Welcome to your Digital Edition of Tech Briefs and …Welcome to your Digital Edition of Tech Briefs...

Welcome to your Digital Edition of Tech Briefs and Motion Design

Included in This Decemberr 2018 Edition: Tech Briefs Motion Design

How to Navigate the Magazines: At the bottom of each page, you will see a navigation bar with the following buttons:

Arrows: Click on the right or left facing arrow to turn the page forward or backward.

Introduction: Click on this icon to quickly turn to this page.

Cover: Click on this icon to quickly turn to the front cover.

Table of Contents: Click on this icon to quickly turn to the table of contents.

Zoom In: Click on this magnifying glass icon to zoom in on the page.

Zoom Out: Click on this magnifying glass icon to zoom out on the page.

Find: Click on this icon to search the document.

You can also use the standard Acrobat Reader tools to navigate through each magazine.

Supplement to Tech Briefs

December 2018

Multi-Axis Motion Controllerfor Gear Testing

Smart Actuators Deliver onthe Promise of Industry 4.0

One-Cable AutomationStreamlines RoboticInspection

Ultralight Gloves ProvideRealistic Haptic Feedback

Click Here Click Here

December 2018 www.techbriefs.com Vol. 42 No. 12

Simulation for EveryoneBlue-Light Imaging Sees Through Fire

Vote for Product of the Year

Inside Ames Laboratory

SPECIAL SECTION: Technology Leaders in Engineering Software

the #1 value in automationOrder Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2018 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405

What’s in your AC Drive? Features galore AND a wealth of options ALL at a great price.

DURAPULSEAC DRIVES

STARTING AT

$433.00(GS4-21P0)

Research, price, buy at:

www.automationdirect.com/drives/ac-drives/gs4

The DURApulse GS4 series of Variable Frequency Drives (VFD) includes many of the same standardfeatures as our other GS drives including dynamic braking, PID, removable keypad, plus so much more:

• Single-phase input capability on all 230VAC models • V/Hz control or sensorless vector control for

improved speed regulation • 100kA Short Circuit Current Rating (SCCR)

capability for industrial environments

• Built-in PLC (up to 10k steps) for drive-relatedlogic and I/O control

• Built-in analog, discrete, high-speed andrelay I/O with expansion capabilities

protocols included

and EtherNet/IP™ protocols

• Smart keypad stores up to four sets of drive

additional GS4 drives • Fire mode and circulatory control mode

Programming software

DURApulse GS4 SeriesAC Sensorless Vector DrivesUp to 300HP!

4 Digital Inputs2 Digital Outputs

6 RelayOutputs

6 DigitalInputs

Upgrade I/O capabilities ANDcommunications options

EtherNet/IP™ Modbus TCP

Free Info at http://info.hotims.com/69513-690

http://info.hotims.com/69513-690


December 2018 www.techbriefs.com Vol. 42 No. 12

Simulation for EveryoneBlue-Light Imaging Sees Through Fire

Vote for Product of the Year

Inside Ames Laboratory

SPECIAL SECTION: Technology Leaders in Engineering Software

http://www.abpi.net/ntbpdfclicks/l.php?201812TBPC1

http://www.techbriefs.com

DID YOU JUST SAYTHE ‘M’ WORD?

YES ... MESH WAS A “FOUR-LETTER” WORD.

CSIMSOFT™ MAKES MESH GENERATION EASIER.GET A GOOD MESH THE SMART WAY.

CSIMSOFT.COM/MESH



cde.com/MLSHSlimpack

Your Mission-critical applicationsrequire SlimPack performance

MLSH Slimpack is designed to meet the most demanding military and aerospace applications. It’s the world’s only hermetic aluminum electrolytic capacitor with a glass-to-metal seal. Slimpack delivers extremely high capacitance at ultra-low temperatures. Energize your next idea with MLSH Slimpack.

Replaces 3 or more wet tantalum capacitors in parallel or series

Less weight and requires less space

Glass-to-metal seal prevents dry-out for exceptionally long life

Superior capacitance retention at -55ºC

Rugged stainless steel case withstands up to 80g’s



© Allied Electronics & Automation, 2018 alliedelec.com 1.800.433.5700

Hundreds of Industries. Thousands of Models.

Unlimited Applications.Hammond offers electronic enclosures

in extruded aluminum, natural or painted die-cast aluminum, ABS plastic,

polycarbonate, and more.

Hammond offers electin extruded aluminum, n

die-cast aluminpolycarbo



4 www.techbriefs.com Tech Briefs, December 2018

Contents

December 2018 • Vol. 42 No. 12

Features10 Products of Tomorrow

13 Innovators Recognized for “Creating the Future”

16 Simulation for Everyone

50 Application Briefs

54 Vote for Product of the Year

56 Facility Focus

60 NASA Spinoff: Ambulance Sterilization Device

Solutions24 Electrical/Electronics

24 Chip with Micro-Hotplate for Self-Healing and SustainableElectronics

24 Gated Chopper Integrator (GCI)

25 Sandwiching Materials in Nanoelectronics

26 Sensors

26 Device Detects Subatomic-Scale Motion

27 Wide-Area Chemical Sensor

28 Ionization-Based Multidirectional Flow Sensor

29 Sensor Combination Detects People by Smell

30 Printable Metal Tags Turn Objects into Smart, ConnectedDevices

30 Real-Time Ion Mobility Sensor System

31 Inductive Non-Contact Position Sensor

32 Imaging

32 Algorithm Enables Faster Analysis of Medical Images

32 Depth-Sensing Imaging System Can Peer Through Fog

34 Blue-Light Imaging Sees Through Fire

35 Compound-Lens Camera for Industry and Smartphones

36 Optics

36 Dynamic Optical Grating Device for Modulating Light

36 Low-Light Night Vision Imaging and Video Capture

37 Active Pointing Monitor for a 2-Axis Optical Control System

37 Portable Acousto-Optic Spectrometers

38 New Laser for Improving Telecommunications and Computing

Departments8 UpFront

11 Q&A

12 5 Ws

59 Advertisers Index

New for Design Engineers52 New on the Market

Special SectionTechnology Leaders in Engineering Software

20 Five Industry Trends Disrupting the Design andManufacturing World

56

50

(Solutions continued on page 6)

30

Stanford Research Systems

Phone (408) 744-9040

Fax (408) 744-9049

email: [email protected]

www.thinkSRS.com

Take a Closer Look...RGA's starting at $3750

Residual Gas Analyzers from SRS are designed to handle the

toughest environments from basic research to semiconductor

process monitoring. Thousands of SRS RGAs are in use

worldwide, and have earned us a reputation for producing

quality vacuum instrumentation at reasonable prices.

Our RGAs have greater dynamic range, higher resolution and

better linearity than competitive models, and are easier to

use. In addition, a dual ThO2Ir filament and a unique four

channel electron multiplier give SRS RGAs a longer lifetime

than other designs.

Simply put, SRS RGAs offer better performance and value than

any other system.

• 100, 200, 300 amu models

• Sensitivity to 5 x 10-14 Torr

• Better than 1/2 amu resolution

• Dual ThO2Ir filament

• Long-lasting electron multiplier

• 6 decades of dynamic range

• Windows software

Free Info at http://info.hotims.com/69513-659Free Info at http://info.hotims.com/69513-659



6 Tech Briefs, December 2018Free Info at http://info.hotims.com/69513-660

Contents

39 Using Sound Waves to Produce Optical Isolators

39 Optimetric Measurements Over Coherent Free-Space OpticalCommunication

40 Mechanical & Fluid Systems

40 Ducted Fuel Injection for Soot Reduction

40 System Makes Opaque Materials Totally Transparent

41 A New Twist Makes Rotating Machinery More Efficient andQuieter

42 Reusable Breakaway Mounting Device

42 SHEAth-based Rollable LEnticular-Shaped and Low-Stiction(SHEARLESS) Composite Booms

43 Ultralight Gloves Provide Realistic Haptic Feedback

44 Shape Memory Alloy Rock Splitters (SMARS)

44 Submarine Swims Without an Engine

45 Variable-Pitch Turbine Blades

46 Power & Energy

46 High-Power-Density Solid Oxide Fuel Cell

46 Alternating Current Photovoltaic Building Block

47 Thermochromic Windows Convert Sunlight into Electricity

48 Battery Provides Electric Vehicles with Immunity from ClimateConditions

48 New Catalyst for Plastic Production also Creates Hydrogen

Product of the MonthThe WT5000 power analyzer from YokogawaCorp. of America (Newnan, GA) incorporates upto seven input channels.

On the coverThis visualization — created using COMSOL Multi -physics® software from COMSOL (Burlington, MA) —shows the von Mises stress distribution in the housingof an induction motor by accounting for electro-mechanical effects. With the computational power andsoftware available today, numerical simulation is a realoption to quickly get answers to complicated technical,scientific, and engineering questions. Once just thedomain of highly skilled analysts, simulation is nowused by everyone in the enterprise. Learn more in thefeature on page 16.

(Image courtesy of COMSOL)

Permissions: Authorization to photocopy items for internal or personal use, or the internal orpersonal use of specific clients, is granted by Associated Business Publications, provided that theflat fee of $3.00 per copy be paid directly to the Copyright Clearance Center (222 Rose Wood

Dr., Danvers, MA 01923). For those organizations that have been granted a photocopy licenseby CCC, a separate system of payment has been arranged. The fee code for users of theTransactional Reporting Service is: ISSN 0145-319X194 $3.00+ .00

52

•

••

on in-stock parts*• on demand•

with competitor part numbers• ISO 9001:[email protected]

800-237-5225MADE IN USA

*Order must be placed by noon PST

Don’t see what you’re looking for?Contact our Custom Department.

Visit our new website!www.centuryspring.com

NOW AS9100 REV D. for aerospace custom spring orders.



A TAND DA

GENERAL

ACQUISITION P

ATPURPOSE DA

TFORMPLA

LOGGERS

GL240 GL8440-WV GLL2000L

• Isolated channels ersatility to hand

•• V•• Portability to capt•• Ease of use lets y

TILIT•

VVERSA

for enhanced measurement dle countless applicationsure data almost anywhereou start capturing data quick

ALM T THE PY A

safety

kly

OF YOUR HAND

se customer code NTFEBG for special pro

• Direct to Excel recording•• Stand-alone or PC-hosted operation

rms recording and 1usec sam•• 1000VDC & 600V•• Individual channel parameters, alarms & scalin••• Robust start & stop triggering

GRAPHTECAMERICA.COM/IN

motion 949.860.4186SContact Graphtec T

mpling intervalsng to engineering units

STRUMENTS

GL7000

com

Specialists at:

ve, Irvine, CAraphtec America, Inc. 17462 Armstrong A©Copyright [email protected]


GL980

G

echnical

U



facebook.com/TechBriefsMagazine linkedin.com/company/tech-briefs-media twitter.com/TechBriefsMag

Connect with Tech Briefs

NASA Awards 2018 Software of the YearA mixed-reality soft-

ware that allows scien-tists and engineers tovirtually walk on Marsreceived NASA’s 2018Software of the YearAward. OnSight usesimagery from NASA’sCuriosity rover to cre-ate an immersive 3Dterrain model, allowingusers to wander theactual dunes and val-leys explored by therobot. The goal of thesoftware — a collabora-tion between Microsoft and Jet Propulsion Lab’s Ops Lab — is to bring scientists closerto the experience of being in the field.

“Being able to visualize Curiosity’s drives and virtually walk them before we actually doit with the rover is really helpful to give me a sense of how safe or challenging the terrainwill be,” said Abigail Fraeman, a member of Curiosity’s science team. In addition tostudying the geology of Mars, the software allows scientists at any location to “meet” onMars with avatars that can walk, point, and interact with one another.

These virtual field trips help the science team study Martian geology using Curiositydata in a collaborative setting. In the future, OnSight will be adapted for the Mars 2020rover and could be applied to other extreme environments that are difficult to visit.

Visit https://opslab.jpl.nasa.gov/

3D Printer “Fingerprints” Could Trace 3D-Printed Guns3D printers have “fingerprints” and like

human fingerprints, no two 3D printers areexactly the same, according to researchers atthe University at Buffalo (NY). They devel-oped an accurate method of tracing a 3D-printed object to the machine from which itcame. The PrinTracker technology could ulti-mately help law enforcement and intelligenceagencies track the origin of 3D-printed guns,counterfeit products, and other goods.

Each layer of a 3D-printed object containstiny wrinkles — usually measured in submil-limeters — called in-fill patterns. These pat-terns are supposed to be uniform; however,the printer’s model type, filament, nozzle size,and other factors cause slight imperfectionsin the patterns. The result is an object that

does not match its design plan. Like a fingerprint to a person, these patterns are uniqueand repeatable. As a result, they can be traced back to the 3D printer.

Visit http://www.buffalo.edu/news/

UPFRONT Linda Bell

Editorial Director

Exploring the SolarSystem? Pack anUmbrella

NASA’s ADEPT(Adapt able Deploy -able Entry Place -ment Technology isno ordinary umbrel -la. It’s a foldable

device that opens to make a round, rigidheat shield, or aeroshell. The designmay someday deliver much larger pay-loads to planetary surfaces than is cur-rently possible. It uses flexible 3D wovencarbon fabric skin stretched over ribsand struts that become rigid when fullyflexed. The carbon fabric skin is the pri-mary component of the entry, descent,and landing thermal protection system.Watch a video of ADEPT on Tech Briefs TV

at www.techbriefs.com/tv/ADEPT

What’s New on Techbriefs.com

Did you know thatNASA has tracked morethan 4,700 “potentiallyhazardous” asteroids? Tospot the near-earth ob -jects requires a communi-

ty — one made up of NASA professionals,amateur astronomers, and engineers fromgovernment labs. In our latest episode ofHere’s an Idea™, we speak to three aster-oid researchers, including NASA’s Plane -tary Defense Officer, Lindley Johnson.Have an idea of your own? Contact me [email protected] us every month on iTunes or subscribe

and listen at techbriefs.com/podcast.

Next Month in Tech Briefs

We kick off 2019 with special coverageof 3D printing/additive manufacturingas well as design and simulation software.

OnSight uses real rover data to create a 3D simulation of the Martianenvironment where mission scientists can “meet” to discuss roveroperations. (NASA/JPL-Caltech)

Nozzle Size

System Inertia

Motor Speed

Model Type

Filament

The printer’s model, filament, nozzle size,and other factors cause slight imperfec-tions in a part’s patterns. (Wenyao Xu,University at Buffalo)

http://www.techbriefs.com/tv/ADEPT

http://techbriefs.com/podcast

https://twitter.com/TechBriefsMag

https://www.linkedin.com/company/tech-briefs-media

https://www.facebook.com/TechBriefsMagazine

In cable design, it’s important to account for capacitive, inductive, and thermal eff ects in the cable parts. For example, diff erent bonding types result in diff erent current buildup and losses. Similarly, phase conductor and armor twist aff ect current distribution in the cable. Knowing this up front will help you make informed design decisions. This is where electromagnetics simulation comes in.

The COMSOL Multiphysics® software is used for simulating designs, devices, and processes in all fi elds of engineering, manufacturing, and scientifi c research. See how you can apply it to cable design.

Make informed design decisions with EM simulation.

comsol.blog/cable-tutorials

Visualization of temperature (left) and magnetic fl ux density norm (center) in the cross section (right) of an industrial-scale cable.



► In-Situ AdditiveManufacturingInspection

NASA Marshall SpaceFlight Center developed anovel method for interim, in-

situ dimensional inspection of additively manu-factured parts. Additive manufacturing processescurrently have limited monitoring capabilities,offering users little to no options in mitigatingthe high levels of product and process failures.The technology is especially useful for the in-process inspection of a part’s internal features(e.g., fluid channels and passages), which cannotbe easily inspected once the print is complete. Bymonitoring the print layer-by-layer in real time,users can pause the process and make correc-tions to the build as needed, reducing material,energy, and time wasted in nonconforming parts.

Contact: Sammy Nabors, Marshall Space Flight CenterPhone: 256-544-5226E-mail: [email protected]://technology.nasa.gov/patent/MFS-TOPS-70

► Sugar-Powered Sensor Detects and Prevents DiseaseResearchers at Washington State University have developed an implantable, biofuel-

powered sensor that runs on sugar and can monitor a body’s biological signals to detect,prevent, and diagnose diseases. The sensor is enabled by the biofuel cell and harvestsglucose from body fluids to run. The sensor could eliminate the need to prick a finger

for testing of certain diseases such as diabetes. The electronics in the sensor use state-of-the-art design and fabrication to consume only a few microwatts of power while being highly sensitive.Coupling these electronics with the biofuel cell makes it more efficient than traditional battery-powereddevices. Since it relies on body glucose, the sensor’s electronics can be powered indefinitely.

Contact: Subhanshu Gupta, Washington State University Phone: 509-335-5045E-mail: [email protected]

► Self-Healing MaterialGrows from CarbonDioxide

A material designed by MITchemical engineers can reactwith carbon dioxide from the air to grow,strengthen, and even repair itself. The polymer,which might someday be used as construction orrepair material, or for protective coatings, contin-uously converts the greenhouse gas into a carbon-based material that reinforces itself. The syntheticgel-like substance performs a chemical processsimilar to the way plants incorporate carbon diox-ide from the air into their growing tissues. Thematerial might, for example, be made into panelsof a lightweight matrix that could be shipped to aconstruction site, where they would harden andsolidify just from exposure to air and sunlight,thereby saving on the energy and cost of trans-portation. If the surface is scratched or cracked,the affected area grows to fill in the gaps andrepair the damage without requiring any externalaction.

Contact: Karl-Lydie Jean-BaptistePhone: 617-253-1682E-mail: [email protected]


This column presents technologies that haveapplications in commercial areas, possibly creating theproducts of tomorrow. To learn more about eachtechnology, see the contact information provided forthat innovation.

Products of Tomorrow

Part Design IR Laser Path

IR Laser Layer Inspected Part

https://technology.nasa.gov/patent/MFS-TOPS-70

Tech Briefs, December 2018 www.techbriefs.com

MICRO-EPSILONRaleigh, NC 27617 / USAPhone +1/919 787 [email protected]

www.micro-epsilon.com

Online sensors Thermal imagers Hand held devices

IR TEMPERATUREMEASUREMENT

Universal color sensors Color sensors for special surfaces

LED analyzers

COLOR SENSORS

NON CONTACTDISPLACEMENTMEASUREMENT Laser sensors Eddy current sensors Capacitive sensors Confocal sensors

CONTACT US

THE AUTHORITY IN MEASUREMENT

Professor RouzbehShahsavari, Civiland EnvironmentalEngineering, RiceUniversity,Houston, TX

Professor Shahsavari and graduate stu-dent Sung Hoon have demonstrated a

process for producing a cement that isstronger, lighter, and more durable thanthe traditional Portland cement.

Tech Briefs: What got you interestedin this project?

Professor Rouzbeh Shahsavari: Con -crete is the most widely used engineeringmaterial. Since such a large amount ofconcrete is consumed, it has a large ener-gy and environmental footprint. We gotthe idea that if concrete could be pro-duced that has greater durability, lastslonger, and doesn’t need as much replace-ment or repair, it would have a lower envi-ronmental impact. Also, with concretethat is twice as strong, you would needhalf the amount for construction becauseit could sustain a load using half the vol-ume. You would then need half the labor,half the transportation, half the rebar —everything becomes half. We decided toattack the problem from a materials per-spective. If we could produce cementmade up of spherical particles, its porositywould be minimized.

Tech Briefs: Don’t particles withdifferent shapes and sizes havefewer spaces between them thanspheres?

Shahsavari: The problem in the cur-rent cement industry is that there is nocontrol over the size and shape of theparticles. Once you mix the cement withwater, and it becomes a slurry that hard-ens, the shapes of the particles are ran-dom. You can have porosity up to a cen-timeter so that water can easily ingressand penetrate to the steel rebar, weaken-ing the structure and reducing its dura-bility. If, however, the spheres were dif-ferent sizes, the smaller ones would fillthe gaps.

Tech Briefs: Are there other possibleapplications for your process?

Shahsavari: Yes. Calcium silicates likecement can be used as thermal insulatorsthat have good tolerance for high tem-peratures. Also, bone tissue has a struc-ture similar to cement — tough and inor-ganic — and importantly, calcium sili-cates are biocompatible. We’re alreadyusing artificial bone for making hips andother body parts. There is a general pricepressure to stay with Portland cement forbuilding construction, but for medicaluse, high quality outweighs price as animportant factor.

Tech Briefs: What process did you useto form the spherical particles?

Shahsavari: From fields such as epi-taxial growth, it is known that if youwant to control shape or size, you needsome sort of template. Our thoughtwas that we could form micron-sizedcalcium silicate spheres around micellesurfactant seeds because they are essen -tially spherical in shape. Althoughthese seed points are very small, theirimpact is high when it comes to shape.

These cement ingredients areattracted to the small templates andgrow on top of each other while retain-ing the same shape as the seeds. Wedemonstrated that if we use techniquessuch as self-evaporation, individualspherical particles come together.Making this self-assembly process moreefficient is the subject of our ongoingresearch.

Tech Briefs: Do you think thisprocess will completely replacePortland cement?

Shahsavari: No, not completely. Port -land cement is in high demand — morethan three billion tons a year globally;however, it may be mixed with Portlandcement to improve its properties. Westill have a lot of details to work out tomake this process commercially viable.

To learn more, read a full transcript, or lis-ten to a downloadable podcast, visitwww.techbriefs.com/podcast.

Q&A


http://www.techbriefs.com/podcast



of Spray-On Antennas

WhatThis method sprays invisibly thin antennas — made from a type oftwo-dimensional metallic material called MXene — that perform aswell as those being used in mobile devices, wireless routers, andportable transducers. MXene titanium carbide can be dissolved inwater to create an ink or paint. The exceptional conductivity of thematerial enables it to transmit and direct radio waves, even when it’sapplied in a very thin coating. Even transparent antennas withthicknesses of tens of nanometers are able to communicate effi-ciently. The thinnest antenna was 62 nanometers — about a thou-sand times thinner than a sheet of paper — and was almost trans-parent. Unlike other nanomaterial fabrication methods thatrequire additives (binders) and extra steps of heating to sinter thenanoparticles together, this method produces antennas in a singlestep by airbrush-spraying the water-based MXene ink. Preservingtransmission quality in a form this thin could allow antennas to eas-ily be embedded — literally, sprayed on — in a wide variety ofobjects and surfaces without adding additional weight or circuitry,or requiring a certain level of rigidity.

WhereDrexel University, College of Engineering, Philadelphia, PA

WhenThe researchers are studying the best ways to apply theMXene material to a variety of surfaces, from glass, to yarn,to skin.

WhyMaking antennas smaller and lighter has long been a goal ofmaterials scientists and electrical engineers, so this discoveryis a sizable step forward both in terms of reducing their foot-print as well as broadening their application. It could makeinstalling an antenna as easy as applying bug spray.

Researchers developed and tested spray-applied antennasmade from a type of two-dimensional material called MXene.

5Ws

WhoManufacturers and users of wearables, functional fabrics, mobiledevices, wireless routers, and Internet of Things devices.

Watch a video about the technology on Tech Briefs TV at www.techbriefs.com/tv/mxene. For more information, contact Britt Faulstick at [email protected]; 215-895-2617.

Spray-applied MXene antennas could open the door fornew applications in smart technology, wearables, andIoT devices.

http://www.techbriefs.com/tv/mxene

A Nanoscience Disappearing ActIf you’ve watched television in anything but

total darkness, used a computer near a win-

dow, or taken a photo outside on a sunny day

with a smartphone, you’ve experienced a

major nuisance of modern display screens:

glare. Most of today’s electronics devices are

equipped with glass or plastic covers for pro-

tection against dust, moisture, and other envi-

ronmental contaminants, but light re flection

from these surfaces can make information

displayed on the screens difficult to see.

Charles Black, Director of the Center for

Functional Nanomaterials (CFN) at Brook-

haven National Laboratory, and Andreas

Liapis, a former CFN postdoc and current

research fellow at Massachusetts General

Hospital’s Wellman Center for Photomedi-

cine, won this year’s Grand Prize with a

method for reducing the surface reflections

from glass surfaces to nearly zero by etch-

ing tiny nanoscale features into them.

This “invisible glass” could do more than

improve the user experience for consumer

electronic displays. It could enhance the

energy-conversion efficiency of solar cells

by minimizing the amount of sunlight lost to

refection and could be an alternative to the

antireflective coatings used in medical lasers

and aerospace components.

Said Black, “We’re excited about the pos-

sibilities. Not only is the performance of

these nanostructured materials extremely

high, but we’re also implementing ideas from

nanoscience in a manner that we believe is

conducive to large-scale manufacturing.”

“We have eliminated reflections from

glass windows not by coating the glass with

layers of different materials, but by changing

the geometry of the surface at the nano -

scale,” added Liapis. “Because our final struc -

ture is composed entirely of glass, it is more

durable than conventional antireflective

coatings.”

Their method of creating surface nano -

textures is amenable to almost any type of

material including silicon (for solar cells) and

several types of plastic. The antireflective

glass can also be made water-repellent, self-

cleaning, and anti-fogging — ideal properties

for car and aircraft windshields.

“Our role in the CFN is to demonstrate

how nanoscience can facilitate the design of

new materials with improved properties,” said

Black. “This work is a great example of that.”

(Continued on page 14)

INNOVATORSRECOGNIZED FOR CREATING THE FUTURE

THE

DESIGN CONTEST 2018

The Create the Future Design Contest was launched in 2002 to help stimulate and reward engineering innova-

tion. In the past 16 years, the annual contest has drawn more than 13,000 product design ideas from engineers,

students, and entrepreneurs worldwide.

Top prizes in the 2018 contest — including the Grand Prize and winning designs in seven categories — were

awarded on November 9 in New York City.

Find descriptions of all winning inventions and honorable mentions at www.createthefuturecontest.com.

See more event photos online at www.techbriefs.com.

Grand Prize winners Andreas Liapis (l) and Charles Black.

INNOVATORSRECOGNIZED FOR CREATING THE FUTURE

Tech Briefs, December 2018 www.techbriefs.com 13

https://www.techbriefs.com/

https://www.createthefuturecontest.com


Solving a LandmineCrisis

“Currently, there are more

than 10 million PFM-1 ‘butterfly’

landmines scattered throughout

Afghanistan and other coun-

tries,” according to Jasper Baur

of Binghamton University in

New York. “These heinous

devices cause thousands of fatal

injuries and amputations each

year.” In fact, said Baur, “80% of

the victims are civilians — primarily children.”

Due to their small size and plastic composi-

tion, common detection methods fail to

locate them.

Baur — with William Frazer, Tim deSmet,

and Alex Nikulin — developed a low-cost

solution to detect these devices. Winner of

the Aerospace & Defense category, the sys-

tem uses drone-based infrared sensing to

detect the difference in thermal conductiv-

ity between the mines and their surround-

ing environment, enabling successful identi-

fication of the devices.

Said Frazer, “Applying our methods and

technology to detect and remediate PFM-1

mines in post-conflict developing nations

has the potential to save thousands of lives.”

Driving ElectromobilityThe future of mobility is electric — but

how can the cost of electric drives be re -

duced, and their efficiency and range

increased? Volabo addressed these problems

with the Intelligent Stator Cage Drive

(ISCAD), winner of the Automotive &

Transportation category.

Common electric vehicles use drive com-

ponents based on voltages up to 400 V; how-

ever, they require extra safety measures dur-

ing crashes and maintenance. ISCAD is based

on a battery voltage of 48 V, fundamentally

eliminating the electrical hazard potential for

passengers, even in heavy crash situations.

ISCAD is an electric traction drive that,

instead of copper windings, uses aluminum

bars in the stator. With the same size bat-

tery, driving range can be increased by 25%.

ISCAD works with batteries, fuel cells, or

other types of energy sources and is not

limited to the automotive market, since

especially at sea, a low-voltage system is

very desirable for safety reasons.

Power from WasteA groundbreaking power system that

turns scrap aluminum into a highly efficient,

safe fuel source is the winner of the

Consumer Products category.

Aluminum has an incredibly high energy

density — double that of gasoline and an

order of magnitude greater than lithium-

ion; however, an oxide layer forms on its

surface when in contact with air, preventing

it from reacting. Processes have been devel-

oped to circumvent this in order to use this

energy density in applications such as rock-

et fuels, but they are very dangerous and

create serious risks of combustion.

Peter Godart and Jason Fischman of MIT

developed a reaction that has the energy

density of rocket fuel, with high levels of con-

trol and safety. The fuel can be made easily

and cheaply from scrap aluminum, and pro-

duces recyclable byproducts. A 3-kW emer-

gency power supply was created that gener-

ates electricity from this fuel; it can be run in

enclosed spaces safely without

worry of inhalation hazards.

Said Godart, “I want to give

people in the immediate after-

math of a hurricane the ability

to provide clean water and

electricity for themselves using

locally sourced materials.”

Shrinking AntennasAntennas have come a long

way from the rabbit ears on

your old TV. But the antenna developed by

Northeastern University’s Hwaider Lin is

about 100 times smaller than the one cur-

rently in a smartphone. Winner of the

Electronics/Sensors/IoT category, Lin said the

magnetoelectric (ME) antenna could eventu-

ally be used in a chip implanted in a patient’s

brain to help treat disorders such as depres-

sion or severe migraines.

Conventional antennas send signals by

bouncing electrons back and forth along a

metal cable. This creates waves of electro-

magnetic radiation that can be picked up by

other antennas tuned to the right frequen-

cy. Changing the size of the antenna changes

the frequency.

Lin’s antenna starts with a different kind of

wave: an acoustic wave. These are slow-mov-

ing physical vibrations and because of their

slower speed, they can match the frequency

of an electromagnetic wave, but will have a

wavelength that is thousands of times smaller.

Applications include biomedical applica-

tions, wearable antennas, and Internet of

Things devices. “So far, the best choice is

biomedical applications,” Lin said. “They

need a really small antenna that can receive

power and transmit information back to

the computer outside.”

Advanced Prosthetic ControlIt is estimated that 1.7 million people in

the U.S. have undergone an amputation.

THE

DESIGN CONTEST 2018

CREATING THE FUTURE

Jasper Baur, winner of the Aerospace & Defense category.

Nanci Hardwick, winner of the Robotics/Automation/Manufacturing category.

Winner of the Medical category, PatrickNercessian.

Hai Minh Duong, winner of the SustainableTechnologies category.

Prosthetic devices can vary widely in func-

tionality, from devices that look like an

upper limb amputee’s hand to prostheses

that have motorized, articulated joints.

Patrick Nercessian and his team at the

Alfred Mann Foundation developed the

Implantable Myoelectric Sensor (IMES) sys-

tem — winner of the Medical category —

that transmits myoelectric signals from

residual muscles of an amputated limb into

the prosthesis. The matchstick-sized sen-

sors can be implanted into the target mus-

cles through a small incision. The signals are

captured and wirelessly transmitted from

the implanted sensor to a decoder box,

which serves as an electronic brain.

The IMES System bridges the brain to the

artificial limb, enabling the signals sent from

the brain to the remaining portions of the

amputated muscles to intuitively control

the prosthesis without the need for invasive

brain or muscle surgery.

No-Melt Metal ManufacturingTraditional methods for additive manufac-

turing of metal parts require the metal to be

melted, which introduces weakness and other

issues. MELD™ technology from MELD

Manufacturing is a solid-state process that

puts the material in a malleable state without

melting. Winner of the Robotics/Auto -

mation/Manufacturing category, MELD can

produce high-quality materials and parts with

low residual stresses and full density, with sig-

nificantly lower energy requirements than

conventional processes.

MELDing also produces materials that

are not susceptible to porosity, hot-crack-

ing, or other common problems that plague

melt-based technologies. Since MELD is an

open-atmosphere process, no special vacu-

ums or chambers are needed for operation,

making it a safer, more efficient, and fully

scalable technology.

The MELD process prints large metal

parts at a scale not yet seen in the metal

additive market. It is not limited in the metal

alloys that can be deposited — aluminum,

titanium, steel, and nickel-based super alloys

use the same machine and the same process.

Added Nanci Hardwick of MELD, “There

is very little waste — it’s a very green

process. In addition, we can repair unweld-

able materials, join or coat dissimilar mate-

rials — the options that this process cre-

ates open up new product opportunities.”

Waste Not …Plastic waste often ends up in oceans and

landfills, affecting marine life and causing

problems such as groundwater contamina-

tion. Globally, the annual consumption of

plastic bottles is expected to exceed half a

trillion tons per year by 2021. A team from

the National University of Singapore —

winners of the Sustainable Technologies cat-

egory — developed a simple, cost-effective,

and green method to convert plastic bottle

waste into polyethylene terephthalate

(PET) aerogels for many uses.

“One plastic bottle can be recycled to pro-

duce an A4-sized PET aerogel sheet. In this

way, we can help cut down the harmful envi-

ronmental damage caused by plastic waste,”

said Associate Professor Hai Minh Duong.

The PET aerogels are soft, flexible, durable,

extremely light, and easy to handle. They also

demonstrate superior thermal insulation and

strong absorption capacity. These properties

make them attractive for a wide range of

applications.

Said co-inventor, Professor Nhan Phan-

Thien, “By adopting PET aerogels that are

coated with fire retardants as a lining materi-

al, firefighter coats can be made much lighter,

safer, and cheaper.” He added, “In highly

urbanized countries like Singapore, carbon

dioxide absorption masks and heat-resistant

jackets made using PET aerogels can be

placed alongside fire extinguishers in high-

rise buildings to provide added protection to

civilians when they escape from a fire.”

Winner of the Consumer Products category,Peter Godart.

The Electronics/Sensors/IoT category winner,Hwaider Lin.


Lena Honsberg accepts the award for theAutomotive & Transportation category.

THE 2018 CREATE THEFUTURE DESIGN CONTEST

WAS SPONSORED BYCOMSOL AND MOUSER

ELECTRONICS.

COMSOL is a global provider of simu-lation software for product design andresearch to technical enterprises, researchlabs, and universities. Its COMSOLMultiphysics® product is an integratedsoftware environment for creating physics-based models and simulation apps. COM-SOL employs more than 450 people in 19offices worldwide and extends its reachwith a network of distributors.

www.comsol.com

Mouser Electronics, a Berkshire Hatha -way company, is an award-winning, autho -rized semiconductor and electronic compo-nent distributor focused on rapid NewProduct Introductions from its manufactur-ing partners for electronic design engineersand buyers. The global distributor's website,Mouser.com, is available in multiple lan-guages and currencies and features morethan 5 million products from over 700 man-ufacturers. Mouser offers 23 support loca-tions around the world to provide best-in-class customer service and ships globally toover 600,000 customers in more than 220countries/territories from its 750,000 sq. ft.state-of-the-art facility south of Dallas, Texas.

www.mouser.com

Mark Your Calendars! The 2019 contestopens for entries on March 1 at

www.createthefuturecontest.com

https://www.createthefuturecontest.com

https://www.comsol.com/

https://www.mouser.com/


With the computational pow -er and software availabletoday, numerical simula-tion is a real option to

quickly get answers to complicated tech-nical, scientific, and engineering ques-tions. Not only has the hardware dou-bled computing capacity every 18months or so over the past decades, butthe numerical algorithms have improvedat the same rate.

The graph in Figure 1 shows the rate ofincrease in processing performance overthe number of years. Note that the verticalaxis is logarithmic scale. From 1968 to2005, the combined rate of performanceincreased a mind-boggling 1014. BothMoore’s Law and the improvement of

numerical algorithms have kept improv-ing since 2005 — the reason we are at thispoint in history when so many previouslyout-of-reach problems can be solved.

Accurate multiphysics models consid-er a wide range of possible operatingconditions and physical effects. Thismakes it possible to use models forunderstanding, designing, and optimiz-ing processes and devices for realisticoperating conditions.

Enabled by these multiphysics modelsof the products they want to design anda culture of collaboration with the con-venience of simulation apps, designersand engineers are pushing the limits oftechnology while reducing the need forphysical prototypes, resulting in better

business and engineering solutions foreveryone in the enterprise.

Topology OptimizationIn recent years, engineers in many indus-

tries have adopted simulation to cut proto-typing costs and speed time to market. Oneexample is the medical device industry.

“In multiphysics modeling, we solveproblems involving multiple physics thatare coupled together. This is of greatimportance for medical device designand bioengineering,” said Nagi Elabbasi,principal engineer of Veryst Engi neering(Needham, MA). “In the human body,you cannot decouple blood flow from thecompliance of the blood vessels. Addi -tionally, if you have a tissue-ablation med-

Simulationfor Everyone


ical device, you cannot decouple the tem-perature field from the electric fieldwhen examining the tissue damage. Thesame principles apply when looking atthe opening and the closing of the heartvalve, which affects the blood flow andvice versa (Figure 2). The valve materialsexperience large deformations andstrains, and have to be very reliable onceput in place. Being able to model all ofthe physics is imperative to designing safeand innovative products,” Elabbasi said.

Topology optimization — typicallyused in the conceptual stage of design— treats the distribution of material as adesign variable and inserts or removesstructures to improve the objective func-tion. Due to the high number of designvariables, only gradient-based optimiza-tion is practical. Topology optimizationhas, of late, dramatically increased inimportance as a structural analysismethod thanks to new and more afford-able additive manufacturing methods.The geometrical shape that a topologyoptimization analysis generates is typi-cally not suitable for traditional manu-facturing methods, but is attainable withadditive manufacturing methods.

Mainly used in structural mechanics,topology optimization is also used forthermal, electromagnetics, and acousticsapplications. Topology optimization with -in structural analysis can answer thequestion: Given that you know the loadson the structure, which distribution ofthe available material maximizes stiff-ness? Or, conversely, how much materialis necessary to obtain a predefined stiff-ness, and how should it be distributed?

Such investigations typically occurduring the concept design stages. Theconflicting goals of stiffness maximiza-tion and mass minimization lead to acontinuum of possible optimal solu-tions, depending on how you balancethe goals against each other.

The topology optimization examplein Figure 3 demonstrates how to obtainan optimal distribution of a fixedamount of material in a steel hook suchthat stiffness is maximized. Changingthe amount of material available leads toa different solution that is also Paretooptimal, representing a different bal-ance between the conflicting objectives.

Materials SimulationThanks to the improved strength and

reduced weight as compared to conven-tional materials, composite materialshave many potential use cases in diverse

Figure 1. Rate of increase in processing performance.

Figure 2. Fluid-structure interaction analysis of an idealized heart valve, including contact modelingand nonlinear material modeling. Deformation, von Mises stress, and velocity magnitude are shown.


fields. Development efforts are under-way in industry to embed functionalitylike sensing, actuation, computation,and communication into compositematerials known as smart compositematerials. A thorough understanding ofthe behavior of such materials is neces-sary in order to design the most accu-rate and reliable composite structures.

Composite materials such as carbon-fiber-reinforced polymer (CFRP) haveoutstanding properties. CFRP is a light-weight material with high stiffness and

high temperature tolerance and istherefore used in the aerospace indus-try, civil engineering, and for high-endsporting goods.

The example shown in Figure 4 illus-trates how carbon crystals form flat rib-bons. Large numbers of these ribbons arebundled together and woven in differentstructures as required by the applicationarea. The bundles have anisotropic ther-mal material properties; the thermal con-ductivity along the fiber axis is much high-er than perpendicular to it.

This type of thermal behav-ior is desired in applicationswhere cooling needs to be pro-vided laterally rather thanthrough the thickness of thematerial; for example, to effi-ciently transport heat fromelectronic components in con-tact with the composite materi-al. Modeling anisotropic mate-rials in fibers is challengingand requires a coordinate sys-tem that “follows” the curvedCAD geometry. Such a curvilin-ear modeling tool is includedin COMSOL Multiphysics.

Adopting SimulationCreating accurate digital

prototypes and deploying sim-ulation apps has become stan-dard practice among industry

leaders. Digital prototypes push thelimits of technology and reduce theneed for physical prototypes, as well ascreate simulation apps to empower col-leagues and customers worldwide totest new ideas.

Often, the key to successful engineer-ing simulations is developing experimen-tally validated models that replace the useof experiments and prototypes alone andgive a deeper understanding of the stud-ied design or process. Com pared to run-ning experimental methods or testingprototypes, modeling allows for quickerand often more efficient and accurateoptimization of processes and devices.

New groups of engineers are continu-ally adopting simulation as a tool. Designengineers add physics to drawings andstudy the effects and optimize the geom-etry under physical constraints. Onsitefield technicians are able to obtainanswers to questions such as: Does thisroad need repaving now? Where exactlyis the water leak in this pipe system?Reverse engineering of a product canenable engineers to assess why and howsomething breaks and accidents happen.

The list of ways simulation will makethe world a better place is endless. Withnew software to create standalone simu-lation applications, evolution will take aleap. Researchers and scientists can nowmake customized applications that areeasy to use for everyone.

This article was written by SvanteLittmarck, President and CEO of COMSOL,Inc., Burlington, MA. For more information,visit http://info.hotims.com/69513-122.

SIMULATION FOR EVERYONE

Figure 4. A heat transfer simulation of a cutout of a carbon-fiber-reinforced polymer embedded inan epoxy matrix.

Figure 3. The optimal material distribution in a steel hook. The material distribution is optimized when subjectedto two distributed load cases: one at the tip of the hook and one along its lower inner curve.


Go beyond analytics. Start engaging real buyers. Thomas WebTrax delivers

actionable opportunity intelligence, with in-market buyer data that allows you to

track, identify and engage the high-value opportunities generated by your online

presence, all on one comprehensive dashboard.

Thomas WebTrax is free for qualifying companies, visit www.Thomasnet.com/webtrax

to learn more.

Introducing Opportunity Intelligence for Industry.





The engineering and manufactur-ing world is rapidly changing —are you changing with it? Theclaim of “reinventing” the funda-

mental tools of an industry is a bold one,but that’s exactly what’s happening now asthe design, engineering, and productdevelopment software that manufacturersdepend on every day is rapidly respond-ing to meet new demands and challenges.

Onshape CEO Jon Hirschtick, an earlyinnovator in the evolution of CAD,founded SolidWorks in 1993. Solid-Works was the first CAD system to run onWindows PCs rather than proprietaryhardware that often costs hundreds ofthousands of dollars. This platform shiftsuddenly made powerful CAD tools avail-able to countless companies that previ-ously couldn’t afford it. He then intro-duced Onshape in 2012 — the first pro-fessional 3D CAD system to run online.This shift ended the isolation of engi-neers on their individual computers.With cloud CAD, design teams couldnow simultaneously work together onthe same 3D model, seeing each other’schanges in real time and preventing mis-takes due to inadequate version control.

Hirschtick declared that “today is stillthe beginning,” and as an industry,“maybe we’re halfway done” with ad -vancing design and manufacturing tech-nologies. Looking ahead, he morerecently identified the five biggest influ-ences impacting the future developmentof CAD software.

1. Autonomous HardwareSome of the most pedestrian products

now contain software or electronic sen-sors. That might be something like a cof-fee machine that remembers how muchcream and sugar you like or even a pil-low with electronic sensors to track yoursleep patterns. Increasingly, hardware isno longer just hardware, making designteams more diverse and complex — andrequiring tools that enable seamlessintegration with electronic and software

components. Among the non-auto man-ufacturing companies currently develop-ing self-driving car technology areGoogle, Apple, Uber, and Baidu(China’s largest search engine). Carshoppers may soon be asking about avehicle’s software before inquiringabout mileage or cargo space.

2. Additive ManufacturingAs new high-tech materials (metals,

gels, polymers, composites, etc.) andprocesses are developed, 3D printersare no longer just for making proto-types. Singapore Airlines, which needsto maintain inventories of thousands ofreplacement parts, has a partnershipwith Stratasys to explore how to reducerepair downtime. Ford Motor Companyrecently filed for a patent for their pro-prietary method of 3D-printing ofbrake discs.

Additive manufacturing is also havinga dramatic impact on medical products

unimaginable just a few years ago. In2019, German biotech company Bella -Seno is scheduled to begin clinical trialson 3D-printed biocompatible polymerbreast implants that stimulate natural tis-sue growth.

3. Agile Product DesignInspired by the idea of Agile De -

velopment, which has been widelyadopted by the software world, manufac-turers are taking a new approach tobuild products faster and with moreinnovation. Agile Design strongly em -phasizes rapid iteration, tight communi-cation among a geographically diverseteam, and an openness to embracingchange. Agile Design favors “respondingto change over following a plan,” usingcustomer feedback to determine thenext set of priorities.

Big companies are embracing the con-cept of “intrapreneurship,” creating astartup effort within their organization

TECHNOLOGY LEADERS Engineering Software

Five Industry Trends Disrupting theDesign and Manufacturing World

BMF Material Technology, a pioneer in micro/nanoscale 3D printing, uses Onshape’s cloud CAD platform forreal-time collaboration between its team in China and their customers worldwide.


[email protected]

kamansensors.com

For more information about our full line of eddy current sensors, contact us today!

Unaffected by Oil, Dirt, Water, Radiation & more

High Precision Displacement Sensors

PositionVibrationAlignment

Dimensioning


that may become a separate spinoff. Forexample, GE Appliances recentlylaunched FirstBuild, an engineeringcrowdsourcing platform where the bestcommunity design proposals are devel-oped into commercial products.

4. Information Flow as a CompetitiveWeapon

Finding cheaper labor and materialsis only a race to the bottom. The realcompetitive edge for today’s manufac-turers lies in speeding up the informa-tion flow at every stage of the process.Old file-based technologies are still cre-ating needless design gridlock — soft-ware crashes, corrupt files, and outdateddata management tools are still blockingcollaboration and slowing companiesdown. China’s BMF Material Technolo-gy, a pioneer in micro/nanoscale 3Dprinting for precision manufacturing, isnow using Onshape’s cloud CAD systemnot for the CAD itself, but to share real-time design information with its globalcustomers and teach them best practicesfor its 3D printers.

5. Millennial Workforce ExpectationsAs the largest demographic in the

workforce today — and projected to be75% of the workforce by 2030 — thisgeneration grew up with mobile andcloud technologies and has never expe-

rienced life without it. Millennials alsowere raised on social networking, andhave little tolerance when communica-tion isn’t instant and when tools aren’tinstinctively collaborative.

Having grown up with a flurryingassortment of new apps available 24/7,the new generation of workers isn’t hes-itant to throw out “old” technology andtry on new solutions like they do cloth-ing. Whether it’s CAD or other engi-neering productivity tools, softwaredevelopers must keep this fickle influxof new customers in mind. Now morethan ever, companies must stay relevantand useful, or die.

ConclusionNone of these industry trends is brand

new — they’ve been around for a fewyears now — but their influence on theeconomy continues to grow. As profes-sional design tools continue to migrateto cloud and mobile (and perhaps to ayet-to-be discovered technology plat-form after that), CAD developers willneed to keep focusing on the ongoingchanges in the engineering and manu-facturing workplace. It’s a constantlymoving target.

This article was written by DarrenGarnick, staff writer for Onshape, Cam -bridge, MA. For more information, visithttp://info.hotims.com/69513-121.

Taiwanese startup Xing Mobility uses cloud CAD to keep its electrical and mechanical engineers in sync on itselectric vehicle designs.




Advertisement

Computational Simulation Software, LLC (dba csimsoft)17 N. Merchant St, Suite 3American Fork, UT 84003Phone: 801-717-2296Fax: 801-717-2288E-mail: [email protected]://csimsoft.com

Company Description

Computational Simulation Software, LLC (csimsoft) is anengineering software developer specializing in mesh genera-tion software for CAE simulations. For more than twodecades, the experienced csimsoft team has co-developedSandia National Laboratories’ CUBIT Geometry and MeshGeneration Toolkit that is widely-used by national labs andU.S. government entities for high-quality mesh creation. Thecommercial and academic versions, Trelis FEA™, Trelis CFD™,Trelis Pro™, and csimsoft Bolt™, are used worldwide for meshgeneration for all types of engineering simulation, includingautomotive, biomedical, energy, heavy equipment, and aero-space simulations.

Before engineers can solve complex problems with engi-neering simulation, they need a mesh, a discrete representa-tion of the CAD model to be analyzed. Sometimes getting agood mesh is extremely hard because of the complexity ofthe geometry being analyzed. csimsoft provides robust toolsfor generating high-quality meshes that result in a more pre-cise solution.

Target Markets

Engineering simulation for• Aerospace and Defense• Automotive• Biomedical Engineering• Consumer Goods• Energy• Industrial Equipment and Machinery

Products/Services Offered

Trelis is a high-end pre-processor for complex FEA and CFDsimulation. It is based on the time-proven CUBIT™ softwarefrom Sandia National Laboratories.

Bolt is a push-button solution for generating all-hex meshesfrom complex geometries with little or no user interaction. Mostmodels can be meshed by simply clicking the Mesh button.

https://csimsoft.com






Advertisement

COMSOL, Inc.100 District AvenueBurlington, MA 01803Phone: +1-781-273-3322Fax: +1-781-273-6603E-mail: [email protected]

Company Description

COMSOL is a global provider of simulation software for prod-uct design and research to technical enterprises, research labs,and universities. Its COMSOL Multiphysics® product is an inte-grated software environment for creating physics-based mod-els and simulation applications. A particular strength is its abil-ity to account for coupled or multiphysics phenomena. Add-onproducts expand the simulation platform for electromagnetics,structural, acoustics, fluid flow, heat transfer, and chemicalapplications. Interfacing tools enable the integration of COM-SOL Multiphysics® simulations with all major technical comput-ing and CAD tools on the CAE market. Simulation experts relyon COMSOL Compiler™ and COMSOL Server™ to deploy appli-cations to their design teams, manufacturing departments, testlaboratories, and customers throughout the world.

Target Markets

Technical enterprises, research labs, and universities.

Products/Services Offered

The COMSOL Multiphysics® software is widely used for engi-neering design and product optimization. Applications includemodeling and simulation of electronic devices, composite mate-rials, mechanical components, packaging and enclosures, bat-teries, additive manufacturing processes, sensors and trans-ducers, connectors and cables, semiconductors and embeddedsystems, RF and microwave devices, and more.

Simulation specialists can turn their multiphysics modelsinto simulation applications with the Application Builder toolavailable in COMSOL Multiphysics®. This provides a new way forteams of engineers and scientists to bring the use of simulationto non-specialists. With COMSOL Server™, simulation applica-tions can be deployed and administrated via a web interface.With COMSOL Compiler™, simulation specialists can compile anapplication into a single executable file for unlimited use anddistribution. Standalone executable applications provide simu-lation specialists with an unprecedented level of freedom in dis-tributing their work to their design teams, manufacturingdepartments, test laboratories, and customers throughout theworld.

www.comsol.com


Visualization of temperature (left) and magnetic flux density norm(center) in the cross section (right) of an industrial-scale cable.

Visualization of the von Mises stress distribution in the housing of aninduction motor by accounting for electromechanical effects.



Microvolt-level signals require gainsof at least a thousand. Offsets and

noise in the amplifier chain will be ampli-fied by the same amount, which can satu-rate the amplifier or swamp the signal soit is not resolvable. Other methods usechopping and/or autozero techniques tolower the offset and noise. The key disad-

vantages of these methods are theyrequire filters before and/or afterdemodulation of the amplified signal anddelay equalization to account for thedelay through the amplifier(s) prior tothe demodulator. The gain of these cir-cuits is generally limited to fixed valuesdetermined by resistors. These methods

are also susceptible to transient noiseassociated with the switching action ofthe modulator.

The Gated Chopper Integrator’s func-tion is to amplify low-level signals withoutintroducing excessive offset and noise andto do this with accurate and variable gain.The unique feature of the technology is


Electrical/Electronics

Chip with Micro-Hotplate for Self-Healing and SustainableElectronicsThis invention is an on-chip immune system against hot-carrier stress, bias temperatureinstability, and total ionizing dose degradation.Ames Research Center, Moffett Field, California

Heat treatment, also known as anneal-ing, is a common step in the semicon-

ductor fabrication process. A build up ofradiation-induced localized charge withinthe semiconductor and insulator alterslocal field distribution, threshold voltage,and leakage current. NASA’s patent-pend-ing technology implements an annealingprocess on a system level directly on achip for annealing defects and improvingdevice performance with heating done inthe laboratory.

The annealing may be performedinside an oven or upon a hotplate. A sys-tem-on-microheater provides defect an -nealing capability for recovering bulktrapped charges and interface states. Thehealing starts simply by heating the chipin a process that can be compared to thatof a human’s immune system — some-thing capable of detecting and quicklyresponding to any number of possibleassaults in order to keep the larger systemworking optimally.

A microheater is monolithically inte-grated on the backside of a genericComplementary Metal Oxide Semi -conductor (CMOS) chip for an on-chipannealing system (figure, left (b)).Compared to a stacked microheater, themonolithic integration reduces the dieprofile that accordingly enhances the

heating power efficiency and heating/cooling rates, which was verified experi-mentally and numerically. The self-healingmicroheater is controlled by a tempera-ture feedback circuit to maintain thedesired temperature.

All circuits under the treatment are unbi-ased in order to avoid any side effects onnormal devices. A control circuit block isprogrammed to monitor a device parame-ter shift, such as the threshold voltage onthe same chip, in order to determine theneed for treatment. A control circuit trig-gers the micro hotplate and senses the tem-

perature to adjust the target temperatureand duration. The microheater and the sys-tem-on-chip are fabricated separately andstacked into a single package that can beimplemented on any arbitrary commercialoff-the-shelf device as a generic approach.

NASA is actively seeking licensees to com-mercialize this technology. Please contactthe Ames Technology Partnerships Office [email protected] or 855-627-2249 to initiate licensing discussions.Follow this link for more information:https://technology.nasa.gov/patent/TB2016/TOP2-278.

backside grindingadhesive

backside grinding

stacked 3D system on μ-heatermonolithic 3D system on μ-heater

backside grinding

CMOS

CMOS

direct μ-heater intergraionon backside of CMOS

adhesive bonding

μ-heater

Figure 1 (b)

(a)

SoC I/O Pad

Figure 2

Microheater

(a) (b)

TraditionalSoC

Parametermonitor

Heatercontrol knob

TemperatureSensor

Feedback loopAnnealing

Microheater

Self-healingengine

Left: (a) Heater die stacked version and (b) monolithically integrated heater version. Right: (a) Sche -matic illustration of self-healing architecture and (b) schematic and images of the fabricated chip.

Gated Chopper Integrator (GCI)This technology is a variable-gain, low-offset, low-noise chopper amplifier for amplifyingmicrovolt-level signals.Goddard Space Flight Center, Greenbelt, Maryland

https://technology.nasa.gov/patent/TB2016/TOP2-278

Many of today’s silicon-based electronic components contain2D mate rials such as graphene. Incorporating 2D materi-

als like graphene — which is composed of a single-atom-thicklayer of carbon atoms — into these components allows them tobe several orders of magnitude smaller than if they were madewith conventional 3D materials. In addition, 2D materials alsoenable other unique functionalities. But nanoelectronic compo-nents with 2D materials have an Achilles’ heel — they are proneto overheating. This is because of poor heat conductance from2D materials to the silicon base.

One of the reasons 2D materials can’t efficiently transfer heatto silicon is that the interactions between the 2D materials andsilicon in components like transistors are rather weak. Bondsbetween the 2D materials and the silicon substrate are not verystrong, so when heat builds up in the 2D material, it creates hotspots, causing overheating and device failure.

In order to enhance the connection between the 2D materialand the silicon base to improve heat conductance away from the2D material into the silicon, engineers have experimented withadding an additional ultra-thin layer of material on top of the 2Dlayer — in effect, creating a “nano-sandwich” with the siliconbase and ultrathin material as the “bread.” Sandwiching 2Dmaterials used in nanoelectronic devices between their 3D sili-con bases and an ultrathin layer of aluminum oxide can signifi-cantly reduce the risk of component failure due to overheating.

An experimental transistor was created using silicon oxide forthe base, carbide for the 2D material, and aluminum oxide for theencapsulating material. At room temperature, the conductance ofheat from the carbide to the silicon base was twice as high with theaddition of the aluminum oxide layer versus without it.

For more information, contact Sharon Parmet at [email protected]; 312-413-2695.

Tech Briefs, December 2018 25Free Info at http://info.hotims.com/69513-669

NEW Screw-Lokfor tougher demands

- Metal back-shells for maximumstrain relief and RF shielding

- Up to 45% smaller and up to75% lighter than Micro-D

- Resists extremes of shock,vibration and temperature

- Excellent out-gassing properties

www.harwin.com/gecko-sl

Higher Reliabilitysmaller footprint

Harwin is an AS9100 accredited company

Sandwiching Materials in NanoelectronicsNano-sandwiching improves heat transfer and prevents overheating.University of Illinois, Chicago

The experimental transistor using silicon oxide for the base, carbide forthe 2D material, and aluminum oxide for the encapsulating material.(Image: Zahra Hemmat)

AIOX

SiO2

Si

the inherent demodulation present in the integrator that elimi-nates the need for filtering and allows the user to accurately varythe gain in finely graduated steps. The reduction of the offset ofthe amplifier is very efficient and lends itself to radiation hard-ened by design implementations. Since total dose can change theoffset due to varying threshold voltages of CMOS transistors, thecircuit adapts and compensates for any variations.

The autozero integrator also adapts to its own varying offsets.The net outcome is variable, accurate gain that is very robust to

supply variations, radiation effects, and aging. The technologywas developed as a multi-channel thermopile signal processor.Lab measurements indicate very accurate amplification withlow offset and noise.

NASA is actively seeking licensees to commercialize this technology.For more information, contact the Goddard Strategic Partnerships Officeat [email protected] or 301-286-5810. Follow this link formore information: https://technology.nasa.gov/patent/TB2016/GSC-TOPS-134.


https://technology.nasa.gov/patent/TB2016/GSCTOPS-134


Sensors

Device Detects Subatomic-Scale MotionThis handheld device can sense the atomic-scale motion of tiny parts with unprecedentedprecision. National Institute of Standards and Technology, Gaithersburg, Maryland

It is relatively easy to measure smallmovements of large objects, but is

much more difficult when the movingparts are on the scale of nanometers, orbillionths of a meter. The ability to accu-rately measure tiny displacements ofmicroscopic bodies has applications insensing trace amounts of hazardous bio-logical or chemical agents, perfecting themovement of miniature robots, accurate-ly deploying airbags, and detectingextremely weak sound waves travelingthrough thin films.

Scientists developed a device that meas-ures the motion of particles traversing dis-

tances almost unimaginably small —shorter than the diameter of a hydrogenatom, or less than one-millionth the widthof a human hair. The handheld devicecan sense the atomic-scale motion of itstiny parts with unprecedented precision.

The researchers measured subatomic-scale motion in a gold nanoparticle byengineering a small air gap, about 15nanometers wide, between the goldnanoparticle and a gold sheet. This gap isso small that laser light cannot penetrateit; however, the light did energize surfaceplasmons — the collective, wave-likemotion of groups of electrons confined

to travel along the boundary between thegold surface and the air.

The researchers exploited the light’swavelength — the distance between suc-cessive peaks of the light wave. With theright choice of wavelength — or equiva-lently, its frequency — the laser lightcauses plasmons of a particular frequen-cy to oscillate back and forth along thegap, like the reverberations of a pluckedguitar string. Meanwhile, as the nano -particle moves, it changes the width ofthe gap and, like tuning a guitar string,changes the frequency at which the plas-mons resonate.

The interaction between the laser lightand the plasmons is critical for sensingtiny displacements from nanoscale parti-cles. Light cannot easily detect the loca-tion or motion of an object smaller thanthe wavelength of the laser, but convert-ing the light to plasmons overcomes thislimitation. Because the plasmons are con-fined to the tiny gap, they are more sensi-tive than light is for sensing the motion ofsmall objects like the gold nanoparticle.The amount of laser light reflected backfrom the plasmon device reveals the widthof the gap and the motion of the nanopar-ticle; for example, the gap changes due tothe motion of the nanoparticle in such away that the natural frequency, or reso-nance, of the plasmons more closelymatches the frequency of the laser light.In that case, the plasmons are able toabsorb more energy from the laser light,and less light is reflected (Figure 1).

To use the motion-sensing techniquein a practical device, the gold nanoparti-cle was embedded in a microscopic-scalemechanical structure — a vibrating can-tilever — a few micrometers long, madeof silicon nitride. Even when they’re notset in motion, such devices never sit per-fectly still, but vibrate at high frequency,jostled by the random motion of theirmolecules at room temperature. Eventhough the amplitude of the vibrationwas tiny — moving subatomic distances— it was easy to detect with the new plas-monic technique.

Figure 1. This schematic shows laser light interacting with a plasmonic gap resonator. An incidentlaser beam (pink beam at left) strikes the resonator, which consists of two layers of gold separatedby an air gap. The top gold layer is embedded in an array of tiny cantilevers (violet). When a can-tilever moves, it changes the width of the air gap, which in turn changes the intensity of the laserlight reflected from the resonator. The modulation of the light reveals the displacement of the tinycantilever. (Brian Roxworthy, NIST/CNST)

Tech Briefs, December 2018

Prices

start from$2,300 per

channel

Fast AWGs with up to

24 synchronous channels!

US: Phone (201) 562 1999 | Asia / Europe: Phone +49 (4102) 695 60

www.spectrum-instrumentation.com

S P E C T R U MI N S T R U M E N T A T I O N

Per fec t f i t – modu lar des igned so lu t ions

DN2.66xPortable Netbox: 5 variations with 2 to 8 channels

Desktop & rack Netbox: 8 variations with 6 to24 channels

DN6.66x

Up to 9 synchronous free-programmable digital MARKER OUTPUTS – creating highly versatile mixed-mode AWGs16 bit arbitrary waveform generator with up to 1.25 GS/sUp to ±3 V output level into 50 Ω512 MSample waveform memory per channel

Prices start from$2,300 per

channel

Similar, though typically larger, mechanical structures arecommonly used for both scientific measurements and practicalsensors; for example, detecting motion and orientation in carsand smartphones. The team’s fabrication approach allows pro-duction of about 25,000 of the devices on a computer chip, witheach device tailored to detect motion according to the needs ofthe manufacturer (Figure 2).

For more information, contact the NIST Technology PartnershipsOffice at 301-975-6478 or [email protected].

Figure 2. These optical micrographs provide a top-down view of severalplasmonic gap resonators, and zoom in on a single device. Bottom rightshows the schematic of a single device. (Brian Roxworthy, NIST/CNST)

Wide-Area Chemical SensorApplications include military and civil chemicalmonitoring, detection of gas pipeline leaks,and indoor chemical monitoring in factories orsemiconductor fabrication facilities.MIT Lincoln Laboratory, Lexington, Massachusetts

The detection and localization of gas releases, such as meth -ane from leaking natural gas pipelines or nitrogen oxides

from failing electrical equipment, require high sensitivity to thetarget gas and insensitivity to non-target gases. Infrared (IR)absorption spectroscopy gives highly specific characterization ofthe identity and amount of airborne chemicals. Traditionally,spectroscopy techniques for long-range chemical sensing separatethe “sensitive to x gas” and “insensitive to x gas” atmosphericmeasurements by quickly switching back and forth between themto reduce errors caused by any atmospheric changes. Because thesamples are not measured at the same time, it is impossible toensure that all atmospheric conditions (e.g., contaminants orhumidity) remain constant between the two measurements.

The Wide-Area Chemical Sensor (WACS) addresses theproblem of temporal atmospheric variation by taking the meas-


urements concurrently. This approachcompensates for spectral drift, atmos-pheric contaminants, and atmosphericscintillation, while simplifying the tech-nical requirements of the laser (e.g., sta-bility, power).

The WACS system uses a spectrally self-referencing technique to decouple the tar-get gas from the background atmosphere.The system consists of a reconfigurable 3.2to 3.8-μm-wavelength laser source with 5-GHz linewidth and ~30-MHz wavelengthstability that is tunable to the target gasspecies, and a self-referencing detectorthat is tuned to the laser source. The laseroperates at a 10-kHz repetition rate and anaverage transmit power of 3 mW. Any lasersource with a linewidth commensurate

with the target gas absorption width andwith sufficient power could be substitut-ed. WACS uses reference gas cells, suchas methane buffered by nitrogen, and alow-concentration gas cell that containsthe target species to calibrate the trans-mitter laser tuning and to verify gas sen-sitivity and specificity.

To detect and discriminate gas clouds, asingle, relatively broadband laser source istransmitted through the atmosphere, andthe laser’s spectral deformation by thematerial it passes through is measured in areceiver. The deformations are matched totargeted materials, enabling the detectionand discrimination of gas clouds at verylow concentrations (~1 part per trillion byvolume) over tens of kilometers. A second

sensor not tuned to the particles of interestcorrects for false alarms caused by atmos-pheric turbulence, variable atmospherictransmission, and other non-target gases.

The ability to separate light that “sees”the gas of interest from light that “does notsee” requires a very narrow, tunable, andstable spectral filter; for this purpose, theWACS system uses a Fabry-Pérot etalon, asingle lossless resonant cavity that consistsof two partially reflective facing mirrors.The etalon transmission varies stronglywith wavelength and with the angle atwhich the light strikes the etalon. All lightencountering the cavity transmits throughit or reflects off it; comparing these twolight intensities enables measurement ofthe gas-induced absorption. This absorp-tion varies over the bandwidth of the opti-cal cavity’s spectral response because oftime-varying but spectrally constant lossescaused by atmospheric scintillation andatmospheric contaminants.

The WACS technique enables the meas-urement of concentrations of specified tar-get gases within the atmosphere at longerranges than those achieved by other activeoptical techniques, while using a muchlower-power laser source for a given range.Additionally, WACS is capable of at leastfive times the absolute sensitivity of othersensors at the longest ranges because of itsability to measure and remove the effectsof spectral drift, atmospheric contami-nants, and atmospheric scintillation.

For more information, contact Dr. Eric R.Statz at [email protected]; 781-981-3784.


Sensors

Band pass andbirefringent

wedge

Beamsplitter

F-P etalon

Aperture

Reflectdetectors

Transmitdetectors

The WACS optical receiver has three major subcomponents: the angle-tunable beamsplitter andassociated relay telescope to provide two angle-tuned optical paths, the Fabry-Pérot (F-P) etalonassembly that translates the angle tuning into spectral tuning, and the detector assembly that pro-vides the four spectral measurements to yield two power-insensitive spectral ratios.

One significant area of research infuel cell technology includes sys-

tems in which a fuel cell is combinedwith another power generation device (aturbine, for example) to create a hybridsystem that combines the advantages ofthe two standalone systems, resulting ina high fuel-to-electricity conversion effi-ciency. Burners are used as the primaryor auxiliary energy source in the turbineportion of the hybrid system. Theseburners usually have one or moresources or inlets using one or morehydrocarbon-based fossil fuels such asnatural gas, liquefied petroleum gas,and liquid hydrocarbon-based fuels.Accurate monitoring and control ofsuch a combustion process is very impor-

tant to ensure the efficient and safeoperation of the hybrid systems.

To optimize the performance of cer-tain industrial processes or apparatus,such as hybrid power generation systemsconsisting of a fuel cell and a turbine, itis necessary to know the flow directionand velocity of gases such as air throughthe system. Differential pressure sensorshave been used for this purpose, but theycan measure flow only in one direction,are slow to respond, and require a highpressure differential to provide accurateflow measurements.

A sensor system and process weredeveloped for multidirectional, real-timemonitoring of the flow direction andvelocity of a gas stream with minimal

pressure drop, such as airflow in a hybridpower generation system. The sensorcomprises an ion source accompanied bya multidirectional ion collection devicenear the ion source.

The method uses a flame to ionize thegas (similar to a flame ionization detec-tor) and electrode pairs arranged alongcommon flow axes to collect the ions. Theaxis of electrode pairs responding to theion flow determines the flow direction;the rate of ion collection per unit timedetermines the flow velocity. This sensorhas no moving parts, and is effective inlow-pressure differential conditions.

For more information, contact JessicaSosenko at [email protected];412-386-7417.

Ionization-Based Multidirectional Flow SensorNational Energy Technology Laboratory, Morgantown, West Virginia

Trained rescue dogs are the best disas-ter workers — their sensitive noses

help them track down people buried byearthquakes or avalanches. But dogsneed breaks. A new measuring device isalways ready for use.

The device consists of small andextremely sensitive gas sensors for ace-tone, ammonia, and isoprene — all meta-bolic products that people emit in low con-centrations via breath or skin. The sensorswere combined in a device with two com-mercial sensors for CO2 and moisture.The combination of sensors for variouschemical compounds is important be -cause the individual substances couldcome from sources other than humans;CO2, for example, could come from eithera buried person or a fire source.

The research also showed that there aredifferences between the compounds emit-ted via breath and skin. Acetone and iso-prene are typical substances that areexhaled. Ammonia, however, is usuallyemitted through the skin. In experimentsin an “entrapment simulator” chamber,volunteers wore breathing masks. In thefirst part of the experiment, the exhaledair was channeled directly out of the cham-ber; in the second part, it remained inside.This allowed the scientists to create sepa-rate breath and skin emission profiles.

The gas sensors are the size of a smallcomputer chip, and are about as sensitiveas most ion mobility spectrometers, whichare large and heavy. The easy-to-handlesensor combination is one of the smallestand cheapest devices that is sufficiently sen-sitive to detect entrapped people. In a nextstep, researchers will test it during real con-ditions to see whether it is suited for use insearches after earthquakes or avalanches.

While electronic devices are already inuse during searches after earthquakes,

these work with microphones and cam-eras, and only help to locate entrappedpeople who are capable of making them-selves heard or are visible beneath ruins.These resources would be complementedwith the chemical sensors. Drones androbots could also be equipped with the

gas sensors, allowing difficult-to-reach orinaccessible areas to also be searched.Further potential applications couldinclude detecting stowaways.

For more information, contact FabioBergamin at [email protected]; +41 44 63242 44.

Tech Briefs, December 2018 29

©2018 Measurement Computing Corporation, 10 Commerce Way, Norton, MA 02766 • [email protected]

Contact us1.800.234.4232

www.mccdaq.com/DAQ-HAT

1 YEAR

Bring Your Pi to Work!

MCC Raspberry Pi measurement HATs were designed to bring high-quality measurements to the ubiquitous low-cost computer. MCC DAQ HATs are the perfect solution for adding professional

quality DAQ capabilities to the Pi platform.

Perfect for:• Embedded system design• Industrial IoT• End-of-line test • Remote monitoring• Edge Computing• Validation/verifi cation test

MCC DAQ HATs are provided with:• Complete SW library for easy

programming• Full set of examples in C® and Python™

• Free technical support• Quality from a trusted source

Measurement Computing now offersDAQ HATs for Raspberry Pi®

MCC 118• 8 channels/board,

up to 64 channels/system • 100 kS/s board,

up to 320 kS/s system

Buy with Confi dence – Take Measurements in Minutes


Sensor Combination Detects People by SmellThis measuring device could be used to search for people buried by an earthquake or avalanche.ETH Zurich, Zurich, Switzerland

The three gas sensors used in the measuringdevice. (ETH Zurich/Andreas Güntner)


Printable metal tags have been devel-oped that could be attached to

everyday objects to turn them into“smart” Internet of Things (IoT)devices. The tags are made from pat-terns of copper foil printed onto thin,flexible, paper-like substrates thatreflect WiFi signals. The tags workessentially like mirrors that reflect radiosignals from a WiFi router. When auser’s finger touches the mirrors, it dis-turbs the reflected WiFi signals in such away that can be remotely sensed by aWiFi receiver, like a smartphone.

The tags can be tacked onto plainobjects that people touch and interactwith every day, like water bottles, walls, ordoors. These plain objects then essentiallybecome smart, connected devices that cansignal a WiFi device whenever a user inter-acts with them. The tags can also be fash-ioned into thin keypads or smart homecontrol panels that can be used to remote-ly operate WiFi-connected speakers, smartlights, and other IoT appliances.

The LiveTag technology consists of low-cost, battery-free, chipless, printable sen-sors that only reflect specific signals within

the WiFi frequency range. By changing thetype of material they’re made of and thepattern in which they’re printed, the tagscan be redesigned to reflect eitherBluetooth, LTE, or cellular signals.

As a proof of concept, LiveTag wasused to create a paper-thin music playercontroller complete with a play/pausebutton, next-track button, and slidingbar for tuning volume. The buttons andsliding bar each consist of at least onemetal tag so touching any of them sendssignals to a WiFi device. The LiveTagmusic player controller was tested toremotely trigger a WiFi receiver, but itcould remotely control WiFi-connectedmusic players or speakers when attachedto a wall, couch armrest, clothes, or otherordinary surface.

LiveTag also was adapted as a hydrationmonitor. It was attached to a plastic waterbottle and showed that it could be used totrack a user’s water intake by monitoringthe water level in the bottle. The waterinside affects the tag’s response in thesame way a finger touch would, as long asthe bottle is not made of metal, whichwould block the signal. The tag has multi-ple resonators that each get detuned at aspecific water level. The tag could be usedto deliver reminders to a user’s smart-phone to prevent dehydration.

For more information, contact LiezelLabios at [email protected]; 858-246-1124.


Sensors

Thin, flexible LiveTag tags in comparison with a piece of photo paper (far left). (Xinyu Zhang)

Printable Metal Tags Turn Objects into Smart, Connected DevicesApplications include monitoring patient recovery and tagging products at retail stores toassess customer interest.Jacobs School of Engineering, University of California, San Diego

Real-Time Ion Mobility Sensor SystemOak Ridge National Laboratory, Oak Ridge, Tennessee

Areal-time ion mobility sensor devel-oped to detect contaminants and

explosives is reliable, sensitive, robust,and inexpensive. The technology im -proves sensitivity and reduces falsealarms for threat agents, and can identi-fy chemicals with a sensitivity of fiveparts per billion.

The device solves problems of long-term monitoring by combining ionmobility spectrometry and differentialmobility spectrometry with membraneseparation. Current methods for long-

term monitoring are complex, expensive,and time-consuming. Ion mobility spec-trometry cannot identify chlorinatedhydrocarbons, has high false alarm rates,and is vulnerable to interference. It is alsoeasily affected by moisture, re sulting infalse alarms. Similarly, differential mobili-ty spectrometry alone cannot monitorchlorinated hydrocarbons.

By coupling the two methods, the newsystem reduces false alarms, separatesinterferents from chlorinated hydrocar-bons, and can successfully identify con-

taminants such as chlorinated hydrocar-bons, perchlorates, and explosives. Inbrief, ion mobility spectrometry filtersthe safe species, while differential mobili-ty spectrometry separates the contami-nants and explosives.

Benefits of the system include compactsize, ambient atmosphere for operation,no vacuum, remote reporting and con-trol, and reduction of false alarms.

For more information, contact JenniferTonzello Caldwell at [email protected];865-241-9485.

The Inductive Non-Contact PositionSensor is a highly accurate sensor for

motion control applications. The sensorwas designed to monitor the precisemovements of an optical inspection sys-tem that measured defects in space shut-tle windows.

Position sensors are used in a rangeof applications, and there are a numberof types tailored to the needs of theapplications. Current non-contact induc -tive sensors are inexpensive but are notprecise. Other sensor types includingeddy current sensors, capacitive sensors,and optical/laser position sensors havehigh precision, but are larger, moreexpensive, and require complex algo-rithms to operate.

Compared to other position sensors,this technology is precise, small, inex-pensive, and provides absolute position.It can measure accuracy of positiondown to 400 nanometers over a totalrange of 200 microns. The sensor usesinexpensive, off-the-shelf componentsand has a total volume of less than acubic inch. A highly linear output makescomputation easy by using a low-costmicrocontroller. The high signal-to-noise ratio allows the sensor to operatein noisy environments.

Although originally designed as a one-dimensional sensor, additional work per-formed in the laboratory improved thedesign to make it two-dimensional as wellas providing the ability to function as atip/tilt sensor. The additional work alsoextended the linear operating regionsubstantially, from about 30 degrees toabout 70 degrees. The sensor design can

be enlarged to accommodate a largerrange of motion; however, enlarging thedesign may result in a loss of resolution.

NASA is actively seeking licensees to com-mercialize this technology. Please contact

Lew Parrish at [email protected] 321-861-5033 to initiate licensing discus-sions. Follow this link for more information:https://technology.nasa.gov/patent/TB2016/KSC-TOPS-67.


Signal Integrity, Compact Design2 Software Packages for DAQ or T&M

• $17 per Channel Possible – Lowest Cost in Industry

• Up to 384 Channels in 19” Instrumentation Rack

• Application Software from $250

• ±0.035% Accuracy

• 1500Vrms Channel-to-Bus Isolation

• PID Software Control - Up to 32 Loops with ReDAQ® Shape - Unlimited Loops with IPEmotion

• –40°C to +85°C Operating Temperature

Rugged PrecisionThe MAQ®20 Industrial

Data Acquisition & Control System

Instrument Class® Signal Solutions

dataforth.com • 800-444-7644


Inductive Non-Contact Position SensorThis sensor has applications in precision motion control, robotic movement, medicaldiagnostics, MEMS accelerometers, and vibration monitoring.John F. Kennedy Space Center, Florida

The tip/tilt sensor prototype.


https://technology.nasa.gov/patent/TB2016/KSC-TOPS-67


Imaging

Depth-Sensing Imaging System Can Peer Through FogComputational photography could solve a problem that affects self-driving cars.Massachusetts Institute of Technology, Cambridge

An inability to handle misty drivingcon ditions has been one of the chief

obstacles to the development of auton -omous vehicular navigation systems thatuse visible light. These systems are prefer-able to radar-based systems for their highresolution and ability to read road signsand track lane markers.

A system was developed that can pro-duce images of objects shrouded by fog

so thick that human vision cannot pene-trate it. It can also gauge the objects’ dis-tance. The system was tested using asmall tank of water with the vibratingmotor from a humidifier immersed in it.In fog so dense that human vision couldpenetrate only 36 centimeters, the sys-tem was able to resolve images of objectsand gauge their depth at a range of 57centimeters.

The fog produced for the study is fardenser than any that a human driver wouldhave to contend with; in the real world, typ-ical fog might afford a visibility of about 30to 50 meters. The system performed betterthan human vision, whereas most imagingsystems perform far worse.

The new system uses a time-of-flightcamera that fires ultrashort bursts of laserlight into a scene and measures the time it

Algorithm Enables Faster Analysis of Medical ImagesThis technique makes the process of comparing 3D scans up to 1,000 times faster.Massachusetts Institute of Technology, Cambridge

Medical image registration is a com-mon technique that involves overlay-

ing two images, such as magnetic reso-nance imaging (MRI) scans, to compareand analyze anatomical differences ingreat detail. If a patient has a brain tumor,for instance, doctors can overlap a brainscan from several months ago onto a morerecent scan to analyze small changes in thetumor’s progress.

This process, however, can often taketwo hours or more, as traditional systemsmeticulously align each of potentially amillion pixels in the combined scans. A

machine-learning algorithm was devel-oped that can register brain scans andother 3D images more than 1,000 timesmore quickly using novel learning tech-niques. The algorithm works by “learning”while registering thousands of pairs ofimages. In doing so, it acquires informa-tion about how to align images and esti-mates some optimal alignment parame-ters. After training, it uses those parame-ters to map all pixels of one image toanother, all at once. This reduces registra-tion time to a minute or two using a nor-mal computer, or less than a second using

a GPU with comparable accuracy to state-of-the-art systems. The algorithm is “unsu-pervised,” meaning it doesn’t require addi-tional information beyond image data.

MRI scans are basically hundreds ofstacked 2D images that form massive 3Dimages called “volumes,” containing a mil-lion or more 3D pixels called “voxels.”Therefore, it’s very time-consuming toalign all voxels in the first volume withthose in the second. Moreover, scans cancome from different machines and havedifferent spatial orientations, meaningmatching voxels is even more computa-tionally complex. This process becomesparticularly slow when analyzing scansfrom large populations.

The algorithm has a wide range ofpotential applications in addition to ana-lyzing brain scans, including lung imaging.The algorithm could also pave the way forimage registration during operations.Various scans of different qualities andspeeds are currently used before or duringsome surgeries, but those images are notregistered until after the operation. Whenresecting a brain tumor, for instance, sur-geons sometimes scan a patient’s brainbefore and after surgery to see if they’veremoved all the tumor. If any part of thetumor remains, the patient must go backto the operating room.

For more information, contact AbbyAbazorius at [email protected]; 617-253-2709.

A machine-learning algorithm can register brain scans and other 3D images more than 1,000 timesmore quickly using novel learning techniques. (MIT)



LOW OUTGASSINGONE PART SILICONES

Non-corrosive systemspass ASTM E595 testing

SERVICE TEMPERATURE RANGE -175°F to +500°F

MasterSil 920-LOLow viscosity • Ideal for conformal coating

• Optically clear

MasterSil 921-LOFlowable system • Ideal for coating sensitive

components • Translucent or opticallyclear in thin sections • Elongation 150-250%

MasterSil 922-LOPaste viscosity • Ideal for bonding applications

r• T anslucent or optically clear in thin sections• Tensile strength 650-750 psi

www.masterbond.com

Hackensack, NJ 07601 USA • +1.201.343.8983 • [email protected]

takes their reflections to return. On a clear day, the light’s returntime accurately indicates the distances of the objects that reflectedit. But fog causes light to “scatter,” or bounce around in randomways. In foggy weather, most of the light that reaches the camera’ssensor will have been reflected by airborne water droplets, not bythe types of objects that autonomous vehicles need to avoid. Andeven the light that does reflect from potential obstacles will arriveat different times, having been deflected by water droplets on boththe way out and the way back.

The new system gets around this problem by using statistics. Thepatterns produced by fog-reflected light vary according to the fog’sdensity. On average, light penetrates less deeply into a thick fogthan it does into a light fog. No matter how thick the fog, thearrival times of the reflected light adhere to a statistical patternknown as a gamma distribution. Gamma distributions are some-what more complex than Gaussian distributions, the common dis-tributions that yield the familiar bell curve. They can be asymmet-rical, and they can take on a wider variety of shapes. But likeGaussian distributions, they’re completely described by two vari-ables. The new system estimates the values of those variables on thefly and uses the resulting distribution to filter fog reflection out ofthe light signal that reaches the time-of-flight camera’s sensor.

The system calculates a different gamma distribution for each ofthe 1,024 pixels in the sensor, enabling it to handle the variationsin fog density that foiled earlier systems — it can deal with circum-stances in which each pixel sees a different type of fog.

The camera counts the number of light particles, or photons,that reach it every 56 picoseconds, or trillionths of a second. Thesystem uses those raw counts to produce a histogram — essentiallya bar graph with the heights of the bars indicating the photoncounts for each interval. Then it finds the gamma distribution thatbest fits the shape of the bar graph and simply subtracts the associ-ated photon counts from the measured totals. What remain areslight spikes at the distances that correlate with physical obstacles.

The system was tested using a fog chamber a meter long. Insidethe chamber, regularly spaced distance markers were mountedthat provided a rough measure of visibility. A series of smallobjects — a wooden figurine, wooden blocks, silhouettes of let-ters — also were placed. The system was able to image evenwhen they were indiscernible to the naked eye.

For more information, contact Sara Remus at [email protected];617-253-2709.

The depth-sensing system was able to resolve images of objects andgauge their depth at a range of 57 centimeters. (Image: MelanieGonick/MIT)




Imaging

Blue-Light Imaging Sees Through FireOrdinary blue light can be used to improve the ability to see objects engulfed by large, non-smoky natural gas fires.National Institute of Standards and Technology, Gaithersburg, Maryland

A blue-light imaging method was de -veloped that can be used to obtain

visual data from large test fires where hightemperatures could disable or destroy con-ventional electrical and mechanical sen-sors. The method provides detailed infor-mation to research ers using optical analy-sis such as digital image correlation (DIC),a technique that compares successiveimages of an object as it deforms underthe influence of applied forces such asstrain or heat. By precisely measuring themovement of individual pixels from one

image to the next, scientists gain valuableinsight about how the material respondsover time, including behaviors such asstrain, displacement, deformation, andeven the microscopic beginnings of failure.

Using DIC to study how fire affectsstructural materials presents the challengeof obtaining images with the level of clari-ty needed for research when bright, rapid-ly moving flames are be tween the sampleand the camera. Fire makes imaging inthe visible spectrum difficult in threeways: with the signal being totally blocked

by soot and smoke, obscured by the inten-sity of the light emitted by the flames, anddistorted by the thermal gradients in thehot air that bend, or refract light.

Glass and steel manufacturers oftenuse blue-light lasers to contend with thered light given off by glowing hot materi-als that can, in essence, blind their sen-sors. Commercially available and inex-pensive blue light-emitting diode (LED)lights with a narrow-spectrum wavelengtharound 450 nanometers were used forthe experiment. Initially, the researchersplaced a target object be hind the gas-fueled test fire and illuminated it in threeways: by white light alone, by blue lightdirected through the flames, and by bluelight with an optical filter placed in frontof the camera. The third option provedbest, reducing the ob served intensity ofthe flame by 10,000-fold and yieldinghighly detailed images.

Just seeing the target wasn’t enough tomake the blue-light method work for DICanalysis. The researchers also had toreduce the image distortion caused by therefraction of light by the flame — a prob-lem akin to the “broken pencil” illusionseen when a pencil is placed in a glass ofwater. The behaviors DIC needed to reveal,such as strain and deformation in a heatedsteel beam, are slow processes relative tothe flame-induced distortion. Multipleimages and large amounts of data were col-lected, and the measurements mathemati-cally averaged to improve their accuracy.

To validate the effectiveness of the imag-ing method, it was applied to two large-scale tests. The first examined how firebends steel beams and the other looked atwhat happens when partial combustionoccurs, progressively charring a woodenpanel. For both, the imaging was greatlyimproved. In the case of material charring,blue-light imaging may one day helpimprove standard test methods. Using bluelight and optical filtering, charring that isnormally hidden behind the flames in astandard test can now be seen. The clearerview, combined with digital imaging,improves the accuracy of measurements ofthe char location in time and space.

For more information, contact MichaelE. Newman at [email protected];301-975-3025.

Graphic illustrating the narrow-spectrum illumination method for imaging through fire. Blue LED light isdirected through a gas fire, reflects off the target object behind the flames, and is captured by a cameraafter passing through an optical filter. This reduces the observed intensity of the flame by 10,000-fold andyields highly detailed images. (Graphic created by N. Hanacek/NIST, based on a concept by M. Hoehler/NIST)

TARGET

LIGHT SOURCE(BLUE LED)

FLAMEOPTICAL FILTER CAMERA

To improve the ability of researchers to “see” through fire, an imaging system was developed usingordinary blue light to dramatically clear the picture. (National Fire Research Laboratory/NIST)


Compound-Lens Camera for Industry and SmartphonesApplications include cameras in cars for parking assistance, or in industrial robots to preventcollisions between man and machines. Fraunhofer Institute for Applied Optics and Precision Engineering IOF, Jena, Germany

Aprocess has been developed that enables the produc-tion of a 2-mm flat camera. The lens is partitioned into 135

tiny facets, similar to the eyes of an insect. The facetVISION cam-era is suitable for use in the automotive and printing industries,in medical engineering, and in smartphones.

Just as with an insect’s eyes, the mini-camera is composed ofmany small, uniform lenses that are positioned close together,similar to the pieces of a mosaic. Each facet receives only a smallsection of its surroundings. The insect’s brain aggregates themany individual images of the facets to a whole picture. In thefacetVISION camera, micro-lenses and aperture arrays performthese functions. Due to the offset of each lens to its associatedaperture, each optical channel has an individual viewing direc-tion and always depicts another area of the field of vision.

The micro-lenses can be manufactured economically in largequantities using processes similar to those applied in the semi-conductor industry for making computer chips. Thousands offacetVISION camera lenses can be manufactured in parallel.

With a camera thickness of two millimeters, this technologyenables a resolution of up to four megapixels — a higher resolu-tion compared to cameras in industrial applications such as robottechnology or automobile production. In medical engineering,the cameras can be used for optical sensors, which will be able toquickly and easily examine blood. In the printing industry, suchcameras are needed to check the print image at high resolutionwhile the machine is running. Other applications include cam-eras in cars that help parking, or in industrial robots that preventcollisions between man and machines.

Compound eye technology is also suitable for integration intosmartphones, which currently include camera lenses that areabout five millimeters thick in order to show a satisfactorily sharpimage of the surroundings. Since the camera is thicker than thesmartphone housing, it sticks out of the smartphone’s back cover.The manufacturers call this the “camera bump.” The cameralenses for smartphones are not made on wafers, but in injection-molded plastic. In this procedure, hot liquid plastic is pouredinto a mold, and robots then assemble the finished lenses intothe smartphone camera.

With the new technology, it would be possible to place severalsmaller lenses next to each other in the smartphone camera.The combination of facet effect and proven injection-moldedlenses would enable resolutions of more than 10 megapixels ina camera requiring just a thickness of about 3.5 mm.

For more information, contact Dr. Kevin Füchsel at +49 3641 807-273; www.iof.fraunhofer.de.

Figure 1. The first prototype of the system transfers the images from thecamera to the smartphone by Bluetooth via a transmission box.(©Fraunhofer IOF)

Figure 2. The facetVISION camera can be industrially manufactured in massproduction. (©Fraunhofer IOF)



Optics

Dynamic Optical Grating Device for Modulating LightThis device dynamically and rapidly changes the spectral properties of reflected ortransmitted light without moving parts.Langley Research Center, Hampton, Virginia

NASA Langley Research Center hasdeveloped a novel optical grating

device that dynamically modulates lightand is capable of controlling the spectralproperties and propagation of light with-out any moving mechanical components.

Spectral properties can be dynamicallycontrolled using MEMS grating de vices butthe speed is limited by weight, spring con-stant, and driving force of the components.Further, the moving parts of these devicescan deteriorate with stress and friction.

By changing the electric field and/ormagnetic field, the index of refraction,the extinction coefficient, the transmissiv-ity, and the reflectivity of the optical grat-ing device may be controlled in order tocontrol the spectral properties of thelight reflected or transmitted by it.Further, the diffraction patterns can beprogrammed from an external circuit.

Since the device works with an appliedelectric or magnetic field alone and with-out mobile mechanical parts, the opera-tion speed can be very fast when com-pared with existing MEMS devices. Andunlike most MEMS devices, NASA’s opti-cal grating device can work both in thetransmission and reflection modes.

NASA is actively seeking licensees to com-mercialize this technology. Please contactThe Technology Gateway at [email protected] or 757-864-1178 to initiate licensing discussions.Follow this link for more information:https://technology.nasa.gov/patent/TB2016/LAR-TOPS-279.

Incoming Light

Incoming Light

(b)(a)

V1

n1 n2 n3 n4 n5

V2 V3 V4 V5

V1

n1 n2 n3 n4 n5

V2 V3 V4 V5

Constructiveinterference

Constructiveinterference

Transparentsubstrate

Destructiveinterference

ReflectiveLayer orsubstrateDestructive

interference

(a) Transmission mode: Different electric or magnetic field on each quantum hole device results in thedifferent index of refraction. (b) Reflection mode: Different electric or magnetic field on each quan-tum hole device results in the different index of reflection. (NASA)

Low-Light Night Vision Imaging and Video CaptureThis viewer can be handheld, helmet-mounted, or tripod-mounted, and can be used duringthe day or at night.Army Communication Electronics Research, Development and Engineering Center, Aberdeen ProvingGround, Maryland

Conventional night vision goggles alluse image intensification (I2) tube

technology that multiplies ambient, visi-ble, and near-infrared light several thou-sands of times, allowing a user to see andoperate in very-low-light conditions. Oneshortcoming of I2 tube night visiondevices is that they cannot generate animage as a video signal that can be dis-played on a monitor or transmitted exter-nally. Further, the devices are sensitive totoo much light, which can over-saturatethe I2 tube and prevent the user fromseeing any scene detail. This problem iscalled “blooming” or a “halo effect.”What is needed is an alternative imaging

device that utilizes wavelengths of theelectromagnetic (EM) spectrum current-ly unused in military environments.

Such a device was developed thatoperates as a direct-view, compact, short-wave infrared (SWIR) viewer-detectorarray, and is sensitive to the visible, near-IR, and SWIR regions.

An atmospheric phenomenon callednight sky radiance emits five to seventimes more illumination than starlight— nearly all of it in the SWIR wave-lengths. Thus, with a SWIR camera andthis night radiance — often called night-glow — it is possible to see objects withgreat clarity on moonless nights. This

allows more photonic radiation to beused to create an image. In addition,SWIR illumination can be used to aidthe sensitivity of the SWIR device.

Photonic energy from a scene entersthe objective lens of the device and isfocused onto the SWIR imaging detec-tor. The detector’s electronics create avideo signal of the scene and provide thevideo signal to the display electronics.The display electronics create an imagefrom the signal and present a visibleimage on the display panel.

For more information, contact Brian Metz ger PhD, at [email protected]; 406-994-7782.

https://technology.nasa.gov/patent/TB2016/LAR-TOPS-279


Active Pointing Monitor for a 2-Axis Optical Control SystemAn inline optical axis fast-steering mirror (FSM) corrects unwanted tip and tilt mitigation.Goddard Space Flight Center, Greenbelt, Maryland

NASA Goddard Space Flight Center hasdeveloped a pointing measurement

detection and control system that moni-tors the real-time optical axis motions(such as tip and tilt) that affect image qual-ity in aerial platforms. To date, there is noknown real-time optical image alignmentand control system available that simulta-neously accommodates the combinedfocal plane functions of science image col-lection and image stabilization control.Current monitoring techniques involvereplicating the science image focal planeand a separate pointing monitor systemthat directly compete for the exact same

focal plane real estate, thus making it aone-or-the-other measurement.

This technology enables correction ofimage degradation introduced by tip andtilt motions. This system operates in boththe visible and IR spectral regions, can beadapted to different optical systems, anddoes not require any special manufactur-ing processes or materials.

This innovative measurement ap proachutilizes a single 2D focal plane detectorarray to collect the necessary science meas-urement image data while at the sametime collecting the engineering opticalaxis motion detection and image control

information. The innovation utilizes astandardized “windowing” electronic con-trol function to read out a single column(1D array) within a 2D spectrometer sys-tem while the readout and control of theremaining 2D array columns are con-trolled by separate and independent con-trol electronics.

NASA is actively seeking licensees to com-mercialize this technology. For more infor-mation, contact the Goddard StrategicPartnerships Office at [email protected] or 301-286-5810. Follow this linkfor more information: https://technology.nasa.gov/patent/TB2016/GSC-TOPS-195.

Portable Acousto-Optic Spectrometers A solid-state design enables field-portable spectroscopy applications.Army Research Laboratory, Adelphi, Maryland

Spectrometers are widely used for appli-cations such as chemical analysis,

remote sensing, quality control, environ-mental monitoring, spaceborne measure-ments, and optical measurements. Mostspectrometers are based on using disper-sive elements such as prisms, gratings, oretalons. These spectrometers typicallyhave moving parts that induce spuriousreadings due to vibrations, and have limit-ed use due to their limited spectral range

and resolution capabilities, which in turnlimit their use when needed for portablefield applications.

Acousto-optical tunable filters (AOTFs)are very powerful tools that can be used inmany spectroscopic applications, includ-ing absorption, emission, fluorescence,Raman, and laser-induced breakdownspectroscopy (LIBS) measurement instru-ments, and inside a traditional or fiberlaser cavity for choosing and tuning fre-

quency of light radiation. They are light-weight, compact, and very useful for field-portable applications. They have no mov-ing parts, are all solid-state construction,require low power, and are insensitive tovibrations. They have high spectral resolu-tion, large field of view, and high through-put. They offer high-speed tuning andscanning of wavelengths, and have reli-able and reproducible operation undercomputer control.

An ongoing problem in using spec-trometers in more applications is theirminiaturization. The size of a spectrom-eter is limited by their required preci-sion and accuracy of measurementsbecause of existing relationships be -tween optical spectral resolution, spec-tral range of a spectrometer, and itsinherent physical dimensions. The opti-cal spectral resolution of commonlymanufactured spectrometers is propor-tional to their dimensions. This is animportant limitation for miniaturizationof spectrometers that generally cannotbe circumvented. Unfortunately, sinceprecise spectrometers for use in environ-mental analysis are often bulky, costly,and expensive to transport and install,many known and important applicationsof spectrometers remain unimplement-ed due to cost and/or inconvenience.

Thus, there is a need for a portableAOTF spectrometer system that is rela-The vibration-insensitive, robust spectrometer for remote applications.

https://technology.nasa.gov/patent/TB2016/GSC-TOPS-195


Optics

New Laser for Improving Telecommunications andComputingThe array can be scaled up in size to create high-power lasers for industrial and defenseapplications.University of California, San Diego

The first laser based on the wavephysics phenomenon called bound

states in the continuum (BIC) has beendeveloped. The technology could revolu-tionize the development of surface lasers,making them more compact and energy-efficient for communications and com-puting applications. The BIC lasers couldalso be developed as high-power lasers forindustrial and defense applications.

BICs are waves that remain perfectlyconfined, or bound, in an open system.Conventional waves in an open systemescape, but BICs defy this norm and staylocalized; they do not escape despite hav-ing open pathways to do so. Previousresearch at UCSD demonstrated, at

microwave frequencies, that BICs could beused to efficiently trap and store light toenable strong light-matter interaction.

BIC lasers can be readily tuned to emitbeams of different wavelengths — a use-ful feature for medical lasers made to pre-cisely target cancer cells without damag-ing normal tissue. The lasers can also bemade to emit beams with specially engi-neered shapes (spiral, donut, or bellcurve), called vector beams, that couldenable increasingly powerful computersand optical communication systems thatcan carry up to 10 times more informa-tion than existing ones.

Light sources are key components ofoptical data communications technology

in cellphones, computers, and astronomy.The new kind of light source is more effi-cient than what is available today in termsof power consumption and speed.

The BIC laser is constructed from athin semiconductor membrane made ofindium, gallium, arsenic, and phospho-rus. The membrane is structured as anarray of nano-sized cylinders suspendedin air. The cylinders are interconnectedby a network of supporting bridges thatprovide mechanical stability to thedevice. By powering the membrane witha high-frequency laser beam, the BIC sys-tem was able to emit its own lower-fre-quency laser beam (at telecommunica-tion frequency).

Surface lasing occurred with arrays assmall as 8 × 8 particles. In comparison, thesurface lasers that are widely used in datacommunications and high-precision sens-ing, called VCSELs (vertical-cavity surface-emitting lasers), need much larger (100times) arrays and more power to achievelasing. The VCSEL may one day bereplaced by the BICSEL, or bound state inthe continuum surface-emitting laser,which could lead to smaller devices thatconsume less power.

The array can also be scaled up in size tocreate high-power lasers for industrial anddefense applications. The next step is tomake BIC lasers that are electrically pow-ered, rather than optically powered byanother lase, enabling them to run off of aconventional battery.

For more information, contact LiezelLabios at [email protected]; 858-246-1124.

Schematic of the BIC laser: a high-frequency laser beam (blue) powers the membrane to emit alaser beam at telecommunication frequency (red). (Kanté group/UC San Diego)

tively less expensive compared to cur-rently available systems that can be pro-duced and packaged for field handhelduse by non-experts.

An AOTF-based spectrometer wasde veloped that can be used for a vari-ety of spectroscopy applications includ-ing ab sorption, emission, fluorescence,Raman, and laser-induced breakdownspectroscopy.

The spectrometer is electronically tun-able with no moving parts, lightweight,compact, and very useful for field-

portable applications. Its solid-state con-struction means it can operate with lowpower, it is insensitive to vibrations, and itruns under computer control. Moreover,it can provide high spectral resolution.

The AOTF spectrometer has severaladvantages over alternative spectrometerdesigns based on filter wheels, diffractiongratings, and Michelson interferometers.It is small, fast, reliable, and can be usedfor applications such as chemical processcontrol, medical diagnostics, spectralradiometry, and real-time composition

analysis in a production/manufacturingenvironment. This instrument fulfills anessential requirement for next-genera-tion spectroscopic instruments.

Military and commercial applicationsinclude detection of chemical and biolog-ical agents, medical and pharmaceuticalapplications, production and manufac-turing control, and environmental sens-ing applications.

For more information, contact Dr. BrianMetzger at [email protected];406-994-7782.


Using Sound Waves to Produce Optical IsolatorsThese devices may solve data capacity challenges for circuits used in computing andcommunications.University of Illinois Urbana-Champaign, Champaign, Illinois

There are challenges involved whenusing magnetically responsive materi-

als to achieve the one-way flow of light ina photonic chip, including the ability toplace compact magnets on a chip. Inaddition, the necessary materials are notyet available in photonics foundries, cre-ating the need for a better approach thatuses only conventional materials andavoids magnetic fields.

Sound waves can be used to produceultraminiature optical diodes that are tinyenough to fit onto a computer chip. Theseoptical isolators may help solve major datacapacity and system size challenges forphotonic integrated circuits — the light-based equivalent of electronic circuits usedfor computing and communications.

Isolators are nonreciprocal or “one-way” devices similar to electronic diodes.They protect laser sources from backreflections and are necessary for routinglight signals around optical networks.Today, the dominant technology for pro-ducing such nonreciprocal devicesrequires materials that change theiroptical properties in response to mag-netic fields.

The minuscule coupling between lightand sound was used to provide a uniquesolution that enables nonreciprocaldevices with nearly any photonic materi-al. Still, the physical size of the device andthe availability of materials are not theonly problems with the current state ofthe art. Laboratory attempts at producing

compact magnetic optical isolators havealways been plagued by large optical loss.A solution is needed that providesenough bandwidth to be comparable tothe traditional magnetic technique.

The new device is only 100 × 200microns in size — about 10,000 timessmaller than a square centimeter — andmade of aluminum nitride, a transpar-ent material that transmits light and iscompatible with photonics foundries.Sound waves are produced in a way sim-ilar to a piezoelectric speaker, using tiny

electrodes written directly onto the alu-minum nitride with an electron beam.These sound waves compel light withinthe device to travel only in one direc-tion. The magnetless isolator surpassedgigahertz bandwidth.

Applications in photonic communica-tion systems, gyroscopes, GPS systems,atomic timekeeping, and data centersare possible.

For more information, contact LoisYoksoulian at [email protected]; 217-244-2788.

An array of 100 x 200-micron optical isolators uses sound to produce one-way light propagation.(Benjamin Sohn)

Optimetric Measurements Over Coherent Free-SpaceOptical CommunicationGoddard Space Flight Center, Greenbelt, Maryland

High-precision ranging (optimetric)instruments are highly desired for

both space navigation and communica-tions as well as gravitational-based sci-ence missions. Traditionally, these meas-urements are made with instrumentssolely dedicated to ranging (i.e. Dopplershift of a microwave carrier providingspacecraft-Earth relative velocity alongline of sight); however, this approach islimited by clock stability, frequency, andplasma-induced group delay variations,

resulting in lower range and range rateaccuracies.

NASA Goddard Space Flight Center hasdeveloped a directed modulated rangingtechnique to improve free space opticalcommunications. Through utilizing coher-ent optical communication to combineoptimetric measurements over an opticalcarrier, one can accurately measureDoppler and absolute ranging. This processworks through a looping and synchroniz-ing iteration, measuring frame, bit, and

phase change values using a phase detectorand clock data recovery apparatus. A dual-mixer time difference (DMTD) approachis also employed, making the system morephase sensitive and easier to calibrate.

NASA is actively seeking licensees to com-mercialize this technology. For more infor-mation, contact the Goddard StrategicPartnerships Office at [email protected] or 301-286-5810. Follow this linkfor more information: https://technology.nasa.gov/patent/TB2016/GSC-TOPS-192.


Most naturally occurring materialshave a disordered atomic structure

that interferes with the propagation ofboth sound and electromagnetic waves.When the waves come into contact withthese materials, they bounce around anddisperse — and their energy dissipatesaccording to a highly complex interfer-ence pattern, diminishing in intensity.That means it’s virtually impossible totransmit data or energy intact acrosswave-scattering media and fully leveragethe potential of wave technology.

For example, with a smartphone, thegeolocation function does not work aswell inside buildings where radio-frequen-cy waves scatter in all directions. Other

potential applications include biomedicalimaging and geological surveying, whereit’s important to be able to send wavesacross highly disordered media.

A system was developed that allowssound waves to travel across such mediawith no distortion. It uses tiny speakersas acoustic relays to offset the wave scat-tering. It has been successfully testedon a real acoustic system. The systeminvolves placing acoustic relays at strate-gic locations so that sound waves canpropagate at a constant amplitude,regardless of what may lie in their path.This method could eventually be usedto make it possible to hide objects likesubmarines.

The tiny speakers can be controlled toamplify, attenuate, or shift the phase of thesound waves. That lets them offset the dif-fusion that results when the waves hitobstacles, thereby reproducing the origi-nal sound exactly on the other side of thedisordered medium.

The system was tested by building a3.5-meter-long air-filled tube and plac-ing various kinds of obstacles such aswalls, porous materials, and chicanesinto it in order to create a highly disor-dered medium through which no soundwaves could pass. The tiny speakers wereplaced between the obstacles and elec-tronic controls were set up to adjust thespeakers’ acoustic properties.


Mechanical & Fluid Systems

System Makes Opaque Materials Totally TransparentMaterials that are normally opaque to sound waves become completely transparent, makingit possible to hide objects such as submarines.École Polytechnique Fédérale de Lausanne, Switzerland

Ducted Fuel Injection for Soot ReductionThis technology can be used in diesel and gas turbine engines, industrial boilers, and forspark ignition engines.Sandia National Laboratories, Albuquerque, New Mexico

Typical direct-injection engines, suchas diesel engines, can produce soot

due to fuel-rich combustion conditions.Filters and catalytic converters are cur-rently used to reduce soot and harmfulemissions, but these systems are expen-sive, large, complex, and they penalizeengine efficiency. Ducted fuel injectiontechnology was developed for the reduc-tion of soot and other EPA-regulatedemissions in direct-injection engines.The ducted fuel injection technologyreduces soot at the point of combustion,thereby reducing the need for theseafter-treatment devices and their associ-ated costs.

The mechanical solution forces eachfuel spray from the fuel injector througha small duct located within the combus-tion chamber. Oxygen is drawn into eachduct due to the pressure field establishedduring fuel injection, and the ensuingenhanced turbulent mixing creates anoptimized mixture of fuel and oxygen.The more-homogeneous fuel mixture is

then released from the duct into thecombustion chamber where it ignites,eliminating soot that results fromunevenly mixed, fuel-rich combustion.

The technology could be key for futureengines because it is an effective, concep-

tually simple approach for lowering sootand other emissions, as well as potentiallyimproving combustion efficiency.

For more information, contact SandiaNational Laboratories at [email protected], orvisit https://ip.sandia.gov.

Bright soot incandescence

Natural luminosity images

Radi

al D

ist.

[mm

]Ra

dial

Dis

t. [m

m]

-10

0

10

-10

0

10

Liquid fuelVapor-fuel/charge-gas mixtureAutoignition zoneProducts of rich combustionDiffusion flameThermal NO production zone

Fuel-injector tip

Duct

Piston bowl rim

Ducted Fuel Injection (DFI)

Without duct (i.e., conventional free-spraycombustion)

With duct (i.e., DFI)

Chemiluminescence only

0 10 20 30 40 50 60 70 80 90Axial Distance [mm]

Components of the ducted fuel injection system (left) and results of the system performance versusdirect injection engine performance.

https://ip.sandia.gov/


See the EZQUAD SERVO

in action!

30097 Ahern AvenueUnion C i ty, CA 94587

Te c h n i c a l S up p o r t(408) 460-1345

- brushed or bldc motors- 5 amps per axis- 16 analog inputs- 16 on/off drivers - home and limit in- live tech support- made in the USA

(510) 471-4000WWW.ALLMOTION.COM

2.25”

4 AXIS SERVOfrom

NEW!


A New Twist Makes RotatingMachinery More Efficient and QuieterThis technology benefits propellers, industrial fans,compressors, and turbines.Armstrong Flight Research Center, Edwards, California

Derived from a design approach for anew wing known as PRANDTL-D,

this technology achieves similar improve - ments for propellers and other rotatingmachinery.

To achieve the innovation’s alternatespanload, Armstrong designers applieda non-linear twist to the propellerblade. The twist moves the load inwardand dissipates the tip vortex over awider area, minimizing its effect ondrag. It also results in a decrease inload at the tip and reduced torque atthe tip. These changes combine toachieve a dramatic reduction in powerconsumption without compromisingthe blade’s other parameters. Spe -cifically, the blade’s diameter and rpmremain unchanged.

Unlike the conventional minimuminduced loss (elliptical) spanload, whichconsumes large amounts of power at thetip of the blade, the new design unloadsthe tip and reduces torque, achieving sig-nificant improvements in efficiency. First-order analysis shows a more than 15 per-cent improvement in power consumptionwhile producing the same thrust. Thedesign also produces significantly lessnoise than conventional blade designs.

NASA is actively seeking licensees to com-mercialize this technology. Please contact theNASA Armstrong Technology Transfer Officeat 661-276-3368 or [email protected] to initiate licensing discussions.Follow this link for more information:https://technology.nasa.gov/patent/TB2016/DRC-TOPS-41.

A 3.5-meter-long tube was built to test the system. (©Alain Herzog/2018 EPFL)

A new control mechanism had to bedeveloped to amplify the sound wave,similar to how optical waves can be ampli-fied with lasers. The new method — theonly one of its kind in acoustics — usesprogrammable circuits to control severalspeakers simultaneously and in real time.

The method for active acoustic controlis similar to that used in noise cancellingheadphones and could potentially be usedfor sounds containing common ambient

frequencies. It could also be used to elimi-nate the waves that bounce off objects likesubmarines, making them undetectable bysonar. Moreover, the theory underlyingthe work could have parallel applicationsin optics or radio frequencies to makeobjects invisible or to take images throughopaque materials.

For more information, contact LaurenceBaumann at [email protected];+41 21 693 16 34.


https://technology.nasa.gov/patent/TB2016/DRC-TOPS-41



Breakaway devices are used to mountobjects to systems or structures (for

example, cars, drones, helmets, build-ings) and prevent damage when theobjects fall away from the system.Unfortunately, even in ideal scenarios,many of these devices have limitations.Breakaway bolts and shear pins havethe complication of breaking andbecoming unusable thereafter. Reset -table mounting devices such as hook-and-loop fasteners, reusable adhesives,or rubber mounting devices do notprovide proper stability in certainapplications. Elec tromagnetic andelectromechanical-based devices can

be quite large and expensive, andrequire a power source.

A reusable breakaway mounting de -vice was developed that can be cus-tomized according to the amount offorce required to break away the mount-ed device. There are two versions of thedevice. One version uses a maximum-strength O-ring to prevent damage to themounted device. The O-ring is mountedwithin a groove to provide stabilizationwhile a tooth ring is tightened aroundthe O-ring. The spacing of the teeth pro-vides a way for the O-ring to compressand release itself when the thresholdforce is reached.

The second version uses a magnetic fieldbetween the breakaway plate and themounting brackets. Using magnets allows asimple way to customize the minimumbreaking force that preserves the mounteddevice. It also allows easy resetting of themounting bracket to its base. Each versionmay further include a tether to prevent lossor further damage to a high-value object.Both versions take different environmentsinto account, such as an angular mount orunderwater situations, while still providinga simple and inexpensive solution.

For more information, contact Joan Wu-Singel at [email protected]; 406-994-7705.

Reusable Breakaway Mounting DeviceSpace and Naval Warfare Systems Command – Systems Center Pacific, San Diego, California

NASA’s Langley Research Center hasdeveloped the SHEARLESS com-

posite boom with a final cross-sectionshape that is lenticular and is flexibleenough to allow elastic flattening andsubsequent coiling around a cylindricalreel/drum. The torsional stiffness of thestructure is also greatly increased and

becomes two orders of magnitude largerthan that of the individual tape-springcomponents alone.

The innovation enables a lightweightstructure that can be stowed on a reelwithout appreciable shear stresses devel-oping in its constitutive composite parts.This allows for unprecedentedly small

coiling diameters for the total thicknessof the structure, which can enable highlycompact designs such as those requiredin CubeSat/small satellite applications.

The SHEARLESS composite boomhas a rollable structure with a largemoment of inertia per unit of storedheight that does not suffer from shear-derived problems. The boom is fabricat-ed from joining two independent tape-springs front-to-front with the use of adurable, seamless, polymer sleeve. Thissleeve allows the two parts to slide pasteach other during the coiling/deploy-ment process so as to minimize shearand its derived problems.

As demonstrated through specificlaminate design of the two inner com-posite parts, the SHEARLESS compositeboom can also be fabricated with a spe-cial inherent feature — bi-stability —that enables designs with minimal mech-anisms and aids in deployment control-lability and reliability.

NASA is actively seeking licensees to com-mercialize this technology. Please contactThe Technology Gateway at [email protected] or 757-864-1178 to initiate licensing discussions.Follow this link for more information:https://technology.nasa.gov/patent/TB2016/LAR-TOPS-272.

SHEAth-based Rollable LEnticular-Shaped and Low-Stiction (SHEARLESS) Composite BoomsThe lightweight support framework for deployable structures can be stowed compactly.Langley Research Center, Hampton, Virginia

SHEARLESS booms: (a) stored, showing efficient coiling diameter and (b) deployed, with gravity off-loaded.

(a) (b)

https://technology.nasa.gov/patent/TB2016/LAR-TOPS-272

Engineers and software developersare seeking to create technology

that lets users touch, grasp, andmanipulate virtual objects while feel-ing like they are actually touchingsomething in the real world. An ultra-light glove — weighing less than 8grams per finger — was developedthat enables users to feel and manipu-late virtual objects. The system pro-vides extremely realistic haptic feed-back and could run on a battery,allowing for freedom of movement.

The DextrES glove can generate upto 40 Newtons of holding force oneach finger with just 200 Volts andonly a few milliwatts of power. It alsohas the potential to run on a verysmall battery. That, together with theglove’s low form factor (only 2 mmthick), translates into an unprecedent-ed level of precision and freedom ofmovement.

DextrES is made of nylon with thinelastic metal strips running over thefingers. The strips are separated by athin insulator. When the user’s fingerscome into contact with a virtualobject, the controller applies a voltagedifference between the metal stripscausing them to stick together viaelectrostatic attraction. This producesa braking force that blocks the finger’sor thumb’s movement. Once the volt-age is removed, the metal strips glidesmoothly and the user can once againmove his fingers freely.

For now, the glove is powered by avery thin electrical cable, but a verysmall battery could eventually beused. The next step will be to scaleup the device and apply it to otherparts of the body using conductivefabric. A potential application exists

in training surgeons. The technologycould also be applied in augmentedreality.

For more information, contact AndreaCrottini, PhD, in the EPFL TechnologyTransfer Office at [email protected];+41 (0)21 693 5047.

Discover Marotta’s CoRe Flow Controls; the optimal solution for

commercial launch vehicle applications. By combining high performance

and high reliability with affordability and availability, the CoRe series

enables system designers to leverage qualified, proven technologies for

today’s advanced NewSpace platforms.

Gain the strategic advantage with CoRe, ready for the next generation of

space transportation and exploration.

Commercia l Reusable F low Cont ro ls

R E A D Y F O R L A U N C H

® www.marotta.com/core

Free Info at http://info.hotims.com/69513-664Tech Briefs, December 2018

Ultralight Gloves Provide Realistic Haptic FeedbackThe gloves enable users to feel and manipulate virtual objects.École Polytechnique Fédérale de Lausanne, Switzerland, and ETH Zurich, Switzerland

The ultralight glove weighs less than 8 gramsper finger and provides extremely realistic hapticfeedback.




Researchers have developed a newpropulsion concept for swimming

robots that exploits temperature fluctua-tions in the water for propulsion withoutthe need for an engine, propellant, orpower supply.

As a proof-of-concept study, the re -searchers developed a 7.5-centimetermini-submarine equipped with paddlesthat were fabricated entirely using amulti-material 3D printer. The paddlesare actuated using a bistable propulsionelement triggered by two shape memorypolymer strips. Designed to expand inwarm water, the polymer strips powerthe robot by acting like muscles. If thewater in which the mini-submarine floatsis heated, the expansion of the musclescauses the bistable element to quicklysnap, triggering a paddle stroke. Thedirectional motion, force, and timing ofthe paddle strokes are precisely definedby the robot’s geometry and material.

At present, each actuating element canexecute a single paddle stroke and mustthen be reprogrammed manually; howev-er, it is possible to fabricate complexswimming robots with multiple actuators.

A mini-submarine was made that can pad-dle forward with one stroke, release its“cargo” (a coin), and then navigate backto the starting point with a second paddlestroke in the opposite direction, all bysensing changes in temperature of thewater. Varying the geometry of the poly-mer muscles allowed the scientists todefine the sequence at which the paddlestroke is triggered: thin polymer strips

heat up faster in warm water and there-fore respond faster than thicker ones.

A potential development would beusing polymers that do not react to thewater temperature, but to other environ-mental factors such as the acidity orsalinity of the water.

For more information, contact FabioBergamin at [email protected];+41 44 632 57 80.

Submarine Swims Without an EngineThe paddling submarine requires no engine, propellant, or power supply.ETH Zurich, Switzerland and California Institute of Technology, Pasadena

Visualization of a simple mini-submarine with two paddles. (ETH Zurich/Tim Chen)

Shape Memory Alloy Rock Splitters (SMARS)This device is a compact, powerful, non-explosive method for fracturing rock-like materials inapplications such as oil and gas drilling.John H. Glenn Research Center, Cleveland, Ohio

Glenn’s revolutionary Shape Memo -ry Alloy Rock Splitters (SMARS)

device is fabricated from nickel-titani-um-halfnium (NiTiHf), nickel-titani-um-zirconium compositions, or a com-bination. These compositions containa secondary, nanometer-sized precipi-tate phase that is produced throughprocesses of compositional controland aging heat treatments. Glenn’snovel materials and processes haveyielded a shape memory alloy (SMA)composition that produces much high-er stresses than other SMAs on thecommercial market.

The SMARS device is composed of:1) SMA material as the actuating mem-ber; 2) a casing heater placed aroundthe SMA member; 3) a DC or AC

power source to provide currentthrough the heater; 4) pointed tips foracute penetration into rock forma-tions; and 5) a hand press to reset theSMA element after each use. In therock-splitting process, a hole equal tothe diameter of the SMA element isdrilled in the portion of the rockwhere the fracture is desired. Next, thepre-compressed SMA is inserted intothe hole, and AC or DC current isapplied to energize the device’sheaters. Once the heater achieves thecritical transformation temperature,the SMA will begin to expand withinseconds. Since its expansion is con-strained by the rock walls, the SMA willeventually exert up to 1,500 MPa ofstress, splitting the rock apart. When

the current is removed and the heatercools, the SMA material returns to itspre-compressed state. At this point,the material can be recovered, so theprocess is repeatable after reshaping.

The SMA actuating members werealso designed to achieve displacementgreater than the material’s strain out-put. Glenn’s SMARS device provideshigh-powered rock fracturing that iscontrollable, reliable, and compara-tively simple without the use of explo-sives, hydraulics, or chemicals.

NASA is actively seeking licensees to com-mercialize this technology. Please contact theTechnology Transfer Office at [email protected] or 216-433-3484. Follow thislink for more information: https://technology.nasa.gov/patent/TB2016/LEW-TOPS-122.

https://technology.nasa.gov/patent/TB2016/LEW-TOPS-122


Variable-Pitch Turbine BladesA tunable blade mechanism maintains high aerodynamic performance and optimal thermal design.Army Research Laboratory, Adelphi, Maryland

Gas turbine blades of conventionalrotorcraft turboshaft engines are opti-

mized to operate at nearly a fixed speedand a fixed incidence angle. If the operat-ing condition of the engine changes, then

the flow through the turbine may need tobe guided to a more optimum direction.

One way to do this is with variable tur-bine nozzle geometry. But this standardmethod has some disadvantages including

increased weight and complexity, as well asa limited operating range since the nozzlevanes can only be turned to a certain pointbefore severe flow incidence angles dis-rupt the rotating blades downstream.

Using incidence-tolerant blades in com-bination with variable-speed power tur-bines in rotorcraft optimizes engine per-formance across a range of power. This isparticularly important for rotorcraft, asmaintaining high fuel efficiency is a chal-lenge. A careful balance must be achievedwith the fuel burn penalties associated withvariable-speed engine capability and thegains made by slowing the main rotorspeed substantially (to 51 percent of take-off speed) as required to maintain highpropeller efficiencies at cruise flight speed.

While these approaches of incorporat-ing variable nozzle vane geometry andincidence-tolerant blading can increasethe operating range of a turbine to someextent, further optimization and per-formance improvements could beachieved by articulating the rotatingblades of the turbine in coordinationwith stator nozzle vanes.

A mechanism and method were devel-oped to articulate the pitch angle of rotat-ing gas turbine blades and stator vanes forvariable-speed applications that alwaysmaintain incidence angles optimized formaximum aerodynamic performance.Within this adaptable articulating bladeassembly, the inner portion of the bladeairfoil base mating with turbine rotor diskis housed with an actuation device used tochange the pitch angle of each rotor bladefrom its base. This rotation changes thegeometry of the blade angle with respectto the incoming flow incidence angle.

By pitching the rotor blades in coordi-nation with the stator nozzle vanes, theflow incidence angles can be maintainedwithin the optimum range for improvedaerodynamic performance. Potentialbenefits to future military and commer-cial aviation gas turbine engines includehighly aerodynamically efficient turbineblades, reduced noise and vibration,reduction of the need for active bladecooling and thermal barrier coatings,increased fuel efficiency and power den-sity, and the ability to fly faster and longer.

For more information, contact BrianMetzger, PhD, at [email protected]; 406-994-7782.

Rotor Pitching

Rotor

StatorStator Pitching

Degrees

Degrees

15

15

D

D

Srf

y

p

Srf

G

A

P

G

X

G

A

P

G

X

(a)

(b)

(c)

(a) The method articulates the pitch angle of rotor and stator blades; (b) Pitching the rotor and statorblades both by 0 degree; and (c) pitching the rotor and stator blades both by 15 degrees.


Power & Energy

High-Power-Density Solid Oxide Fuel CellThis compact and versatile energy source has potential uses in unmanned vehicles, utilitypower, regenerative power, and electric and hybrid vehicles.John H. Glenn Research Center, Cleveland, Ohio

NASA’s Glenn Research Center hasdeveloped a novel solid oxide fuel

cell (SOFC) with five times the specificpower density of currently availableSOFCs. This highly efficient SOFC canoperate on a wide range of both hydro-gen and hydrocarbon-based fuels in -cluding methane, diesel, or jet fuel with-out reformers.

Rather than heavy metal interconnects,Glenn’s innovative bi-electrode supportedcell (BSC) uses a thin layer of electricallyconductive LaCaCrO3 (LCC) for currentcollection. To improve strength duringthermal cycling and simplify stack manu-facture, its design is structurally symmetri-cal with a thin yttria-stabilized zirconia(YSZ) electro lyte supported on either sideby a porous support structure.

Electrodes are made by freeze-casting,a modified tape casting technique thatcreates the many microchannels neededfor gas diffusion in the YSZ electrodeusing green tape. Prior to electrode

impregnation to create the anode andthe cathode, the entire BSC supportstructure is sintered at a temperature of1400 °C. This results in less internalresistance thanks to the nearly identical

coefficients of thermal expansion of theYSZ electrolyte and LCC layer.

This design is highly versatile. Theanode-impregnated material can easily bechanged to nearly any metal such as tin orcopper without any modification to theBSC, allowing for thinner layers and betterperformance characteristics. Also, sincethe BSC cells are fabricated entirely fromceramic materials, they can operate athigher temperatures, and the formation ofhermetic, ceramic-to-ceramic seals is possi-ble. The result is a BSC SOFC that canachieve high specific power densities thatare five times higher than state-of-the-art(up to 2.5kW/kg), and a volumetric powerdensity that is eight times higher than state-of-the-art (up to 7.5kW/L).

NASA is actively seeking licensees to com-mercialize this technology. Please contact theTechnology Transfer Office at [email protected] or 216-433-3484. Follow thislink for more information: https://technology.nasa.gov/patent/TB2016/LEW-TOPS-120.

Air

Air

Fuel

Fuel

Glenn’s lightweight and low-volume SOFC canoperate on a wide range of fuels.

Alternating Current Photovoltaic Building BlockThis system combines almost all of the electrical and mechanical elements of aphotovoltaic system.Sandia National Laboratories, Albuquerque, New Mexico

Today’s photovoltaic power systems aregenerally comprised of a single photo-

voltaic module or multiple modules con-nected by combinations of series and par-allel circuits as a photovoltaic array. In thecase of a single-module system producing

alternating current (AC) power output,the photovoltaic module is connected tothe inverter or load through a junctionbox (J-box) that incorporates a fuse to pro-tect the photovoltaic module if backfeed-ing from other sources (e g; a power utility

or a battery) is possible. The photovoltaicmodules used in these systems are config-ured either with or without a frame.Frameless photovoltaic modules are gen-erally referred to as a laminate. For con-ventional systems that utilize multiple lam-inates or modules, the laminates or mod-ules are interconnected via junction boxesor flying leads and external wiring thatmust be rated sunlight-resistant and sizedto carry the rated currents. Some conven-tional photovoltaic system installationsrequire that the direct current (DC) andAC wiring be installed in properly sizedand anchored conduit.

A typical method of interconnecting theDC circuits in a conventional photovoltaicsystem is to have a J-box at the top of each

The AC PV Building Block combines, contains, and integrates almost all of the electrical andmechanical elements of a PV system.

https://technology.nasa.gov/patent/TB2016/LEW-TOPS-120


photovoltaic module that provides the ter-minal block to connect the module circuitto flying-lead conductors that are then fit-ted with a connector. The J-box also hous-es the series or “blocking” diode oftenrequired by codes and standards to protectthe module, especially if more than twostrings of modules are paralleled at thecombiner box or at the inverter. The mod-ule is often constructed with a bypassdiode(s) that is(are) usually required forconventional photovoltaic applications.This ar rangement is used to connect mod-ules in series. Modules are connected inse ries until the summed operating voltageis within the optimum DC voltage windowof the central or string inverter. The con-nections are typically made under themodules by plugging connectors togetheror at distributed J-boxes. Some installa-tions leave insufficient space to al low theinstaller to make the connections reliably.The central inverter can generally handlemultiple strings of photovoltaic modulesthat are then wired in parallel in a string-combiner assembly or box before DCpower is fed to the inverter.

The AC Photovoltaic (PV) BuildingBlock provides a fully integrated and self-containing AC PV Building Block de viceand method that allows photovoltaic appli-cations to become true plug-and-playdevices. The AC PV Building Block elimi-nates all DC wiring, the requirement forthe fuse, the need for bypass diodes orseries diodes, the J-box, and connections.All connections except the final AC con-nections are part of the integrated pack-age of the invention.

The AC PV Building Block combines,contains, and integrates almost all of theelectrical and mechanical elements of aPV system while eliminating the tradition-al DC voltage concerns of today’s PV sys-tems. The building block consists of aninnovative module and method by whichAC PV power is generated in the form ofDC. Furthermore, the DC will be convert-ed to AC, and power will be exportedthrough one or more power conversionand transfer units attached to the module.The Building Block can be used as a PVpower source that has only AC power out,and can be used alone or in an array.

The AC PV Building Block can beemployed with any size and/or shape ofphotovoltaic system that provides ACpower to: 1) the utility grid, 2) mini-grids utilizing other sources of AC elec-trical generation often referred to ashybrid systems, or 3) standalone powersystems that typically use electricalenergy storage and an inverter to sup-ply AC power to off-grid loads such asremote residences, communicationsstations, emergency lighting, and themultitude of remote energy systemsrequiring AC power.

Additionally, the invention can becombined to form complete photovolta-ic energy systems that use a single ormultiple photovoltaic modules wherethe entire power interconnection, con-version, protection, and combining cantake place within a listed or certifiedstructure that also is used to mount,attach, and join photovoltaic modules.

For more information, contact SandiaNational Laboratories, Intellectual Prop -erty Office at [email protected], or visithttps://ip.sandia.gov.

Relying on advanced materi-als such as perovskites and

single-walled carbon nano -tubes, a window technology wasdeveloped that responds toheat by transforming fromtransparent to tinted. As thewindow darkens, it generateselectricity. The color change isdriven by molecules (methyl -amine) that are re versiblyabsorbed into the device.When solar energy heats up thedevice, the molecules are driv-en out, and the device is dark-ened. When the Sun is notshining, the device is cooledback down, and the moleculesre-absorb into the window device, whichthen appears transparent.

The device allows an average of 68percent of light in the visible portion ofthe solar spectrum to pass through whenit is in a transparent, or bleached, state.When the window changes color — aprocess that took about three minutes of

illumination during testing — only 3percent is allowed through the window.

Existing solar window technologies arestatic, which means they are de signed toharness a fraction of the sunlight withoutsacrificing too much visible light trans-mission needed for viewing, or for thecomfort of building occupants. The

proof-of-concept established asolar power conversion effi-ciency of 11.3 percent.

In testing under 1-sun illu-mination, the 1-square-cen-timeter demonstration devicecycled through repeated trans -parent-tinted cycles, but theperformance declined overthe course of 20 cycles due torestructuring of the switch-able layer. Ongoing researchis focused on improving cyclestability.

The technology could beintegrated into vehicles, build-ings, and beyond. The elec-tricity generated by the solar

cell window could charge batteries topower smartphones or onboard elec-tronics such as fans, rain sensors, andmotors that would open or close thewindows as programmed.

For more information, contact HeatherLammers at [email protected];303-275-4084.

Thermochromic Windows Convert Sunlight into ElectricityThis device dynamically responds to sunlight by transforming from transparent to tintedwhile converting sunlight into electricity.National Renewable Energy Laboratory, Golden, Colorado

The switchable photovoltaic window dynamically transforms fromtransparent to tinted. (Photo by Dennis Schroeder/NREL)

https://ip.sandia.gov/


Power & Energy

Researchers have developed a new,low-cost catalyst for plastic produc-

tion that turns a biorefinery productinto a starting material for the synthesisof plastics, which could represent a sus-tainable alternative to widespread PET.At the same time, hydrogen can also beformed during the reaction.

The nickel boride catalyst — whichdoes not contain any precious metals —is readily available and affordable com-pared to many other catalysts. It can turnthe biorefinery product HMF (5-hydrox-ymethyl-furfural) into FDCA (2,5-furan -

dicarboxylic acid), which can be pro -cessed into polyesters. PEF — an alterna-tive to PET — can thus be produced.

In tests, the catalyst turned 98.5 per-cent of the starting material HMF intoFDCA in half an hour; no waste productswere created. The catalyst was designedto be effective under the same condi-tions under which hydrogen productionis also successful. The researchers werethus able to use the starting material tosynthesize hydrogen as the potentialenergy source. Hydrogen is usuallyacquired from water using electrolysis,

which also produces oxygen. The partic-ularly energy-consuming reaction step,oxygen evolution, was eliminated whenthe researchers linked up hydrogen evo-lution and FDCA production.

The team also clarified the reactionstep-by-step using electrochemical meth-ods and infrared spectroscopy. For thefirst time, the chemists were able to trackin real time which intermediate prod-ucts turn HMF into FDCA.

For more information, contact ProfessorDr. Wolfgang Schuhmann at [email protected]; +49 234 32 26200.

New Catalyst for Plastic Production Also Creates HydrogenRuhr-Universität Bochum (RUB), Germany

Battery Provides Electric Vehicles with Immunity fromClimate ConditionsThe self-heating battery allows rapid charging independent of outside temperature.Penn State University, University Park, Pennsylvania

Conventional lithium-ion batteries can-not be rapidly charged at tempera-

tures below 50 °F. Electric vehicles arepopular on the West Coast because theweather is conducive to quick charging.Once the vehicles are moved to the EastCoast or Canada, there is a tremendousissue with charging.

A new battery was created that can self-heat, allowing rapid charging re gardlessof the outside chill. The battery allows 15-minute rapid charging at all tempera-tures, even as low as -45 °F. When ownerscan recharge car batteries in 15 minutesat a charging station, electric vehicle refu-

eling becomes nearly equivalent to gaso-line refueling in the time it takes.Assuming that charging stations are liber-ally placed, drivers can drive long dis-tances without worries.

The self-heating battery uses a thinnickel foil with one end attached to thenegative terminal and the other extend-ing outside the cell to create a third ter-minal. A temperature sensor attachedto a switch causes electrons to flowthrough the nickel foil to complete thecircuit when the temperature is belowroom temperature. This rapidly heatsup the nickel foil through resistance

heating and warms the inside of the bat-tery. Once the battery's internal temper-ature is above room temperature, theswitch turns opens and the electric cur-rent flows into the battery to rapidlycharge it.

The self-heating battery could with-stand 4,500 cycles of 15-minute chargingat 32 °F with only a 20% capacity loss.This provides approximately 280,000miles of driving and a lifetime of 12.5years. A conventional battery testedunder the same conditions lost 20%capacity in 50 charging cycles.

Lithium-ion batteries degrade whenrapidly charged under 50 °F because,rather than the lithium ions smoothlyintegrating with the carbon anodes, thelithium deposits in spikes on the anodesurface. This lithium plating reducescell capacity, but also can cause electri-cal spikes and unsafe battery conditions.Currently, long, slow charging is theonly way to avoid lithium plating under50 °F. Batteries heated above the lithi-um plating threshold, whether by ambi-ent temperature or by internal heating,will not exhibit lithium plating and willnot lose capacity.

The fast-charging method will allowmanufacturers to use smaller batteriesthat are lighter and safer in a vehicle.

For more information, contact A’ndrea ElyseMesser at [email protected]; 814-865-9481.

A fast charging battery for all outside temperatures rapidly heats up internally prior to charging bat-tery materials. (Chao-Yang Wang/Penn State)

Upcoming...

Webinars

Please visit www.techbriefs.com/webinar594


Slawomir S. PiatekSenior University Lecturer ofPhysics, NJIT; ScientificConsultant, Hamamatsu

The Latest Technologies for Energy HarvestingTuesday, December 4, 2018 at Noon U.S. EST

Jeff CrystalCOO,Voltaic Systems

Christian FellCOO and VP,Technology & CustomSolutions, POSITAL-FRABA

This 60-minute Webinar on energy harvesting is part of the Technical Webinar Series from the editors of Tech Briefs Media. Threeexperts will look at the latest technologies related to this important subject area. This Webinar will explore energy harvesting withsolar panel/Li-ion battery hybrids, harvesting energy for low-power electronics, and the use of batteries for long-life remote devicesin harsh environments.

Sol JacobsVP and GM,Tadiran Batteries


ToF & FMCW Automotive LiDARs: Design Challenges

Tuesday, December 11, 2018 at 2:00 pm U.S. EST

Once only fantasy, autonomous vehicles are becoming reality thanks to advances in laser technology and photodetection. However,fully autonomous vehicles require an array of sensory systems to provide information about the vehicle’s surroundings. This Webinarfocuses on both types LiDAR, discussing the physics principles of both concepts, pointing out pros and cons of each, and explain-ing the many engineering challenges associated with designing each type of LiDAR.

This 60-minute Webinar includes: • Live Q&A session • Application Demo • Access to archived event on demand

This 60-minute Webinar includes:• Live Q&A session • Application Demo • Access to archived event on demand

Speakers:

Speaker:

Tyler MaddenGlobal Product Manager,Data & Devices Business Unit,TE Connectivity

Discover How Unique Cable & ConnectorSolutions are Taking 3D Printing to New Levels

Now Available on Demand Until October 2, 2019

In today’s fast-paced, quick development cycle marketplaces, the need for rapid prototyping and quick-turn sampling is critical. 3D printing/additive manufacturing has quickly surfaced as the solution for this need.This Webinar disucusses how cable and connector systems can enable 3D printing, as we dive into solutions that can enable your 3Dprinter designs.

Speaker:

Webinars on Demand!

http://www.techbriefs.com/webinar592



APPLICATIONBRIEFS

Crash Test Dummies Get Older andBetter with 3D PrintingMarkforgedWatertown, MAhttps://markforged.com

The crash test dummy has come of age over many decadesas the gold standard for safety testing of automobiles.

Organizations like the National Highway Traffic SafetyAdministration (NHTSA), the Insurance Institute forHighway Safety (IIHS), and other agencies throughout theworld continually update the requirements for driver andpassenger protection. These updates require automakers toinvest significant resources to ensure that their vehicles passmuster and that the crash dummies they use in their carsrealistically reflect what happens in the types of collisions

these groups will be testing. Crash test dummies should

reflect the full variety ofhuman body types. Goingbeyond the first male-only

dummies, the family hasbeen expanded to in-

clude female, child,infant, and most re -cently, elderly bod -ies, which haveturned out to be aunique challengefor Humanetics,a leading manu-facturer of crashdummies.

Humanetics’elderly dummy, in -

troduced in Decem -ber 2017, represents

an important devel-opment in vehicle-test-

ing technology, and isdesigned to meet the unique

characteristics of the world’s grow-ing aging population. Research hasshown that elderly occupants are morelikely to sustain internal injuries during

certain crash scenarios since bones aremore fragile and soft tissues are lessrobust. To reflect this, Humanetics’newest dummy captures the biofidelicnature of a 70-year-old female — 161 cm

in height and 73 kg in weight — and isexpected to have a significant impact on

how the vehicle-safety community measuresimpact responses in crash events.

Due to the nature of the industry (crash test dummies arevery expensive and can be re-used multiple times, so vehiclemakers tend to order them in small quantities), Humanetics isoften asked to produce custom products in low volumes. Asthey worked to cost-effectively develop their latest elderlydummy model, Humanetics decided to look into 3D printing(additive manufacturing) to more quickly fulfill their needs forsmall-batch production, less expensive replacement parts, andfaster turnaround times. Now, all of the components of thenew elderly dummy, from the pelvis to the head assembly, areadditively manufactured.

3D Printing Provides Solutions As the elderly dummy project began, Humanetics’ design

engineers felt that some of the expensive steel components intheir crash dummies could be replaced with 3D-printed plasticand rubber components. But they were having difficulty find-ing a material with the durability to withstand the forces andimpacts of their unique crash-testing environment.

Design engineer Kris Sullenberger is responsible for day-to-day 3D printing operations at the Humanetics ATD manufac-turing facility in Huron, OH. He operates several 3D printingmachines from different manufacturers and was looking for away to use plastic components to replace the elderly dummy’ssteel ribcage assembly.

The traditional process creates the rib out of a piece of springsteel that is formed and heat-treated. Then a piece of dampingmaterial is glued to the inside of the rib to control the responseto impact. The rib is left to set, then tested, and the dampingmaterial is trimmed several times to achieve the desired per-formance. But the process is expensive and inconsistent; steelparts degrade over time, plastic and vinyl components are sub-ject to hardening and shrinkage, and it all impacts the accuracyof the many sensors loaded onto a crash dummy.

Sullenberger tried using a plastic/rubber compound fromone leading 3D printer manufacturer, but while the partmatched many of the properties they were looking for, it wasn’tstrong enough. After 20 hits, the ribs started to crack.

He researched other solutions and reached out to AdaptiveCorporation, a digital-to-physical product lifecycle companythat provides Markforged 3D printers. Adaptive suggestedHumanetics consider using Markforged’s Onyx, a carbon-com-posite material reinforced with continuous Kevlar fibers. Apart was made for dynamic testing. The piece met Humanetics’specifications, so they ordered a complete set of ribs, put themon an elderly dummy, and conducted 60-70 impacts with no vis-ible deformation or damage.

After the successful trial, Humanetics purchased their ownMarkforged Mark Two 3D printer to make ribs and other skeletalcomponents. Humanetics is seeing Onyx material costs similar tothose of the previous steel, and significant efficiencies are nowcoming from those threefold gains in rib durability over the plas-tic/rubber alternative they considered. Manufacturing a set of ribsconventionally used to take two to three weeks. With the Mark Two,a single rib can be printed in 24 hours and a full set in a week.

An “elderly”crash-testdummy. (Imagecourtesy ofHumanetics)



www.techbriefs.tv

Fracture-Resistant‘Rebar Graphene’ Rice University researchers havefound that this rebar graphene ismore than twice as tough aspristine graphene. Carbon nano -tubes act as reinforcement bars.

www.techbriefs.com/tv/rebar-graphene

How to Make SolarCells Printable,Paintable, and FlexibleAlso from Rice University: organicphotovoltaics using ‘thiol-ene’molecules that infiltrate the polymerand make the material stretchablewithout losing efficiency.

www.techbriefs.com/tv/stretchy-solar

Kinetix: Building Cell-like, DeformableStructuresFeaturing a design resembling acell structure, MIT’s kinetiXmaterial can transform into avariety of shapes uponcompression.

www.techbriefs.com/tv/kinetiX-material

FEATURED SPONSOR VIDEO:One-Component Silver Conductive EpoxySystem Master Bond Supreme 10HTS is a user-friendly, one-component, silverconductive epoxy featuring a remarkable array of properties along withexceptionally simple processing.

www.techbriefs.com/tv/Supreme-10HTS

Sponsored by

M A T E R I A L S C H A N N E L

Crash dummy torso showing 3D-printed components. (Image courtesy ofHumanetics)

Most of the more complex parts on the dummy are molded.Producing the molds out of machined steel can be expensiveand time-consuming. In comparison, a 3D-printed mold canbe replaced in a day or two, saving between 40% and 60% inassembly and labor costs.

Humanetics’ models also include the softer internal organsthat are represented in terms of regions (such as the thoracic orabdominal). Test systems are created to represent each overallregion, rather than an individual heart or lung. While regionaldata is important, researchers would like to have a more in-depth understanding of the characteristics of the specific organswithin those regions — which is where 3D printing is providingnew answers for the elderly crash dummy in particular.

In the abdominal region, the liver is on one side of the bodyand the spleen is on the other. To better understand the differ-ent deflection characteristics of each organ, Humanetics hasbegun 3D-printing organs individually to see how their quali-ties contribute to overall regional crash-test readings. Elderlypeople tend to have more flesh in front of the bones, whichaffects how a person moves within a seatbelt system and howthe belt interacts with the passenger’s body during a crash. Theability to generate new organs using 3D printing technologywill lead to shorter lead times, improved restraint systems, andsafer vehicles.

For Free Info Visit http://info.hotims.com/69513-116


http://www.techbriefs.tv

http://www.techbriefs.com/tv/Supreme-10HTS

http://www.techbriefs.com/tv/rebar-graphene

http://www.techbriefs.com/tv/stretchy-solar

http://www.techbriefs.com/tv/kinetiX-material

Data Acquisition DevicesThe USB-1808 Series simultaneous-sampling data

acquisition devices from Measurement Computing

Corp., Norton, MA, provides synchronous and concurrent

voltage I/O, waveform output, counter input, quadrature encoder

input, timer output, and digital I/O. They offer synchronous I/O opera-

tions at rates up to 50 kS/s per channel. The devices feature eight 18-bit

differential or single-ended analog inputs, simultaneous sampling up to

200 kS/s per channel, two analog outputs, four digital I/O, external clock

I/O, external digital triggering, and pattern triggering.


Elastomeric ConnectorsFujipoly America Corp., Carteret, NJ, offers

Fujipoly® Zebra® Gold 8000A elastomeric connec-

tors that transfer both data and power between parallel components and

circuit boards while exhibiting electrical resistance of less than 25 m .

The connectors are constructed from a low-durometer silicone core

wrapped with 100 parallel rows of flat, gold-plated copper wires per inch,

allowing them to accommodate PCBs with pad center spacing down to

0.25 mm. Each 0.050 × 0.127-mm gold-plated element can deliver a cur-

rent-carrying capacity of 500 mA. They are suited for board-to-board elec-

tronic packaging applications with tight pad spacing and board separation

tolerances. The connectors can be specified in custom lengths from .200"

to 6.00" and heights ranging from .10" to .50".


Power SourcesSaelig, Fairport, NY, introduced the

Preen AFV-P Series of programmable AC

power sources with DC output and preci-

sion measurement capabilities available in four power levels: 600 VA, 1250

VA, 2500 VA, and 5000 VA, providing clean power with THD less than

0.3% at 50/60 Hz. They deliver a continuously variable output voltage of

0-310 VAC and frequency of 40-500 Hz (optionally 15-1000 Hz). The units

provide programmable features (step/ramp/transient) and 1,200 test

steps in 50 built-in memory sets, as well as a transient generation function-

ality that allows simulations of voltage variations, surges, sags, dropouts,

and frequency disturbances for simulating global AC power conditions.

Measurement features include RMS voltage, RMS current, true power,

apparent power, power factor, crest factor, and reactive power.


Surge Protection DevicesTranstector Systems, Hayden, ID, released the I2R-

Series modular DIN rail AC surge protection devices

for industrial applications ranging from automation

and control to communications. They are optimized

for any environment with UL Type 1 and Type 2 requirements.

Configurations are available for all standard electrical service applications

up to 690 Vac, including single-phase, split-phase, delta, and three-phase

WYE. Features include a reverse chassis direction capability that allows

cable entry from top to bottom, remote visual status indication, IP 20 fin-

ger-safe design, and 75-kA surge capacity that protects critical equipment

against both high-energy transients and long-term exposure to harsh elec-

trical environments.


Power ModulesArrow Electronics, Centennial, CO, offers Analog

Devices’ µModule system-in-package power solutions

that integrate analog ICs, power switches, and passive

components. Control and monitor functions include

output voltage monitoring, sequencing, and margining; current monitor;

temperature monitor; and fault log. The modules are provided in BGA

and LGA packages. The pad assignment of the package is uniform for easy

PCB design. Both RoHS-compliant and SnPb terminal finishes are avail-

able in the BGA package. Package height is 1.82 mm or 1.91 mm (LGA)

to allow placement on the back side of the PCB or under a common heat

sink with digital devices such as FPGAs, ASICs, and processors.


Threaded InsertsSI® inserts from PennEngineering®, Danboro,

PA, permanently install in plastic assemblies to

provide reusable metal threads for mating hard-

ware and allow for repeated disassembly and re-attach-

ment. Repeated reuse will not damage the metal threads or compromise

attachment integrity. Types include brass inserts and lead-free stainless

steel and aluminum versions. All inserts install permanently in plastic and,

depending on series, can either be ultrasonically pressed and/or heat

staked, molded-in during the injection molding process, or cold-pressed

into a pre-molded or drilled hole. They can be specified in unified or met-

ric thread sizes in a variety of designs and lengths.



New on the

MARKETProduct of the Month

Yokogawa Corporation of America, Newnan, GA, released the WT5000 power analyzer that achieves accu-

racy of ±0.03% at 50/60 Hz, allowing precision evaluation of power consumption, loss, and efficiency of elec-

trical and electronic devices. It uses an 18-bit converter with a sampling frequency of 10 MS/s to capture

waveforms from high-speed inverter devices while producing a stable measurement. The device incorporates

up to seven input channels. Plug-in modular input elements can be swapped directly by the user. The 30A

and 5A elements can be switched for applications involving electric vehicles or fuel-cell vehicles. Using the

device equipped with /MTR1 and /MTR2 options, it is possible to evaluate up to four motors simultaneously with one unit. An external current

sensor input function is standard in the input element of both the 30A and 5A input elements to meet applications requiring evaluation of larg-

er-current devices. For much higher currents (up to 2000A RMS), dedicated high-current sensors are available.


New on the

MARKET








Power SuppliesCUI’s Power Group, Tualatin, OR,

announced VGS-B Series compact, chassis-

mount AC-DC power supplies housed in an

enclosed metal case. They offer power ratings

from 35 to 350 W with 30-mm profiles and packages as small as 99 ¥ 82

¥ 30 mm (3.89 ¥ 3.22 ¥ 1.18"). They feature an operating temperature

range of -20 to +70 °C and are metal-enclosed. The power supplies

carry single-output voltages of 12, 24, 30, and 48 Vdc, depending on

the series, and an adjustable output trim. All models feature a screw

terminal interface, along with over current, over voltage, and over tem-

perature protections.


CAD Conversion SoftwareCoreTechnologie, Mömbris, Germany,

offers 3D_Evolution Simplifier software for

automatic simplification of CAD data. The

tool is also a converter that handles the read-

ing and writing of all popular formats such

as Catia, NX, SolidWorks, Creo, and Inventor. The removal of internal

geometry for the calculation of envelope geometries can be achieved

within seconds by pressing a button. The technology ensures the auto-

matic analysis and repair of 3D models. Model simplification can be per-

formed for any number of files and directories. When processing CAD

data for visualization in virtual or augmented reality, the software

reduces the number of polygons without quality disadvantages.


Buttons and IndicatorsBanner Engineering, Minneapolis, MN, released the S22

Pro Series of multicolor touch buttons and indicators for

use on machine panels, cabinets, and in other industrial

control applications. They feature an illuminated flat surface

and utilize RGB technology to produce multiple color

options in each device with no programming required. The

touch buttons resist false triggering caused by the buildup of detergents,

oils, and other materials, as well as direct water spray. They require no

physical pressure to operate and are activated by a bare or gloved hand.


Portable Power UnitLarson Electronics, Kemp, TX, released the MPD-

480.3P-112.5KVA-240.208.120-4X60A portable power

distribution unit that steps down 480V three-phase pri-

mary voltage to 240/208-120V three-phase. The system

is mounted on a cart equipped with portable features

for transportation. Once the voltage has been stepped

down from 480V, it is passed to the secondary side of the transformer,

which features four watertight IEC 309 pin and sleeve receptacles that

allow operators to connect 240V, 60-amp devices. Customization includes

cords (length, type, and cord cap), voltage, phase (single or three),

wiring configurations, panel types, breakers, receptacles, mounting sys-

tems, and materials.


3D Design SoftwareFrustum, Boulder, CO, offers GENERATE®

interactive generative design software that allows

engineers to interact and iterate in real time with

generative design models. The 3D design software

enables users to interactively specify the functional requirements of their

design, and the design will automatically be modeled to meet those

requirements. The design output is functional and does not have to be

remodeled in CAD. The Windows-based software features native CAD file

import, real-time FEA, single- and multi-body optimizations, and stan-

dard and user-defined material library.


High-Strength EpoxyEpoxySet, Woonsocket, RI, offers EB-350M-7, a one-

part epoxy that can be cured in one minute at 180 °C.

It has a high glass transition temperature of 132 °C and

is rated for continuous use from -55 to 220 °C. The

anhydride-free epoxy features medium viscosity for easy

dispensing. It is suited for surface mount applications that require com-

plete cure in one reflow cycle or rapid production operations where

structural support is required.


Image SensorON Semiconductor, Phoenix, AZ, introduced the

KAI-50140 50-megapixel-resolution charge-coupled

device (CCD) image sensor for inspection of smart-

phone displays, circuit boards, and mechanical assem-

blies. The sensor supports frame rates up to 4 fps through the use of flex-

ible 1-, 2-, or 4-output readout architecture. It is available in a ceramic PGA

package in both monochrome and Bayer Color configurations.


Vision SystemOmron Automation Americas, Hoffman

Estates, IL, introduced the FH Series vision

system with Multi-Direction Multi-Color

Light technology that can automatically detect small defects and subtle

changes in color, and simultaneously detect defects with different character-

istics. The technology changes illumination angles, directions, and colors,

depending on the characteristics of the object under inspection.


Analog Output SensorAW-Lake, Oak Creek, WI, introduced the FAC-S™

analog output sensor that hardwires with any flowmeter

to provide voltage, current, or Bluetooth connectivity of

readings. It produces a scalable voltage or current out-

put for download to a PLC or other control system. A

Bluetooth-enabled mobile app connects to the sensor,

enabling wireless setup and troubleshooting from a

mobile device. It features an input range from 0.25 to

5,000 Hz with five user-selectable outputs.













VOTE FOR

Find out more about the 12nominated products and cast your vote by visiting:www.techbriefs.com/poy

Only one vote per person will be counted. All votes must be submitted by January 18, 2019.

Each December, we ask our readersto cast their votes in the annual TechBriefs’ Readers’ Choice Product of theYear Awards. Each month, our editorschoose a Product of the Month thathas exceptional technical merit andpractical value for our design engineer-ing readers.

You’re invited to cast your vote forthe one product among those 12Products of the Month listed here thatyou feel was the most important newproduct introduced to the engineeringcommunity in 2018.

The Readers’ Choice Product of theYear winners will be announced in TechBriefs and at www.techbriefs.com.

The 2018 Nominees Are:

ACCES I/O ProductsUSB-AIO Analog I/O Modules

COMSOLCOMSOL Multiphysics® Version 5.4

Hexagon Manufacturing IntelligenceHxGN SMART Quality Software

Keysight TechnologiesPathWave Test and Measurement

Platform

Opto 22groov EPIC® System

Pepperl+FuchsR200/R201 Photoelectric Sensors

SEGGER Microcontroller SystemsemPack Operating System for IoT

Stanford Research SystemsBGA244 Binary Gas Analyzer

Teledyne LeCroyWaveSurfer 3000z Oscilloscopes

Yokogawa Corp. of AmericaWT5000 Power Analyzer

Fluke Corp.3560 FC Sensors/3502 FC Gateway

AltairHyperWorks® 2018 Simulation Software


http://www.techbriefs.com/poy

Free Info at http://info.hotims.com/69513-677 Free Info at http://info.hotims.com/69513-678 Free Info at http://info.hotims.com/69513-679



Free Info at http://info.hotims.com/69513-688Free Info at http://info.hotims.com/69513-687Free Info at http://info.hotims.com/69513-686

Free Info at http://info.hotims.com/69513-683 Free Info at http://info.hotims.com/69513-684

Free Info at http://info.hotims.com/69513-681Free Info at http://info.hotims.com/69513-680

REDUCE COSTS &IMPROVE EFFICIENCY WITHCENTRITECSHAFT SEALSCentritec centrifugal sealsdeliver unmatched shaft

sealing performance. Our patented, rotating cham-ber design creates a pressure barrier that keeps lubri-cants in and contaminants out. Capable of vertical orhorizontal operation, Centritec seals do not requiretight axial or radial alignment — excelling in appli-cations where temperature, motion, speed, andvibration are critical factors. Learn more atcentritecseals.com.

Centritec Seals

ONE PART SILVER CONDUC-TIVE EPOXYSilver filled epoxyadhesive system

Master Bond EP3HTSDA-2 was developed for crucialthermal management applications. It possesses a highthermal conductivity of 45-49 BTU•in/ft2•hr•°F. Thiscompound can be applied in ultra thin bond linesand contains particles with an average size of 2-3microns. Most importantly EP3HTSDA-2 exhibitsvery low thermal resistance of 2-3 ¥ 10-6 K•m2/W.https://www.masterbond.com/tds/ep3htsda-2

Master Bond Inc

100% DIGITAL &ANALOG METERREPLACEMENT!Nuclear, MIL-Spec & Indus -trial Grades • NEI 08-09 CyberComplaint • Loop, AC/DCSignal, or Externally Powered

• 4 Digits (-9.9.9.9 to 1.9.9.9) • Display/Con -troller/Transmitter • Automatic Tri-Color Bar, Serial,& Relays • LOOP FAIL Alarm with Serial Run TimeStamp Output • Self Diagnostics • ConstantBrightness From 4-20mA • USB/RS485 • LifetimeWarranty. (520) 748-7900, www.otekcorp.com

OTEK Corporation

WAVEFARERFOR AUTORADAR SIMULATIONWaveFarer™ is a

high-fidelity radar simulator for drive scenario mod-eling at frequencies up to and beyond 79 GHz. Near-field propagation and scattering methods computeraw radar returns from target objects while consider-ing multi-path interactions from ground reflectionsand other structures. https://www.remcom.com/wavefarer

Remcom

POWERINGINDUSTRIALLASER DIODEAPPLICATIONSThe small LD15-CHA deliv-ers 15A output current up to28V. Safety features include

clipping current limit and slow start circuit. Bandwidthis 280 kHz to 1 MHz. Three photodiode current rangesare available. Stability: <200 ppm (CC) and 0.026%(CP). RMS noise: 35 μA. Noise current density: 100nA/ Hz. Ideal for material processing and industri-al cutting applications using laser diode bars or stacks.https://www.teamwavelength.com/product/ld15cha-15-a-30-v-laser-diode-driver/

Wavelength Electronics


P R O D U C T SPOTLIGHTREVERSE RECOVERY TIME TESTERS

For MIL-STD-750-4 Method 4031.4AVR-EB2A-B: Condition A, for low current diodesAVR-EB4-B: Condition B, for medium current diodesAVR-EB5-B: Condition B, for PIN diode lifetime char -acterizationAVR-CC2-B: Condition C, for high power diodesAVR-CD1-B: Condition D, for medium current andMOSFET parasitic diodeswww.avtechpulse.com

Avtech Electrosystems Ltd.

LASER MICRO-MACHININGLaser systems and con-tract manufacturing,PhotoMachining hasthe latest technology –femtosecond, picosec-

ond and nanosecond lasers for heat free microman-ufacturing. From prototype to mass production,start-ups to Fortune 500 companies, our expertise isavailable for you. For a free analysis of your applica-tion, contact us today: [email protected],603-882-9944, www.photomachining.com.

PhotoMachining, Inc.

MODEL & SIMULATEDESIGNS, DEVICES,AND PROCESSESCOMSOL Multiphysics® is an inte-grated software environment forcreating physics-based models andsimulation applications. Add-on

products expand the simulation platform for electro-magnetics, structural, acoustics, fluid flow, heat trans-fer, and chemical applications. Interfacing tools enablethe integration of COMSOL Multiphysics® simulationswith all major technical computing and CAD tools.Simulation experts rely on COMSOL Compiler™ andCOMSOL Server™ products to deploy applications totheir colleagues and customers worldwide.https://www.comsol.com/products

COMSOL, Inc.

T56 VIBRATIONACTIVATEDLCD HOURMETERThe hour meter fea-

tures 6-digits with an hourglass icon as a runningindicator. This unit operates only when it is intro-duced to vibrating equipment. This meter can beinstalled anywhere with no special wiring or powersource to operate. The internal battery supplies allthe necessary power. This compact tamper-proofmeter is 100% encapsulated with potting compoundenabling it to operate in even the most extreme con-ditions. www.techbriefs.com/enm201810

ENM

TOUCHPANEL DISPLAYSDATA IMAGE offersa full line of displayswith Capacitive orResistive Touch sen-sors in a wide range

of sizes. Many sizes, formats, and options. Completecustomization options available. Full turnkey servic-es. Contact [email protected] or www.dataimagelcd.com.

DATA IMAGE

FIBER OPTIC PRECISIONTIMING SIGNAL TRANSMISSION SYSTEMSLiteway, Inc. offers a full line of fiber optictransmission systems deigned to transmitprecision timing signals including IRIGmodulated, IRIG unmodulated (DCLS),IRIG Converters (modulated to/fromDCLS), 5 MHz to 10 MHz precision

sine waves, distribution amplifiers and GPS NMEA/1pps systems and all are ready to operate immediately.All systems are designed and manufactured in theUSA, are sold under the LuxLink® trademark andcustom systems are available. Visit www.luxlink.comor call Liteway, Inc. at 1-516-931-2800.

Liteway, Inc.

MAGNETIC SOLUTIONS FORSENSOR APPLICATIONSMagnet Applications® hasbeen supplying industries

like yours with magnetic solutions for over 50 years.Our expertise incorporates the complete range ofpermanent magnet materials for your sensor applica-tion including Alnico, Ferrite, Samarium Cobalt andNeodymium Iron Boron as well as production routesincluding sintering, extrusion, calendering, compres-sion bonding and injection molding. http://www.magnetapplications.com/markets/magnetic-sensors/

Magnet Applications®














FACILITY FOCUSFACILITY FOCUS

Ames Laboratory is a government-owned, contractor-operat-ed national laboratory of the U.S. Department of Energy

(DOE), operated by and located on the campus of Iowa StateUniversity in Ames, IA. For more than 70 years, AmesLaboratory has successfully partnered with Iowa State Universityand is unique among the DOE laboratories in that it is physicallylocated on the campus of a major research university.

The lab was formally established in 1947 by the AtomicEnergy Commission as a result of the Ames Project’s successfuldevelopment of the most efficient process to produce high-purity uranium metal in large quantities for atomic energy.

After the discovery of nuclear fission in 1939, the U.S. govern-ment decided that the development of atomic energy warrant-ed a consolidated national effort and asked leading scientists tojoin in the endeavor. In 1942, Iowa State College set up anddirected a chemical research and development program toaccompany the Manhattan Project’s existing physics program.

Nobel Physicist Enrico Fermi was sure that a self-sustainingchain reaction could be triggered by bombarding the uranium

nucleus with thermal neutrons. For the chain reaction to besuccessful, tons of uranium metal needed to be produced witha purity far beyond what was commercially available.

Several industries and university laboratories started investi-gating better methods for producing uranium metal. TheAmes group soon developed a process for producing pure ura-nium, making it possible to cast large ingots of the metal at dra-matically reduced costs.

The first successful self-sustaining chain reaction initiatingthe controlled release of nuclear energy occurred December 2,1942 at the University of Chicago. The Ames Project furnishedone-third of the uranium metal used in the successful demon-stration of the first chain-reacting pile.

After proving that a chain reaction could be self-sustainedand controlled, the need for pure uranium greatly increased.The Ames Project produced as much metal as possible untilindustry took over the process in 1945. The Ames Projectdeveloped new methods for both melting and casting uraniummetal, making it possible to cast large ingots of the metal andreduce production costs by as much as 20-fold. This uraniumproduction process is still used today. Ames produced morethan 2 million pounds (1,000 tons) of uranium for the Man -hattan Project, advancing wartime efforts to uncover thesecrets of atomic power and protect national security.

Areas of ExpertiseAmes Lab has broadened its scope beyond materials

research over the years. Examples of specific projects includeworld-class fundamental photosynthesis studies to help in thedesign of synthetic molecules for direct solar energy conver-sion, and development of a remote-controlled analysis systemthat will acquire and analyze samples from hazardous wastesites at greatly reduced risk and cost.

Other projects include harnessing the power of the mostadvanced computing systems available for scientists unlock-ing the secrets of revolutionary new materials like supercon-ductors, fullerenes, and quasicrystals; and the synthesis andstudy of nontraditional materials such as organic polymersand organometallic materials to serve as novel semiconduc-tors, processable pre-ceramics, and nonlinear optical sys-tems.

Key areas of expertise are materials design, synthesis, andprocessing; analytical instrumentation design and develop-ment; materials characterization; catalysis; computationalchemistry; condensed matter theory; and computational mate-rials science and materials theory.

Divisions and ProgramsAmes seeks solutions to energy-related problems of national

concern through four divisions:Division of Chemical and Biological Sciences – This division

develops and applies theoretical, computational, and experi-

Ames Laboratory

Researcher Yibole Hargen prepares a caloric material sample for evalua-tion as part of CaloriCool™, an early-stage research consortium led byAmes Laboratory that is searching for a metallic compound that has thepotential to radically change refrigeration technology as it currentlyexists.


mental methods to the study of surface reaction phenomena,cluster science and nucleation, biological processes, and catal-ysis. Research has led to improved processes for biodiesel pro-duction. CBS also develops new techniques to obtain anunprecedented look at living cells. Enhanced chemical imag-ing with high spatial and temporal resolution is another keyarea of development.

CBS capabilities include advanced characterization methodsincluding neutron and x-ray scattering, angle-resolved photo -emission, solid-state NMR, ultra-sensitive chemical and struc-tural analysis, and ultra-precise frequency measurements. Thedivision also designs and synthesizes materials for energy-relat-ed applications including energy-efficient conversion, genera-tion, transmission, and storage.

Critical Materials Institute – The Critical Materials Institutebrings together leading researchers from other DOE nationallaboratories, academia, and industry to develop solutions todomestic shortages of rare earth materials and other materi-als critical to U.S. energy security. CMI researchers have dis-closed more than 90 inventions, filed more than 50 patentapplications, have been awarded six patents, and licensed fivetechnologies.

CMI focuses on technologies that make better use of materi-als and eliminate the need for materials that are subject to sup-ply disruptions. These critical materials are essential forAmerican competitiveness in clean energy. Many materialsdeemed critical by the U.S. Department of Energy are used inmodern clean energy technologies, including wind turbines,solar panels, electric vehicles, and energy-efficient lighting.Actual or threatened shortages of essential raw materials createrisks for U.S. manufacturing and energy security.

Rare earth elements emerged as critical materials in 2010,with their essential roles in high-efficiency motors, generators,and advanced lighting; lack of supply diversity; and growingdemand. Rare earth metals and alloys are not produced in theUnited States despite the availability of geologic resourcesbecause the processes required to separate individual rareearths from one another and then convert them to metals andalloys are inefficient, costly, polluting, and potentially damag-ing to worker health and safety. Beginning this year, CMI focusexpanded beyond rare earths to include cobalt, gallium, indi-um, lithium, manganese, platinum group metals, tellurium,vanadium, and battery-quality graphite.

Simulation, Modeling and Decision Science – Computationaltools, algorithms, and strategies are developed to analyze,understand, create, design, and build complex engineered,natural, or human systems. This complex systems-basedapproach is critical to addressing issues of energy systemdesign, environmental impact, and sustainability.

Materials Preparation Center – The MPC is a specializedresearch center recognized for its unique capabilities in thepreparation, purification, single crystal growth, and character-ization of rare earth metals, alkaline earth metals, and refrac-tory metal materials.

BreakthroughsAmes Lab scientific discoveries have led to new technologies

that have impacted our lives in many ways. • Ames developed the process that enables scientists to pro-

duce the purest rare earth and other materials used in aca-demic and industrial research today.

• Some 17,000 analytical laboratories worldwide are reapingthe benefits of pioneering work in inductively coupled plas-ma spectroscopy.

• An analysis tool enables the rapid and accurate determina-tion of up to 80 elements in metals, alloys, and liquids such

Researchers at the Critical Materials Institute (CMI) invented a magnetrecycling process in which magnets are dissolved in water-based solu-tions, recovering more than 99%-purity rare earth elements. The materi-als recovered have been reused to make new magnets, and recoveredcobalt shows promise for use in making battery cathodes.

A self-destructive working lithium-ion battery is capable of delivering 2.5Volts and dissolves or dissipates in 30 minutes when dropped in water.The battery can power a desktop calculator for about 15 minutes. Self-destructing electronic devices could keep military secrets out of enemyhands or save patients the pain of removing a medical device.


Facility Focusw w w . t e c h b r i e f s . c o m

Publisher ........................................................Joseph T. PrambergerEditorial Director............................................................Linda L. BellEditor, Photonics & Imaging Technology.................Bruce A. BennettDigital Editorial Manager ................................................Billy HurleyAssociate Editor ........................................................Edward BrownContent Strategist, Audience Development..................Kendra SmithProduction Manager.................................................Adam SantiagoManufacturing Manager...........................................Kevin ColtrinariCreative Director ...........................................................Lois ErlacherGraphic Designer ....................................................Annette MurphyMarketing Director.................................................Debora RothwellDigital Marketing Coordinator .................................Kaitlyn SommerMarketing Assistant ...................................................Dylan LegardaAudience Development Director .....................Christine OldenbrookAudience Development Coordinator ...........................Stacey NelsonSubscription Changes/[email protected]

TECH BRIEFS MEDIA GROUP, AN SAE INTERNATIONAL COMPANY261 Fifth Avenue, Suite 1901, New York, NY 10016(212) 490-3999 FAX (646) 829-0800Chief Executive Officer...................................Domenic A. MucchettiExecutive Vice President ...........................................Luke SchnirringTechnology Director .................................................Oliver RockwellSystems Administrator..................................................Vlad GadounDigital Development Manager...................................Peter BonavitaDigital Production Manager ............................................Howard NgDigital Media Associate..........................................Md JaliluzzamanDigital Production Associate.............................................Jerry AultzDigital Production Associate...............................Andrew GreenbergDigital Production Associate ........................................Symba WongCredit/Collection ..........................................................Felecia LaheyAccounting/Human Resources Manager.......................Sylvia BonillaAccounts Receivable Assistant..................................Nicholas RiveraOffice Manager .......................................................Alfredo Vasquez

TECH BRIEFS ADVERTISING ACCOUNT EXECUTIVESMA, NH, ME, VT, RI, Eastern Canada ...............................Ed Marecki.................................................................................(401) 351-0274

CT ............................................................................Stan Greenfield ..............................................................................(203) 938-2418

NJ, PA, DE.....................................................................John Murray................................................................................ (973) 409-4685

Southeast, TX .............................................................Ray Tompkins.................................................................................(281) 313-1004

NY, OH.......................................................................Ryan Beckman.................................................................................(973) 409-4687

MI, IN, WI ..........................................................................Chris Kennedy .........................................................................(847) 498-4520 ext. 3008

MN, ND, SD, IL, KY, MO, KS, IA, NE, Central Canada................Bob Casey ................................................................................ (847) 223-5225

Northwest, N. Calif., Western Canada...........................Craig Pitcher(408) 778-0300

S. Calif., AZ, NM, Rocky Mountain States........................Tim Powers.................................................................................(424) 247-9207

Europe — Central & Eastern .......................................Sven Anacker..............................................................................49-202-27169-11

Joseph Heeg49-621-841-5702

Europe — Western .........................................................Chris Shaw...............................................................................44-1270-522130

886-4-2329-7318

Integrated Media Consultants....................................Patrick Harvey................................................................................ (973) 409-4686

Angelo Danza.................................................................................(973) 874-0271

Scott Williams.................................................................................(973) 545-2464

Rick Rosenberg.................................................................................(973) 545-2565

Todd Holtz................................................................................ (973) 545-2566

Christian DeLalla(973) 841-6035

Casey Hanson(973) 841-6040

Reprints...........................................................................Jill Kaletha .................................................................................(219) 878-6068

as oil, serum, blood, and soils. Thisdetermination is accurate down to lev-els of a few parts per trillion.

• A novel smart material was developedthat has the ability to adapt to outsideenvironmental influences. Terfenol-Dis a magnetorestrictive material thatconverts electrical power to mechani-cal power and vice versa. The materialfound its first use in sonar technologyfor the military but is now used inindustrial applications.

• Ames designed and demonstrated theexistence of photonic bandgap crys-tals, which make it possible to developmore precise and efficient lasers.

• Industry has a new ally in its efforts toremove hazardous lead-based soldersfrom the environment. Ames’ lead-free alloy of tin-silver-copper has beenwidely adopted by the electronicsindustry for use in all types of devicessuch as computers and cellphones.Lead-free solder has been licensed bymore than 60 companies in theUnited States and around the world.

• High heat conditions can be theenemy of maintaining strong bondsbetween ceramic composites used inthe fabrication of solar arrays. Aprocess was developed for creatingtough ceramic glue for joining contin-uous-fiber ceramic composites thatpromotes mechanical bond toughnessin solar arrays at operating tempera-tures of up to 1800 °C.

• A ceramic coating made from an alloyof boron-aluminum-magnesium (BAM)

can be applied to surfaces in industrialhydraulic pumps to reduce frictionand increase wear resistance. Theresult: a potential reduction in U.S.industrial energy usage of 31 trillionBTUs annually by 2030 or a savings of$179 million a year. The coating alsohas a second application as a frictionreducer on industrial cutting tools.

• Ames helped create left-handed mate-rials, which exhibit fascinating opticalproperties not found in naturallyoccurring materials. This discoverycould help scientists create ultra-high-resolution imaging systems with appli-cations in aerospace, solar power, andcommunications.

• A technique was developed that quan-titatively analyzes the chemical con-tent of a single human red blood cell.Multiplexed capillary electrophoresistechnology is now the standard analy-sis tool used for DNA sequencing.

• The next generation of refrigerationtechnology may get its “cool” from amaterial and, at the same time, helpsave the environment. Taking advan-tage of the magnetocaloric effect, anenvironmentally benign alloy of gado -linium-silicon-germanium could re -place harmful chemical coolants asthe cooling method in large supermar-ket chillers and air conditioners.

Tech TransferAmes Laboratory is committed to

developing and transferring technolo-gies. Each year over the past decade, ithas generated an average of 10 patentsfrom DOE-supported research and entersinto about five technology license agree-ments and/or options. Collaborationsbetween industry and Ames can helpboth parties meet their common techno-logical objectives, while reducing devel-opment costs and risks. Under PrivatelyFunded Technology Transfer (PFTT), thelaboratory, contractor, and inventorsshare in any monetary success derivedfrom DOE-funded intellectual property.

DOE’s Office of Energy Efficiency andRenewable Energy sponsors a searchabledatabase of the National Laboratories’energy technologies available for licens-ing, and patents and patent applications.

For information on technologies availablefor licensing, visit the tech portal at https://techportal.eere.energy.gov/lab/ames. Forfur ther information, contact Stacy Joiner,Program Manager, at [email protected] 515-294-5932.

Developed at Ames Laboratory by IverAnderson, John Smith, Chad Miller, and RobertTerpstra — with co-inventor Frederick Yost ofSandia National Laboratory — lead-free solderis found in most consumer electronic devicessuch as smartphones, laptops, and tablets.With this innovation, more than 50,000 tons oflead per year will no longer be released intothe environment worldwide.


mailto:[email protected]

















































https://techportal.eere.energy.gov/lab/ames

Allied Electronics ..................................3 ................................................alliedelec.com

AllMotion, Inc. ..............................................41 ..............................................www.allmotion.com

AutomationDirect..........................................COV IV ............................www.automationdirect.com

Avtech Electrosystems Ltd. ............................55 ..........................................www.avtechpulse.com

Centritec Seals ..............................................55 ..................................................centritecseals.com

Century Spring - MW Industries ....................6 ..........................................www.centuryspring.com

Computational Simulation Software ..............1, 22......................................................csimsoft.com

COMSOL, Inc. ........................................9, 23, 55 ..............................www.comsol.com

Cornell Dubilier Electronics ............................2............................................cde.com/MLSHSlimpack

Data Image Corp. USA ..................................55..................................................dataimagelcd.com

Dataforth Corporation ..................................31 ........................................................dataforth.com

Digi-Key Electronics ..............................COV I, COV II ................................DIGIKEY.COM

ENM ............................................................55 ..................................................www.enmco.com

Excelitas Technologies ..................................COV III ..........................................www.excelitas.com

Graphtec America, Inc. ..................................7 ............................graphtecamerica.com/instruments

HARWIN PLC ................................................25 ....................................www.harwin.com/gecko-sl

Kaman Precision Products ............................21 ................................................kamansensors.com

Liteway Inc. ..................................................55 ..................................................www.luxlink.com

Magnet Applications® ..................................55 ..............................www.magnetapplications.com

Marotta Controls ..........................................43..........................................www.marotta.com/core

Master Bond Inc. ..................................33, 55 ..........................www.masterbond.com

Measurement Computing Corp.............29 ........................www.mccdaq.com/DAQ-HAT

Micro-Epsilon Messtechnik GmbH ................11 ........................................www.micro-epsilon.com

OTEK Corporation ........................................55................................................www.otekcorp.com

PhotoMachining, Inc. ....................................55 ....................................www.photomachining.com

Remcom ......................................................55........................http://www.remcom.com/wavefarer

Seastrom Mfg. ..............................................35 ........................................www.seastrom-mfg.com

Siskiyou Corporation ....................................33 ................................................www.siskiyou.com

Spectrum Instrumentation GmbH ..................27 ......................www.spectrum-instrumentation.com

Stanford Research Systems, Inc. ....................5 ..................................................www.thinkSRS.com

Tech Briefs TV................................................51 ..................................................www.techbriefs.tv

Thomasnet Industrial Network ......................19 ..............................www.Thomasnet.com/webtrax

Wavelength Electronics ................................55....................................www.teamwavelength.com

Motion Design

Aerotech, Inc...............................................COV IV........................................www.aerotech.com

AutomationDirect ........................................COV II ............................www.automationdirect.com

Brother International Corporation ................3 ..........................................BrotherGearmotors.com

C-Flex Bearing Co., Inc. ..............................19 ........................................................C-FLEX.COM

ContiTech North America ............................17 ..................www.WeHaveAnAnswerForThat.com

Delta Computer Systems, Inc. ......................20 ........................................www.deltamotion.com

Master Bond Inc. ................................18................................www.masterbond.com

MOCAP ......................................................19 ................................................www.mocap.com

NB Corporation of America..........................7 ........................................www.nbcorporation.com

Oriental Motor USA ....................................15 ................................................orientalmotor.com

R+W America, L.P. ....................................10 ..........................................www.rw-america.com

Regal Beloit Corporation..............................11 ..........................................www.regalbeloit.com

SEW Eurodrive USA ....................................1 ..................................................seweurodrive.com

The Carlyle Johnson Machine Company ......2 ....................................................www.cjmco.com

THK America ..............................................COV III ......................................https://tech.thk.com/

Universal Robots USA, Inc. ..........................9 ....................................................urrobots.com/ATI


Tech Briefs, ISSN 0145-319X, USPS 750-070, copyright © 2018 in U.S. is published monthlyby Tech Briefs Media Group, an SAE International Company, 261 Fifth Avenue, Suite1901, New York, NY 10016. The copyright information does not include the (U.S. rightsto) individual tech briefs that are supplied by NASA. Editorial, sales, production, and cir-culation offices at 261 Fifth Avenue, Suite 1901, New York, NY 10016. Subscription for non-qualified subscribers in the U.S. and Puerto Rico, $75.00 for 1 year. Single copies $6.25.Foreign subscriptions one-year U.S. Funds $195.00. Digital Copies, $24.00 for 1 year sub-scription. Remit by check, draft, postal, express orders or VISA, MasterCard, andAmerican Express. Other remittances at sender’s risk. Address all communications for sub-scriptions or circulation to Tech Briefs, 261 Fifth Avenue, Suite 1901, New York, NY 10016.Periodicals postage paid at New York, NY and additional mailing offices.

POSTMASTER: Send address changes and cancellations to Tech Briefs, P.O. Box 47857,Plymouth, MN 55447.

AdvertisersIndex

Advertisers listed in bold-face type have banner ads on the Tech Briefs Web site — www.techbriefs.com

Advertiser Page Web Link Advertiser Page Web Link

Supplement to Tech Briefs: 2

https://www.techbriefs.com/


SPINOFFSpinoff is NASA’s annual publication featuringsuccessfully commercialized NASA technology. Thiscommercialization has contributed to the developmentof products and services in the fields of health andmedicine, consumer goods, transportation, public safety,computer technology, and environmental resources.

Sterilizing Fogger Cleans Ambulances with a BreezeNASA know-how with atomic oxygen helped develop an ambulance sterilization device.

When paramedics come to a home,the last thing anyone worries

about is where the ambulance was earli-er that day. But traces of earlier callscould be lingering on the equipment,bags, or even the uniforms the EMTsare wearing, and they could be spread-ing disease. A product designed withNASA’s help aims to sterilize the rigand gear to make it safer for thepatients and the paramedics.

The product uses atomic oxygen andoxidation — two things NASA is famil-iar with, explained Sharon Miller. “Iwork in space environment testing atGlenn Research Center, and primarilywhat I do is look at how materials onspacecraft react when they’re in theenvironment of upper atmospheres ofplanetary bodies and in space.”

In stable form, oxygen is made up oftwo oxygen atoms bonded together as apair. In contrast, atomic oxygen is a sin-gle O atom, which means it is not stableand wants to react with anything that itcomes in contact with to make a stablechemical compound. The destructiveproperties of atomic oxygen can be har-nessed for a very positive outcome: ster-ilization. “Atomic oxygen removes anyhydrocarbon from a surface,” Millerexplained.

Jason Thompson started working as aparamedic more than 20 years ago, buthe didn’t start thinking about disinfect-ing ambulances until 2014. Like everyEMT, he knew and followed precau-tions that include washing his handsand wearing gloves. But there was noprotocol for cleaning the ambulance ormedical equipment after a call. In 2014,the Ebola epidemic was at its height,and medical personnel were among themost vulnerable to infection, bringingthe question of infectious disease expo-sure to the forefront.

Thompson, who by then was workingfor Emergency Products + Research(EP+R, Kent, OH), said he and his col-leagues realized that Ebola was only thetip of the iceberg, and they concluded

that there needed to be a fast and inex-pensive way to sterilize an ambulanceand everything in it. EP+R wantedsomething that was inexpensive, fast,and left no residue since wiping takesextra time and, if an unsterile cloth isused, could risk recontaminating theentire surface. By 2015, EP+R haddecided on a machine that sprayed outthe sterilizing chemical in a mist or fog,but the team had many questions. Whatwas the best chemical agent to use?Would the fog interfere with the elec-tronics on the ambulance?

Through NASA’s Regional EconomicDevelopment Program, field centersoffer consultation with a NASA subjectmatter expert. EP+R was paired withGlenn Research Center, and theiradvice made all the difference. Millersaid the team wasn’t as far from a solu-tion as they thought. She helped themset up a testing protocol to see whatimpact, if any, the sterilizing processhad on the sensitive electrical equip-ment on the ambulance and helpedthem find scientific literature thatwould answer their questions. Amongother things, Miller helped EP+R see

that the electrostatic fogger they wereconsidering was potentially a risk forthe electronics on the ambulance. Sheprovided advice that helped them tomove in another direction.

Just a few months later, EP+R wasdelivering its first units. The product,called AMBUstat, uses a small fogger tocreate a mist with a solution that con-sists of water, peracetic acid, and hydro-gen peroxide. Peracetic acid and hydro-gen peroxide are both excellent disin-fectants and mixed together in a solu-tion, tend to be more stable and work atlower concentrations. The chemicalreactions take just minutes, but to get afull clean, EMTs open the drawers,doors, oxygen bags, and supply bagsand hang them from the horizontalrail, enabling the fog to hit everything.And if the engine and air conditioningare running, it will also clean the ventsand ducts. It takes less than an hourfrom start to finish to destroy almost 99percent of the organisms in that space.

Everything fits into a single backpackand costs just $2,195 for a starter set,which includes a first case of the disin-fectant fluid. Refills cost around $250per case and provide enough for 24 to30 treatments, depending on the size ofthe ambulance.

Visit https://spinoff.nasa.gov/ Spinoff2018/hm_1.html.

EP+R consulted with NASA to determine thebest way to deliver atomic oxygen in a deviceto sterilize ambulance interiors. This small,inexpensive device creates a mist that can killclose to 99 percent of microorganisms in lessthan an hour.

The same oxidation process that kills microbesalso causes metal to rust. NASA helped EP+Rensure the sterilizing mist wouldn’t rust or oth-erwise harm the ambulance engine or any ofthe delicate electronics onboard.

https://spinoff.nasa.gov/Spinoff2018/hm_1.html

Advance Your Innovation with End-to-End Photonic Solutions

From discrete components, to turnkey modules, to complete systems...

Engage Excelitas for single-source ease and reliability across every aspect of

your system’s photonic requirements. We excel in delivering sophisticated

custom solutions that enhance system performance, expedite time-to-market

and ultimately sharpen your competitve edge. Discover your partner for

application-specific expertise and enabling photonic technologies.

www.excelitas.com • www.qioptiq.com

From Source to Sensor... and Everything in Between

BIOMEDICAL CONSUMERPRODUCTS

INDUSTRIALSCIENTIFIC &ANALYTICAL

SEMICONDUCTOR DEFENSE &AEROSPACE

ILLUMINATION

DETECTION

TRANSMISSION

• Lasers & Illumination

• Optics & Optomechanics

• Sensors & Detection

• Electronic Components & Systems

• Sophisticated Custom Solutions



the #1 value in automation

Order Today, Ships Today!* See our Web site for details and restrictions. © Copyright 2018 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405

What’s in your AC Drive? Features galore AND a wealth of options ALL at a great price.

DURAPULSEAC DRIVES

STARTING AT

$433.00(GS4-21P0)


www.automationdirect.com/drives/ac-drives/gs4

The DURApulse GS4 series of Variable Frequency Drives (VFD) includes many of the same standardfeatures as our other GS drives including dynamic braking, PID, removable keypad, plus so much more:

• Single-phase input capability on all 230VAC models • V/Hz control or sensorless vector control for

improved speed regulation • 100kA Short Circuit Current Rating (SCCR)

capability for industrial environments

• Built-in PLC (up to 10k steps) for drive-relatedlogic and I/O control

• Built-in analog, discrete, high-speed andrelay I/O with expansion capabilities

protocols included

and EtherNet/IP™ protocols

• Smart keypad stores up to four sets of drive

additional GS4 drives • Fire mode and circulatory control mode

Programming software

DURApulse GS4 SeriesAC Sensorless Vector DrivesUp to 300HP!

4 Digital Inputs2 Digital Outputs

6 RelayOutputs

6 DigitalInputs

Upgrade I/O capabilities ANDcommunications options

EtherNet/IP™ Modbus TCP




Supplement to Tech Briefs

December 2018

Multi-Axis Motion Controllerfor Gear Testing

Smart Actuators Deliver onthe Promise of Industry 4.0

One-Cable AutomationStreamlines RoboticInspection

Ultralight Gloves ProvideRealistic Haptic Feedback

the #1 value in automation

Order Today, Ships Today!* See our Web site for details and restrictions. © Copyright 2018 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405


www.automationdirect.com/power-transmission

Precision GearboxesIf it is precision you need, our SureGear family of precision gearboxes is an excellent solution. They are available in a wide range of ratios and styles, and provide high-precision motion control at an incredible price.

• Servomotor gearboxesstart at $408.00

• Small NEMA motor gearboxesstart at $261.00

Helical GearboxesIronHorse® inline helical gearboxes

provide smooth and quiet operation

while delivering high power transfer.

Cost-eff ective alternatives to SEW

Eurodrive and/or Nord brands.

• 5 frame sizes, with 7 gear ratios• NEMA C-face mounting• Sized to handle from 1 to 20 hp• Helical gearboxes start at $398.00

Gear-Up for Savingswith affordable power transmission components!

Timing Belts, Pulleys, and CouplingsOur SureMotion line of timing belts, pulleys, and couplings provide dependable speedand torque transfer without unwanted slippage or speed variation.

• Timing pulleys start at $6.25• Timing belts start at $2.00• Couplings start at $11.00

IronHorse® Worm Gearboxes

Worm gearboxes are built to withstand the toughest applications while delivering reliable speed reduction and increased torque output. Cast iron models are available in right hand, left hand, dual shaft, and hollow shafts variants - now in larger frame sizes. Aluminum frame models have hollow shafts.

Cast Iron Modelsstarting at:

$159.00WG-175-005-L

Aluminum Modelsstarting at:

$96.00WGA-30M-010-H1



seweurodrive.com | 864-439-7537

Control Freak?If you like being in control, then

SEW-EURODRIVE is your perfect

partner! We put you in charge of

every move with our gearmotors

and electronics. No headaches, no

whining, and virtually no maintenance.

You build it and we move it…simple!

Don’t you wish all partners were this

easy…?

CoIf you

SEW

partn

every

and e

whin

You b

t y

…?

Don’t

easy



www.cjmco.comPhone: 860-643-1531

291 Boston Tpke, Bolton, CT 06043

Engineering Solutions for Clutches & Brakes

Clutches, Brakes and PowerTransmission Products• electrical, mechanical, pneumatic

& hydraulic models• system design and integration • expert engineers working on every order

Highest Torquein the Smallest Space... or the largest.Maxitorq® clutches and brakes deliverpower, reliability and are customized tomeet your exact needs. Land, sea and air –CJM is everywhere.

AS9100D/ISO 9001:2015/Certified


FEATURES4 Smart Actuators Deliver on the Promise of Industry 4.0

APPLICATIONS8 One-Cable Automation Streamlines Robotic Non-Destructive

Inspection Systems

12 Multi-Axis Motion Controller Accelerates Gear Testing

TECH BRIEFS14 High-Performance Cageless Bearings with Minimal Frictional Loss

14 A New Twist Makes Rotating Machinery More Efficient andQuieter

15 Optical Gyroscope-on-a-Chip

16 Ultralight Gloves Provide Realistic Haptic Feedback

17 Active Pointing Monitor for a 2-Axis Optical Control System

DEPARTMENTS18 New Products

ON THE COVERTo test gear strength, both static and cyclic forces areapplied to gear teeth. As a result, general-purposetest machines often are not suited for this application.A test systems manufacturer instead chose to build adedicated machine for gear testing using an electro-hydraulic motion controller from Delta ComputerSystems (Battle Ground, WA) that could control mul-tiple motion axes simultaneously. Learn more onpage 12.

(Image courtesy of Delta Computer Systems)

4

18

8

2 Motion Design, December 2018


ODUCINGINTR

comother.com

866.523.6283BrotherGearmotors.c

• Synchronous no-slip motor provides superior control• Wide speed range can reduce need for multiple ratios• Extreme high efficiency – class ie4 motor PLUS hypoid gearing• No fan on most units

Call us today for a sample gearmotor to try out! Gearmotorsmarketing@BroFree Info at http://info.hotims.com/69513-614



A s Industry 4.0 initiatives bringmore and more industrial axes ofmotion into the realm of automa-

tion, the need for cost-effective controlacross them grows as well. Advances inrobotics, connectivity, cloud computing,artificial intelligence, data analysis, mobil-ity, and numerous other areas are con-verging to push global industry to newplateaus of operational efficiency and cre-ating roles for automated actuators inplaces previously thought impractical.

Enabling actuators to play a centralrole in Industry 4.0 initiatives has beenthe integration of microelectronics intowhat were previously mechanical systems.The use of just a few wires to connectpower sources and networks improvesactuator controllability and design flexi-bility for machine builders, while simpli-fying installation, diagnostics, and main-tenance for end users. These factors com-bine to enable automation on previouslymanually operated axes, which can con-

tribute to increased efficiencies in plants,vehicles, and buildings. The most impor-tant benefits a design engineer canexpect from this new generation of smartactuators include:

Low-level power switching (PLC compati-ble). Traditional actuators often rely onlarge, power-inefficient relays or inde-pendent controllers to extend, retract, orstop the extension tube. Onboard elec-tronics implement H-bridge-type switch-ing inside the actuators, making them eas-

Smart Actuators Deliver on the Promise of Industry 4.0

Lower-cost actuators with embedded smartcapabilities can be beneficial for intermittentapplications in industrial automation plants.The actuators offer flexibility, cost efficiency,and intelligence. (Thomson Industries, Inc.)

Motion Design, December 2018 5

ier to control with low-level power signalsfrom external sources. This enables pro-gramming of the embedded electronicswithout the need for complex bus com-munications while reducing electricalshock hazards. Low-level power switchingalso simplifies design by allowing the useof lower-rated control components andputs less stress on system batteries andcharging systems. Managing power withonboard electronics can reduce current atthe switches or contacts from 20A to lessthan 22mA, enabling a more efficient andless expensive system design.

Dynamic braking. Once the power is cutto an actuator, it could take

between 5 and 10 mm of coastbefore the actuator arrives

at a full stop, dependingon how the actuator ismounted. The dynamicbraking feature reducesthis coasting to abouthalf a millimeter by elec-tronically forcing a shortbetween the motorleads inside the actua-tor. This improves re -peatability and posi-tioning capability.

End-of-stroke indica-tion. Confirmation thatan actuator reachedeither end of its strokeis important for safety

and performance,especially in con-nected operations.

It can provide, forexample, an inter-

loop function betweentwo mechanisms. Or, if the actu-

ator is used to lock a device intoplace, a simple LED light triggered

by the output can confirm that it islocked, protecting the operator from

unsafe conditions while extending theworking life of the actuator.

Improved position feedback. Knowingexactly where the actuator is at everypoint of the stroke is a major benefit ofintegrated electronics. This can beaccomplished by embedding a poten-tiometer, which would deliver absoluteposition feedback immediately, or byembedding an encoder that would pro-vide incremental feedback indirectly bycounting and reporting on pulses. Suchadvanced position control enables pro-gramming of the drive to perform with

an infinite number of movement profilesand custom motion strategies; for exam-ple, users can program the actuator toseek forward a few millimeters or make asmall set of movements back and forth toreach a desired position. And becausethe system knows what it is supposed todo and monitors performance in realtime, it can flag potential variances andtrigger advanced algorithms to managealarms, corrections, or shutdown.

Condition monitoring. Smart actuatorscan also monitor their own health, pro-viding a safety net for actuator operation.They can monitor temperature and shutdown at anything that indicates an over-load — both in extension and retraction— which provides consistent fulfillmentover the life of the actuator. The elec-tronics know whether the system isreceiving enough voltage for the job athand and can adjust accordingly. Theycan accumulate data on the number ofcycles performed and pace of operationacross shifts. Having such timely faultdetection is increasingly critical as larger,integrated automation schemes becomemore dependent upon actuators.

Real-time communications. Key to manyIndustry 4.0 projects is the ability ofsmart actuators to communicate across anetwork. The position feedback, end-of-stroke indication, condition monitoring,and diagnostics can be shared across aJ1939 CAN bus, PROFINET, Ethernet/IP, or other industrial network protocols,integrating operations and improvingmaintenance efficiency. Previously man-ual activities can now integrate with larg-er and more complicated controlschemes and workflow strategies.

Through such networks, smart actua-tors are currently delivering solutions infour main areas: industrial automation,operation of off-road vehicles, structuralautomation, and patient care.

Industry 4.0 in the PlantIn industrial settings, smart actuators

are used in applications requiring maxi-mum controllability and connectivity,including material handling, intermit-tent load management, robotics, auto-mated guided vehicles (AGVs), and syn-chronized load management.

Material handling. Manufacturers oflogistics trains are increasingly deploy-ing smart actuators to help increase loadcapacity, regulate operations, and re -duce maintenance. Low-level switching(PLC-compatible), verified positioning,and end-of-stroke shutoff are among thefeatures frequently applied in theseapplications.

Intermittent load handling. Industrialtasks such as raising or lowering a con-veyor to handle cartons of various sizescan be handled cost efficiently withsmart actuators. If such adjustments areneeded only a few times a day, automa-tion with conventional technology wouldbe difficult to justify. Because smart actu-ators have minimal external infrastruc-ture requirements, they can be deployedcost effectively. Furthermore, the use ofsmart actuators also might enable analy-sis of data, which could improve theprocess by optimizing the frequency ofadjustments.

AGVs/robotics. AGVs that move aroundthe plant, receiving goods from convey-ing stations and transporting them toother stages of production or delivery,can benefit from smart actuators. As theAGV approaches a conveyor, for exam-ple, it could signal an actuator to open ahatch and select goods from that hatchusing image recognition technology.Once filled to capacity, the AGV moves tothe next station. Such integration likelywould not have been feasible — or evenconsidered — prior to Industry 4.0 inno-vation. Smart actuators are also being

With just two wires for power (orange line) and two for network communications (blue line), smart actuatorsprovide efficient, compact communications with each other and with gears, sensors, and other devices (greenbox). (Thomson Industries, Inc.)


used in automated valet parking systemsin which patrons use their smartphonesto signal that they are ready to pick uptheir cars, and an actuator-driven, robot-ic assembly delivers their car to them.

Synchronized load balancing. For largework platforms, smart actuators can besynchronized to self-correct as loadsshift. For assembly stations, they can pro-vide similar ergonomic lift support foroff-center or awkward loads. For liftgates, they can enable smoother han-dling without the complexity and main-tenance requirements of a traditionalhydraulic solution. For industrial logis-tics trains, they can automatically correctimbalances between the front and back-end loads. And for doors on ovens andlarge processing equipment, they canenable smoother, safer opening andclosing.

Industry 4.0 Off-HighwaySmart actuators are also supporting inno-

vation in the mobile off-highway (MOH)market on agricultural and constructionvehicles, marine vessels, and even publictransportation. End users are seekingimproved efficiency and simplified wiring.

Ergonomics. Standard operating proto-col of some MOH vehicles requires rais-ing the hood to check engine compart-ments before each run; however, as atrend toward larger engine compartmentsrequires heavier hoods, these are becom-ing more difficult to handle. Deployingan actuator on either side of the hoodmight help raise and lower it, but largerhoods can buckle. Deploying an actuatoron both sides of the hood and synchroniz-ing them across a vehicle network, howev-er, results in more ergonomic, safer, andbetter maintained equipment.

Integrated control for construction andagricultural equipment. Large equipmentoften features multiple functions thathave traditionally been isolated ordependent upon multiple externalstructures such as switches and cables.Today, combine manufacturers can useJ1939 networking capability to synchro-nize control of actuators across morethan 20 axes, including those control-ling a rock trap door, gate latch, ladder,grain tank, and auger.

Industry 4.0 in FacilityAutomation

In structural automation and patientcare, smart actuators are providing easeof control, improved safety, and some-times quieter operation.

Louver control. Actuators can be timedto regulate the entry or obstruction ofsunlight into a building at various pointsthroughout the day.

Solar energy optimization. To store max-imum energy, solar panels must move insynchrony with the Sun. One solar panelmanufacturer accomplished this byusing the J1939 CAN bus protocol to syn-chronize operation of large solar panelsas they track the Sun’s position, minimiz-ing impact of wind shear and reducingthe need for specialized supports.

Patient care. With patient-handlingequipment in health facilities, synchro-nization can improve the quality of careby controlling operation of lift tablesand columns, and stair lifts.

Connecting the FutureMany of today’s Industry 4.0 applica-

tions involve actuators connecting withother actuators in intelligent ways, butwe are well on the brink of somethingmuch bigger. Given their controllabilityand communications capabilities, it isnot difficult to imagine extending thereach of smart actuators for increasedintegration with other similarly en -hanced sensors, data acquisition devices,and production equipment. These ad -vancements have set the stage for pro-duction and automation engineers todefine the actuator applications that willshape the next generation of industrialinnovation.

This article was written by Håkan Persson,Global Product Line Director – Actuators, atThomson Industries, Radford, VA. For moreinformation, visit http://info.hotims.com/69513-321.

Smart actuators are widely used in various plants where manual intervention can be avoided. For example,system designers can now program the actuators in advance to perform an automated switch in control con-veyors (top). The actuators also provide controllability for logistic trains and automated guided vehicles.(Thomson Industries, Inc.)


…With Tapped or Threaded ShaftsOff-The-Shelf.Our Most RequestedDiameters AndPre-Cut Lengths Are Now Available, With Ends Precisely Machined.

Case Hardened Carbon or Stainless Steel*.

• We never anneal so O.D. is ultra precise.

• Travel length sections 6˝ – 36˝.

• Reliable O.D. tolerances.

• 1/4 – 1½˝ diameters.

• Saves you time.

• Fast delivery.

*Externally threaded shafts are only available in case hardened Carbon Steel.

End YourMachiningHeadaches




There are few industries where thedemands for material testing and quali-

ty assurance are more challenging than inthe aerospace industry. Ensuring the safetyof all human passengers, crew, and cargowith fully inspected materials and compo-nents is no simple task.

Genesis Systems Group is a full-servicerobotic systems integrator, supporting themanufacturing, transportation, and aero-space markets. The company offers 24/7support from its world headquarters inDavenport, IA and additional branches inJapan and Mexico. For the aerospace mar-ket, Genesis specializes in robotic non -destructive inspection systems (NDIs).

The NSpect™ line of NDI solutionsfrom Genesis is designed to reliablyinspect large surface areas as quickly aspossible in aerospace applications. High-tolerance inspections are required todetermine whether materials are manufac-tured with acceptable quality and do nothave any flaws or indications greater thana specified size. The NSpect systems alsowork to minimize the risks associated withtraditional testing processes for all kinds ofaerospace components, including thosefor large and small aircraft, satellites, andeven full-sized rockets.

To inspect aerospace components andmaterials with high accuracy, Genesis inte-grates robots with ultrasonic process equip-ment that conducts thorough transmissionultrasound with a sender and a receiver.Common ultrasound test types includepulse echo, phased array, and shearogra-phy. NDI systems from Genesis can alsoconduct water-based and air-coupled ultra-sound, eddy current, gauss meter, emer-gent, and non-emergent testing types. Therange of materials that can be inspected isvast, but most commonly involve steel, alu-minum, and composite materials.

Robotic Systems Designed forthe Ultimate Test

The NSpect systems combine ultrasonicinspection data with robot positional infor-mation and present it as A-Scan, B-Scan,and C-Scan images. This eliminates theneed for manual inspections of large com-ponents that have very high tolerancerequirements. “Preventing fatigue andidentifying defects in components withoutaffecting material integrity is challenging,

even for experienced professionals,” saidWhitney Moon, Director of the AerospaceDivision at Genesis Systems Group.

An important component in these sys-tems is a 6-axis articulated robot paired witha virtual encoder called the Genesis BlitzModule. Through extensive C++ program-ming, the Blitz Module can take all robotpositions and create a virtual encoder withsix degrees of freedom in about 200microseconds. This is intended for gridsizes that are measured in increments of 1mm or less. “In the inspection world, this iscalled pulse-on-position,” explained RyanSteckel, Automation Systems Engineer atGenesis Systems Group.

“The Blitz Module takes the inspectiondata from the material under test and cor-relates the data with the position of theinstrument or sensor. The faster the pulsescan be sent, the faster the robot can runand the more productive the NDI systemsare as a result,” said Steckel. The recog-nized standard to send these pulses is 10ms, while the Blitz Module can send pulsesin just 1 ms.

Another new development fromGenesis is called the RoboPogo, a part-holding system with multiple articulatedrobots for components undergoingNSpect NDI testing. A single RoboPogosystem can handle complex parts withmultiple geometries.

“In 2017, Genesis took on a projectthat required the fixturing of especially

large parts for NDI. Doing this with tradi-tional hard tooling or manually adaptedfixtures would be very cumbersome andexpensive,” Moon explained. When hold -ing parts that are between 10 and 110feet long, a robotic solution makes sensebecause it can twist and rotate measure-ment devices around multiple geome-tries with a single system. Robots haveadvantages over gantry positioners be -cause they are more flexible to accom-modate varied processes and can betterhandle automatic tool changers for on-the-fly adjustments.

PC-Based Control SimplifiesIntegration

“The applications we address withsolutions like the RoboPogo are verycomplex, so we need automation systemsthat simplify our designs,” Moon said.“This is why we incorporate advancedPC-based control systems from Beckhoff.In our experience, automation solutionsthat rely on standalone devices for specif-ic processes only complicate designs.Our approach is to streamline automa-tion, and PC-based controllers are attrac-tive in this context because we can put alltasks under one roof.” Genesis Systemsintegrates all functions into one Beck -hoff embedded PC that can run the PLC,safety PLC, HMI software, Windows OS,and essentially any inspection softwareused by Genesis.

A new development from Genesis Systems Group is called the RoboPogo, a part-holding system with multiplearticulated robots for aerospace components undergoing NSpect™ NDI testing.

One-Cable Automation Streamlines Robotic Non-Destructive Inspection Systems

Motion Design, December 2018 9Free Info at http://info.hotims.com//69513-606

Today, Genesis Systems Group typicallyuses the Beckhoff CX2030 embedded PCequipped with a 1.5 GHz Intel® Core™ i7dual-core processor. This device providesenough processor performance for mostof the company’s applications. “We usethe CX2030 embedded PC networkedover EtherCAT on our systems with 20robots, and we still only use about 25 per-cent of the CPU capacity,” explainedSteckel. “Gathering all the NDI data andmaintaining communication with 20 dif-ferent KUKA robots within a millisecondis impressive — a testament to the value ofPC-based control and EtherCAT.”

For the most complex NDI systems,Genesis uses the CX2040 embedded PC,which increases the performance with a2.1 GHz Intel® Core™ i7 quad-coreprocessor. The different CPU cores areassigned specific tasks, such as end-of-arm tool collision sensing, positionmonitoring, and more. For simpler ap -plications that employ a single robot,Genesis Systems usually opts for theCX9020 embedded PC with an ARMCortex™ processor.

System programming and runtime ishandled using TwinCAT 3 software fromBeckhoff. This makes it possible for Gen -esis Systems to run PLC, motion control,safety logic, inspection software, HMI, andWindows OS all on one embedded PC.“The engineering environment accommo-dates Structured Text and object-oriented

programming, which helps us grow theRoboPogo concept, as some systems havefour robots, some have as many as 20,”Moon said. “We can expand or reduce thisdynamically with minimal programmingchanges that we might otherwise have towork through with Ladder Logic, forexample. With the TwinCAT software

NSpect systems from Genesis combine ultrasonic inspection data with robot positional information and presentit as A-Scan, B-Scan, and C-Scan images.

I actually thought the robot wouldn’t stand it.

Juan Puente, thermal spray supervisor, Aircraft Tooling Inc. (ATI)

the need for safety guarding.Easy in-house programming meant robot was up and running in only 4 hours.

Maintenance-free UR cobots operate continuously in harsh environment

They were surprised. We’re not. See why: urrobots.com/ATI


suite, Genesis engineers are also able tocreate entire programs on their PCs andeasily update or troubleshoot applicationsremotely, rather than having to physicallytravel to our customer locations all overthe world.”

Object-oriented programming (OOP)also introduced significant time savings forGenesis Systems Group. With OOP, it’s eas-ier for Genesis to take existing code

libraries that have already been developedand implement them in entirely new sys-tems. “With OOP, we no longer spend sub-stantial amounts of time redoing large por-tions of code to address new processes fora different configuration,” Steckel ex -plained. “To start up a new system, it’smuch easier to just set basic parametersrather than rewriting every line of code.For example, when setting up a system with

shearography on one system and switchingto ultrasonic on the next, I do not spendtime searching through many files to locateshearography-specific controls. I simply re -place my instance of shearography with theultrasonic function block.”

EtherCAT Cuts Cabling andBoosts Robot Safety

On the networking side, RoboPogo andother NDI systems from Genesis are basedon EtherCAT, which is widely accepted bymajor robot manufacturers around theworld. EtherCAT promotes extremely ac -curate measurements and highly precisesystem synchronization, which is critical fortest and measurement applications. Gene -sis was also an early adopter of EtherCAT Pand One Cable Automation technology,which combine power and data transmis-sion on one industrial Ethernet cable. “AsGenesis Systems began to work with morecommercial airplanes and spacecraft,many applications extended for hundredsof feet,” Moon said. “Having to run thenumerous cables involved back to enclo-sures is especially time-consuming andexpensive in these cases. That’s whyGenesis Systems Group uses EtherCAT Ptechnology to route the power andEtherCAT network around entire fixtureswithout running lines way back to a mainenclosure from each stand.”

To drastically reduce these cable runs,a large percentage of the I/O devicesdeployed by Genesis Systems are Ether -CAT P Box and EtherCAT Box moduleswith IP 67 protection. These can bemounted directly on machinery androbot arms for the direct connection tosensors, actuators, and other field devicesmuch closer to the process. This cutsdown the required cabling and reducesthe size of electrical cabinets or elimi-nates them completely. “Because ourNSpect systems often require water tocarry ultrasonic inspection signals, IP rat-ings are very important,” Steckel ex -plained. “Accordingly, our I/O systemmust be highly resistant to moisture intesting environments.”

Integrated safety technology in theEtherCAT I/O system takes the form ofTwinSAFE, which provides additional ben-efits for robotic systems. “Implementingsafety with industrial Ethernet and distrib-uted I/O helps us increase the level ofsafety functionality in our designs andminimize our reliance on traditional safetyrelays,” Moon said. “Using TwinSAFE,

10 Motion Design, December 2018Free Info at http://info.hotims.com/69513-607

THE COUPLING. ABSOLUTE PRECISION 0.1-100,000 NM.

WWW.RW-AMERICA.COM


Motion Design, December 2018

Regal and Sealmaster are trademarks of Regal Beloit Corporation or one of its affi liated companies.

©2016, 2018 Regal Beloit Corporation, All Rights Reserved. MCAD18046E • 10044E

you could reduce time required for bearing changeout?

The multiple

award-winning

Sealmaster® Large

Bore Performance

Gold Line Mounted

Ball Bearings feature a

patented Time Saving™

axial groove in the inner

ring bore. The axial

groove at the setscrew

locations allows for easier

bearing removal and the

ability to reuse the shafting

with minimal clean up, saving

more than just time! Available

for shaft sizes 2 7/16” and up.

www.regalbeloit.comCreating a better tomorrow™...


we’ve reduced our required number oftraditional safety relays by 90 percent.EtherCAT diagnostics also help boost thesafety in our systems with built-in tools thatcan identify the exact location of any errorfrom a device connected to the network.”

Another important I/O technologyfor Genesis is the EL6695 EtherCATbridge terminal, which enables real-timedata exchange between EtherCAT I/Osections with different masters. “Whilethe EL6695 is not itself a TwinSAFEdevice, it gives us increased ability to reli-ably connect more safety zones via theEtherCAT system,” Steckel explained. “Italso allows our safety zones to be recon-figurable on the fly. For example, we canhave one established safety zone, thenan operator can close a gate, resulting intwo different zones. Safe loading canhappen in one zone, but the system con-tinues running in the other. This waspreviously not possible with other PLCsand safety interfaces we worked with.”

EtherCAT also extends to the motioncontrol platforms designed by Genesis.Beckhoff AX5000 Servo Drives with inte-grated safe torque off (STO) are used toraise and level testing platforms. Someplatforms are transported on wheels andwhen they reach parts for inspection,the AX5000 and connected AM8000 ser-vomotors raise up the platform, stabilizeit, and level it. This is used for headstockand tailstock positioners and any othertype of motion system used. “We alsointegrate One Cable Technology (OCT)connections between our Beckhoff ser-vomotors and drives, leading to addi-tional cabling and installation savingscomparable to what we experience withEtherCAT P,” Moon said.

Upon Closer Inspection,Significant Savings Observed

Once evaluation began in earnest, PC-based control technology was rapidlyaccepted by Genesis, resulting in a swiftimplementation. “The Genesis engineer-ing team was quick to realize significantbenefits from PC-based control for theseindustry-specific applications,” said DennisSowada, Regional Sales Engineer atBeckhoff Automation. “This team’s deeptechnical expertise, combined with strate-gic planning, rapidly produced a compre-hensive control platform that also includesadvanced EtherCAT P networking.”

Hardware, software, cabling, and net-working in the PC-based control platformhave combined to promote significant sav-ings observed by Genesis. This has madethe company more flexible to cost-effec-tively develop NDI systems like RoboPogothat tackle some of the most complex test-ing applications imaginable. “By addingOne Cable Automation, Genesis Systemscan reduce NDI system cabling by up to 50percent for drives, motors, sensors, actua-tors, and pneumatic valves,” Steckel said.“As we plan future developments, we knowEtherCAT P can also be applied towardlarger devices, such as entire electrical cab-inets and eventually robots.”

“Through the combined use of PC-based control technologies and EtherCAT,Genesis Systems also reduced cabling andinstallation time of all electronic compo-nents by 50 percent,” Moon added.“Additionally, we reduced the space need-ed in our electrical cabinets and enclo-sures by 20 percent.”

This article was contributed by BeckhoffAutomation, Savage, MN. For more informa-tion, visit http://info.hotims.com/69513-322.

Genesis leverages Beckhoff CX2030 embedded PCs networked over EtherCAT on systems with 20 robots, andstill only uses about 25 percent of the CPU capacity.




Materials testing and characteriza-tion is often a lengthy process. It

can take more than a year and billions oftesting cycles for a manufacturer to char-acterize the properties of a new metalcompound to be used in a critical appli-cation such as a component of an auto-motive or jet engine.

Typically, the testing regimen is pre-scribed by an OEM in accordance withprocedures specified in industry organiza-tion standards; for example, one testingmethod for bending fatigue of gear steelsis outlined in SAE Standard 1619 using astandard fixture and standard geardesign. Companies manufacturing auto-motive and aerospace engines often referto this and other standards as they specifythe materials and designs of gears to beused in their applications, as do compa-nies manufacturing test systems that verifyproduction gears meet the standards.

The prescribed testing can also beused in a pre-production environment as

companies evaluate changes in materialsdesigned to improve the characteristicsof end products; for example, in the caseof engine gears, the goal with fuel con-sumption in mind is to reduce assemblyweight without decreasing the strengthof critical components. Another goal isto increase power density — the ability todeliver more power through the geartrain without increasing the size of thegears involved. One company that is pro-viding test systems for use in this field isSymbrium Inc. of Raleigh, NC.

When gear strength is tested, researchlabs apply both static and cyclic forces togear teeth, looking to see when cracksstart, and measuring how long it takesbefore a gear tooth fails. “Static forces areapplied while measuring tooth strain ortooth deflection to determine yield andultimate strength of the gear steel. Thendynamic forces are applied to determinethe fatigue life or endurance limit,” saidWes Blankenship, President of Symbrium.“Our customers study different alloys andprocesses used in gear manufacture to tryto increase fatigue strength.”

Test System AlternativesThere are two main approaches to test-

ing automotive or aerospace compo-nents. One is to apply a general-purposetest platform that is connected to a loadframe created for the specific device. Thesecond approach is to use test systemsthat are totally customized for the partic-ular application. Blankenship fa vors thelatter approach. “General-purpose testmachines are very expensive to be doinga simple test like exercising a gear tooth,”he said. “By building a dedicatedmachine to do gear testing (Figures 1 and2), we can increase the speed of the test-ing operation and enable testing of mul-tiple devices in parallel.”

In order to operate multiple testingoperations at the same time, Blankenshiplooked for an electrohydraulic motioncontroller that could control multiplemotion axes simultaneously. Another crit-ical need was a controller with a very shortcontrol loop time so that subtle changesin how the device under test responds tothe test cycle can be detected between testcycles. After building a spreadsheet con-taining info on different alternative

motion controllers, Blankenship selectedthe RMC200 motion controller (Figure 3)from Delta Computer Systems (BattleGround, WA). The RMC200 is capable ofrunning control loop times as fast as 250microseconds.

How the Controller is Used“The motion controller drives a high-

end servo valve, applying cyclic loading55 to 100 times per second at 100+ kilo-newtons (20-some thousand pounds),which it controls to within ±1 newton,”said Blankenship.

The dynamic loading applied to thegear tooth is measured using a load cellconnected to the motion controller,

Multi-Axis Motion Controller Accelerates Gear Testing

Figure 1. A Symbrium gear test stand. Symbrium’stest control system controls multiple test standssimultaneously.

Figure 2. Close-up view of a Symbrium gear testingfixture.

Figure 3. Delta’s RMC200 can control up to 32motion axes simultaneously.


while the position of the hydraulic axisis measured using a non-contact laserdisplacement sensor that is capable ofsensing distance down to a tolerance oftwo microns in order to detect a break.

When the system detects a crack(Figure 4), it can either stop immediate-ly or maintain the cyclic loading veryaccurately until the tooth breaks,enabling the tracking of crack propaga-tion. “Being able to detect a microscop-ic crack prior to the sample actually fail-ing is very important to our customersbecause they can do more advancedanalysis on the gear,” said Blankenship.“It’s the speed of the motion controlprocessor that makes this possible.”

Besides closing the control loop andadjusting the load on the gear toothunder test over 1,000 times/second, thecontroller has enough spare horsepow-er to perform additional functions aswell. “We used to use a PLC to handlesafety checking, but we threw the PLCout and can do the machine 100% withthe Delta controller outfitted with anI/O module,” said Blankenship. “I’mcomfortable doing it and can get CEapproval without the PLC. The controlsare more streamlined with a singleprocessor in the system.”

The RMC200 was programmed usingthe RMCTools software provided forfree by Delta to support its motion con-trollers. “The controller was very easy toprogram,” said Blankenship. “The heavylifting came in optimizing the controlalgorithm.” For that, the Symbriumengineers used special tools provided inDelta’s RMCTools package, guided byassistance from the Delta team.

The Results Whereas other gear testers are capable

of running 40-Hz test cycles, Blankenship’spurpose-built load frame is running testsfor Fortune 500 powertrain companies atspeeds up to 100 Hz. “For the price of oneoff-the-shelf test frame, we can handlethree test frames that each produce resultsthree times faster,” he said. “That’s a nine-times cost-effectiveness advantage overother testing approaches.”

The capacity of the Symbrium design isactually even higher. With the RMC200included, the design can run up to six teststations off the same multi-axis controller(see Figure 5). “An additional benefit ofautomating the test process is that we canrun the tests unattended,” said Blank-

enship. “We can detect very minutecracks and shut the machine down withinone cycle without operator intervention.”

With the success of the metal gear testsystem, Symbrium has moved on to devel-op a smaller variant of the machine, pro-ducing 20 to 500 pounds of force that can

be used to test the strength of gears madeout of plastics.

This article was written by Reid Bollingerof Delta Computer Systems, Battle Ground,WA. For more information, visit http://info.hotims.com/69513-323.

Figure 4. A crack in the gear tooth is visible at the top center of the photo.

Figure 5. The Symbrium control module is capable of operating multiple test stands at the same time. On topof the module enclosure is an RMC200 controller.



The global bearings market is expect-ed to grow significantly due to increas-

ing commercial and industrial machineryand manufacturing activity. Bearings areused in virtually every machine that con-tains a rotating shaft to rotate freely withminimal friction.

The design of conventional cagelessbearing systems is inefficient due to both

sliding and incidental friction losses as wellas viscous losses due to the requirementfor lubrication. Hence, the main problemis mechanical inefficiency. Additionally,some of the systems also incorporate com-plex components into their design, such asgear teeth or harmonic gear cups thatincrease cost. For heavy-duty vehicles, 26%of the fuel energy is spent overcoming par-

asitic frictional losses such as bearing loss.If bearing loss can be significantly re -duced, the fuel efficiency of such systemscould be significantly improved.

A normal cageless bearing was devel-oped with added rolling separator ele-ments to overcome these issues. Thisdesign reduces friction by ensuring therolling elements are only ever in purerolling, as opposed to sliding contactthat involves higher frictional losses.Additionally, these elements are not insliding contact with the inner race.

The proposed bearing system elimi-nates sliding friction losses by ensuringthat all contacting surfaces have the samevelocity, leading to pure rolling, therebyreducing incidental contact. This designcan be modified into a friction drivetransmission device with a small form fac-tor by splitting the outer race into twoparts. The result is a low-cost, low-noiseand high-efficiency system with no slid-ing, incidental, and viscous losses.

For more information, contact RyneDubose at [email protected].

Cylindrical roller bearing to support radial loads. The inner race is shown in light blue, the outer race in grey,separators in dark blue, and load- bearing rollers in gold.

High-Performance Cageless Bearings with MinimalFrictional LossApplications include portable medical devices, robotics, and other applications with mediumforce requirements.University of Pennsylvania, Penn Center for Innovation, Philadelphia

Derived from a design approach for anew wing known as PRANDTL-D,

this technology achieves similar improve-ments for propellers and other rotatingmachinery.

To achieve the innovation’s alternatespanload, Armstrong designers applied anon-linear twist to the propeller blade.The twist moves the load inward and dis-sipates the tip vortex over a wider area,minimizing its effect on drag. It alsoresults in a decrease in load at the tip and

reduced torque at the tip. These changescombine to achieve a dramatic reductionin power consumption without compro-mising the blade’s other parameters.Specifically, the blade’s diameter andrpm remain unchanged.

Unlike the conventional minimum in -duced loss (elliptical) spanload, whichconsumes large amounts of power at thetip of the blade, the new design unloadsthe tip and reduces torque, achieving sig-nificant improvements in efficiency. First-

order analysis shows a more than 15 per-cent improvement in power consumptionwhile producing the same thrust. Thedesign also produces significantly lessnoise than conventional blade designs.

NASA is actively seeking licensees to com-mercialize this technology. Please contact theNASA Armstrong Technology Transfer Officeat 661-276-3368 or [email protected] to initiate licensing discussions. Follow thislink for more information: https://technology.nasa.gov/patent/TB2016/DRC-TOPS-41.

A New Twist Makes Rotating Machinery MoreEfficient and QuieterThis technology benefits propellers, industrial fans, compressors, and turbines.NASA’s Armstrong Flight Research Center, Edwards, California

https://technology.nasa.gov/patent/TB2016/DRC-TOPS-41

Motion Design, December 2018 15Free Info at http://info.hotims.com/69513-609

Gyroscopes are devices that helpvehicles, drones, and wearable

and handheld electronic devices knowtheir orientation in three-dimensionalspace. Originally, gyroscopes were setsof nested wheels, each spinning on adifferent axis. But in a cellphone, amicroelectromechanical system (MEMS)sensor measures changes in the forcesacting on two identical masses that areoscillating and moving in oppositedirections. These MEMS gyroscopesare limited in their sensitivity, so opti-cal gyroscopes have been developed toperform the same function but withno moving parts and a greater degreeof accuracy using a phenomenoncalled the Sagnac effect.

Optical Gyroscope-on-a-ChipThe gyroscope is smaller than a grain of rice — about 500 times smaller than the currentstate-of-the-art device.California Institute of Technology, Pasadena

The new optical gyroscope — shown here with grains of rice — is 500 times smaller than the current state-of-the-art device. (Credit: Ali Hajimiri)


Engineers and software developers areseeking to create technology that lets

users touch, grasp, and manipulate virtualobjects while feeling like they are actuallytouching something in the real world. Anultralight glove — weighing less than 8grams per finger — was developed thatenables users to feel and manipulate virtu-al objects. The system provides extremelyrealistic haptic feedback and could runon a battery, allowing for freedom ofmovement.

The DextrES glove can generate up to40 Newtons of holding force on each fin-ger with just 200 Volts and only a few mil-liwatts of power. It also has the potential torun on a very small battery. That, togetherwith the glove’s low form factor (only 2mm thick), translates into an unprece-dented level of precision and freedom ofmovement.

DextrES is made of nylon with thin elas-tic metal strips running over the fingers.The strips are separated by a thin insula-tor. When the user’s fingers come intocontact with a virtual object, the con-troller applies a voltage differencebetween the metal strips causing them tostick together via electrostatic attraction.


Named after the French physicistGeorges Sagnac, this is an optical phe-nomenon rooted in Einstein’s theoryof general relativity. To create it, abeam of light is split into two, and thetwin beams travel in opposite direc-tions along a circular pathway, thenmeet at the same light detector. Lighttravels at a constant speed, so rotatingthe device — and with it, the pathwaythat the light travels — causes one ofthe two beams to arrive at the detectorbefore the other. With a loop on eachaxis of orientation, this phase shift —the Sagnac effect — can be used to cal-culate orientation.

The smallest high-performance opti-cal gyroscopes available today are big-ger than a golf ball and are not suit-able for many portable applications.As optical gyroscopes are built smaller

and smaller, so too is the signal thatcaptures the Sagnac effect, whichmakes it more difficult for the gyro-scope to detect movement. Up to now,this has prevented the miniaturizationof optical gyroscopes.

Caltech engineers developed a newoptical gyroscope that is 500 timessmaller than the current state-of-the-art device yet can detect phase shiftsthat are 30 times smaller than thosesystems. The gyroscope achieves thisperformance by using a new techniquecalled “reciprocal sensitivity enhance-ment.” Reciprocal means that it affectsboth beams of the light inside thegyroscope in the same way. Since theSagnac effect relies on detecting a dif-ference between the two beams as theytravel in opposite directions, it is con-sidered nonreciprocal.

Inside the gyroscope, light travelsthrough miniaturized optical wave-guides (small conduits that carry lightthat perform the same function aswires do for electricity). Imperfectionsin the optical path that might affectthe beams — for example, thermalfluctuations or light scattering — andany outside interference will affectboth beams similarly.

This reciprocal noise was weededout while leaving signals from theSagnac effect intact. Reciprocal sensi-tivity enhancement thus improves thesignal-to-noise ratio in the system andenables the integration of the opticalgyro onto a chip smaller than a grainof rice.

For more information, contact KathySvitil, Director of Research Communi ca -tions, at [email protected]; 626-395-8022.

Ultralight Gloves Provide Realistic Haptic FeedbackThe gloves enable users to feel and manipulate virtual objects.École Polytechnique Fédérale de Lausanne, Switzerland, and ETH Zurich, Switzerland

The ultralight glove weighs less than 8 grams per finger and provides extremely realistic haptic feedback.


WE HAVE AN ANSWER FOR THAT.

CONTI® SYNCHROCHAIN CARBON never needs

oiling or retensioning and greatly increases

performance for applications with extremely

high torque. Let’s talk soon if you need

a better drive combination.

WeHaveAnAnswerForThat.com

LOCKED INTOOLD TECHNOLOGY?


This produces a braking force that blocks the finger’s or thumb’smovement. Once the voltage is removed, the metal strips glidesmoothly and the user can once again move his fingers freely.

For now, the glove is powered by a very thin electrical cable,but a very small battery could eventually be used instead. Thenext step will be to scale up the device and apply it to other partsof the body using conductive fabric. Potential applications existin healthcare; for example, training surgeons. The technologycould also be applied in augmented reality.

For more information, contact Andrea Crottini Ph.D. in theEPFL Technology Transfer Office at [email protected]; +41(0)21 693 5047.

Active Pointing Monitorfor a 2-Axis OpticalControl SystemAn inline optical axis fast-steering mirror (FSM)corrects unwanted tip and tilt mitigation.Goddard Space Flight Center, Greenbelt, Maryland

NASA Goddard Space Flight Center has developed apointing measurement detection and control system

that monitors the real-time optical axis motions (such as tipand tilt) that affect image quality in aerial platforms. Todate, there is no known real-time optical image alignmentand control system available that simultaneously accommo-dates the combined focal plane functions of science imagecollection and image stabilization control. Current monitor-ing techniques involve replicating the science image focalplane and a separate pointing monitor system that directlycompete for the exact same focal plane real estate, thusmaking it a one-or-the-other measurement.

This technology enables correction of image degradationintroduced by tip and tilt motions. This system operates inboth the visible and IR spectral regions, can be adapted todifferent optical systems, and does not require any specialmanufacturing processes or materials.

This innovative measurement ap proach utilizes a single2D focal plane detector array to collect the necessary sci-ence measurement image data while at the same time col-lecting the engineering optical axis motion detection andimage control information. The innovation utilizes a stan-dardized “windowing” electronic control function to readout a single column (1D array) within a 2D spectrometer sys-tem while the readout and control of the remaining 2Darray columns are controlled by separate and independentcontrol electronics.

NASA is actively seeking licensees to commercialize this technology.For more information, contact the Goddard Strategic PartnershipsOffice at [email protected] or 301-286-5810. Follow thislink for more information: https://technology.nasa.gov/patent/TB2016/GSC-TOPS-195.



Motion Design, December 2018

+1.201.343.8983 • [email protected]

One Part, Dual CureNanosilica Filled

Epoxy System

One Part, Dual CureNanosilica Filled

Epoxy SystemUV22DC80-1

• Dual curing; utilizes UV light and heat Cures at 80°C in shadowed out areas

• Dimensionally stable & abrasion resistant Nanosilica filled

• Optically clear Refractive index: 1.52

www.masterbond.com


Motor/Drive/Controller

Advanced Micro Controls (Terry ville, CT)

offers a size 17 PLC-based SMD Series integrat-

ed stepper motor/drive/controller system.

The integrated solutions are suited for new

machinery, retrofits, and rapid changeover

applications. The SMD17E2 (NEMA 17) inte-

grated motor combines an 80-oz. in. (0.56 N-

m) torque stepper motor with a DC drive and

Ethernet/IP and Modbus-TCP interface in a

single, compact design. The embedded

Ethernet switch simplifies multi-axis applica-

tions and optional encoder feedback elimi-

nates the need for a separate home limit switch.

The motors feature built-in EtherNet/IP and

Modbus-TCP network connectivity, embedded

Ethernet switch, SynchroStep™ technology,

optional integrated encoder (incremental or

multi-turn absolute), IP67-rated versions, gear-

boxes, and compatible cord sets. All of the

motors are programmed from the host con-

troller, so no separate software is needed.

For Free Info Visithttp://info.hotims.com/69513-304

Integrated MotorsApplied Motion Products (Watsonville, CA) introduced three models of

StepSERVO™ integrated motors that provide high-speed motion control

for high-throughput applications such as automated test and measure-

ment, and automated assembly. Using closed loop feedback and advanced

control technology, the motors create more torque for higher acceleration.

The motors draw just enough current to control the load, automatically reducing current to the

motor when the load is not demanding torque. The TSM Series features 8 digital inputs, 4 digital

outputs, and 1 analog input, and supports RS-232, RS-485, CANopen, Ethernet, EtherNet/IP, and

Modbus communications. SSM Series motors feature 3 digital inputs, 1 digital output, and 1 ana-

log input. TXM Series motors combine the features of the TSM Series with IP65-rated environ-

mental capabilities and M12 connectors for operating in wet and dusty environments.


Planar XY StagePI L.P. (Auburn, MA) offers the V-738 XY translation stage designed in a three-

piece arrangement for improved geometric performance. The integrated

planar design provides orthogonality of <100 μrad and straightness/flatness

of 2 μm. Three-phase brushless linear motors drive both axes, transmitting

the drive force (200N peak) to the motion platform directly without friction.

The ironless motors provide smooth running with velocity control due to the lack

of cogging effects caused by permanent magnets. Acceleration of 1G is achieved

with maximum velocity of 0.5 m/sec. The XY-travel range is 100 mm per axis. Other models in the

series include the V-731 XY stage with 200 ¥ 200-mm travel and the V-741 XY stage with 300 ¥ 300-mm

travel. Integrated optical linear encoders provide position resolution down to 1 nanometer.

Mechanical position repeatability is 0.1 μm and minimum incremental motion of 20 nanometers is

achieved.


Electric Linear ActuatorsThe RSX family of extreme force electric linear actuators from Tolomatic

(Hamel, MN) features precision-ground planetary roller screws for reliable

performance in demanding conditions including cold weather operation.

The family includes two frame sizes capable of achieving 18,000 lbf to 30,000

lbf (80 kN to 133 kN) max force. Features include a Type III hard coat anodized

aluminum housing to withstand demanding environments; standard thrust rod anti-

rotation; IP67 rating for water, dust, and corrosion resistance; and compatibility with servomotors

and gearboxes up to 215-mm frame sizes. The actuators are available with white epoxy coating

and stainless steel thrust rod.


Rotary Actuator SystemOriental Motor (Torrance, CA) introduced the 60-mm frame size DGII

rotary actuator equipped with an AlphaStep AZ Series absolute encoder step-

per motor. The rotary actuator is used with four types of AZ Series DC input

drivers (stored data type, pulse input driver with built-in RS-485 communica-

tions, pulse input type, and multi-axis driver with EtherCAT communication).

It is a complete rotary actuator system that eliminates the need for additional sensors. It can work

in applications where step and direction are required or in applications where PLC or touch-

screens (HMI) are being used, without the need for additional modules connected to the PLC.

The system is compatible with a wide range of master controller types and control methods.


AccelerometerPCB Piezotronics (Depew, NY) released the Model EX356A73 triaxial charge

accelerometer designed for use in environments with ambient temperatures up

to 900 °F/482 °C. It features a frequency range up to 4,000 Hz with a ±5% toler-

ance, and is packaged in a nickel alloy, hermetically sealed housing with three 10-

32 coaxial jacks. It also utilizes a UHT-12 sensing element with no pyroelectric out-

put, reduced thermal noise spikes that eliminate false alarms during monitoring, and

shear mode crystals to prevent base strain and transverse measurement errors.









Motion Design, December 2018 19Free Info at http://info.hotims.com/69513-612


Absolute EncodersEncoder Products (Sagle, ID) introduced Models

A58HE and A58SE EtherCAT-ready, multi-turn absolute

encoders designed for harsh factory and plant environments.

They are particularly suited to applications where Fieldbus connec-

tivity is required and the encoder has to retain absolute position infor-

mation after power-off events. The A58HE is a 58-mm encoder in a hollow

bore construction; the A58SE is a 58-mm shaft encoder available with either

a clamping flange or synchro flange. Features include multi-turn resolution

up to 43 bits, up to 16 bits of single-turn resolution, bore sizes to 0.375" or

15 mm, shaft diameters to 0.375" or 10 mm, operating temperature range

of -40 to 85 °C, and continuous digital position monitoring.


Power ClampsDestaco (Auburn Hills, MI) introduced

TCC-2E Series Tolerance Compensation Clamps

that provide flexibility in welding and assembly

applications that require the clamping of compo-

nents of differing thicknesses or tighter tolerances.

The clamps are suited for flexible manufacturing

applications in the automotive, aircraft, and consumer goods industries.

The clamps are available in a variety of sizes. They feature an enclosed

body that protects the internal mechanism and have been tested to be

maintenance-free for three million operating cycles. Various cylinder

designs with unlockable non-return check valves, hold-open devices, and

rod-lock units are available.


Gimbal MountThe AU300-AER three-axis gimbal mount

from Optimal Engineering Systems (Van

Nuys, CA) features full 360° rotation of each

axis and handles loads to 10 kg (22.5

pounds). It has a clearance of 300 ¥ 300 mm

around the roll axis stage. The azimuth stage

rotary table is mounted on a 360 ¥ 360 ¥ 13

mm plate with handles and has predrilled

accessible mounting holes for integration into new or existing applica-

tions and for increased stability. The three axes are driven by bi-direc-

tional stepper motors. Each axis features low-backlash worm gear

drives and precision V-groove and cross roller bearings for resolution

of 3.6 arc seconds, and repeatability and positional accuracy to 36 arc

seconds. Travel speed of each axis is 8 degrees per second. Electrical

connections are made using three 9-pin DB-9 connectors.


Torque MotorsTecnotion (The Netherlands) offers rotary torque

motors with a magnetic design optimized for max-

imum flux density and copper fill to provide

very high torque-to-volume ratios. The

motors feature encapsulated windings and

include two types of thermistors as standard fea-

tures. Motor sizes from 68 to 160-mm diameters are

available. They can be integrated directly into the

machine structure; an open inner diameter enables wire and

cable feedthrough. Completely sealed stators and integrated temperature

protection and measurement sensors are included. They provide contin-

uous torque ratings ranging from 0.27 Nm to 63.5 Nm and speeds rang-

ing from 190 rpm to 6918 rpm.








20 Motion Design, December 2018Free Info at http://info.hotims.com/69513-691

Motion TesterNorman Tool (Evansville,

IN) offers the 2-Axis Motion

Pro Tester that simulates

both finger pushes and fin-

ger swipes. It is designed to

provide a range of finger

pressing and/or sliding/rub-

bing mo tions to be used for

contact and button testing, as well as to test for

wear and durability. The machine can test all

types of buttons and switches, as well as moni-

tors, screens, displays, and anything that may

get wear from human fingers or other similar

types of rubbing, pushing, or sliding. The sys-

tem also tests membrane switches, silicone

keypads, and computer keys.


Stepper MotorsThe NEMA-

AMT112S step-

per servomotors

from CUI’s Mo tion

Group (Tualatin, OR)

are available in NEMA

8, 11, 14, 17, and 23 frame sizes with a step

angle of 1.8° and holding torques ranging

from 3 to 270 oz-in (0.021 to 1.90 N-m). When

paired with a controller, the motor and

encoder combination provides closed-loop

feedback for a complete servo system.

Integrated with the stepper motors is the

AMT11 incremental encoder series that fea-

tures 22 programmable resolutions from 48 to

4096 PPR, a digitally set zero position, and

CMOS voltage output waveforms. The resolu-

tions are fully programmable without having

to remove the encoder from the motor.


Planetary GearboxesGAM (Mount Prospect, IL) released EPR

and PER Series right-angle bevel planetary

gearboxes. Featuring a

spiral bevel gear input

to an inline planetary

gear output, the gear-

boxes are available in

ratios of 3:1 to 1000:1 and in a wide range of

sizes and configurations. The EPR Series fea-

tures five output options including three differ-

ent shaft outputs, a hollow shaft output, and a

flange output. The PER employs output bear-

ings and is used in motion control applications

where axial and radial loads are minimized.

The PER has a metric or NEMA shaft output

option. Both are available with motor mount-

ing plates to accommodate most servomotors.


Motor Control Integrated CircuitMicrosemi Corp. (Aliso Viejo, CA), announced the LX7720 radiation-toler-

ant motor control integrated circuit that works with a field programmable

gate array (FPGA). Features include four half-bridge N-channel MOS-

FET drivers, four floating differential current sensors, pulse-modulated

resolver transformer driver, three differential resolver sense inputs, six

bi-level logic inputs, and fault detection. The circuit also features 100-krad total

ionization dose (TID) and 50-krad enhanced low-dose radiation sensitivity. Power drivers are via

external field-effect transistors (FETs).







Large InventoryContributes to quick delivery

2D/3D CAD & Product

Major Credit Cards AcceptedVisa, Mastercard, and American Express

Easy AccessClear lead times and prices are listed in the store(no RFQ required)

Grease MSDSGrease MSDS (Material Safety Data Sheets) can be downloaded

Available for USA/Canada/Mexico CustomersWe ship to the USA (mainland), Canada, and Mexico

THK America, Inc.

Collect Shipping Available Quotation FileCart contents can be downloaded as quotation

PURCHASE PRODUCTS

www.thkstore.com

ONLINE

Contact [email protected] ORDERS.

Technical Support Available• [email protected] • https://tech.thk.com/




HexGen® Hexapods by AerotechThe next-generation in 6 degree-of-freedom positioning

HexGen® hexapods coupled with our control and visualization software make accurate six degree-of-freedom positioning incredibly easy.

• Powerful controls and software with motion visualization in any work or tool coordinate system

• Simple graphical view of coordinate systems and pivot-point locations

• Precision positioning – accuracy to ±0.5 µm and resolution to 20 nm

Contact an Aerotech application engineer or visit our website for more information on how Aerotech hexapods can improve your positioning application.

Complex and Precise 6-DoF Motion...Simplified

HEX RC Multi-Axis Robotic Controller

HexGen Visualization Software

HEX500-350HL

www.aerotech.com • 412-963-7470AF0818A-RAD



Welcome to your Digital Edition of Tech Briefs and …Welcome to your Digital Edition of Tech Briefs...

Documents

Transcript of Welcome to your Digital Edition of Tech Briefs and …Welcome to your Digital Edition of Tech Briefs...