the resulting fuel can supply. And finally, there is not a lot of carbon in seawater. Seawater is 1.4% CO

2.

Jim Deggit

If this is for real and is an indication of the “science” in the U. S. military, they need to start firing a lot of people, starting with the idiot who approved this garbage.

Brian Dermot

The concept sketches and idea for

the veh icle star ted in 2001 and

sat for a while until our patented

ski was developed. The ski turned

our vehicle from a difficult-to-ride

vehicle into the fun, easy-to-ride

machine it now is. We have had

people from 10 years old to well

over 70 riding vehicles in just sev-

eral minutes of practice with no

instruction and, in some cases, do-

ing extreme maneuvers just not

possible with other vehicles.

I could go on and on but the

S n ow Ru n n e r a n d S n ow H a w k

fit different niches in the market

place (cost, size, weight, end user,

zero pollution electric, etc).

Good luck and have a great

winter snow season. — Jim Wade

Seawater not fit for fuel?

Why do we neglect the obvious, cold fusion? It still takes nuclear

RS# 113FEBRUARY 14, 2013MACHINE DESIGN.com14

WHAT MOVES YOUR WORLD

IT’S TIME TO CHANGE

THE FUTURE OF

MOTION CONTROL.

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industry you’re in. For more information call 866-580-7610.

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Download our comprehensive white paper on electric and hydraulic

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RS# 114

SCANNING FOR IDEAS

Suppressor reduces muzzle flash and noise

Adjustable bipod supports rifle

Magazine lets shooter rapidly fire five rounds but is sized to not interfere with alignment of barrel.

Adjustable cheek piece lets shooter align his eye with the

telescopic sight

Folding stock shortens the length of the rifle, letting it be

carried in a backpack.

Telescopic sight magnifies targets by a

factor of up to 25.

Full-length aluminum

chassis

Fixed butt plate and spacers

Three-position safety

Short throw bolt

Free-floating barrel

Edited by Stephen J. Mraz

For more on new rifles and their design, scan this code or go to http://

machinedesign.com/

article/a-21st-century-

rifle-0112

Rifle lets sniper set new record

The L115A3 long-range rifle was used by a British soldier to hit and kill two Taliban targets at a distance of 8,120 ft, a record for sniper shots. The weapon is a version of the 338 Lapua Mag-num rifle from Accuracy International of North America Inc.in Fredricksburg, Va. (www.accuracyinternational.us), the U. S. headquarters of a British firm. It was modified under the British Ministry of Defense’s Sniper System Improvement Programme. So now it fires an 8.59-mm round, which is heavier than the

original 7.62-mm round and, therefore, less likely to be af-fected by winds during long shots. It also has a spotting

scope that magnifies by a factor of 25 instead of the original scope which only has 12× magnification.

Muzzle velocity also increased from 838 to 936 meters/sec.

The civilian version of the rifle is avail-able to qualified buyers, but prices

are in the $9,000 range.RS# 401


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common thermoplastics used in injection molding. Enter code MA13A.

© Proto Labs 2013 ISO 9001:2008 Certifi ed ITAR Registered Visa/Mastercard AcceptedRS# 115

Friction discs

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SCANNING FOR IDEAS

Torque limiter protects machinery

When torque is transmitted from one machine compo-nent to another, equipment can be damaged when a jam prevents rotation of the driven component. To prevent torque overloads from transferring to costly upstream components, en-gineers at Mach III Clutch Inc. Walton, Ky. (www.

machiii.com), have devel-oped a series of torque lim-iters that prevent damage by slipping until the over-load stops or the machine shuts down.

The torque out-put of the device is proportional to the compression of the disc spring and can be set or adjusted in the field. The device comes in 30 dif-ferent models with torque capacities rang-ing up to 17,257 lb-in. There are also five different mounting options.

RS# 402

FEBRUARY 14, 2013MACHINE DESIGN.com18RS# 116

Timing pulley

Setscrew

O-ring seal

Precision-machined drive

plates

Disc spring

Adjustment nut

Bronze bushing

www.pelicanoem.com/mdPELICAN PRODUCTS , INC.

23215 Early Avenue, Torrance, CA 90505 866.628.9890 (TOLL FREE) Q 310.326.4700 Q FAX 310.326.3311

All trademarks are registered and/or unregistered trademarks of Pelican Products, Inc., its subsidiaries and/or affiliates.

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Harnessing our global resources, Pelican-Hardigg Advanced Case Solutions™ develops custom case solutions using a multidisciplinary process under the industry’s most experienced project management team. Driven by your product’s specifications, usage and environmental analysis, these custom case solutions can provide you with the highest level of Mission Critical confidence in the field – guaranteed.

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RS# 117

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A few examples of the Stratasys 3D Printer line.

3D technology is all around us. It’s changing how we design and manufacture products, make movies, heal our bodies and interact with the world. Work that used to take place on a page or screen now reaches into space. And faster than ever before, 3D technology is transforming our world.

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the world with mass production. It brought luxuries to the middle class, good wages to workers and econo-mies of scale to investors. Today, companies like BMW already know that DDM is mass production’s heir

The Future of 3D Technology From This Day, Forward By David Reis,

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A pediatric engineering research lab has developed and 3D-printed custom devices for their smallest patients.

This rover includes about 70 FDM parts, including housings, vents and fixtures.

a Delaware hospital creates a durable ABS-plastic exo-skeleton customized to perfectly fit one child, Emma, allowing her to play, explore and hug for the first time. Then that researcher can make a 3D-printed exoskel-eton to fit a different child. And another. And a dozen more. Now 15 children with rare disorders can raise their hands because of mass customization.

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apparent. One factory-floor fixture, a nameplate-ap-plication device, offers an elegant example. Liberated from tooling constraints, BMW engineers reduced the device’s weight by half and replaced its blocky stock-metal handles with ergonomic grips — a great relief to workers who might lift the fixture hundreds of times per shift.

Today, NASA can shape a complex, human-sup-porting vehicle suitable for Martian terrain, despite the fact that its parts are too complex to machine, too rapidly iterated to outsource and too customized for traditional tooling.

In a 3D world, we leave behind injection mold-

RS# 118


Throwable robots paddle along thanks to upgraded servomotors


ReconRobotics Inc., Edina, Minn., decided to upgrade its 1.2-lb throwable recon-naissance microrobot to include paddlelike wheels specifically designed for climb-ing. But to do so, the company had to boost the power of the wheel-driving servo-motors. “The robot had to be able to lift its own weight,” explains ReconRobotics Product Management Engineer Casey Carlson. “The original ThrowBot was designed to navigate relatively uncluttered urban environments and could surmount some household objects such as power cords. But we wanted the robot to be able to rou-tinely climb obstacles such as door thresholds and other obstructions commonly found within and around urban dwellings. We also wanted to keep the same size and shape for the main body of the robot, which houses all of the functional aspects of the robot including motors.”Resembling a small dumbbell, the new ThrowBot TXT comprises a pair of 4.5-in.-

diameter wheels linked by a 1.5-in.-diameter, 6-in.-long crossbar. It is tough enough to survive a 30-ft drop onto concrete. SWAT teams and military personnel typically throw the small robots into hostile areas to get remote video and audio of poten-tially deadly situations. A human operator pilots the robot with a wireless joystick.

Each wheel is driven independently by a 10-mm-diameter, high-power-density dc motor from MICROMO, a member of the Faulhaber Group, in Clearwater, Fla. The 1016 coreless dc micromotors in the ThrowBot TXT are specified to be run at a maxi-mum voltage of 6 V, but the engineers at ReconRobotics needed extra power, which called for feeding the motor at 10 V. “We needed the motor to output about 65% more power than what the motor was originally rated for,” says Carlson.

The standard version of the motor comes with gold brushes. To tolerate the overdriving, MICROMO swapped in silver brushes and added a capacitor ring that minimizes damage to the brushes from arcing. The team also modified the motor windings to optimize output for a particular performance point the ReconRobotics team required. MICROMO also terminates the gearmotors by soldering custom cable assembles to the terminals, as well as mounting a pinion on the front shaft. Finally, MICROMO set up mean-time-to-failure testing to validate the new motor.ReconRobotics also modified the clutching mechanism between the wheels and

motor-drive system on the new ThrowBot TXT. The clutch decouples the wheels from the drive in hard landings so the instantaneous acceleration does not damage the gearmotor. The clutch is designed to disengage just above the maximum torque of the motor. Thus, there is no energy wasted transferring motor torque to the wheels. When higher torque is applied during impact, however, the clutch disengages, pre-venting the landing shock from reaching the motor and gearhead.

MICROMO delivers an assembly consisting of motor, gearhead, and cabling. As a result, the modules arrive at Recon already tested and operational. “The more plug and play we can get, the better,” says Carlson.

Though the ThrowBot TXT is relatively new to market, Recon says the response from customers has been quite positive, which Carlson attributes in part to the perfor-mance of the motors. “They give us the performance and lifetime we need and MICROMO is willing to lend its ex-pertise and adapt the motor to our needs.” MD

Resources:MICROMO, www.micromo.com

RS# 406ReconRobotics, www.recon-scout.

com/

MACHINE DESIGN also covered an earlier model of the robot, machinedesign.com/article/high-

density-servos-make-possible-

compact-recon-missions-0217

The ThrowBot XT weighs just 1.2 lb

and can be thrown up to 120 ft thanks

to a suspension system that prevents

shock loads from damaging the servomotor drivetrain. Each

wheel is driven by its own high-energy-density servomotor.

FEBRUARY 14, 2013 MACHINE DESIGN.com 23

Quick Disconnectvs Hard-Wiring: What is the

ideal connectivity systemfor your industrial application? askTURCK.com

©2013 TURCK


A Sopwith Dolphin, a World War I fighter aircraft made by Sopwith Avia-tion, the same company that made the Sopwith Camel, was fully restored using parts scavenged from other Dolphins along with parts made to specs from original drawings. Those remanu-factured parts include a pair of music-wire exten-sion springs for the pair of Lewis machine guns. The new springs were built by Lee Spring, Europe, which is headquartered in the U. K. They closely match the original set, which were 2.25-in. long, made out of 20-gauge steel wire with a 5/16-in. OD. Extension springs are generally loaded in tension and have hooks or loops on their ends which let them apply a pull force. Extension springs are usu-ally attached to components at both ends, and when those components are moved apart, the spring tries to move them back toward each other.

The Dolphin was the first fighter plane to boast four machine guns — two Vickers guns pointing forward

through the propellers, and a pair of Lewis guns fir-ing forward and upward, and mounted on top of the wings. While 1,778 Dolphins were built, this restored version is believed to be the only Dolphin now in exis-tence. Restoration on the Dolphin began in 1968, and now that it’s finished, the plane sits on display at the RAF Museum in Hendon, U. K. MD

RS# 119

Only 45 years to restore World War I fighter

Resources:Lee Spring, www.leespring.com

RS# 407RAF Museum, rafmuseum.

org.uk/research/collections/

sopwith-dolphin-5fi/

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Nanotube pencil “draws” sensorsChemists at the Massachusetts Institute of Technologyhave new tools for creating carbon-nano-tube sensors: pencils. But the graphite in these pencils has been replaced with a compressed powder of car-bon nanotubes. This makes cre-ating sensors as easy as drawing a line on a sheet of paper.

Carbon nanotubes are carbon atoms linked together to form a tube. The carbon provides little opposition to the flow of electrons, creating a low-resistance path compared to normal carbon. Gases bind to the nanotubes, impeding electron flow and raising the tube’s electrical resistance, which is key to making the simple sensors.

The first sensor made with the new tech-nology detected ammonia. Researchers drew lines of nanotubes between gold electrodes imprinted on a piece of paper and applied an electrical current. As the nanotubes attracted ammonia gas, the resistance changed. So re-sistance measurements indicated the amount of ammonia present.

Different kinds of paper provide different responses, with sensors drawn on smooth pa-per yielding the best reactions. Surprisingly, test results have remained consistent even when marks aren’t uniform.Researchers hope that with adjustments,

sensors could detect nearly any gas, includ-ing nerve gas. Soldiers could then carry pen-cils to quickly build sensors to detect chemi-cal weapons.

Other gases being investigated include ethylene, emitted by ripening fruit. Ethylene sensors might show whether fruit being shipped or stored is too ripe. Likewise, nano-tubes sensitive to sulfur could lead to sensors that detect natural gas leaks. MD

Resources:Massachusetts Institute of Technology, www.mit.edu

Nanotube sensor video, youtu.be/kWTrZxt4j50

MIT chemists designed a new type of pencil lead consisting of carbon nanotubes, allowing them to draw carbon nanotube sensors onto sheets of paper.

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CoDeSys lets users issue commands and transfer files over the network without authentication.

point is that the CoDeSys runtime offers a transmission-control-protocol listener service. The listener service typically runs on port 1200, although ports 1201 and 2455 were used on other controllers. Services provided by this listener include a command-line interface where instructions may be

sent directly to the ladder-logic runtime service and a file-transfer service that permits download-ing and uploading logic files.

Unfortunately, CoDeSys software executes this connection without user authentication. Anyone who knows how can connect through the CoDeSys software to execute commands and transfer files. For example, they can stop and start the running ladder logic, wipe the PLC memory, and list files

and directories. As the runtime operates with high-level privileges, all sub-directories and files are accessible, including critical system files such as /etc/passwd and /etc/shadow in Linux and the Window’s registry in CE.Right now, the only sure way of securing this or any industrial system is

to keep it off any network. However, IT staff can make access more secure by placing systems on private networks that can only be entered through specific machines that carry out user authentication. MD

Ladder-logic software vulnerable to hackersResearchers have discovered a design flaw lets anyone carry out com-mands without authentication on software called CoDeSys, which is widely used in industrial controls.

CoDeSys is an IEC 61131-3 software suite from 3S-Smart Software Solutions GmbH, Germany, that runs ladder-logic operations. It is used by over 260 manufacturers to run ladder-logic programs on PLCs, drive controllers, and other industrial controls. The vulnerability was uncovered by the company Digital Bond, Sunrise, Fla., during its Project Basecamp, a research effort to demonstrate the fragility of industrial control systems.Researchers at Digital Bond used a Wago IPC 758-870 Model PLC as

their test unit, but say all systems running CoDeSys PLC software seem affected. The Wago PLC runs embedded Linux on an

x86 central-processing unit, but other operating sys-tems such as Nucleus RTOS and Windows CE

Resources:3S-Smart Software Solutions GmbH, www.

codesys.com

Digital Bond, www.

digitalbond.com

are also affected. Given the way CoDeSys oper-ates within the OS, manufacturers of-ten run the ladder logic with elevated root or administra-tor privileges. Or they use an OS that does not have user privilege controls.

One critical


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Software simulates rugged offshore machinesResearchers at the University of Agder in Norway are using MapleSim simulation software, from Maplesoft, Waterloo, Ont., Canada, to predict the performance of complex offshore material-handling equipment. In the short term, the work helps designers pick components. In the long run, it aims to automate more of the design process.

Offshore oil and gas-drilling rigs cost millions of dollars a day, so crews need to get the job done as quickly as possible. Crews must assemble thousands of meters of flexible pipe while work-ing safely on a remote platform with limited space in all kinds of weather.

Modern drilling platforms use highly specialized material-handling equipment to move components quickly and keep the rig on schedule. Equipment is typically hydraulically oper-ated. Most modern platforms also have sophisticated elec-

tronic controls that simplify operation and help support automation.The design of the control systems can be challenging because the

behavior of cranes in motion depends on how the control valves and hy-draulic actuators operate, the crane’s inertia and its load, and the complex interactions among components. Researchers hope to simplify designs by giving engineers a way to build and run detailed simulations of equipment before they assemble a single part.

“The model-based-design approach lets users model the entire struc-ture and control system in sufficient detail to get a realistic idea of a drill-ing rig’s performance,” says project head Morten Kollerup Bak. “MapleSim can divide the whole system into mechanical, hydraulic actuation, and electrical-control models.” The software includes a large library of standard elements and also lets engineers easily incorporate custom parts.

“We had hoped to build hydraulic models from standard catalog data,” says Bak. “But component manufacturers don’t always provide the data needed to model the behavior of components in dynamic conditions.” To get this data, Bak built custom models of key components such as control valves and vali-dated their accuracy by conducting tests on single components.

Once Bak is confident of the custom elements’ performance, he incor-porates them into MapleSim models of the actuation system and evaluates the complete crane’s likely performance. “We already built a model of an existing crane and demonstrated that it accurately predicts the real crane’s behavior. The model lets us study the likely impact of design changes to individual components.”

And to use the model for design automation, researchers input perfor-mance requirements and the software searches the component library for the best option. The software studies thousands of parameters, a task de-signers would find dull, difficult, and time consuming.Searches like these need efficient search algorithms. Bak plans to use

the Complex Method found in Matlab and Simulink, from MathWorks,Natick, Mass., to which MapleSim directly links. “This populates the simula-tion with a number of randomly generated designs and evaluates the per-formance of each,” he says. “The algorithm also picks the poorest perform-ing design and factors in that data.” The process repeats until the solutions converge on the optimal result.

Currently, Bak uses stability and accuracy as performance criteria. There-fore, the design yielding the lowest level of hydraulic oscillations that can precisely follow the position reference is best. In the future, Bak plans to add other criteria such as price and long-term reliability. MD

Resources:Maplesoft, www.

maplesoft.com

RS# 408MathWorks, www.

mathworks.com

RS# 124FEBRUARY 14, 2013 MACHINE DESIGN.com 29


Inverse design code boosts HVAC efficienciesWhen Daikin Industries in Japan set out to develop a fan for its new line of air conditioners, engineers wanted to use 3D inverse-design technol-ogy instead of standard CAD software. In the standard ap-proach, geom-etry is changed iteratively using CFD analysis and physical tests. But the inverse approach computes geometry for a certain flow distribution where the loading distribution is specified. Then the blade geometry is computed.

This inverse approach is a more sys-tematic way to handle aerodynamic turbomachinery because the input specification can be used to rapidly generate new prototypes once it has been chosen for a given criteria (such as minimum loss, cavitation suppression, or secondary-flow suppression). The 3D inverse approach was possible because of the TURBOdesign software suite from Advanced Design Technology in Lon-don. ADT supplies tailor-made software, design services in turbomachinery, and aerodynamic design codes that let engi-neers control blade design.

“TURBOdesign1 had already in-creased the efficiency for our compres-sors, so we expected it would also work for fans,” says researcher Toru Iwata at Daikin Industries’ Environmental Tech-nology Laboratory.

TURBOdesign1 is currently the only nonproprietary software for designing turbomachinery that can do 3D inverse design. “We were almost immediately productive using the software to design our fan,” says Iwata. “Then, it took only about a year to become fully versed in all its capabilities. The software let us re-duce development time and slash mate-rial use, as well as develop new models of high-efficiency fans.” MD

Resources:Advanced Design Technology, www.

adtechnology.co.uk

Daikin Industries,www.daikin.com


RS# 126

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REPORTER’S NOTEBOOKLOOKING BACK

10 YEARS AGO — 2003Be the next Dick Tracy: Wear your PDA on your wrist. That’s the idea of new Palm-powered watches from Fossil Inc., Dallas. The Wrist PDA is sleek, compact, and lightweight, says Fossil, and fully compatible with the Palm OS platform from PalmSource

Inc., Sunnyvale, Calif. Contract manufacturer Flextronics, Sin-gapore, developed the Wrist PDA, bringing it from concept to completion in just five months.

The Wrist PDA sports an illuminated touch-

screen with a stylus tucked into the band for Graffiti

input, 2-Mbyte internal memory, a rocker switch, and rechargeable battery. An infrared port supports beaming between all Palm-powered devices. Applications already loaded into the watch include Address Book, Date Book, Memo Pad, Calculator, and To Do List.

30 YEARS AGO — 1983Longest ball screw?: A 60-ft preci-sion-ground ball-bearing leadscrew was turned out recently by 20th Century Machine Co., Sterling Heights, Mich. The firm believes the ball screw is the longest ever pro-duced in the U. S. The screw will be used on a lathe that will turn the out-side diameter of a large forg-ing. The screw boasts a thread tolerance within 0.005 in. per lineal foot. An internal ball-return circuit totally en-closed within the nut body protects against damage during shipment and installation, as well as during operation.

50 YEARS AGO — 1963The latest wrinkle in tire manufac-turing are tiny metal kerfs that put vertical ridges inside grooves, rein-forcing the tread. Ridges present after the kerfs are removed make the tire more rug-ged, keep stones out, and increase wear by reducing squirming action of tread elements as they contact the road. The kerfs are used by B.F. Goodrich Tire Co. in molding its new Extra Miler truck tires, and the company credits them with extend-ing tire life by 32%. MD


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RS# 127

REPORTER’S NOTEBOOKCOMPANY NEWS

TEACHING LABMeasurement-services provider Agilent Technologies, Santa Clara, Calif., and Bangor Univer-sity, Bangor, North Wales, have opened a laboratory at the School of Electronic Engineering at the university. The lab is equipped

with Agilent instruments to help in the teaching of undergraduate and postgraduate courses in elec-tronic engineering.

STRATEGIC ALLIANCEEAO Corp., Milford, Conn., and Digital Switching Systems LLC,

Raleigh, N.C., have formed an alliance to develop and promote rug-gedized intelligent keypads and digital switching technology for the heavy-duty/specialty vehicle, ma-chinery, and public transportation markets. EAO is a HMI systems and components supplier and Digital Switching Systems manufactures open-source keypad solutions.

CERTIFICATION AND TESTING SERVICESTÜV SÜD America, Peabody, Mass., a testing and certification services firm, will now offer test-ing and certification services to the Indian Boiler Regulation 1950 (IBR) as an Inspecting Authority and Competent Authority recog-nized by the Central Boilers Board in India. Compliance to the IBR is mandatory for all material or com-ponent manufacturers of boilers, boiler piping, mountings, fittings, and valves that export their prod-uct for use in India.

DONATIONThe Omron Foundation Inc., Schaumburg, Ill., has donated $20,000 to the American Red Cross Hurricane 2012 Fund to assist Hurricane Sandy victims through the Red Cross disaster relief and recovery efforts. The company also encouraged its employees to make individual donations in support of local relief efforts, which are matched by Om-ron Foundation within program guidelines.

RELOCATIONSSICK Inc., Minneapolis, , a manu-facturer of sensors, safety systems, machine vision, and automatic identification products for fac-tory and logistics automation, is expanding and relocating its facili-ties to the Eagle Creek Industrial Park in Savage, Minn.

VersaLogic Corp., Eugene, Oreg., is expanding and moving its head-


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and direct digital manufac-turing solutions, and Objet develops, manufactures and markets ultrathin-layer, high-resolution 3D printing solu-tions for rapid prototyping and rapid manufacturing.

AWARDSpirol Industries Ltd., Windsor, Ont., Canada, has received the General Motors 2012 Supplier Quality Excellence Award. GM engineers and personnel consider quality performance in areas of line interruptions, recalls, and cor-rective actions to determine award winners. Spirol manufactures fas-tening and joining components.

HEV AND EV MATERIALSFabrico, Kennesaw, Ga., a maker of flexible materials converting and advanced-assembly capabilities, has partnerships with DuPont, 3M, Von Roll, and ITW Formex that let it provide the latest in electrical insulation materials and adhesives. After 2013, the specifi-cations for EV and HEV insulating materials will increase to H-class, with the requirement that these motor materials hold up to 180°C.

AGREEMENTSpaceClaim Corp., Concord, Mass., and Geomagic, Morrisville, N. C., will produce the first-ever product for designing 3D parts directly from 3D scan data. Space-Claim provides flexible and afford-able 3D for engineering design and manufacturing. Geomagic offers products that advance and apply 3D technology.

SERVICE EXPANSION3D Systems Corp., Rock Hill, S. C., is expanding its Quickparts on-demand parts service with the launch of its proprietary instant online quoting engine in Europe. Quickparts provides quick-turn custom manufacturing services for engineers and designers to create real plastic and metal parts fast for their prototyping and production needs. MD

nies Stratasys Inc., Min-neapolis, and Objet Ltd., Rehovot, Israel, is complete. Stratasys is a provider of 3D printing

quarters to Portland. It will main-tain a satellite office in Eugene. VersaLogic provides high-quality board-level products for embed-ded OEM applications.

MERGERThe merger of 3D printing compa-


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SENSOR SENSE

Pulse-ranging technologyLaser-based distance measurement often serves as a way of positioning parts, navigating automated vehicles like stacker cranes, and measur-ing the dimensions of objects like boxes. There are three common technologies behind laser-distance measurement: optical triangula-tion, phase correlation, and true time-of-flight (TOF) technology.Some products claim to use TOF, when they actually employ phase

correlation instead. Phase correlation has significant weaknesses compared to true TOF; it has shorter measurement distances, greater sensitivity to object color, and is more susceptible to environmental influences like lighting. Because of this confusion, the term pulse-ranging technology, or PRT, is used to define true TOF technology.

Pulse-ranging-technology sensors emit short bursts of high-inten-sity laser light at up to 250,000 times/sec. The light intensity of a PRT sensor can be up to 1,000× greater than that of a phase-correlation sensor, which uses an emitter that is on continuously.

The light bursts travel to an object or reflector and then reflect back to the sensor’s receiver, or light-sensitive element. The sensor mea-sures the time lapse from the emission of the light burst to the detec-tion of the burst by the sensor’s receiver element. This time is then used to calculate the distance from the sensor to the detected object: s = c × t

l/2, where s = distance measured in meters, c = speed of light

in air (299,792,458 m/sec), and tl = measured elapsed TOF of the light

burst in seconds.Because phase correlation measures distance based on the shifted

phase angle of reflected light, its use is limited to the range over which the light phase can shift by up to 360°. If a phase-correlation device is used beyond that range, it may falsely identify the range as a 360° phase shift closer or farther away. The PRT design does not have any such limitation. MD

Pepperl+Fuchs (www.pepperl-fuchs.us) supplied information for this column.

Edited by Robert Repas

PRT sensors measure the time needed for a burst of laser light to travel to the target object and return to the sensor. It then calculates the distance to the target object using that time and the speed-of-light constant.

Receiver

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Transmitter


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COMMENTARY

Stephen J. MrazSenior Editor

Acquihire: When companies have more money than brainsLife can be good for engineers, especially those whiz kids involved in Internet/social media start-ups. What prompts this observation is the fact that some large, well-funded firms like Facebook and Google are in desperate need of high-quality, high-tech engi-neers. These companies are unwilling to rely solely on the traditional routes used to round up technical talent. They don’t want to waste time or money on headhunters, recruiting from colleges, or growing their own talent. So they go the “acquihire” route.

This tactic calls for the company in need of brainpower to reach into its deep pockets and buy an entire company just to get its engineering employ-ees, usually just a handful. The start-up’s intel-lectual property is shelved and the products it was working on are mothballed.

It’s a win/win situation all around, almost.The newly hired engineers get a significant

amount of cash, often as signing bonuses, and possibly higher salaries. They must also get quite an ego boost — it must be satisfying to have a major company buy your employer just to get your services. The purchasing company can then explain to engineers already working for it that the new hires are making the same salary, they just had to be compensated for the equity in the firm they were in. Engineers or staffers not hired by the new owner, however, might be a bit miffed.

The start-up owners get to make a profit out of the deal, sometimes enough to finance a permanent retirement. At the least, they will be able to say their brainchild was snapped up by some savvy, successful company.

Investors backing the start-up get some money back, and maybe even some profit. This must be especially sweet if they know the start-up would have needed another round of major financing before even a glimmer of profits appeared on the horizon.

And, of course, the big company can put is newly acquired high-tech Top Guns to work in a hurry. In some instances, the larger company also manages to eliminate a potential competitor.

But there are people who aren’t too happy about such deals.In some instances, the start-up already has a product in the marketplace,

usually an app. Its customers have grown to depend on and even love it. These people are not too happy when the killer app they cherish suddenly disappears from the market never to return. This happened when Thinkfusewas “acquihired” by Salesforce.com, which then quickly shutdown Think-fuse’s product, some online software that let people share progress reports. They told customers to use another piece of similar software, Mailchimp.

Even the former owners can end up second-guessing their business de-cision. But they can always start another new company somewhere down the road, and a six or seven-figure payout makes for a mighty soft pillow to cry on. MD

Start-up owners

get to make a

profit out of the

deal. Investors

backing the

start-up get some

money back. But

there are people

who aren’t too

happy about such

deals.


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TAVENNER ON SAFETY

Rolling equipment, fractured feet

In a recent incident, an employee rolled a piece of equipment weighing 740 lb into a room for cleaning. During cleaning, one wheel accidently rolled into a drain causing the apparatus to tip and fall onto the worker. He received immediate medical attention for several injuries including a fractured ankle, tibia, and fibula.

How could this injury have been avoided?The right caster — Matching the best caster design to the equipment

it supports makes for easier movement and more stability. The wrong caster can be a direct source of injury if the floor is not in good condition. Cracks, holes, and drains can stop moving equipment from rolling and make it tip. Strains or more-severe injuries often follow when employees try to overcome the floor defect. The right caster may not eliminate the issue but can help prevent it.

Equipment stability — Those who design heavy mobile equipment should keep in mind that stability is critical to avoiding these types of injuries. Facilities with damaged floors, protruding objects, tight corners, large cracks, or holes are unfortunately commonplace. So it is important to design-out as many risks as possible before equipment gets put in use.

Floor-drain design — Drains should be as flush as possible with the floor while still maintaining enough pitch to remove water. This point might seem obvious, but it is commonly missed or businesses aren’t prompt about fixing a damaged drain grating. The more flush the grating system is with floor, the less likely an employee is to roll equipment into the drain.

Defect-free floors — In many facilities, floor condition plays a large part in accidents. All floors should be free of holes, cracks, and defects that can cause slip, trip, or, in this case, tip-over hazards. OSHA has requirements for floor conditions that can be found in 29 CFR 1910.22(a)(3). While this standard doesn’t identify drains, it is critical for people designing facilities to include them in analysis and design considerations. It is easy to over-look the location and type of drains as well as other floor-safety elements though they can be a primary cause of injuries.

Standard operating procedures — Employees can reduce the risk of injury by following procedures and using safe practices. It can often be a challenge to move a 740-lb large piece of equipment into a washing area — especially so if you are trying to do it by yourself. Just as it often takes two people to lift heavy objects, the same concept is in force when moving heavy, awkward, or unstable wheeled equipment.

All in all, equipment designers can’t count on employees being trained to follow best practices for moving heavy equipment and handling other nonroutine tasks. Correct procedures can enable good decision-making and go a long way in reducing the risk of injury. Good designs can em-power employees to make safe choices that go a long way in avoiding incidents and ensuring they go home at the end of the day.

— Joe Tavenner

Joe Tavenner, CSP, CFPS, is a long-time Certified Safety Professional who works in occupational safety and design for safety. Got a question about safety? You can reach Joe at [email protected].

Edited by Leland Teschler


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RS# 137

VANTAGE POINT

Meeting and beating new-product cost targetsIf you are working on a new-product-development ini-tiative (NPI), you’re likely under pressure to hit specific cost, weight, market, and quality targets under tight time frames. Designing and making products that meet all these criteria, particularly cost, can be extremely challenging.

The cost implications of design decisions made dur-ing development are often more significant than most manufacturers realize. Cost overruns reduce profit mar-gins. And time spent “firefighting” cost surprises delays introduction. Expensive postproduction rework can also result. At the core of these challenges is the inability to accurately identify, assess, and manage detailed prod-uct costs early in a product’s life cycle.

Best-in-class companies start managing costs at the earliest stages of product design, letting engineering, manufacturing, and sourcing teams collaborate on cost analysis. As a result, the firms realize benefits, including: • Getting cost targets right the first time, before prod-

ucts or parts go into production.• Quickly evaluating the cost of design alternatives, let-

ting engineers focus more on product innovation and less on cost analysis.

• Identifying the real cost drivers behind a product design and minimizing engineering changes later in the release cycle where they cost more to address.

• Eliminating long waits for price quotes from internal experts and external suppliers.

• Creating “should-cost” estimates to help select ven-dors, validate quotes, and negotiate with suppliers.

It’s not uncommon for engineering, sourcing, and manufacturing teams to complain that product-cost-management (PCM) activities slow them down. In fact, the opposite is true — PCM can actually speed devel-opment. Efficiency gains often come out of faster cost estimates from suppliers and less late-stage, expensive rework. Cost-management operations fit naturally into engineering and sourcing processes, and the right PCM software complements the tools most companies al-ready use.

There are some core requirements for effectively managing new-product costs, including:

Early cost visibility. NPI teams must know early on how different design alternatives impact costs. Compa-nies should evaluate tools that let engineers determine cost by automatically pulling geometric and feature in-formation from CAD models. Team members who are not cost or manufacturing experts can quickly create an estimate and compare it against established target costs.

Also, regularly reassess costs as features and designs change, to evaluate trade-offs and cost impacts. OEMs

should establish cost-evaluation milestones at stage gates in the NPI process to assess the implications of various design ideas and alter-natives. Sourcing managers and manufacturing engineers should also have early visibility into product designs and up-to-date cost estimates, so they can comment on alternative designs, sourcing options, and manufacturability.

Cross-functional view of product cost. Providing prod-uct costs to cross-functional teams at each stage of de-velopment is also important. This ensures that all par-ties access the same information, collaborate early, and work to prevent late-stage cost surprises. The resulting benefits are significant. For instance, sourcing manag-ers can consider make-versus-buy decisions earlier. This can improve profitability and make better use of supply-chain partners and their design and manufacturing ex-pertise. Manufacturing engineers can regularly evaluate designs for manufacturability and suggest changes that reduce cost and time-to market. And cost engineers get a broader range of information, giving them greater influ-ence over a project’s overall economics.

Integration with enterprise systems. It’s important that PCM software works with existing PLM or ERP systems. Common requirements include loading a bill of materi-als and carryover part costs from the enterprise system, and storing PCM cost data in the PLM or ERP database to create a closed-loop flow of information.

Without these core practices and tools PCM remains highly manual and decentralized, and cost-engineering teams have limited ability to reduce product costs. For example, they may only focus on a portion of a prod-uct because they do not have the resources to cost all components. They are also forced to assess costs when designs are nearly final, severely limiting the window of opportunity to identify and act on potential cost sav-ings. It also leads to inconsistent estimation methods with static information that is difficult to update, man-age, and share.

Best-in-class manufacturers are distancing themselves from their competition with a systematic approach that makes product-cost management a normal course of responsibility and decision-making. Effective PCM pro-grams can increase profit margins, ensure faster time to market, and improve product quality, too. MD

aPriori (www.apriori.com) develops product-cost-management software used in sourcing, manufacturing, and design engineering.

Edited by Kenneth Korane

Julie DriscollVice President, Strategic Marketing & Product ManagementaPriori Inc.Concord, Mass.


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RS# 138

CAD

The Creatr 3D printer comes precalibrated.

itself from other consumer printers in several regards, says company co-founder Mathijs Kossen. First, unlike other printers, the device is made entirely of aluminum, so it is sturdy and steady. “And it also has larger, more-reliable electronic components,” he says. “For example, stepper-motor drivers in consumer printers typically break almost right away. We replaced them with professional drivers, as well as a more-robust belt and driving shaft. The printer, therefore, wears out less quickly.”

While most printers in the Creatr’s price range (approximately $1,500) need calibration, the Creatr comes preassembled and precalibrated, so us-ers can just start printing, out of the box. “The machine targets people who don’t want to spend 20 to 40 hours building a machine and calibrating it — they just want to design immediately. This makes our printer accessible to a broad range of people.”

In addition, the 23 × 27 × 23-cm build volume is large for a consumer printer. What’s more, the device sports an optional dual extruder. “The Creatr builds using thermoplastic extrusion. A machine with a single extruder would

It seems just about everyone is busy printing objects in 3D. Examples range from high-end airfoils to jew-elry, lattice structures, and even self-portrait figurines. Here, we kick the tires of a few machines, both con-sumer and commercial. The machines we profile have one thing in common

— a price tag of under about $20,000. And most are much

less expensive.

LeapFrogAimed at the home user, the

Creatr 3D printer from LeapFrogin the Netherlands distinguishes

Technology once deemed too

expensive for wide use has infiltrated

manufacturing and even become a hit

with consumers.

Authored by

Leslie GordonSenior Editor

Resources:

FormLabs, www.formlabs.com

LeapFrog, www.lpfrg.com

Mcor Technologies Ltd., www.

mcortechnologies.com

RepRap Ltd., www.reprap.org

Stratasys, www.stratasys.com

The changing face of

3D printing

The model of a head shows the capabilities of Mcor’s full-color-version printer.


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RS# 139

CAD

The relatively inexpensive Form 1 stereolithography machine can print detailed models like this Eiffel Tower.

The Mojo can build parts such as this medical model of a foot, which would be used for preoperative surgical planning.

print ABS, for everyday design engineers who use CAD as part of their jobs. The company first introduced its other FDM product lines, including the Dimension in 2001 at about one-half the price of other 3D equipment available at that time. It has since developed numerous Dimension products, taking the price down to about $20,000. About five years ago, the company introduced the uPrint, which was in the $15,000 to 20,000 price range. The Mojo came out in April 2012. It is said to be the first professional-grade printer to cost less than $10,000.

“What’s striking about the Mojo is its shape and size,” says Cobb. “The machine really mimics the form factor of a 2D printer one might get from HP. Also, its software lets users drag and drop from CAD files, as well as quickly print second, third, or fourth models. The system also ar-ranges the parts in the build envelope.

Mojo build material, which is in the form of a filament, along with the feed head, is all part of the print cartridge. Stratasys says users can set up the printer in about 10 to 15 min.

not be able to build a bridge, for example,” says Kossen. “To make the pylon, when the first layer on the road is printed, the plastic coming out of the nozzle would fold down into the air. But the second extruder fills in that space with a soluble material, letting users print almost ev-ery shape and form. When the build is complete, users can easily wash out the water-soluble material that supports overhangs during a build.”

Building materials are in the form of a filament that comes on reels. The machine prints ABS or PLA plastic. PLA is a little more brittle than ABS with a lower melt temperature, making it possible to print smoother edges. “Users might be more likely to print end models with ABS,” says Kossen. “On the other hand, they may be more likely to print display models out of PLA. PLA is also bio-degradable. Interestingly, ABS is the material used to make Legos.”

The Creatr typically builds in 200-micron layers. “But mechanically and experimentally, it’s possible for the toler-ances to go much lower, say, to 100 microns,” says Kossen. The speeds of the X and Y axes go up to 0.35 m/sec and the extrusion speed is 200 mm/min. The machine can print an iPhone casing in about 10 to 15 min.

FormLabsAccording to FormLabs founder Maxim Lobovsky, the

Cambridge-Mass.-based company recently introduced the Form 1, the first stereolithography (SL) machine that is anywhere close to costing only $3,000.

“We have made it easy to use the machine to tar-get what we call ‘pro-sumers’ or designers, engineers, and mak-ers,” he says. “The software is intuitive and it includes tools to handle the fin-

ishing steps. The machines use a less-common ver-sion of SL, where resin is exposed from the bottom of the tank, rather than from the top. We didn’t invent that overall process, but we simplified it and reduced costs. For example, new lasers on the mar-ket make that part of the system way less expensive.”

For materials, the machine uses a proprietary photopolymer, a liquid in a bottle that costs about $149/liter. “The resin price is about half that of the higher-resolution machines, says Lobovsky.

The machine produces layers with a minimum thickness of 25 microns and a minimum feature size of 300 microns. The machine prints at a typical rate of about 15 mm of height per hour. The build envelope is 4.9 × 4.9 × 6.5 in.

StratasysStratasys Technical Director John Cobb says the

company recently introduced the Mojo 3D printer, which uses fused-deposition modeling (FDM) to


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RS# 140

CAD

The RepRap “Huxley” is copying itself.

any self-replicating object, whether it’s a butterfly or a whale, must sit at a whole series of points that are optimal in relation to their surroundings. And most of the surroundings are themselves self-replicating entities,” he says. “This idea of op-timal positioning is the basis of a rigorous mathematical idea that supports an evolutionary stable strategy.”

Says Bowyer, “The RepRap copies itself by printing its own parts, but it obviously can’t succeed on its own — it needs a human to put the bits and pieces together, which is the equivalent of insects helping flowers reproduce. How might the machine persuade humans to do that? The answer is by giving them consumer goods. Humans then have an incentive to help the machines copy themselves. This is a way to make the machine stable in the world.”

By the machine’s nature, it had to be open source, says Bowyer. “Should you put a machine that copies itself out in the world and try to patent it, what you are saying is, I’ve made a machine that copies itself. Now, world, you can’t copy it,” he says. “That’s a recipe for spending the rest of your life in court trying to stop people from using the ma-chine for the one thing it was designed to do.”

Estimates are that between 20,000 and 30,000 machines now exist. Bowyer’s company is currently shipping ma-chines at the rate of about 100/month. The build envelope is about 8 × 8 × 5.5 in. The machine prints in layer thick-nesses of 0.020 in. The minimum feature size is 0.080 in.

Mcor TechnologiesWith its Iris 3D printer, Mcor Technologies Ltd. in

Ireland has modernized an old idea — that of creating 3D

The Mojo comes with its own part-cleaning apparatus, which Stratasys calls the WaveWash 55. The size of a tra-ditional coffee maker, the WaveWash 55 is geared toward desktop users. It holds up to a gallon of water, which is good for about 8 lb of material. Users simply drop the soap in the water and place parts in the cleaner. It removes the support material in about 15 to 30 min, depending on part complexity. The printer and accessories come in a bundle costing about $9,900.

The Mojo’s build envelope is 5 × 5 × 5 in. It prints in layer thicknesses of 0.007 in.

RepRapProThe RepRap 3D printer, which also prints using ther-

moplastic extrusion, is touted as being “self-replicat-ing.” This label comes from Adrian Bowyer, director of RepRapPro Ltd. in the U. K., who says that even as a child, he was interested in creating a self-replicating machine.

“One only has to look at the natural world to see what can be created by things that copy themselves, which is af-ter all, the very definition of a biological entity,” says Bow-yer. “When I was an academic, my university bought a few RP machines, and as an engineer, I found them a complete liberation. For the first time, I had a device that let me sit at a computer screen and design whatever I wanted and then have it in my hand an hour or so later. Once I became aware of the versatility of the technology, it seemed a good way to make a machine that could copy itself.”

In this endeavor, Bowyer was concerned that whatever he created would be “evolutionarily stable.” “This is to say,

3D printing from Staples?

Mcor recently struck a deal with Staples

to launch a new 3D printing service called

“Staples Easy 3D,” online via the Staples

Offi ce Centre at www.staples.nl.

Consumers, product designers, archi-

tects, health-care professionals, educators,

and students can simply upload electronic

fi les to the Centre and pick up the mod-

els in their nearby Staples stores, or have

them shipped to their address. Staples

creates models using the Mcor Iris, a 3D

printer said to have the highest color ca-

pability in the industry and the lowest op-

erating cost of any commercial 3D printer.

Printed objects might include prototypes,

art objects, architectural models, medical

models, and 3D maps. The service will be

available in the Netherlands and Belgium

early in 2013 and quickly roll out to other

countries, says a company spokesperson.


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RS# 141

CAD

The Iris builds up models from sheets of office-size paper.

hesive. The machine cuts the paper with a tungsten-carbide blade.

“We have been in business since 2005,” says MacCormack. “The Iris is both low cost and eco friendly. All of our competitors are either using a plastic or powder to produce 3D models. Parts that come out of the Iris are strong and high quality. They have a resolution of 0.1 mm, about the thickness of a sheet of paper, so surfaces are smooth and parts can be quite complex. The machine mostly targets the commercial and educa-tional markets.”

Recently, the company introduced a full-color version of the printer. It applies colored ink to white paper and from that builds up 3D models. “The quality of the print is high — 5,760 × 1,440 × 508 dpi and 1 million colors,” says MacCormack.

The company sells its products in an interesting way. “As well as buying the machine outright, users can pur-chase one of our ‘3D plans,’ which go for one, two, or three years. The price is set and users can use the machine and also get unlimited consumables — as many blades and as much glue as needed to run the machine for the length of the contract. This opens the door to educational and professional users who couldn’t otherwise afford the technology.” The machines start at $15,000.

The Iris build size is 9.39 × 6.89 × 5.9 in. Layer size is 0.004 in. MD

adhesive, making waste removal dif-ficult. The old machine also cut with a laser, which proved to be a fire haz-ard. In addition, the models from this machine were brown because the la-ser burned the paper. In contrast, the Iris uses sheets of office paper and it selectively applies the water-based ad-

models by gluing together layers of paper. Many designers may remem-ber a similar idea that surfaced years ago. According to Mcor spokesperson Deidre MacCormack, the difference between the old Helisys machine and the Iris is that the Helisys used a large roll of paper that was preapplied with


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RS# 143

Water hammer can affect most any fluid system with rapidly changing flows.

FLUID POWER

Water hammer (or steam hammer) is a violent flow transient in piping named for the loud banging it generates. It can affect almost any fluid system that experiences rapidly changing flows, including power-plant piping, water-supply systems, pumped storage facilities, oil pipelines, and hydraulic and general fluid-handling lines.

Water hammer is not just a nuisance. It can rupture or collapse pipes, uproot anchors, and cause other calamities associated with excessive pipe movement. Proper design and operation prevent such destruction.

Pressure wavesTo design piping systems that stand up to the forces that water hammer gen-

erates, engineers first need to recognize pressure-wave propagation in pipes. This includes both the size and swiftness of the pressure surge, and how pres-sure waves affect pipe.

Suddenly closing a gate or valve builds up pressure by Δp that propagates up-stream at the speed of sound. The pressure wave is reflected at the reservoir or junction and travels back to the gate, changing pressure in the pipe by –Δp. The wave reflects off the closed gate, turns into a negative pressure wave and travels toward the reservoir for a second round trip. The pressure wave decays in two to three cycles.

Engineers can determine the magnitude of the pressure surge by considering a layer of fluid adjacent to the gate (as shown in the Control volume illustration). As the gate closes to block flow, the resulting boundary forces on the control volume accelerate the fluid mass inside.

Violent flow transients

can destroy piping.

Here’s a look at the

causes, and how to

head off problems.

Authored by:

Moo-Zung LeeWest Hills, Calif.

Edited by Kenneth J. [email protected]

Key points:• Water hammer can affect most any fluid

system with rapidly changing flows.

• It can rupture or collapse pipes, uproot or damage supports, and break connections to equipment.

• Solutions include well-designed restraints, slowing valve openings, and eliminating entrapped air.

Resources:Moo-Zung Lee has a BSME from the National Taiwan Univ., MSME from the Univ. of Houston, and a Ph.D. from New York State Univ. at Stony Brook. He has nearly 40 years experience in power-plant construction and dynamic and stress analyses of nuclear-power-plant piping and aerospace and defense systems.

Taming

WATERHAMMER


RS# 144

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FLUID POWER

(po + Δp)A + ρA(V

o + ΔV)2 – p

oA – ρAV

o2 = ρA(a – V

o)Δt(–ΔV/Δt)

Δp = –ρ(a – Vo)ΔV – ρ(V

o + ΔV)2 + ρV

o2

Δp = –ρaΔV(1 + Vo/a) ≈ –ρaΔV.

The acoustic velocity of water in Schedule 40 to 60 steel pipes is about 4,000 fps. For steam or gases, calculate acoustic velocity using:

a = (144gckpv)0.5.

The specific heat ratio, k, is 1.25 to 1.3 for steam and 1.4 for air and most gases.

For quick full-gate closings, ΔV = –Vo, the pressure surge and corresponding

force on the gate are, respectively:

pmax Sf (aVo ) Sf avW

A

Sf a

W

gcA

Sf a

W

gcA

Fmax pmaxA Sf a(W / gc ) (momentum equation)

A safety factor, Sf =1.1, is generally appropriate for surge-pressure calcula-

tions. Pressure surges measured in 24-in. main steam pipes of power plants dur-ing turbine trip tests are less than 5% above the analytical prediction using these equations. This is a reasonable validation of this calculation method which ne-glects friction, compressibility, and related factors.

Pressure designPressure design for water-hammer load must consider both rupture and

buckling failures. Overpressure may rupture the pipe from hoop-tension fail-ure. Hoop-tension stress in a pipe wall from internal pressure is:

Shp

= pr/h = pdi/2h, p = p

0 + Δ

¡

Longitudinal stress in pipe is half of the hoop stress. But it must be combined with tensile and bending stresses from all concurrent loads and could dictate the design.

Pressure wave traveling in pipe

Gate open

Gate shut

L

Vo

Δp wave

V0

aV = 0

–Δp wave

V = 0 a

–Δp wave

aV = 0

Δp wave

V = 0a

Reservoir

t < 0

0 < t < L/a

L/a < t < 2L/a

2L/a <t < 3L/a

3L/a < t < 4L/a

Sudden gate or valve closing creates a pressure wave that travels through the pipe. Here, V = flow velocity, V

o = initial flow velocity, and a = acoustic

velocity.


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FLUID POWER

If pipe pressure (po – Δp

max) becomes negative, the pipe may collapse or

buckle from external pressure. The critical net external pressure for buckling a cylindrical shell is:

Low-pressure, large-diameter pipes and bellows are most vulnerable to buckling. The external pressure from underground seepage on buried pipes or tunnel linings can be high enough to buckle pipe during water-hammer events, when drained, or even during construction. Stiffener rings can be used instead of thicker shells. The critical pressure per unit axial length for buckling a ring is:

qcr = 3EI/r3.

A good practice is to weld the stiffener to the outside of the shell wall with full-penetration continuous welds so that the combined moment of inertia of the cross section exceeds the sum of the two individual moments of inertia.

The speed of pressure surge at the gate depends on valve characteristics in terms of mass flow rate versus time. A typical nonlinear valve-characteristic curve may be approximated by a straight line. The linear effective closing time is about one-half to one-third of the nominal stroke time. For linear-valve char-acteristics, surge pressure ramps up to Δp

max in time, t

g, and then remains con-

stant. This is a ramp function, Δp(t), defined as:Δp(t) = Δp

max(t/t

g), 0 ≤ t ≤ t

g; Δp(t) = Δp

max, t

g ≤ t.

The longitudinal load on a pipe section is generated by a wave front hitting the two ends with a time lag. Consider a straight pipe section between elbows B

1

and B2 shown in the accompanying graphic. The wave front reaches B

1 at time t

1

and arrives at B2 at t

2. Forces on B

1 and B

2 are time-shifted ramp functions:

ΔF(t) = Δp(t)A; ΔF1(t) = -ΔF(t–t

1), ΔF

2(t) = –ΔF(t–t

2).

The net unbalanced force on the pipe section is a trapezoid pulse:ΔF

s(t) = ΔF

1(t) + ΔF

2(t) = –ΔF(t–t

1) + ΔF(t–t

2).

Control-volume boundary forces

Mass element

Gate shut

a Vo

po

+ Δp

Vo

+ ΔV

ρA(Vo

+ ΔV)2

momentum

(po

+ Δp)A

a – V0

Mass element

(a – Vo)Δt

po

Vo

ρAVo

2, momentum

poA

This graphic shows forces acting on a mass element (ignoring friction). Here, A(a-V

o)Δt is the mass volume and

Δp is the pressure surge.


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For long pipe sections, defined as Ls ≥ at

g, ΔF

smax = ΔF

max. For short pipe sec-

tions, where Ls< at

g, ΔF

smax = ΔF

max(t

2–t

1)/t

g. Thus, short sections are subjected

to smaller forces because the wave front hits B2 before ΔF

1(t) reaches the peak.

For Ls < L

cr = at

g, the load on the pipe section is smaller.

This indicates that unbalanced forces, ΔFsmax

, on pipe sections can be re-duced by slowing down the valve for L

s < L

cr. Most pipe sections in utilities and

other plants are shorter than these critical lengths.

Dynamic-load factorDynamic-load factor (DLF) is a multiplier to estimate maximum dynamic

load from static load considering the input interactions with the single degree-of-freedom dynamic system. For example, in loading an object on a scale, if the scale swings to 15 lb before settling down to 10 lb, the static load on the scale is 10 lb while the maximum dynamic load on the scale is 15 lb. So DLF is 1.5.

DLF depends on the input pulse shape, how rapidly the load is applied, and system stiffness. DLF for a particular input pulse is cus-tomarily presented as a function of τ/T, where τ = the time interval that defines the input pulse and T= the system’s natural period of vi-bration. Water-hammer load on a pipe section is a trapezoidal or triangular pulse when L

s = at

g. The

maximum response to a trapezoi-dal pulse may occur before or af-ter the input decays. In the former, DLF of the ramp function is used; for the latter, the residual DLF ap-

Valve-flow characteristics

LINEAR-VALVE CHARACTERISTICS

Flow rate (W)

100%

0%

Effective closingtime (t

g)

Stroke time (t)

CORRESPONDING

PRESSURE SURGE

Pressure surge Δp

max

0 tg

Time

Δp(t)

Linear flow-rate change

Actual flow-rate change Gate flow-rate characteris-tics can be linearized for simplicity. For linear-gate char-acteristics, the corresponding pressure surge is a ramp function.

Longitudinal forces in pipes

ΔF1(t) ΔF

2(t)

B1 B

2Δp wave

Ls

Water hammer can impart longitudinal loads on a pipe section.


FLUID POWER

plies. Those DLFs are plotted with τ = tg and τ/T = f

nt

g in the chart, DLF for wa-

ter-hammer loads. The design DLF, an envelope of all the above, is an educated approximation on the part of the design engineer.

Problems, solutionsWater hammer induces longitudinal loads on pipe sections, resulting in ex-

cess pipe movements that can overstress the pipe or break small branches. It may uproot anchors, permanently deform supports, or overload connections to adjacent equipment. Pipes may even ram the surrounding structures or equip-ment. Therefore, piping must be restrained to handle water-hammer loads at or near the sources and limit movement.

Water-hammer restraints include axial and offset restraints, and equipment connections. In selecting the restraint type, engineers must consider other loads such as thermal movement of the pipe. Typical restraints include:• Rigid rod, clamp, and bracket devices are common for cold-pipe supports.• Snubbers lock up and function like a rigid strut when subjected to a fast-

acting axial force, and otherwise allow slow thermal movements with little resistance.

• U-bolt clamps may slip or bend under out-of-plane load.• Expansion joints may slip if either end is not rigidly held. (The expansion joint acts like a hydraulic jack.)

The separation force, pA, on an expansion joint may be huge even without water hammer, though water hammer may expose otherwise hidden support weaknesses. Neglecting these forces often leads to support failure around an expansion joint. Small branch pipes must be flexible enough to tolerate move-ments, or they may be overstressed and even break. Long and large pipes such as penstocks are typically anchored at the bends and have an expansion joint in every section between anchors.

Design

Ramp

Triangular Trapezoidal, residual

DLF for water-hammer loads

Dy

na

mic

-lo

ad

fa

cto

r

2.0

1.5

1.0

0.5

0

τ/T

0 1 2

The dynamic-load factor is a multiplier used to estimate maximum dynamic loads based on static-load conditions.


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Quick gate opening directly ramps up pressure to accelerate the fluid mass, and the wave front rushes ahead at the speed of sound. A fast actuator-operated valve that taps water from a high-pressure source could cause water hammer in a branch line. Loose parts in a valve assembly may rattle to initiate water ham-mer under certain conditions.

Slowing the valve’s closing rate reduces water-hammer loads on piping. The wicket gates of hydraulic turbines and main steam-inlet valves of steam turbines in power plants must close quickly to prevent turbine generators from excess overspeeding when the unit at a high output is cut off from the power grid. Here, the quick-closing gate causes water/steam hammer and the piping system must be ready to bear the loads.

On the other hand, many valves close much faster than necessary simply because they’re driven by fast actuators. If the hydraulic or pneumatic actuator speed is not adjustable, inserting an improvised flow restrictor (tube connector with a small flow area) on the actuator control fluid line slows the actuator with-out impairing its force capability.

How slow is a slow valve? Pick the pressure-wave round trip time, tr = 2L/a,

as a benchmark. By slowing the valve to tg > t

r, the –Δp wave returns to the gate

before full gate closure to cancel further pressure surges. This proportionally reduces the crest of the pressure surge.

pg pmax

trtg

, or pg (Sf )aVo

2L

atg

(Sf )

2LV0

tg

, pg po

By setting an acceptable pressure-surge magnitude, one can calculate a nec-essary t

g. Actual valve-closing time required, (2 to 3)t

g, depends on the valve

characteristics.Entrapped air may also cause annoying water hammer. Air gets trapped by

filling an empty pipe with liquid too quickly while impeding orderly evacua-

Calculating water-hammer loadsAs an example, consider a power-plant steam turbine that draws

2.8 × 106 lb/hr saturated steam at 900 psia through a 400 ft, 24-in. Sch. 60 pipe.

Assume the turbine inlet valve closes in 50 msec to shut off the fl ow linearly. Assume

fn ≥ 20 Hz for the piping system.

Here are typical calculations to determine water-hammer loads on the pipe

section.

For 24-in. Sch. 60 pipe, A = 382.35 in.2, di = 22.064 in., and h = 0.968 in.

Saturated steam is at p = 900 psia (po = 885.3 psig) and specifi c volume v =

0.50091 ft3/lb.

Specifi c heat ratio k = 1.265 (Ref. Flow of Fluids Through Valves, Fittings and Pipes, Crane

Technical Paper 410).

Acoustic velocity in steam a = (144gckpv)0.5 = 1,626 fps.

Safety factor Sf = 1.1.

Pressure surge Δpmax

= Sf × aW/(Agc) = 1.1 [1,626(2.8 × 106/3,600)]/(382.35 × 32.2) =

1.1 × 102.73 = 113 psi.

Maximum internal pressure pmax

= po + Δp

max = 998.3 psig.

Minimum internal pressure pmin

= po – Δp

max =772 psig. Buckling is not an issue.

Hoop stress in pipe St = (p

maxd

i)/(2h) = 11.38 ksi.

Maximum force from the pressure surge on the gate ΔFmax

= Δpmax

A = 43.2 kip.

Critical pipe length Lcr

= atg = 1,626 × 0.050 = 81.3 ft.

Dynamic load factor (DLF) = 1.3 from the chart for τ/T = fnt

g ≥ 20 × 0.05 = 1.

Longitudinal loads on the pipe sections are calculated as follows:

Ls > 81.3 ft, R = ΔF

max × DLF = 43.2 × 1.3 = 56.2 kips.

Ls < 81.3 ft, R

s1 = (56.2 /81.3) = 0.691 kip/ft (load per foot of pipe length). For example,

for Ls = 50 ft, R = R

s1L

s = 0.691 × 50 = 34.6 kip.

Pressure wave traveling frequency f = a/(4L) = 1 Hz.

Given that the minimum tensile strength of typical power-piping ASTM A106

steels is at least 48 ksi (yield stress about 30 ksi), it appears this pipe would handle

water-hammer loads.

RS# 150

pg , for tg tr

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Special Designs

FLUID POWER

tion of the air. An unusually low static head at the bottom of a vertical pipe may indicate an entrapped air column. When fluid flows, air is pushed up and down in elevation, and pressure at particular locations fluctuates and disturbs flow and jolts the pipes. The compressed, entrapped air expands as it approaches the exit to atmosphere and thrusts the water slug in front at high speed. The air and water with a huge density disparity alternately exit the pipe and the reactive momentum ρAV 2 changes abruptly to jolt the pipe and shake the entire line.

Because filling operations are infrequent and can be planned, it is more cost effective to give sufficient time to fill or discharge the line slowly to alleviate the impact of air entrapment, rather than fortify the supports. Long and large pipes like penstock use a bypass valve to slowly fill the line and evacuate air through an air-release valve at the highest eleva-tion. The air-release valve stays open when dry and shuts while flooded. Shut-off force come from the buoyancy of a bulky hol-low disk.

An engineer’s prior-ity for hand ling water hammer is to remove the sources or minimize the effects. Slowing valves and avoiding air entrapment can eliminate many head-aches. But when quick valve action is mandatory and water hammer is in-evitable, piping systems must be designed to ac-commodate the loads. MD

Nomenclature A = Pipe flow area, in.2

a = Acoustic velocity, fps

di = Internal diameter of pipe, in.

E = Modulus of elasticity, psi

F(t), ΔF(t), Fs(t) = Fluid force on gate, incremental,

on pipe section, lbf

fn = System natural frequency of vibration, sec-1

gc = Mass-gravitational constant, (32.2 fps2)(lb/lb

f)

h = Wall thickness of shell, in.

I = Moment of inertia of area, in.4

k = Specific heat ratio (cp/c

v)

L, Ls, L

cr = Length; general, pipe section, critical, ft

p, po, p

cr = Pressure; general, initial, critical, psi

Δp = Pressure surge from valve closing, psi

qcr

= Critical buckling pressure of circular ring per unit length of center line, lb

f/in.

r = Internal radius of shell or pipe, in.

Sf = Safety factor for pressure-surge calculation

Shp

= Hoop stress of shell, psi

T = 1/fn natural period of vibration, sec

tg = Effective gate closing time, sec

tr = Pressure wave round trip time (t

r = 2L/a), sec

V, Vo = Flow velocity; general, initial, fps

W = Flow rate, lb/sec

v = Specific volume, ft3/lb

μ = Poisson’s ratio

ρ = Mass density, lb/in.3

τ = Characteristic time of pulse, sec

Effect of gate-closing time

Fast-closing gate: tg ≤ t

r, Δp

g = Δp

max

Δpmax –Δp

g

tr = 2L/a

tg

tr Time

Slow-closing gate: tg

> tr, Δp

g = Δp

max(t

r/t

g)

Δpmax

Δpg

tr

tg Time

Slowing the valve-closing time reduces the effects of water hammer.


RS# 152

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RS# 153

INSTRUMENTATION

Authored by:

Jim Schwartz National Instruments Corp.Austin, Tex.

Edited by Leland [email protected]

Key points:• Consider the complete system before testing begins.

• Account for hardware, software, data storage and processing, and the testing environment when developing a test system.

ITM, www.un-yah.com/

More on this case study, http://www.ni.com/cranetest/

National Instruments Inc., www.ni.com

Tips for

largemachinerytestsystems

Choice of strain gage Strain gages have nearly

unlimited variations based on qualities such as size,

sensitivity, material-temperature coefficients, temperature ranges,

and measurement axis. Pay attention to the strain-gage properties and the material it mounts on. Here, 32 strain gages mount to each lattice

section along the entire length of the boom, according to the methods described in SAE J987.

Measurements of buckling stresses in the crane boom

lattices came from single-axis 350-Ω strain gages used in a

quarter-bridge configuration. In total, ITM used 144 strain gages

along the length of the boom.

Lead-wire resistance and shunt calibration

A strain measurement is essentially a resistance

measurement, so lead-wire resistance can cause offsets.

Quarter-bridge measurements are inherently sensitive to the resistance of wiring between the sensor and measurement device. So long wire runs on off-highway equipment are a

problem. A method called shunt calibration can quantify the lead-wire resistance and nullify this

effect, either in software as data is acquired or in postprocessing.

What to look out for when

sensors get widely dispersed

over big machines.

With data-acquisition projects, the costs of delays are often high. That’s particularly true for heavy machinery like cranes, mining shovels, and excavators. Examples come from obstacles commonly faced by engineers mea-suring strain along the length of a 300-ft crane boom made by Manitowoc Cranes, Manitowoc, Wis. Mark Yeager and Tim Carlier, test engineers for Integrated Test and Measurement (ITM), Milford, Ohio, a service provider (employed by Manitowoc Cranes) specializing in challenging test applications, took these measure-ments over several weeks. MD


Visualizing test data When testing large cranes under potentially dangerous

loading conditions, the ability to visualize and interpret the data in real time can prevent failures and make things less risky for personnel. This application

employed a structural test environment called iTestSystem from ITM that included capabilities to

process the data during acquisition.

Data storage and postprocessing Test systems for compliance with safety standards must output data in a standard file format. Because

ITM collected data in a standard file format, Manitowoc engineers could analyze data and verify test results

using existing in-house software.

Electromagnetic interference

Noise sources like TV and radio stations can affect

measurements, necessitating data filters to ensure

accuracy. For example, the NI CompactDAQ data-acquisition platform from National Instruments

includes integrated signal conditioning such as filtering, amplification, and excitation.

Quarter-bridge measurements

Instrumentation options are limitless. You need to

chose hardware that can be optimized for the application.

ITM engineers used NI C Series modules with the NI CompactDAQ platform.

Each module includes built-in bridge completion,

excitation, amplification, and filtering required for making quarter-bridge strain-gage

measurements.

Shielding from the elements Most large equipment won’t fit in a test lab. It’s usually exposed to the elements. Each piece of instrumentation should sit in rugged, sealed

enclosures. In ITM’s case, NEMA-4X enclosures protected instruments.

Safety standards Engineers at ITM had to pay close attention to

SAE J987, which outlines the methods for testing static loads on a lattice-boom crane. This let them supply Manitowoc with the test results to show

compliance. SAE J987 dictates this particular test, but nearly every large piece of machinery has

certain standards and codes.

Instrumentation and documentation The safety standard usually includes the required instrumentation accuracy, calibration procedures, and documentation steps for the final report. But different manufacturers may have more detailed or stringent requirements. Failure to understand

them can cost hours of test time.


FASTENING/JOINING

Inserts like this let engineers use screws to attach components to plastic parts. Manufacturers can use heat or ultrasonics to install inserts in thermoplastics, and each has its advantages and disadvantages.

Authored by:

Christopher G. JeznachApplication EngineerSpirol International Corp.Danielson, Conn.

Edited by Stephen J. [email protected]

Resources:Spirol International Corp., www.spirol.com

method. Engineers should consider the advantages and disadvantages of both meth-ods before purchasing instal-lation equipment or finaliz-ing manufacturing plans.

Ultrasonic installationDuring ultrasonic installa-

tion, a relatively small down-ward force, typically gener-ated by a pneumatic cylinder, presses the insert into a pre-drilled or molded hole while an ultrasonic horn converts

electric power into high-frequency vibrations. Those vibra-tions get delivered to the insert-plastic interface through direct contact with the insert. The vibrations generate enough heat to melt the plastic around the insert. Equip-ment needed for ultrasonic installation includes an elec-tronic power supply, cycle controlling timers, an electrical or mechanical energy transducer, and an ultrasonic horn.

Here are some of the advantages of ultrasonic installation:• It is generally fast for inserts under 0.250-in. OD,

leading to short cycle times. These times increase with insert size.

• The machines can be changed to accommodate dif-ferent sized and shaped inserts.

• Ultrasonic-installation machines can also be used for plastic-to-plastic welding and other processes.

There are two primary

ways of putting

threaded inserts into

thermoplastics. Here are

the pros and cons of each.

Plastic parts and assemblies are becoming more common as engineers work to reduce costs and weight in their designs. But plas-tics often aren’t strong enough to support fas-teners such as screws or bolts. Using screws to attach parts to plastic housings, for example, often ends with stripped threads, failed hous-ings, and assemblies that fall apart.

To get around this limitation, engineers first install threaded metal inserts into plastic parts. They give screws and bolts stronger metal threads to mate with, letting plastic parts be easily assembled, taken apart, and repeatedly reassembled.

Two of the most common methods for in-stalling inserts into thermoplastic parts are heat and ultrasonics. (Thermoplastics can be remelted a num-ber of times. Thermosets, on the other hand, have a one-time reaction and cannot be remelted, making them un-suitable for heat or ultrasonics.)

Insert basicsWith both heat and ultrasonic installation, remelted

plastic firmly holds inserts in molded or drilled holes by conforming tightly to the knurls, barbs, and undercuts around the outside of the inserts. But the installation pro-cess must create enough remelted plastic to entirely fill these external patterns to get maximum performance, including pullout and torque resistance, when the plastic solidifies.

Both heat and ultrasonic installation depend on melting the plastic around the inserts, but results can vary with each

Putting inserts in plastic parts:

ULTRASONICor HEAT?


RS# 155

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RS# 156

RS# 157

FASTENING/JOINING

Inserts can be installed using an ultrasonic machine (left) or a heat machine (right). Each melts plastic around the insert, where it can solidify and keep the insert in place.

When the plastic is properly heated, either by direct heat or ultrasonics, it flows in and around the patterned features on the insert (left). When the insert is not heated, the plastic does not flow around the patterned knurls (right), which means the insert will not be as firmly seated in the plastic and could fail under load.

Now here’s a look at the downside of ultrasonic installation:• Insufficient melt, or not enough plastic being melted, can result in inserts being reamed into solid plastic. This so-called cold pressing can damage inserts and the plastic parts. Cold pressing can be caused by several factors. For example, bad fixturing/clamping of the plastic part can dissipate vibrations, pre-venting enough heat from being gener-ated around the insert. Slight size varia-tions of inserts or holes can also lead to cold pressing. And if inserts are driven too quickly, the plastic does not have time to fully melt, creating high stresses and poor retention in the plastic. This can lead to part failure during installa-tion or, even worse, in the field.Although sophisticated controls can

prevent cold pressing, the cost of such controls nearly doubles the price of an al-ready expensive ultrasonic installation machine.

Here are some of the other downsides of ultrasonic installation:• Ultrasonic vibrations can chip metal particulates and f lakes off of inserts. These flakes could prevent the inser t f rom seating properly, thus weak-ening the plastic-to-insert connection. The flakes are also unsightly.

• U l t r a son i c i n s t a l l a t ion machines are loud due to the metal-on-metal contact between the insert and ultra-sonic horn. And the bigger the insert , the louder the noise.

• It is difficult and costly, if not impossible, to install mul-tiple inserts simultaneously, depending on the design.

• Using the wrong vibrational frequencies or downward force damages inserts.

• Extra caution needs to be taken when using non-headed inserts to ensure proper contact is made between insert and the horn. Otherwise, it is likely that the inserts’ internal threads will be damaged.

• Ultrasonic horns are expen-sive. They are also subject

to wear and often need to be replaced. It is common for them cost over $1,000.

Heat installationMachines that rely on heat to install inserts

use one of two approaches. In some, a metal tip transfers heat to the insert. In the others, in-serts are preheated and pneumatically pressed into predrilled holes in the plastic. In both ap-proaches, inserts are pushed into the plastic by a controlled force, usually less than 50 lb. Heat installation also requires the entire in-sert be heated, not just the metal-plastic inter-face. So for proper installation, inserts should have enough thermal conductivity so that plas-tic around the insert quickly heats and melts. That’s why two of the most common insert materials are brass and aluminum. Once the

plastic melts, it fills the insert’s retention features, then solidifies while inducing minimal stresses.

Good thermal conductivity also lets inserts cool quickly after installation.Here are some of the advantages of heat

installation• Reliability and consistency. Lower instal-

lation forces let inserts be installed into thin-walled parts which would be destroyed by ultrasonic equipment. With stable and


®

RS# 159 RS# 160

RS# 161

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Easy 3 Step

FASTENING/JOINING

installation also works with headed and nonheaded inserts.

• Automation. Heat-insertion equip-ment can be equipped with vibra-tory bowl feeders so operators never need to touch the inserts during installation. This is important for small inserts, which are difficult to handle and orient.

• M in ima l ma intenance . Hea t machines seldom need maintenance (if ever). Maintenance and spare-part costs are low, and heat tips cost approximately $55.

• Better performance. Completely heating inserts lets melted plastic fully flow into all retention features. Ultrasonically installed inserts sometimes are insufficiently heated.

One problem with heat installa-tion is that it takes longer if inserts aren’t preheated. In fact, ultrasonic installation has quicker insertion and shorter cooling times, giving it shorter cycle times than heat in-sertion when installing a single un-heated insert. However, preheated inserts will have comparable in-stallation times compared to ultra-sonic equipment. In addition, when installing multiple inserts simulta-neously, heat insertion offers faster throughput.

As much as 75% of an insert’s per-formance depends on how well it was installed, therefore all the factors that affect installation must be carefully controlled to maximize performance. In general, heat installation gives us-ers more flexibility, consistency, and performance at a lower cost. But with so many different combinations of inserts, plastics, and performance re-quirements, manufacturers should partner with fastening and assembly experts. After all, choosing the right insert and installation process can be the difference between failure in the field and integrity for the life of the assembly. MD

• Easy insertion into deep recesses. Longer heat tips can place inserts in a part’s deep recesses which would be inaccessible to an ultrasonic horn.

• Versatility. Platen-style machines can install several inserts on different planes. And prototyping or low-volume applications can be handled by manual machines. The same machine can also install inserts of different sizes by switching out the interchangeable heat tips. Heat

adjustable temperature, force, and depth settings, installed inserts have predictable pull-out and torsion-failure forces, which can be tailored for applications.

• Noise levels. Heat installation is quieter than ultrasonic installation.

• More economical. Heat installation machines cost about half of ultrasonic equipment because they are less com-plex and do not require as many components.


1-2 Axis Multi-axis

RMC75 and RMC150 Motion Controllers

• 1, 2, or up to 8 axes

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Squeeze more from existing machines.

Call 1-360-254-8688 or choose your controller at deltamotion.com

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A MECHANICAL INDEXER.YOU’RE PROBABLY STILL USING

RS# 163 RS# 164

RS# 165

TM

MOTIONCONTROL TECHNOLOGY GUIDE

Any plant using linear motion

requires maintenance workers to

regularly apply lubrication to linear

guides, because insuffi ciently lubricated

mechanical components exhibit excessive

wear, performance problems, and premature

failure. However, manual lubrication

practices can be pricey, due to recurring

maintenance-personnel wages and the cost of

the lubricant itself. Such lubrication expenses

are even higher for remotely located grease

fi ttings, or those requiring downtime for

servicing.

One alternative for linear-motion

applications is lubed-for-life or

maintenance-free guides. Typically, these

subcomponents incorporate lubrication

storage and delivery systems to drastically

reduce or even eliminate the need to reapply

lubricant after bearings go into service.

Their drawback is complexity and cost.

Yet another alternative is maintenance-

free bearings with integrated mechanical

features in the bearing slider that store and

deliver oil. Such guides and ways abound,

but are typically designed for either the

longest possible maintenance-free intervals

or design compactness.

A third linear-component lubrication

option aims to meet both design objectives.

These long-life maintenance-free linear-

motion products are manufactured in

roller-guide, ball-guide, and ball-spline-

based shaft-guide versions. Track widths

from 5 to 65 mm exist, with the largest

guides offering a basic static load rating

of 172,000 lb. All leverage lubricating

elements of sintered-resin powder and

a steel backing. The working resin

surface has a porous structure that can be

Boosting reliability with

lubricating surfaces

Before oil impregnation, the resin par-ticles are fusion-bonded for strength. Af-ter oil impregnation, lubricant is retained in cavities formed by the resin particles.

Authored by:

John LongoIKO International Inc. Parsippany, N. J.

Resources:For more information on IKO’s Super MX roller, ML/ME/MH ball, and MAG ball spline guides equipped with C-Lube technology, visit ikont.co.jp/eg.


* See our Web site for details and restrictions.

© Copyright 2013 AutomationDirect, Cumming, GA USA

All right reserved.

the #1 value in automation

Our encoders can squeeze

into thesmallest places

TRD-MX500BD

shown actual size

• Small body with 25 mm diameterand 29 mm depth

• 4mm diameter solid shaft

• Resolutions from 100 to 1024pulses per revolution

• Open collector output (5 - 12 or12 - 24 VDC), or line driveroutput (5 VDC)

• Up to 100 kHz response frequency

• 2m cable with tinned ends

• IP50 environmental rating

• Mounting bracket and couplingsalso available

TRD-MX series Koyoincremental industrial encoders

have small 25mm diameterbodies, rugged solid shafts, and

a variety of output types.

Also available are hundredsof encoders in mounting framesizes up to 2.5 inches (SAE)

or 78mm (metric).

All encoders are in stock forsame-day shipping.


1-800-633-0405


For complete details andpricing, visit:

www.automationdirect.com/encoders

impregnated with copious amounts

of oil; the elements are formed into

either a plate or sleeve shape and

integrated into the bearing’s slider.

They then release the impregnated

oil slowly through direct, continual

contact with the linear guide’s

internal rolling elements for

maintenance-free operation to

20,000 km or fi ve years — which

is often the entire application life.

All of the geometric iterations offer

the same maintenance-free interval.

Therefore, the engineer can choose

the suitable product based on load

type, duty cycle, and other application

factors.

Let’s take a closer look at each style:

• Roller guides — Designed for

applications requiring maximum

stiffness and resistance to moment

loads, these feature a slider on a

balanced set of four cylindrical rollers.

Here, the impregnated-oil element

is fashioned into a plate housed just

behind the slider’s end plates.

• Ball guides — These run on

recirculating steel balls that run

through a sleeve made from the oil-

impregnated sintered resin. As the

balls travel through the sleeve, they

pick up oil and transfer it to the rail.

• Ball-spline guides — These

incorporate an internal oil-

impregnated plate-shaped element, so

as the balls traverse this plate, they

pick up oil — allowing both the balls

and spline shaft to be lubricated. MD

On this ball guide, oil is lifted and distribut-

ed by the balls. The resulting fi lm protects both the balls and rail from direct metal-on-metal contact.

Shown here is a linear way equipped with external oil-impregnated elements. The latter adds no volume to the design footprint.


Cast Iron Right Angle Gear Reducers:

x Box Sizes 1.33-3.25;

5:1-60:1 Ratios

x Drop-In Replacement

For All Major Makes

x Units Filled With

Synthetic Oil

WorldWide Electric Corporation

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Learn more about

WWE products!

Aluminum Right Angle Gear Reducers:

x Two Bearings On Input & Output Shafts

x NEMA Motor Input Flanges

x No Vent Plug or Breather Needed

x Drop-In Replacement For All Major Makes

Motors:

x Permanent magnet dc

x 56 and 56c frame AC

x Stainless Steel


Don Cameron

Improving the energy effi ciency of industrial

applications is top of mind for today’s design

engineers. Variable-frequency drives (VFDs)

can make a difference by regenerating power

that would otherwise be lost as heat in hoisting

and other motion-control scenarios.

In what applications is power regeneration possible?

Many applications are a good fi t for regen drives. Overhead crane-hoisting mechanisms, elevators and

escalators, heavy conveyor loads in mining operations, large-inertia centrifuges, and stamping presses are a few examples.

What are the chief benefi ts of employing regenerative drives?

Regenerative drives save users electricity, which is often the main motivator for adoption. Due to their very nature, applications such as those listed above have a load that tends to override or overdrive the motor shaft. When overridden, the motor acts as a generator and feeds power back to the VFD. A regenerative drive then routes this power back to the line. Without such a drive, the potential to harness this free electrical energy is lost, whether it’s generated by gravity or the load itself. Instead, the power dissipates as heat in a resistor bank or brake-chopper unit. Frequently, these units are external to the VFD.

Safety is another concern. External resistors can get extremely hot, which not only introduces “off-limits” fl oor space, but also increases fi re risk. Using a

VFDs: Boosting effi ciency in hoisting applications

Authored by:

Don Cameron Senior Product ManagerMitsubishi Electric Automation Inc.Vernon Hills, Ill.

Resources:Mitsubishi Electric Automation Inc., (847) 478-2100, www.meau.com




All right reserved.


Our encoders are in stock

and ready foranything

• 50 mm diameter and 35 mm depth

• Splash proof (IP65 rating)

• 8 mm solid or hollow shaft

• Incremental models:

- Resolutions from 3 to 2500pulses per revolution

- Line driver or Totem poleoutput (has sinking andsourcing capability)

- Up to 100 kHz responsefrequency

• Absolute models:

- Resolutions from 32 to 1024pulses per revolution,expressed in 5 to 10-bit graycode outputs

- Open collector outputs

- Up to 20 kHz responsefrequency

TRD-N and TRD-NA series Koyoencoders offer a wide rangeof outputs and resolutions,starting at just $119.

Additional series of Koyo encodersare available, starting at just $90.


1-800-633-0405





Mitsubishi’s A701 regenerative drive integrates all the

necessary components into a single box to

save installation time and reduce the design

footprint.

no special jobsite engineering required. By integrating components including the power supply, reactors, braking unit, and converter module, the installation footprint is reduced by an average of 50% versus a component-based solution. No special motors are necessary to complete the system.

Any fi nal advice for engineers planning to set up a power-regeneration system?

The tipping point for adopting an integrated regenerative drive solution often hinges on the ability to save on electricity costs, and the ability to document the expected savings. Unlike fan and pump applications, however, these estimates are not so easy to ballpark. Too many variables, including system inputs such as friction and gearbox effi ciency, must be considered. The only way to accurately predict the outcome is to set up the respective solutions on identical equipment and document net energy consumption. Some drive manufacturers are willing to facilitate a “try before you buy” scenario to ease the rationalization process. A two-to-three-year return on investment is a reasonable assumption in most cases. MD

regenerative drive eliminates this concern.

Relying on resistors can also limit performance. For example, a machine using brake choppers may need to be throttled back to avoid a situation marked by glowing red-hot resistors — not the ideal way to determine a machine’s cycle time. If the energy is instead fed back to the line, throughput can be based on more relevant criteria.

How is a typical regenerative-power system confi gured?

One option is to use component-based regeneration solutions, in which the converter and other components are assembled external to the drive. Pure brake choppers are another.

However, these setups pose signifi cant risk compared to all-in-one designs. Any initial cost advantage of a component-based solution can be negated by lengthy installation times or component failures. Regarding potential failures, an engineer must determine whether individual components will continue to be available.

If not, the end user will need to engage in “fi x-it-now” engineering should a component fail — a suboptimal situation if the application is unloading ship cargo by the metric ton, for example.

Are there other ways to set up regenerative systems that might save space, cost, or energy?

Yes. Another option is to install a factory-engineered solution that integrates all necessary components into a single box. For example, some drives look and install just like a regular inverter, with


ATLAS® Digital Amplifi ers—the

latest innovation from PMD—pack an

amazing amount of output power in an ultra compact

design. These single-axis amplifi ers provide high-

performance torque control of DC brush, brushless DC,

and step motors. And, while they’re as small as a paper

clip, they offer up to 1 Kilowatt of total output power—

all without breaking the bank. Learn more about the big

advantages of thinking small in digital amplifi cation.

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Safety hazards associated with moving machinery can

be reduced or eliminated with articulating physical

barriers and torque limiters. Key to this undertaking

are detailed analyses and engineered solutions.

Isolating pinch pointsScissor-lift mechanisms, tilt tables, and similar equip-

ment represent potential sources of injury because pinch

points can be created when these mechanisms move. One

way to protect against these hazards is to enclose moving

parts with bellows that deter personnel from reaching into

hazardous areas — yet permit machinery motion. Other

benefi ts are improved machinery aesthetics and protection

against dust, debris, and foreign objects.

Practical protectionof motion designs and workers

GorFrame bellows are constructed of various materials and internal wires that maintain its shape. They’re flexible to accommodate lateral and linear motion.

Authored by:

Steve PiacsekProduct Development EngineerA & A Mfg. Co. Inc.New Berlin, Wis.

Resources:For information on networked safety and IEC safety standards, visit motionsystemdesign.com/mag/machine_

safety/index.html.

RS# 169


1-800-633-0405


• Small body with 2.0 in. diameterand 2.15 in. depth

• 0.375 in diameter solid shaft

• Removable 2.5 in. round flange

• Resolutions from 100 to 2500 pulses per revolution

• Line driver or Totem pole output(has sinking and sourcingcapability)

• Up to 100 kHz(totem pole) or200 kHz (line driver) response frequency

• Military-style connector (matingconnectors and pre-made cablessold separately)

• IP65 environmental rating



All right reserved.


Our encodersaren’t afraid of a little water

TRDA-25 series Koyoincremental encoders are IP65

rated, with military-styleconnectors for easy installation

and replacement.

SAE and metric-dimensionencoders are also available in

more shaft sizes and resolutions.




Weld curtains protect against welding flash and UV radiation while containing weld spatter.

In one iteration, heavy-duty accor-

dion-type skirting is made from rigid

PVC coextruded with fl exible high-cy-

cle polymer hinges and fabricated cor-

ners. The resulting rigid, movable cover

is suitable for lift tables and vertical-

motion applications. Vents allow uni-

form airfl ow during operation, while tie

strips guarantee proper expansion and

retraction.

For applications necessitating lateral

and linear motion, such as medical table

bases, imaging tables, dental chairs,

and amusement rides, bellows can be

constructed using various materials and

internal wires that maintain the necessary shape. Fabrication from myriad ma-

terials is possible, including some that meet UL burn standards or incorporate

antimicrobial agents. Suitable for shear-type or lateral movement, the design’s

compactness allows retraction into tight spaces.

Controlling machine motion with safety clutchesIn the name of safety, motion designs such as CNC machine-tool doors

and gear mechanisms can also be controlled with slip clutches. A continu-

ous slip clutch is a cost-effective safety option that can provide surprisingly

long life in myriad applications. A

typical unit consists of a cartridge

and a housing. The cartridge is

set screwed or keyed to the input

shaft. The housing is similarly at-

tached to the output shaft. Else-

where, the clutches connect via a

bronze bearing to output gears or

pulleys to allow their relative mo-

tion with the input shaft.

In short, torque is transmitted

from the fl ats on the clutch hub

to mating fl ats on inner plates

through friction pads to the outer

plates — then through torque pins

to the housing and output gear or

pulley. Torque level is controlled

by compressing the springs with

an adjusting nut. For a fi xed-

torque clutch, a collar is attached

to the hub in a fi xed position rather than the adjusting nut.

Either the input shaft or the housing can act as the input; the other member

is then driven. Torque capabilities are from a few ounces-inch to 1,000 lb-in.

Automated access doorsAutomatic-door actuators, which reverse automatically when objects are

detected in their path, are available for retrofi tting to existing automatic ma-

chining centers with single or double doors. For workers, these reduce injuries

from repetitive door operation and crushing incidents.

One door design incorporates a preprogrammed control module allowing

Steelflex roll-up metal covers protect the pits of this large fiber-placement machine at a manufacturer of composite aircraft fuselages, allowing workers to safely access machine subsections.


With more than a thousand different series, models,sizes, and options there is a Novotechnik non-contact rotary

position sensor to match your application, and there’s one very good reason to choose Novotechnik: A level of precision that’s unmatched in

the industry. Whether you’re looking for non-contacting, or even touchless, single-turn, or multi-turn rotary position sensors, Novotechnik has the sensor youneed. They are all detailed in our 96-page rotary position sensor catalog. For your

free copy, contact Novotechnik.Setting A Higher Standard:• Operating lives to: unlimited movements• Independent linearity to ± 0.3º• Resolution to 0.09º• Repeatability to <0.03% of signal range• Maximum rotating speed to: unlimited rpm• Sealed to protection class IP 69• Absolute measurements to 360º• Housing diameters from 13 mm

Novotechnik U.S., Inc.155 Northboro RoadSouthborough, MA 01772Tel: 508-485-2244 • Fax: 508-485-2430

For complete information, visitwww.novotechnik.com/ncr

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MOTION CONTROL

This removable jackhammer jacket reduces sound intensity by about 88% to help protect workers’ hearing.

several input and output commands.

These can be wired into the ma-

chine’s controller or a simple on-off

circuit; key outputs and messages

can also be fed to a controller. Dis-

tinct benefi ts are unlimited travel

distances, self-calibration, electric

(pneumatic-free) operation, and no

need for limit switches, light cur-

tains, pressure switches, or photo

eyes. Integrated braking engages at

all positions. Some large-equipment

OEMs of large machinery report that

operators required to open and close

safety doors can experience shoulder

pain, and door actuators reduces re-

petitive shoulder injuries by half or

more.

Covering open pits and other hazardous openings

Large machine tools such as

planer mills often are installed par-

tially below fl oor level, resulting in

potentially hazardous pits. Often,

workers must remove pit grates or

slats to service the machine. Here,

metal roll-up, walk-on covers of-

fer an alternative. Typically made

of reinforced stainless steel, these

covers allow partial pit access while

preventing falls at other times or into

other pit areas.

Case in point: One aircraft manu-

facturer uses large fi ber-placement

machines to build fuselages from

composites. Adjustable tailstocks of

the two-station machine travel on

Continued on page 82

RS# 172

RS# 171


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RS# 173

Airpot®CorpMotion Controlled. Problem Solved.

When your inventive vision calls for pneumatic control of force, motion, and displacement that delivers unparalleled

accuracy and resolution, it’s Airpot first. Our problem- solving line up of instrument -quality products will keep your project moving. And our Accurate Force Pneumatics is the key. With a precision glass cylinder/seal-free piston technology, coupled with ultra-high quality pneumatics, you’ll find products that give you levels of force and motion control nearly unobtainable by any other pneumatic means. What’s more, many of our products can outlast any machine you put them in. And that’s something we can guarantee! So, when your specifications call for a damping, actuation, pressure

sensing, or displacement device that is optimized for exceedingly accurate and repeatable force control — and at a cost lower than other methods providing comparable function and performance— give one of our application engineers a call. Let’s get started. Whether you’re designing or improving a product line to better serve your customers, or building specialized equipment for research, high-level testing, or precision assembly, get AirpotCorp involved early in your process. Call 800-848-7681 or visit airpot.com. We will move you in ways you might never have imagined.

Accurate Force Pneumatics. L et it move you.

Airpot® & Airpel® are registered trademarks of Airpot Corporation, Norwalk CT USA.MADE IN USA


Lost luggage is annoying

to travelers and incurs

signifi cant expense for

airlines. One new system

employs a panel PC, camera,

lighting, conveyor belts, and

encoder feedback to scan

bags for more-reliable sorting.

Modern airport baggage-handling systems quickly route enormous quanti-

ties of luggage, but basic computer scans and manual sorting remain signifi cant sources of error. For the latter, airport staff must judge at a glance whether a bag can travel on dedicated conveyor belts without causing problems. Overly bulky items can jam conveyor tunnels, round luggage can roll off belts, and backpacks with loose straps or handles can get trapped on pinch points. Most nonstandard items are manually segregated during pas-senger check-in, but they frequently

end up back in the general baggage stream when travelers change planes for fl ight connections.

To address this problem, a new system called Bagcheck was jointly developed by Type22 of Delft, Netherlands, and Vanderlande In-

dustries, the Netherlands, a global package-handling supplier. After luggage has been weighed and stamped with a barcode label, a con-veyor moves it to the Bag-check station for scanning. However, unlike a security check, the system scans the luggage item’s outlines rather than its contents.

How it works“By using a contour

scan camera, Bagcheck generates a detailed 3D image of a bag’s out-lines from above. Then a light cur-tain generates side views, to record how tall the luggage is and whether it has a round shape, for example,” explains Jorick Naber, Type22’s

Baggage-scanning systemminimizes lost luggage

The Panel PC synchronizes a camera, lighting, and conveyor belts by using high-resolution encoder feedback over an EtherCAT network.


Airpel®

The Anti-Stiction Air Cylinder

Get our Anti-Stiction Air Cylinder free. With no piston seals to wear out and no lubricant to leak out,

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Visit airpel.com and request our free Airpel demonstrator. Or call 800-848-7681 to speak with one of our helpful design engineers.

Airpel® and Anti-Stiction® are registered trademarks of Airpot Corporation, Norwalk CT MADE IN USA

an initial implementation phase at Amsterdam Airport Schiphol is now underway. At existing installations, baggage jams and blockages on conveyor belts have been reduced by 40% and lost luggage instances have been signifi cantly minimized. MD

explains Naber. Line rates up to 4,000 Hz require 125-μsec control cycles — so the camera is linked with the PC via 1-Gbit Ethernet. “Other PLC and soft PLC systems fail to deliver suffi ciently short cycle times, but Beckhoff’s Ether-CAT fi eldbus components combined with TwinCAT NC PTP software do the job with fast and accurate data communication.”

The Panel PC also delivers on data capacity, integrating controls with an SQL database that stores all scanned-luggage image data. The information is used to evaluate Bag-check decisions against jam occur-rences, allowing adaptive learning to improve future sorting decisions. Items missing their labels can also be identifi ed: Here, Bagcheck matches scanned luggage images with those of the untagged item to trace the luggage to its owner.

Finally, Bagcheck software al-lows virtual separation of luggage that is stacked or snagged together. In traditional systems, stacked luggage often causes conveyors to stop or, even worse for travelers, mistakenly direct both bags to the same aircraft.

Five Bagchecks are in use at London Heathrow Airport with additional systems on order, and

technical director. Luggage unsuit-able for the standard conveyor can then be fi ltered out within 1 or 2 sec.

The camera scans passing lug-gage at 4,000 1-mm contours/sec. A CP6502 Panel PC with a 19-in. TFT display from Beckhoff Automation, Burnsville, Minn., leverages feed-back from high-resolution encoders to synchronize the camera, lighting, and conveyor belts.

“The design relies on high-resolution images, so the line-scan cameras and LED lights must be synchronized very accurately with the conveyor velocity and position,”

A new luggage-scanning system called Bagcheck employs a Beckhoff Panel PC to reliably sort bags to the correct destinations. The control panel shown here indicates which luggage items can pass through normal transport routes and which items have problematic shapes or features.

The Bagcheck camera scans passing luggage at 4,000 contours/sec to generate 3D bag images. Unusually shaped luggage is then separated from the main luggage stream — reducing jams by 40%.

Resources:For more information, visit type22.aero, vanderlande.com, and beckhoff.com.


Actuatorline has all the precision you need – and won’t keep you waiting

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This collapsible sound barrier is easily moved and transported to reduce sound levels from noisy machinery.

Nonmetallic roll-up covers can contain corrosive fumes while allowing tank access.

guideways located in a pit below fl oor level. Production workers must access

workpieces as they’re produced, necessitating pit covers during production,

yet also requiring a way to remove the covers for repairs and adjustments.

Grating is time consuming to move, and slats require complex support struc-

tures that complicate maintenance tasks.

Instead, the aircraft manufacturer uses rugged walk-on metal pit covers

with extruded aluminum stiffening ribs bonded to stainless-steel sheets; there

are no hinges to collect debris. These roll up onto steel rollers equipped with

take-up mechanisms.

Roll-up covers can also be used to enclose chemical tanks and other vessels

to contain fumes or prevent injury. These covers are not designed to support

the weight of workers, so they are made of lighter materials such as polypro-

pylene to withstand corrosive fumes. Wiper strips can keep the cover under

tension and remove debris before retraction; electric motors and gear drives

are employed in the take-up mechanisms.

Protecting against welding fl ash and spatterPortable screens protect workers’ eyesight against welding fl ash and UV

radiation, and confi ne weld spatter. Basic weld curtains on stands can be

moved around the factory fl oor to provide shielding where needed. Freestand-

ing curtain modules simplify work-cell assembly.

Motorized weld curtains take it a step further in custom-engineered frames —

suitable for robotic-welding areas and

automated equipment. Some incor-

porate gearless direct-drive motors

that can be programmed to open to

various widths at speeds to 2 m/sec.

Reducing equipment noise levels

The noise levels of some equip-

ment, such as that on construction

sites, are diffi cult to reduce. Howev-

er, portable sound barriers can be set

up to suppress sound. Some designs

retract into compact wheeled cases

for easy transport. Unlike traditional

sound curtains consisting of basic

frame-mounted material, these use

multilayer materials incorporated

into a pleated accordion design that

Continued from page 78

Continued on page 84


RS# 177

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ReliabilityinaClutch...a clutch, brake or power

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we love to do. Our precision

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products consistently prove

reliable and dependable in

every application. Underwater,

on the ground and in the air,

CJM is everywhere.

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2013 FIRST Robotics Competition now underway

Last month, inventor Dean Kamen commenced the 2013 FIRST

Robotics Competition (FRC) season with the kickoff of a new game called Ultimate Ascent. Nearly 51,000 high-school students in 81 cities around the world joined the 2013 kickoff event via live NASA-TV broadcast and Webcast.

“There is no stimulus package that will have as much return as stimulating a bunch of kids to become the workforce of the future, the problem solvers, the creators of the future,” says Kamen.

The 2013 game will be played between two alliances of three teams each. Each alliance competes by trying to score as many fl ying discs into their goals as possible during a short match. Discs scored in higher goals score more points. The match ends with student-designed robots trying to climb up pyramids located near the middle of the fi eld. FRC teams receive a parts kit of motors, batteries, a control system, PC, and a mix of automation components — with no instructions. Working with mentors, students have six weeks to design, build, program, and test their robots to meet the season’s engineering challenge. Teams then participate in regional and dis-trict competitions. For more information, visit usfi rst.org. MD

increases sound mitigation and simplifi es setup. For excessively hot operations,

screens can also double as heat shields when suitable materials are used.

Other equipment may be muffl ed directly with specially designed jacketing.

Pavement breakers, commonly called jackhammers, produce 120 to 125-dB

sound levels at the ear of the operator and approximately 90 dB at a distance

of 50 ft. A light jacket reduces these levels by around 9 dB, which cuts the

breaker’s perceived loudness by half. The jacketing can reduce sound intensi-

ty, which leads to hearing loss, by 88% because most of the noise is produced

by the breaker’s internal components.

The 2-lb jacket, made of three layers of material sewn together, is wrapped

around the breaker and fastened with industrial Velcro. It covers the lower

housing from just below the handle bar and encloses the opening at the bottom

that allows the tool bit to travel. A suspender strap over the handlebar keeps it

from blowing off due to air pressure.

In addition to reducing noise levels, the jacket protects the worker from

the exhaust air of these pneumatic units and the oil that often spews onto the

worker’s legs. Finally, refl ective strips make it visible at night for improved

operator safety. MD

Continued from page 82


FABCO-AIR – www.fabco-air.com – phone 1-352-373-3578

Multi-Power® Air Cylinders

H o w t o g e t h y d r a u l i c c y l i n d e r f o r c e s f r o m c o m p r e s s e d a i r

Multi-Power® Air Cylinders

w w w . f a b c o - a i r . c o m

. . . deliver forces equivalent to low pressure hydraulics using only shop air pressure. Forces from under a hundred pounds to over 22 tons !

. . . are easy to install having only two port connections and a variety of mounting styles.

. . . cost far less and are cleaner than hydraulics.

. . . conserve energy by using only one piston for retract stroke.

. . . produce forces up to four times that of a conventional, single piston air cylinder.

Get orders fi lled in 2 days

5 body styles. Bores 1/2” to 12”. Strokes 1/8” to 12”.

Fabco-Air attaches multiple pistons to a common shaft and provides internal air passages through the shaft to all pistons.

Supply air applied to the extend port energizes all pistons simul-taneously enabling tremendous thrusts to be obtained.

What these cylinders do – How they work –

Specifications: 4" bore x 5" stroke, Magnetic Piston, Shock and Speed Control.

High force in a small footprintfor an automotive application –

Multi-Power® cylinder adapted to a Fabco-Airlinear slide has optional Dial-A-Stroke® feature.

Supplying 4,720 lbs. of force at 100 PSI, the unit has a custom mounting/bearing block with 8 pre-loaded, sealed linear ball bearings supporting 4 hardened, precision guide shafts and a steel tool mounting plate. The Dial-A-Stroke® option enables precision adjustment of the extend stroke.

Specials like this amount to almost half of our business. We can design, prototype and deliver custom samples within 72 hours! FABCO-AIR solves problems. Let us help !

Cutaway view of a 4-piston model in extend mode

2-piston Multi-Power® cylinder with clevis mount

Retract port

Extend port

Air vent slot in baffl e plate

Male rod extension

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RS# 179


Headlines in Motion• NEW BOOK FOR YOUNG

AUTOMATION PROFESSIONALS

A new book from the International

Society of Automation (ISA) is designed

to help the next generation of automation

engineers steer clear of common career

obstacles. 101 Tips for a Successful

Automation Career by Gregory K.

McMillan and P. Hunter Vegas offers

guidance on technical issues as well as

interpersonal and workplace situations.

• ISO STANDARDS ON ELEVATOR

AND ESCALATOR COMFORT

An updated ISO standard aims to

improve passenger experience when

using elevators, escalators, and moving

walkways. The new standard aims to

determine ride quality by specifying the

defi nition, measurement, processing,

and expression of vibration and noise

signals that affect user experience.

• NIST EXPERIMENTS CHALLENGE

THEORY OF ELECTROMAGNETISM

A cornerstone of physics may

require some revision if fi ndings at the

National Institute of Standards and

Technology (NIST) are confi rmed.

Recent experiments suggest that the

current theory of electromagnetism —

one of the four fundamental forces in the

universe — may not accurately account

for the behavior of atoms in exotic, highly

charged states. MD

Precision geared products market deceleratesAccording to a new report from IMS Research, Aus-

tin, shipments of precision geared products (gearboxes

and geared motors with backlash ratings of less than

20 arc-min) were nearly 80% higher in 2012 compared

to 2009. However, uncertainty about the Eurozone econ-

omy and China’s slower economic growth are leading

factors in the more than 1% decline expected for pre-

cision geared product shipments in 2013. Nevertheless,

this market’s value is projected to reach nearly $1.7 bil-

lion with more than 1.8 million units shipped in 2013.

Precision gearbox shipments, which accounted for

more than 95% of the precision geared products mar-

ket in 2012, increased by more

than 70% from 2009 levels due to

pent-up demand for servo-driven

machinery and increased access to

capital. The new report, The World

Market for Precision Gearboxes

and Geared Motors, indicates

shipments will exceed 2 million

units by 2016 despite decelerat-

ing growth. For more information,

visit imsresearch.com. MD


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.544ZTUFNT$PSQPSBUJPO 4FOTPST%JWJTJPOt3001 Sheldon Drive Cary, NCt5FMtwww.mtssensors.com [email protected]

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RS# 181

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ORR ON ENGINEERING

The nature of designAs a systems manager for Metro Nashville in the early 70s, I helped build one of the first municipal automated mapping systems. This endeavor even-tually brought me into contact with a wide variety of designers — people turning ideas into practice.

At the time, I thought of designers as almost god-like because it seemed as if they created something from nothing. However, after a while, I learned that designing ex nihil (“from nothing”) is rare. Most designers actually redesign existing products.

Thus began my long quest to better understand design. Reading technical books and speaking to professors showed me that little had been written about design itself. Instead, people wrote about the design of specific things such as buildings, engines, fenders, and appliances. It was as if designing of a fender was thought to be utterly unlike designing a building.

However, this idea seemed incorrect. After all, design can be thought of as a process of concretiza-tion. It involves moving things from the world of the symbolic — the “sign” world — and placing them in the world of the actual. De-sign. This spell-ing of the word “design” comes from Gabriel Rico’s Writing the Natural Way. In discussing left-brain (rational, logical) and right-brain (intuitive, holis-

tic) issues, she refers to the “sign mind” and the “de-sign mind.”Exploring designs symbolically — through mind-mapping, schematic draw-

ing, and simulation — lets us test ideas quickly and inexpensively. But these ap-proaches only go so far. Building prototypes often reveals issues designers didn’t even think of. So most design settings need both approaches. This means that the best designers use both hemispheres of their brains.

To elaborate on this theme, design is closely related to art, but is not the same. Examples abound of highly functional, ugly designs and of nonfunctional, beautiful designs. Yet some products such as Apple’s are examples of the conflu-ence of design and art — they are both beautiful and utilitarian.

The trial-and-error process that design entails is actually a dialectic — a principle attributed to the historian Hegel. Hegel’s model of thesis-antithesis-synthesis was used to interpret human history by Karl Marx (?). A thesis — an idea, concept, or principle — gives rise to an antithesis, which represents “objec-tions” to the thesis. Comparing the two gives rise to something new, a synthesis.

On your next design project, think of what you are doing as a dialectic. De-fine and refine your thesis (concept). Then build a prototype, thinking of it an antithesis of the thesis. Not because it is the opposite, but because it is a reflec-tion in the real world of what was in your head. The antithesis will teach you about the pieces you left out, or the pieces that don’t work the way you thought they would. Next, create a synthesis, which you can then proceed to refine similarly. This kind of overview thinking about the nature of design — that it is iterative, progresses from abstract to concrete, and is dialectical — can help you improve your designs.

Please send comments to: [email protected] — Joel Orr

Resources:Joel Orr, Copywriter,www.joelwritescopy.com, (650) 336-3937

Edited by Leslie Gordon

Design is closely

related to art,

but is not the

same. Examples

abound of highly

functional, ugly

designs and of

nonfunctional,

beautiful designs.


RS# 183

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RS# 184

RS# 185

SOFTWARE REVIEW

The flat pattern of a Porsche 996 fuel bladder was used to program a CNC cutting machine.

KeyCreator’s prune and graft functions can determine the internal volume of fuel bladders and tanks, as well as be used to copy features.

Our engineers at Aero Tec Labo-ratories, use KeyCreator 3D CAD software to design crash-resistant, nonexploding fuel-bladder tanks for aircraft, race cars, and perfor-mance boats. Our company makes many standard bladder tanks and custom designs for high-end cus-tomers such as NASCAR, Ferrari, Boeing, Lockheed, NASA, and the U. S. military. Our customers require that the tanks fit in ever-changing compact spaces. Design revisions for custom fits are fre-quent and necessary.

Here is where KeyCreator’s direct-modeling approach helps us satisfy our customers. The com-pany has been using KeyCreator since the software was known as Cadkey. I am familiar with Solid-Works and Pro/Engineer from my previous employers. Having worked with both featured-based and direct modeling, I can say that KeyCreator lets us complete tasks at least 20% faster than if we used traditional feature-based CAD.

KeyCreator 3D Direct CAD is a complete direct modeler that does not use a feature tree to cre-ate geometry. Users simply create or modify models by directly ma-nipulating displayed geometry. The software works on any geom-etry regardless of whether it is im-

ported from another CAD system or is a native KeyCreator file.

Not having to work from a feature tree lets us quickly make a lot of changes. Working directly on models makes it easier to ma-nipulate them so they meet design or customer requirements. Key-Creator also impresses customers when used in online collaboration meetings. The software lets us display a design and start making changes on the fly with our cus-tomers watching. They always ask what program we are using.

Customers send us many CAD file formats, including Catia, SolidWorks, Pro/Engineer (or Creo), and Rhino for-mats. The direct model-ing in KeyCreator gives us the flexibility to work with these files. And when we receive native Catia V5 files from our sister branch in England, Key-Creator can ma-nipulate these files more easily and with fewer errors. That’s because we import native files directly into KeyCreator Direct CAD in-stead of using STEP or IGES files as a go-between. The software mod-els native Catia V5 files as shells. KeyCreator trims and stitches the

shell into a solid and then creates solid features so we can make de-sign changes.

Designs often vary year to year, resulting in slightly different part dimensions. For instance, many customized fuel bladder designs start with a preexisting basic shape. Instead of breaking existing models and starting from

scratch, KeyCreator’s Direct Dimension

Driven Edit-ing and

Dynamic Move modifies the preex-

isting shape on the fly by let-

ting us select faces and then pull them into the desired location or other-

wise modify them. In addition, prune and graft

functions help us develop or modify new designs by allowing the copying and pasting of pre-existing features from another

model for use into the current design.

Aero Tec Labs has also made a customized KeyCreator KXL executable file that creates flat patterns from 3D models. This gives us the proper bending flaps to manufacture designs. It takes only two clicks to complete what would have taken about 16 clicks, saving at least an hour of engi-neering time on each design.

Many fuel tanks and bladders

Authored by:

David Legemaat Senior Mechanical Design EngineerAero Tec LaboratoriesRamsey, N.J.

Edited by: Leslie Gordon

Resources:

Aero Tec Laboratories, www.atlinc.com

The software comes from Kubotek USA Inc., 2 Mount Royal Ave., Marlborough, MA 01752, (508) 229-2020, www.kubotekusa.com

RS# 426

Direct modeler builds a better fuel tank


www.machinedesign.com/rsc

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A finished, FIA FT3-approved fuel bladder for a Porsche 996.

The KeyCreator model of the Porsche 996 fuel bladder as viewed from the front topside.

Direct CAD. After a few months, it’s clear how much they appreciate di-rect modeling. We send them off with educational seats of KeyCreator, and they continue to use it for senior design pro-grams. The college is consider-

ing using KeyCreator in its CAD department. More colleges should

do this to give students and new CAD users another way of completing design work.

I highly recommend Key-Creator Direct CAD Modeling,

especially if you work with several CAD file formats on a

daily basis or if you need to make changes quickly. You’ll find that what

would normally take four to five days is now completed in 4 to 5 hours. That’s what it has done for Aero Tec Labs. MD

are part of larger, more-complex assemblies, so file size can be-come an issue. File sizes can eas-ily reach 500 to 600 Mbytes. After recent face-to-face training with “Dr.” Walt Silva, author of introduc-tory guides to KeyCreator, we began using referenced assemblies. Switching to this new way of referencing (which lets parts used more than once in an assembly be dynami-cally referenced in each of their locations) lets Aero Tec Labs keep files from getting too large. The training gave us the confidence to expand our use of KeyCreator and in-crease our productivity.One wish is that KeyCreator included

automatic cabling and piping functions. Instead of having to create splines, it would be faster to have a logic-driven tool that would let users click to points and quickly generate cabling or piping features.We expose college interns to lots of prac-

tice with mechanical design and using KeyCreator

RS# 186


SPOTLIGHT MECHANICAL SLIDES,

Modular motion axes and systems

Ball-screw axes with recirculating ball-bearing guide EGSK and EGSP focus on precision, repetition accuracy, compact

dimensions, and rigidity. The steel housing of these axes form the guide rail, which prevents accumulative tolerances through production. Four rows of balls give the guide carriage the same basic load ratings in both radial coordinate directions.

The mechatronic multiaxis systems handle gripping, joining, rotating, and positioning. Designers can use the systems with standardized handling systems and combine them individually. The ready-to-install systems reduce the number of interfaces.Festo Corp., 395 Moreland Rd, Box 18023, Hauppauge, NY 11788, (631) 435-0800, www.festo.com/usa

RS# 448

Linear drive with adjustable pitchModel RG linear drives feature a man-ual pitch control for a 10:1 adjustment of the drive’s linear pitch. Seventeen drive units are available, each having a specific maximum linear pitch (the lin-ear distance the drive will move on the shaft per one revolution of the shaft). Users can turn the pitch control down in 0.01 increments across 100 discrete settings.

The adjustable pitch feature allows a variable-speed drive system to keep the drive motor running at a constant speed without requiring changes or adjustments. Once set, the pitch will remain the same regardless of the drive motor speed.

Where a specific linear pitch range is required, the traverse shaft may be driven via belt and pulley linkage to the main driveshaft. The ratio between the two pulleys establishes the linear pitch range.

The unit’s rolling-ring bearing assembly per-mits adjustment of the linear pitch. The angle of the bearing assembly relative to the shaft is ad-justable via the pitch control. Turning the pitch control changes the bearing angle which changes the drive’s pitch, causing the unit to move faster or slower per one shaft revolu-tion. This effectively changes the linear speed of the drive unit independent of drive-motor speed.Amacoil Inc., 2100 Bridgewater Rd., Aston, PA 19014, (610) 485-8300, www.

amacoil.com RS# 446

Inch couplingsA new series of inch couplings features a lattice design, which allows for large axial, radial, and angular misalignments while transmitting high torque loads with zero backlash. The S50CLM-... and S50SCLP... Series consists of 35 couplings that feature a maximum angular offset of 7° and bores ranging from 0.125 to 1.250 in. Maximum torque ranges from 5 to 300 lbf-in. The hubs are made of 6061 aluminum; the discs of 420 stainless steel or polyamide resin; and the end flanges of 416 stainless steel.

Sterling Instrument, 2101 Jericho Turnpike, Box 5416, New Hyde Park, NY 11042, (516) 328-3300, http://sdp-si.com/web/

html/newprdlatticecoupling.htm RS# 447


DRIVES, & GEARS

Linear-motion systemThe new Omega Module linear motion system fea-tures a low traveling mass that enables high speeds. The belt drive is fixed to both ends of the main body and looped around the driveshaft of the table part in the shape of the Greek letter “Ω”, reducing the module’s mass and making it highly dynamic. By guiding the module’s table part over ball-rail systems, the unit can achieve a high degree of rigidity for precise movements.

Higher dynamics over longer distances in feed units is possible due to its low traveling mass and fast belt drive. The stationary drive can not only be set up in any posi-tion, it can being used as a vertical axis. A pneumatic clamping element maintains the position at standstill and also clamps hanging loads.

The module comes in three sizes. With a stationary main body, users can specify custom lengths up to 5,500 mm and choose frames in widths of 55, 85 or 120 mm. In the largest size, mechanics are designed

Maintenance-free actuatorsThe new Type ES and Type EC actuators offer long–term maintenance-free operation. Featuring a caged-ball LM guide-type SRS and rolled ball screw equipped with a QZ Lubricator, the Type ES actuator operates for extended periods with-out requiring mainte-nance. Caged technology uses a syn-thetic resin cage with a patented curvature that cradles each ball and separates it from the next one. The spaces between the rolling elements retain grease to act as a lubrication sys-tem. The guide also acts as its base. The ES comes in four models with widths ranging from 32 to 50 mm, heights from 40 to 52.5 mm, and strokes from 50 to 600 mm.

The Type EC actuator also uses a rolled ball screw equipped with a QZ Lubricator and comes in two models with widths ranging from 40 to 48 mm, heights from 48.5 to 57.5 mm, and strokes from 50 to 300 mm.THK America Inc., 200 E. Commerce Dr., Schaumburg, IL 60173, (847) 310-1111, www.thk.com

RS# 449

Variable-speed drivesGuided by global positioning systems, custom vari-able-speed drives meter and dispense seed and fertil-izer. The drives are used as a prime mover connected to a motor, or as a secondary drive connected to a shaft in the machine’s driveline. When used as a prime mover, the drive acts as a variable-speed device; as a second-ary drive, it becomes a variable-ratio device. The drive permits slow or fast, small or large speed changes.

Request free information via our

Reader Service Web site at


for input torques up to 154 Nm. The module offers acceleration speeds up to 50 m/sec² and

speeds up to 5 m/sec.Bosch Rexroth Corp., 2315 City Line Rd., Bethlehem, PA 18017, (610) 694-8352, www.boschrexroth-us.com

RS# 451

The variable-speed feature permits more-accurate settings for the map-based feeding and seeding pro-cess. The drives can accommodate varying terrain and soil conditions where real-time changes in fertilizer output are required. For seeding, the flexible drives help accommodate the narrow time-window for best seeding and for different application rates needed for seeding corn, wheat, oats, and other crops.

Many design options are available, including differ-ent power inputs using chain, belt and couplings.Zero-Max, 13200 Sixth Ave. N, Plymouth, MN 55441,(800) 533-1731, www.zero-max.com

RS# 450


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SPOTLIGHT MECHANICAL SLIDES, DRIVES, & GEARS

Harmonic gearheadA harmonic gearhead featuring the latest har-monic, strain-wave gearing technology replaces larger, high-ratio planetary gearheads. The unit features high torque, true zero backlash, and ex-tremely precise positional accuracy.

A gearing-forward design overlaps com-ponents, allowing the gears to be integrated into the same plane as the bearing. This narrow, rigid design, combined with a large, rugged, crossed-roller output bearing, handles all combinations of radial, axial, and overturning moment loads.

The gearhead is available with the company’s roller-pinion system (RPS). The gear-head is integrated directly into the pinion without adding any length to the system, resulting in zero backlash from the driving-motor shaft through to the driven load for both linear and rotary motion. The design virtually eliminates cumulative error. The RPS reportedly outperforms traditional rack-and-pinion systems with a roller pinion/rack combination that’s easily adapted to any application. The pinion consists of bearing-supported rollers that engage a tooth profile. Two or more rollers connect with the rack teeth in opposition at all times, eliminating backlash. The RPS rollers approach the tooth face in a tangent path and then smoothly roll down the tooth face. The low-fric-tion design delivers 99% efficiency in converting rotary to linear motion, reducing wear and providing longer service life at high speeds up to 36.1 fps.Nexen Group Inc., 560 Oak Grove Pkwy., Vadnais Heights, MN 55127, (651) 484-5900, www.nexengroup.com RS# 452

ServocouplingsA diverse line of servocouplings are for use in applications such as

stepper and servosystems, linear actuators, ball screws, leadscrews, encoders, and valve actuation. The line includes rigid, beam, four-beam, Oldham, jaw, disc, and bel-lows couplings.Ruland Manufacturing Co. Inc., 6 Hayes Memorial Dr., Marl-borough, MA 01752, (508) 485-1000, www.ruland

RS# 453


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RS# 190RS# 189

match your needs. Ultimate flexibility for

high volume production.Small and medium volume production or

prototypes? Then IMS.baseline is the fast

and reliable solution with a selection of

Standard Planetary Gears.

Germany | USA | Mexico | China

Gear Technology. Worldwide.

IMS Gear Planetary Gears Inc.

440 Viking Drive Suite 110

Virginia Beach, VA 23452

phone 757-227-5553 x401 www.imsgear.com

Planetary Gears.High quality for all volumes. IMS Gear off ers the optimum solution and the process that you need.

From prototypes to high-volume series.

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PRODUCTS

in turn contributing to energy efficiency. Three variants of the module for con-necting 20-mA, 1-A, and 5-A transform-ers are available.B&R Industrial Automation Corp., 1250 Northmeadow Pkwy., S-100, Ro-swell, GA 30076, (770) 772-0400, www.br-automation.com RS# 465

Energy-measurement moduleThe X20AP energy-measurement module measures voltages, currents, frequencies, and reactive components on all phases. Current and voltage measurements up to the 31st harmonic elevate the module to high-precision level while its extreme sensitivity and fourth channel let it measure leakage currents on neutral lines.

The unit preprocesses signals and provides measurements together with calculated effective performance values as sets of digital variables. Measurement-value curves re-corded by the module provide the basis for optimizing traverse paths within a machine,

Adjustable-frequency ac drivesThe Series NFX9000 adjustable-fre-quency ac drives provide adjustable speed control of three-phase motors. The drives come with an easy-to-un-derstand removable keypad and feature volts/Hertz motor control and RS-485 serial communi-cations. The unit provides quiet motor operation, high motor efficiency, and smooth low-speed performance.Omega Engineering Inc., One Omega Dr., Stamford, CT 06907, (203) 359-1660, www.omega.com

RS# 466

Locking washersX-Series multifunc-tional washers combine wedge-locking protection against spontaneous bolt loosening (from vibration and dynamic loads) with a spring effect to protect against slackening due to settlement and relaxation.

RS# 191


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Martin offers the industry's broadest product range with fast delivery from stock, same day / next day rebores and alterations, fast turnaround times on Made-to-Orders.

Our broad selection continues to grow with complete inventories in 30 North American branch locations.

Guided-motion air cylindersA new family of guided-motion air cylinders features extended load-carrying capabilities. Twin guide shafts provide precision, nonrotating po-sitioning. Users can choose sleeve or ball bearings. Four mounting methods are available and dowel pin holes on mounting surfaces provide accuracy. Magnetic pistons

are standard. Optional sensors adjust easily in linear slots in the housing. The cylinders of-

fer bores from 12 to 63 mm and strokes to 100 mm. Ask for Catalog #FGM-10.Fabco-Air Inc., 3716 NE 49th Ave., Gainesville, FL 32609, (352) 373-3578, www.fabco-air.com

RS# 467

Request free information via our

Reader Service Web site at


Impact sensor

The Series KG impact sensor monitors the motion and performance of a ma-chine or device. Featuring single-axis/bidirectional sensitivity, the sensor at-taches to the moving part of a machine or device and monitors impact and then relays the measurement to the user. A PLC interprets the signal to warn of er-ratic operation or shuts down a system to prevent catastrophic failure.

Features of the sensor include a predictive maintenance device that detects change in impact; productivity tripwire that alerts appropriate person-nel of a machine crash, indicates when a machine has crashed, and stops produc-tion of bad parts; and counts impacts or extreme vibration (<400 Hz), as well as monitors centripetal forces.PHD Inc., Box 9070, Fort Wayne, IN 46899, (800) 624-8511, www. phdinc.com RS# 468

Each washer pair has cams on one side and radial teeth on the op-posite side to secure the bolted joint with tension instead of friction. The washers’ conical shape creates an elastic reserve in the bolted joint to compensate for the loss of preload and prevents slackening.Nord-Lock Inc., 1051 Cambridge Dr., Elk Grove Village IL 60007, (877) 799-1097, www.nord-lock.com/x-series-video

RS# 469

RS# 192



EZ FLEX™ LINEAR SERVO CONVEYING SYSTEMSHigh precision in-line belted con-

veying systems powered by

Centricity’s servo indexing

technology.

Turnkey solutions with a variety of

belt materials including bolt-on or

weld-on tooling.

Simple touch screen configuration

includes bi-directional motion

profiles for setting index distance,

random positioning, continuous

run, and teach mode. Many other

features standard.

Simple mechanical and electrical

installation easily integrates with

today’s control systems.

CENTRICITY CORPORATION

www.centricity.net

330-545-5624

RS# 255

Wondering if we carry a cable that meets your specs? Need to

complete your cabling system with the right accessories? Then the

2012/2013 HELUKABEL® Cables and Wires and 2013/2014 Cable

Accessories Catalogs are must have items for your office.

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New tutorials and podcasts on Learn Web site “What is a PLC” plus many more

topics on industrial control prod-

ucts including new videos and

podcasts on AutomationDirect’s

free self-service learning site.

Visit http://learn.automationdirect.com

to watch these and other tutorials

on a range of industry topics.

High- PerformanceMagnetsNew cata log features h igh performance magnet materialssuch as NdFeB and SmCo,molded magnets, ceramic anda lnico magnets. MCE offersmagnet circu i t design, custom fabrication, assembly,and advanced coatings. Complete traceability is offered. P h o n e : ( 3 1 0 ) 7 8 4 - 3 1 0 0 ,

Fax:(310)784-3192; [email protected];www.mceproducts.com

Magnetic Component Engineering

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RS# 251

RS# 260

RS# 263

RS# 254

RS# 259

RS# 262

Free design guide to servo-hydraulicmotion control

www.deltamotion.com

Popular, practical 64-page guidewith 16 topics by Peter Nachtwey:s#LOSED LOOP#ONTROLs3IZING#YLINDERSAND6ALVESs3ELECTING!CCUMULATORSs4RANSDUCERSAND2ESOLUTIONs4UNINGFOR/PTIMAL0ERFORMANCE

Fabco-Air.comGainesville, Florida

Air Table Slides

Dual pistons double thrust.

Repeatable workpiece

mounting via dowel hole &

slot on table surface.

Magnetic pistons are

standard. 3 ways to mount

body. Bores 8 to 25mm

Strokes 10 to 150mm

DATA FILE LITERATURE ADVERTISING


Access our Reader Service

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request information on the

products and services found

in the pages of MACHINE DESIGN.

RS# 257

RS# 264

RS# 253

!

BEI’s Industrial Encoders for Dummies

Visit www.beisensors.com/dummiesfor your free copy today

Motion Control It’s What We Do

1 .800 .377 .6329

. com

High Performance Motion ControllersBacked by

Our Exceptional Customer Support

CPV Manufacturing

Valves & Fittings Provide Leakproof Protection to 6,000 psi26HDO 6\VWHP YDOYHV DQG ÀWWLQJVDUH UDWHG IRU KHDY\GXW\ OLTXLG RUJDV VHUYLFHV DQG SURYLGH \HDUV RIUHOLDEOH OHDNSURRI RSHUDWLRQ 7KHXQLTXH26HDO6\VWHPGHVLJQDOORZVRSHUDWRUVWRFKDQJHRXWYDOYHVDQGRWKHUFRPSRQHQWV IRUPDLQWHQDQFHZLWKWKHVLPSOH WXUQRIDXQLRQQXW7KHÁDWIDFHGÀWWLQJVDUHMRLQHGZLWKDUHVLOLHQW2ULQJLQDFORVHWROHUDQFH

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RS# 252

RS# 261

ACE Stainless Industrial Shock Absorbers for Long Life Applications

Made of V4A high quality stainless

steel for long life and extreme

environment applications. The ACE

PMC Series includes a Teflon bellows

cap that protects against damaging

environmental agents.

Ideal for packaging, food processing,

medical, marine and more. Energy

capacities from 175 to 30,000 in. lbs/

cycle (20 to 3,400 Nm/cycle).

ACE Controls Inc. Farmington Hills, MI

(800) 521-3320 (248) 476-0213

Email: [email protected]

www.acecontrols.com

RS# 250

RS# 256 RS# 258

Seal Master Corp., Kent, OH

SEALS, ACTUATORS,GRIPPERS AND BAGS

Solve difficult closure prob-

lems with custom-built, fab-

ric-reinforced, fully molded

elastomeric Seal Master®

inflatable seals. With close

tolerance capability and re-

sistance to compression,

they’re ideal for imaginative production and processing

applications too. Engineered specialties include fabric-

reinforced bags, bladders, plugs and other custom rubber

products. Design assistance offered.

Taylor Devices Inc.

TAYLOR DEVICES UNI-SHOKTaylor Devices offers the Uni-Shok industrial

shock absorber for high-speed, au-

tomated machinery. Available in

14 models, Uni-Shok provides

up to 5000 in-lbs. of

capacity. Patented,

self-adjusting fluidic

metering system eliminates adjustment down-time. Features

stainless steel piston rod, internal coil spring reset, bronze

bearings, silicone fluid and threaded body for mounting ease.

Contact: Taylor Devices Inc., 90 Taylor Dr., N. Tonawanda, NY

14120-0748.

Phone: 716.694.0800 Fax: 716.695.6015

Web site: www.taylordevices.com

MICROMO part of the FAULHABER Group is the quality

leader for full service, value-added dc motor solutions.

Decades ago, the “Faulhaber

coil” built an industry. Today,

MICROMO partners with

customers in medical,

robotics and defense markets

from custom design to

delivery through innovative

technologies such as

brushed, brushless, stepper,

piezoelectric and linear

motors. Call MICROMO at

800-807-9166, or visit our

web site at

www.micromo.com.

The DPGM409 covers the full spectrum in pressure measurement with Gage, Sealed Gage, Absolute, Compound Gage, Vacuum, and Barometric pressure ranges. Its core is a highly stable micromachined silicon sensor with a very high 0.08% accuracy. Each unit is supplied with a 5-point NIST traceable calibration certificate and is tested to industrial CE standards. A user selectable analog output of either 0 to 5 Vdc, 0 to 10 Vdc or 4 to 20 mA is standard on all models and a built-in wireless transmitter option is also available. The electronics are enclosed in a stainless steel and ABS housing that is washdown rated and has a unique magnetic stylus system for programming that prevents accidental programming changes. The display has large 25.4 mm (1 in) digits plus a 0 to 100% bargraph. MIN/MAX/AVG readings are front panel programmable and free data logging and charting software is included. A wireless transmitter option is available to transmit the readings to a receiver in your control room. Power comes from a long life lithium battery (included) with a typical life of 4 years.Price Starts at $695

OMEGA Introduces DPGM409 Pressure Gauge with Metric Fittings and Ranges

Omega | Stamford, CT USA | www.omega.comEmail: [email protected] | Twitter: @OmegaEng

Facebook: http://www.facebook.com/pages/Omega-Engineering/121219014465Phone: 1-800-TC-OMEGA or 203-359-1660

POWER TRANSMISSION STRETCH BELTSPyramid Inc. has manufactured round and flat Pyrathane® belts for over 40 years. Pyrathane® belts are used in a wide variety of low and fractional horsepower drive applications such as live-roller conveyor systems, as well as transport devices for paper, currency and small parts. Pyrathane® belts are manufactured to our customers’ specifications and are of the highest quality with exceptional abrasion resistance and durability.Pyramid Inc.522 N. 9th Ave. E. • Newton, IA 50208Phone: 641-792-2405 • Fax: 641-792-2478E-mail: [email protected]: www.pyramidbelts.com

RS# 270

RS# 267

“Nomex®” Insulating Tubing & BobbinsNomex® is a calendered, aramid

insulation paper that, when wound

into an insulating tube with appro-

priate binders, offers superior high

temperature resistance and high

dielectric strength in insulating

tubing and bobbins Nomex also

possesses excellent mechanical

toughness, resilience and high

mechanical strength. Full PDF Lit

file available at www.pptube.com.

Precision Paper Tube Co., IncThe Original - Since 1934

847-537-4250

www.pptube.com

[email protected]

®”Nomex” is a registered trademark of the DuPont Co.

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High Performance Epoxy AdhesiveEP30HT

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Smalley Steel Ring Company

New Smalley Engineering & Parts CatalogSmalley’s new catalog combines

existing Spirolox Retaining Ring

and Smalley Wave Spring selec-

tions with series recently released

from Smalley. Now a single catalog

includes new: Hoopster Rings, Met-

ric Wave Springs, Constant Sec-

tion Rings and more. Over 10,000

standard parts in carbon and stain-

less steel; free samples available.

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BUSINESS INDEX

This index includes all significant references to parent companies mentioned in feature editorial material within this issue of MACHINE DESIGN. It doesn’t cite companies listed solely in the Products and Lit Section. Page numbers listed refer to the pages where the articles begin.

Ferrari . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Festo Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Flextronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32FormLabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Fossil Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32GM Technical Institute . . . . . . . . . . . . . . . . . . . . . . . . 12General Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Geomagic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36George Washington University . . . . . . . . . . . . . . . . . 8Google . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Heidenhain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Helisys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Henry Ford Trade School . . . . . . . . . . . . . . . . . . . . . . 12Hong Kong Polytechnic University . . . . . . . . . . . 102IKO International Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 72IMS Research . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86ITW Formex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36igus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Indian Institute of Technology. . . . . . . . . . . . . . . . 102Institut Superieur de L’Aeronautique

et de l’Espace. . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Integrated Test and Measurement . . . . . . . . . . . . . 64International Society of Automation. . . . . . . . . . . 86Khalifa University of Science (UAE) . . . . . . . . . . . 102Kubotek USA Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90LeapFrog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Lee Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Littelfuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Lockheed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90MIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Mach III Clutch Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Manitowoc Cranes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Maplesoft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Massachusetts Institute of Technology . . . . . . . . 26MathWorks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Mcor Technologies Ltd. . . . . . . . . . . . . . . . . . . . . . . . 50Metro Nashville. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88MICROMO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Microsoft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Mitsubishi Electric Automation Inc. . . . . . . . . . . . . 74NASA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84, 90NASCAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90National Institute of Standards and Technology . 86National Instruments Corp. . . . . . . . . . . . . . . . . . . . 64National Taiwan Univ. . . . . . . . . . . . . . . . . . . . . . . . . . 54New York State Univ. at Stony Brook . . . . . . . . . . . 54Nexen Group Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94OSHA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Objet Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Omron Foundation Inc. . . . . . . . . . . . . . . . . . . . . . . . 34PalmSource Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39RAF Museum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24ReconRobotics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23RepRapPro Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Ruland Manufacturing Co. . . . . . . . . . . . . . . . . . . . . 94Salesforce.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40SICK Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Sopwith Aviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24SpaceClaim Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Spirol Industries Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . 36Spirol International Corp. . . . . . . . . . . . . . . . . . . . . . 66Sterling Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Stratasys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Stratasys Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36THK America Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93TÜV SÜD America. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Tesla Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Thinkfuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Type22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Univ. of Houston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54University of Agder . . . . . . . . . . . . . . . . . . . . . . . . . . . 29University of Virginia . . . . . . . . . . . . . . . . . . . . . . . . . . . 8University of Wyoming. . . . . . . . . . . . . . . . . . . . . . . 102Vanderlande Industries . . . . . . . . . . . . . . . . . . . . . . . 80VersaLogic Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Von Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Wago . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Zero-Max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

20th Century Machine Co. . . . . . . . . . . . . . . . . . . . . . 323D Systems Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363M 363S-Smart Software Solutions GmbH . . . . . . . . . . . 27A & A Mfg. Co. Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Accuracy International of North America Inc. . . 16Advanced Design Technology . . . . . . . . . . . . . . . . . 30Aero Tec Laboratories . . . . . . . . . . . . . . . . . . . . . . . . . 90Agilent Technologies . . . . . . . . . . . . . . . . . . . . . . . . . 34Amacoil Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92American Red Cross . . . . . . . . . . . . . . . . . . . . . . . . . . 34Apple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88aPriori Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44B.F. Goodrich Tire Co.. . . . . . . . . . . . . . . . . . . . . . . . . . 32

Bangor University . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Beckhoff Automation . . . . . . . . . . . . . . . . . . . . . . . . . 81Boeing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Bosch Rexroth Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . 93British Ministry of Defense . . . . . . . . . . . . . . . . . . . . 16Daikin Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Digital Bond . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Digital Switching Systems LLC. . . . . . . . . . . . . . . . . 34DuPont. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36EAO Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34FIRST Robotics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Fabrico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Facebook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Faulhaber Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23


ADVERTISER INDEX

RS# . . . . . . . . COMPANY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE

196 . . . . . . . . . .A&A Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . .104

134 . . . . . . . . . .Ace Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

113 . . . . . . . . . .Aerotech, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

153 . . . . . . . . . .Airfloat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

174 . . . . . . . . . .Airpot Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

175 . . . . . . . . . .Airpot Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

142 . . . . . . . . . .Amacoil, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

145 . . . . . . . . . .Animatics Corporation. . . . . . . . . . . . . . . . . . . . . . . . .56

150 . . . . . . . . . .ASM Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

103 . . . . . . . . . .Automationdirect.com . . . . . . . . . . . . . . . . . . . . . . . . . 3

166 . . . . . . . . . .Automationdirect.com . . . . . . . . . . . . . . . . . . . . . . . .73



138 . . . . . . . . . .Autonics USA Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

120 . . . . . . . . . .Avnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

146 . . . . . . . . . .Avnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

127 . . . . . . . . . .B&R Industrial Automation . . . . . . . . . . . . . . . . . . . .33

197 . . . . . . . . . .Baldor Electric Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBC

140 . . . . . . . . . .Banner Engineering Co . . . . . . . . . . . . . . . . . . . . . . . .49

194 . . . . . . . . . .BEI Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

198 . . . . . . . . . .Bimba Manufacturing Company . . . . . . . . . . . . . .BC

131 . . . . . . . . . .Bison Gear & Engineering. . . . . . . . . . . . . . . . . . . . . .37

178 . . . . . . . . . .Carlyle Johnson Machine Co. . . . . . . . . . . . . . . . . . .84

163 . . . . . . . . . .Centricity Corporation . . . . . . . . . . . . . . . . . . . . . . . . .71

116 . . . . . . . . . .Contrinex Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

143 . . . . . . . . . .Control Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

164 . . . . . . . . . .Delta Computer Systems, Inc.. . . . . . . . . . . . . . . . . .71

156 . . . . . . . . . .Dexmet Corporation. . . . . . . . . . . . . . . . . . . . . . . . . . .67

171 . . . . . . . . . .Diamond Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

151 . . . . . . . . . .Diequa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

187 . . . . . . . . . .Dura-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

106 . . . . . . . . . .EBM-Papst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

104 . . . . . . . . . .Exair Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

179 . . . . . . . . . .Fabco Air, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

139 . . . . . . . . . .Galil Motion Control Inc. . . . . . . . . . . . . . . . . . . . . . . .47

173 . . . . . . . . . .Harmonic Drive LLC. . . . . . . . . . . . . . . . . . . . . . . . . . . .79

177 . . . . . . . . . .Haydon Kerk Motion Solutions . . . . . . . . . . . . . . . .83

148 . . . . . . . . . .Helukabel USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

125 . . . . . . . . . .Hiwin Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

147 . . . . . . . . . .Igarashi Motor Sales . . . . . . . . . . . . . . . . . . . . . . . . . . .58

154 . . . . . . . . . .IKO International Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .63

191 . . . . . . . . . .IMS Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

149 . . . . . . . . . .Intech Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

105 . . . . . . . . . .Kepner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

108 . . . . . . . . . .Lee Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

110 . . . . . . . . . .Magnetic Component Engineering, Inc. . . . . . . .10

192 . . . . . . . . . .Martin Sprocket & Gear . . . . . . . . . . . . . . . . . . . . . . . .97

182 . . . . . . . . . .Master Bond, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

180 . . . . . . . . . .Maxon Motor USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

126 . . . . . . . . . .MICROMO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

111 . . . . . . . . . .Moog Components Group . . . . . . . . . . . . . . . . . . . .11

114 . . . . . . . . . .Moog Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

181 . . . . . . . . . .MTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

112 . . . . . . . . . .National Instruments Corporation . . . . . . . . . . . . .13

157 . . . . . . . . . .Nexen Group Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

188 . . . . . . . . . .Nippon Pulse America Inc . . . . . . . . . . . . . . . . . . . . .95

172 . . . . . . . . . .Novotechnik U.S., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . .78

109 . . . . . . . . . .Ogura Industrial Corp. . . . . . . . . . . . . . . . . . . . . . . . . .10

102 . . . . . . . . . .Omega Engineering Inc . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . .Ondrives.us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

121 . . . . . . . . . .Oriental Motor USA Corp . . . . . . . . . . . . . . . . . . . . . .26

122 . . . . . . . . . .Oriental Motor USA Corp . . . . . . . . . . . . . . . . . . . . . .27

117 . . . . . . . . . .Pelican Products Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .19

132 . . . . . . . . . .Pepperl+Fuchs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

133 . . . . . . . . . .Pepperl+Fuchs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

169 . . . . . . . . . .Performance Motion Devices, Inc. . . . . . . . . . . . . .76

190 . . . . . . . . . .Peter Paul Electronics Co. Inc. . . . . . . . . . . . . . . . . . .95

162 . . . . . . . . . .PHD Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

184 . . . . . . . . . .Precision Paper Tube Company . . . . . . . . . . . . . . . .89

115 . . . . . . . . . .Proto Labs, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

185 . . . . . . . . . .Pyramid Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

155 . . . . . . . . . .Quality Bearings & Components. . . . . . . . . . . . . . .67

183 . . . . . . . . . .Quality Transmission Components . . . . . . . . . . . .89

165 . . . . . . . . . .RJS Corporation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

136 . . . . . . . . . .Rollon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

176 . . . . . . . . . .Rollon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

193 . . . . . . . . . .SAB Associated Wire Products . . . . . . . . . . . . . . . .100

130 . . . . . . . . . .Setco USA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

141 . . . . . . . . . .Setco USA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

101 . . . . . . . . . .SEW Eurodrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC

128 . . . . . . . . . .Smalley Steel Ring Company . . . . . . . . . . . . . . . . . .34

107 . . . . . . . . . .Spirol International Corporation . . . . . . . . . . . . . . . . 8

189 . . . . . . . . . .Stock Drive Products. . . . . . . . . . . . . . . . . . . . . . . . . . .95

118 . . . . . . . . . .Stratasys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2021

135 . . . . . . . . . .Taylor Devices Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

While every effort has been made to ensure the accuracy of this index, the publisher cannot be

held responsible for any errors or omissions.

144 . . . . . . . . . .TDK-Lambda Americas Inc. . . . . . . . . . . . . . . . . . . . .55

159 . . . . . . . . . .Techno Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

152 . . . . . . . . . .Techno Omil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

123 . . . . . . . . . .Thomas Division . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

124 . . . . . . . . . .Thomas Division . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

158 . . . . . . . . . .Trans-Tek Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

161 . . . . . . . . . .Trim-Lok Company . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

119 . . . . . . . . . .Turck Incorporated . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

195 . . . . . . . . . .U.S. Tsubaki Incorporated . . . . . . . . . . . . . . . . . . . . .103

160 . . . . . . . . . .VIC Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

137 . . . . . . . . . .Wittenstein . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

167 . . . . . . . . . .WorldWide Electric Corporation . . . . . . . . . . . . . . .74

186 . . . . . . . . . .Xenon Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

129 . . . . . . . . . .ZERO-MAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

RS# 194

BUSINESS STAFF

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E D I TO R I A L

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CLASSIFIEDS

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© 2012 U.S. Tsubaki Power Transmission, LLC. All Rights Reserved.

THE ULTIMATE POWER TRANSMISSION COMPONENT PACKAGE

2)'(4#(!).s2)'(4302/#+%4s2)'(402/4%#4)/.s2)'(4#!,,

Tsubaki components. Your lifeline to less downtime.Productivity is profitability. The right products make the difference between sinking and swimming. Let Tsubaki’s family of Chains, 3PROCKETS0/7%2 ,/#+®AND/VERLOAD0ROTECTIONPRODUCTSKEEPYOUROPERATIONABOVEWATERWITHOPTIMUMDRIVE SYSTEMCOMPONENTSsupport and strategies. Find your perfect configuration with our SINGLE SOURCESOLUTION4SUBAKICOMPONENTSCOMBINESUPERIORdesign, performance and compatibility for smooth sailing. Let Tsubaki come to the rescue. www.ustsubaki.com/md

BACKTALK

Wing Yi Curie, Miss Chi Yuk Fung, and Mr. Ng Ka Kui of the Hong Kong Polytechnic University; Dereck Bastienne, Kaltham Saeed Khalfan Al Romaithi, Kaltham Yousef Khalfan Al-Ali, and Abdel Rahman Farraj of the Khal-ifa University of Science (UAE); and Danial Barkhurst, Kodi Dixon, Cody McKinney, and Tyler Stingley from the University of Wyoming.Students had to apply the basic principles of alternative

Relay winnersFirst place in ASME’s 2012 Student Design Competition: Energy Relay went to engineering students Clement Jambou and Olivier Sintive from the Institut Superieur de L’Aeronautique et de l’Espace in Toulouse, France. Mandar Zope, Mayank Porwal, and Kumar Keshav from the Indian Institute of Technology, Bombay, took 2nd place. Third place was a three-way tie between Miss Hau

RS# 195

Manus competition

The Sixth Manus competition is underway. The international con-test, sponsored by igus, East Provi-dence, R. I., seeks innovative and challenging applications that use self-lubricating, maintenance-free polymer bearings to improve tech-nology and reduce costs. Winners will receive cash prizes totalling over $11,000.One area that can be improved

through the use of dry-running plastic bearings is machine safety. According to an MIT study, ma-chine stoppages resulting from insufficient lubrication cost up to $240 million in the U. S. alone.

To enter, write a short descrip-tion of the polymer-bearing appli-cation, describe how the bearings solved the problem, and accompa-nying photos or drawings.

Applications using all-plastic or plastic-compound bearings are permitted, but not those that use bearings coated in plastic. Go to www.igus.com/manus to enter. Deadline for entries is February 28, 2013. MD


TORQUE CONTROL FOR DRIVING, CAPPING AND OTHER

APPLICATIONS WHERE THRUST LOADS ARE APPLIED.

V-SERIESPOLYCLUTCH

• Horizontal and vertical installation without driveshaft modifi cations

• New self-supporting hub design leads to easy installation

• Proven long life friction materials: Slip clutches can slip continuously or intermittently for over 30 million cycles

• 10 to 150 inch pounds torque

• Integrated ball bearing allows thrust loads up to 650 pounds without any effect on torque

A division of A&A Manufacturing Co. Inc.

1-800-298-2066 email: [email protected] polyclutch.com

P O L Y C L U T C H ® M E C H A N I C A L S L I P C L U T C H E S

BACKTALK

READER SERVICES

Letters to the editor: Please include your name, address, and daytime phone number. Letters may be edited for brevity and to focus on essential points.

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energy when designing four self-propelled devices that would collectively compete in a relay race. Each device had to contain an onboard energy source to trigger the subsequent device.

For the 2013 competition, the challenge is to design a Remote Inspection Device. Following the tragedy at the Fukushima nuclear facility after the Tohoku earthquake and tsunami in March 2011, the nuclear industry issued a

Request for Proposal to design and build a small, remotely controlled inspection vehicle that could determine the level of radioactivity at specified locations and inspect for damage, protecting humans from absorbing high doses of radioactive contamination. Participants must design a vehicle to negotiate around obstacles, both in getting to the inspection points and bringing the sensor to the desig-nated return area. MD


The First Name in Power Transmission

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RS# 197

ENGINEERING A BETTER EXPERIENCEEvery problem can’t be solved by off-the-shelf solutions. From space constraints to

caustic environments, and everything in between, the Bimba design team has tackled

the toughest actuation challenges. It’s all about helping you develop the perfect solution

spec’d to your application. At Bimba, no custom project is too small—and we think

that’s a pretty big deal. Visit us online at bimba.com

© Copyright 2013 Bimba Manufacturing Company. All Rights Reserved.

RS# 198

Design 14 February 2013

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