machine design mayo 20 del 2010
TRANSCRIPT
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A dose of sealing solutions.
RS# 111
The Race is On for the World’s Smartest Design Engineer!www.smartestdesignengineer.com
May 20, 2010A Penton Media Publication
Tune in to EngineeringTV.com
WHERE ADHESIVES EXCEL WITH PLASTICS, page 54
TUBING THAT DOESN’T CHOKE HYDRAULIC SYSTEMS, page 60
CONNECTORS ARE CRITICAL IN PORTABLE MEDICAL GEAR,
page 66
PIEZOMOTORS FOR COMPACT MOTION SYSTEMS, page 72
© COPYRIGHT 2010 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED
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RS# 102
FEATURES
INDY 500
DeltaWing Racing CarsDeltaWing is taking a radical approach on many fronts. In addition to being supported by key IRL
teams rather than an established chassis builder, DeltaWing has pledged an open-source design pro-
cess. Anyone can access the car’s specs and CAD drawings, and anyone can submit original design
ideas.
The concept has produced a radical design, including a 160-lb, 2.0-liter, 300-hp, four-cylinder, turbo-
charged engine, that is projected to weigh 1,030 lb with a driver and cost around $600,000. The engine
and transmission are nonstressed members of the chassis, so the car can accommodate diff erent pow-
ertrains. DeltaWing is pushing for IRL to restrict fuel-delivery rate to the engines and leave other engine
specs up to teams.
The smaller powerplant and mass are made possible in part by bodywork that nearly encloses both
sets of wheels. Distance between front wheels is 24 in. while in back it is 70 in. Cutting the drag of open
wheels, narrowing the track, and beefi ng up the front fairing, let DeltaWing cut the drag coeffi cient 60%
teams competing.
Early this year, IRL President Brian Barnhart outlined what the organization is looking for in a new car, and designers were quick to respond. Five firms have entered the competition for the 2012 chassis, including current chassis construc-tor Dallara, Parma, Italy, and LeMans and ChampCar designer Lola, Huntingdon, Cambridgeshire, U.K. Swift Engineering, San Clemente, Calif., a seasoned design firm, notably of the current Formula Nippon design, is also developing an entry.
onship in 2008 and 2009.
Car criteriaIRL clearly set out its expectations for the new car in February. The new
chassis must meet current safety standards, but winning designs need to pro-pose additional ways to prevent crashes and make them less dangerous for driv-ers, crew, and spectators.
“It is often said about the 3S of racing — safety, strength, and speed — that
IndyCar 2012therace is on
MAY 20, 2010MACHINE Design.com44 MAY 20, 2010 MACHINE Design.com 45
Safety, better efficiency,
and more-exciting racing
are revving up the chassis
designs competing to run at
IndyCar events in 2012.
MOTORS & DRIVES TECH GUIDE
A miniature piezo-linear motor mounted on the left side of the circuit board can reach velocities of 200 mm/sec. The right side of the board holds the motor-drive electronics.
onse to mechanical stimulus.
avoid several problems
that beset ordinary
motors in medical uses.
Medical-devicemakers warm up
MAY 20, 2010MACHINE Design.com72
Access our Reader Service
Web site to quickly find and
request information on the
products and services found
in the pages of MACHINE DESIGN.
www.machinedesign.com/rsc
Piezomotors streamline medical-device performanceFewer mechanical parts to
wear out and service as well
as positioning with higher
accuracy, it’s no wonder
these little piezo devices
are fast becoming medical-
device manufacturers’
motor of choice.
IndyCar 2012: The race is onRace officials are close to choosing
which of five proposed chassis will be
racing at Indy in 2012.
72
44
60
54
66
Engineering tricks make parts stickDurable, low-cost, low-surface-
energy plastics are widely used,
but engineers must take special
care to ensure strong and lasting
adhesive bonds.
Sizing tube lines for efficient hydraulicsThe right size tubing limits fluid-
friction losses that cause pressure
drop, heat generation and, in
the case of suction lines, pump-
damaging cavitation.
Connecting with portable medical devicesEngineers designing connectors
for portable medical equipment
must take into account
mechanical, electrical, and
safety concerns.
VOLUME 82ISSUE 9
MAY 20, 2010
NO PURCHASE NECESSARY. A PURCHASE WILL NOT INCREASE YOUR CHANCES OF WINNING. LEGAL RESIDENTS OF THE UNITED STATES (D.C.), 18 YEARS AND OLDER. VOID WHERE PROHIBITED.
Contest ends 12/31/2010. For Official Rules and prize descriptions, visit www.smartestdesignengineer.com. Sponsor: Penton Media, Inc., 249 W. 17th St., New York, NY 10011
Ladies and Gentlemen…
Start your engines, rev up
your brains, and hit the road
to becoming the World’s
Smartest Design Engineer!
www.smartestdesignengineer.com
Auto racing is about more than getting cars to go as fast as possible. Premier groups like the Indy Racing League (IRL) also want to keep drivers safe, fans engaged, and technology relevant to real-world consumer applications. They also want more
To that end, IRL’s IndyCar chassis is getting a refresh. Officials are hoping to choose a chassis and engine platform for the 2012 season by June 1 of this year.
The field’s two relative newcomers are BAT Engineering, Indianapolis, led by principals with experience at Lola and other race-car constructors such as Reynard and March, and DeltaWing Racing Cars, Indianapolis, featuring the technical head of Target Chip Ganassi Racing which took the IndyCar champi-
to 0.24. Replacing the rear wing with a vertical fi n keeps the car stable in turns but doesn’t add drag
on straightaways. And the absence of front and rear wings makes the car less sensitive to “dirty” air
when following closely and leaves a cleaner wake.
Simulation and full-size wind-tunnel testing confi rm that 80% of the aerodynamic downforce acts
on the rear of the car, which also supports 72.5% of the mass. This aero and mass balance give better
traction to the 12.5-in.-wide rear tires during acceleration without adding weight. Stability is also en-
hanced by a six-speed, driver-controlled diff erential with full torque vectoring and active stagger that
eliminates the need for diff erent diameters on the inner and outer tires on oval tracks.
Bodywork in front of the front wheels and behind the engine absorbs crash energy to further pro-
tect the driver. Tegris polypropylene composite from Milliken & Co., Spartanburg, S.C., will add impact
and intrusion resistance without adding weight to DeltaWing’s prototype. Compared to glass and
carbon-fi ber composites, Tegris resists two to fi ve times the impact energy, has comparable
stiff ness, and is easier to manufacture and recycle.
Piezoceramic
motors and actuators
piezomotorsto
Piezoelectric motors and actuators have many advantages over conventional electromagnetic (EM) motors for med-ical equipment. Current medical applications for piezoelec-tric devices include ultrasonic emitters, artificial fertiliza-tion, medical nanomicroliter pumps, micromonitoring, surgery devices, and MRI-compatible robots. They are particularly useful for pick-n-place systems as used for microdose dispensing, cell penetration and cell imaging in cytopathology, and medical material handling.
Piezoelectric actuatorsA piezoelectric (or just piezo) actuator is a solid-state de-
vice that uses the change in shape of a piezoelectric material when an electric field is applied to create motion. A piezoelectric-ceramic element produces mechanical energy in response to electrical signals, and conversely, is capable of producing electrical signals in resp
The use of piezoelectric materials dates back to 1881 when Pierre and Jacques Curie observed that quartz crystals generated an electric field when stressed along a primary axis. The term piezoelectric derives from the Greek word “piezein,” meaning to squeeze or press, relating to the electricity that re-sults from pressure applied to a quartz crystal.
Piezoelectric ceramics consist of ferroelectric materials and quartz. Piezo-ceramic elements typically start as high-purity powders of piezo materials such as PZT (plumbum, zirconate, titanate) that are pressed to shape, fired, elec-troded, and polarized. Polarization uses high electric fields to align the material
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RS# 103
DEPARTMENTS READER SERVICES
Letters to the editor: Please include your name, address, and daytime phone number. Letters may be edited for brevity and to focus on essential points.
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ON THE COVERBAT Engineering’s proposed
2012 Indy-car design.
EDITORIALThe formula for innovation
EDITORIAL STAFF
LETTERS
SCANNING FOR IDEASUsing electricity to keep hydraulic and lubricating fluids clean
Medium-pressure ball valve for long-term service
REPORTER’S NOTEBOOK
LOOKING BACK
BERKE ON SAFETYInvestigating farm accidents
isn’t just child’s play
WORLDS’ SMARTEST DESIGN ENGINEER
MOTION & DRIVE TECH GUIDE PRODUCTS
SOFTWARE REVIEWScalable software for gearbox
and driveline engineering
PRODUCT SPOTLIGHTSafety sensors & networks
PRODUCTS
DATA FILES
BUSINESS INDEX
AD INDEX
BUSINESS STAFF
BACKTALK
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MAY 20, 2010MACHINE Design.com4
Why should a photovoltaic system save energy if it can generate an infinite amount from a free source? The answer lies in the total efficiency of the system, and this is where ebm-papst EC technology comes into play. Our energy-saving EC fans cool the important power electronics with minimal load thus delivering the full potential of generated energy. Our products provide a significant improvement in the efficiency via electronic controllability, durability and extremely low power consumption. In doing so, they contribute to the cost-effectiveness of the entire solar power station. For more information
on ebm-papst EC technology, visit www.ebmpapst.us
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Green fan. For green power.
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AC EC
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conventional technology
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RS# 104
What’s new online machinedesign.comE
DIT
OR
’S W
EB
PIC
KS
Win a trip to Napa!Bishop-Wisecarver celebrates its
60th anniversary and is searching for
the most-creative application for its
DualVee linear-guide wheels. One
winner will receive a trip for two to
San Francisco, Napa Valley, or Lake
Tahoe. All it takes to enter is a 60-sec
video, and the deadline is June 15.
For more details, visit http://bwc.com.
Innovation tour hits the road Wago Corp.’s Innovation in
Automation Tour has two vehicles
patterned after trade-show booths
carrying automation, interconnect,
and electronic products across North
America. Each stop features new
products, pick-and-play displays,
interactive demos, and product
samples, along with specialists who
can address specific application
needs. View the schedule or
request a stop at www.wago.us/
innovationtour.htm.
Enclosure sizing software Rittal’s Therm 6.0 enclosure climate-
control specification software,
available at www.rittal-corp.com/
software, helps users select and size
industrial-enclosure coolers for the
best performance and efficiency.
It determines cooling capacity and
recommends the best cooler, based
on factors such as size, ambient
temperature, humidity, and heat
loss from installed electrical
components.
High-density flex circuits Minco’s new brochure and 20-
page test report on high-density
interconnect flex circuits are
available for download at www.
minco.com. The circuits reportedly
save up to 40% of the space and
weight of traditional flex circuits.
NEW VIDEOSRegenerative drivesEngineers from B&R Industrial Automation talk about regenerative-drive
technology and how it relates to sustainable machine design. The discussion
includes active front ends, power factors, cooling options, and servomotor
considerations, as well as advice on where these drives are best applied.
Compact-rail technologyMost linear bearings must have perfectly parallel rails to run smoothly without
excessive friction or binding, but aligning the rails can be time consuming. An
expert from Rollon Corp. discusses linear-bearing alignment and demonstrates
a new design that reduces the need for highly accurate setups. View these at the
Videos section of http://machinedesign.com.
WEIGHTWATCHER PROTOTYPESRapid prototyping large models usually means heavy
parts. Solid Concepts has developed a new polymer
for a stereolithography process called ID-Light, and it
lets designers build thin layers on an internal lattice. In
some cases, it cuts part weight by nearly 90%. See more
at http://engineeringtv.com.
New tutorials and podcasts on Learn Web site
Learn more about PLCs and other industrial control products with several new videos and podcasts on AutomationDirect’s free self-service learning site, http://learn.
automationdirect.com.
The Click PLC Series now spans 14 videos, starting with “What is a PLC?” and progressing through a hardware overview and system configuration tips, installing the FREE programming software, and creating a simple program. Other PLC topics include simple DirectLogic PLC programming examples and the basics of Ethernet communications.
Other new videos include a two-part series on universal signal conditioners. HMI, drives/motors, motion control, and sensor overviews are also available.
A new podcast presents an interview by industry expert Dan Hebert with Jeff Payne, AutomationDirect’s Programmable Controller product manager. Hear a discussion of commercial off-the-shelf technologies and their adoption into industrial-control products.
Visit http://learn.
automationdirect.com to watch these and other tutorials on a range of industry topics.
MAY 20, 2010MACHINE Design.com6
EDITORIAL
With U.S. unemployment still hovering above 9%, there is a lot of hand wringing about innovating our way out of economic malaise. If the economy can create enough start-up companies, so the thinking goes, the benefits will be enough to swamp out poor policy decisions by politicians who created the economic mess in the first place.
Alas, no one really knows the formula for mass-producing start-up compa-nies. Efforts aimed at recreating cradles of innovation like Silicon Valley have generally produced mediocre results.
So it is useful to analyze parts of the world where start-ups do, in fact, flour-ish. The country that probably holds first-place honors in this area is Israel, which has the highest density of start-ups in the world, 3,850 at the most recent count, one for every 1,844 Israelis.
It is fair to ask what kind of environment breeds these sorts of figures. And that is what Dan Senor and Saul Singer did in a recent book called Start Up Na-tion. One thing that becomes immediately clear from their research is that most countries would have a difficult time duplicating Israel’s prowess at minting start-ups.
But perhaps the biggest point in Israel’s favor for nurturing start-ups is the fact that most of its citizens serve in its military, in various capacities, well into their 30s. For one thing, pervasive military service breeds healthy questioning of orders regardless of who gives them. One reason: In civilian life, a lieutenant might well report to one of his sergeants. And Israel’s size (it is a bit larger than the state of New Jersey) oftentimes forces its residents to pick up multiple skills. Their jack-of-all-trades mode of agile thinking works well in many start-up settings.
There is one area in particular where the U.S. could learn something from the factors driving Israel’s start-up mentality. In Israel, a person’s academic past is often less important than his or her military past, say Senor and Singer. Elite forces are trained in finding cross-disciplinary solutions to specific military problems. The same knowledge and experience is ideal, they say, for creating new companies.
That isn’t to say the U.S. services don’t impart the same kind of training, but, “When it comes to U.S. military resumes, Silicon Valley is illiterate,” say Senor and Singer, who go on to remark about the waste of excellent leadership talent coming out of Iraq and Afghanistan: “The American business world doesn’t quite know what to do with them.”
A typical experience is that noted by one American vet who managed large numbers of people and equipment in a war zone. After explaining all this during a job interview, the response was, “That’s very interesting, but have you ever had a real job?”
That kind of attitude doesn’t bode well for the 1.4 million U.S. citizens on ac-tive duty and 800,000 reservists whose military training could help reverse the current economic gloom.
— Leland Teschler, Editor
The formula for innovation
DON’T BE A SPOTTER — BE A QUALIFIER!If you’ve been watching the race for the World’s
Smartest Design Engineer from the grandstands, now
is the time to rev up your engines and hit the track. It’s
fun to watch Automation Boy, NATHAN, nanotube,
and kingph lap each other . . . It’d be even more
fun to beat them!!
RS# 106
MAY 20, 2010MACHINE Design.com8
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>L»]L�NV[�L]LY`[OPUN�JV]LYLK�:4
:LL�\Z�H[�,HZ[�7HJR��)VV[O�����EDITORIAL STAFF
Leland E. Teschler, Editor, [email protected]
Kenneth J. Korane, Managing Editor, [email protected]
SENIOR EDITORSLeslie Gordon,
Stephen J. Mraz
AUTOMOTIVE & NEWS FEATURES
Stephen J. Mraz, [email protected]
CAD/CAM Leslie Gordon,
ELECTRICAL, ELECTRONICS Robert J. Repas, Jr.,
FASTENING, JOININGJessica Shapiro,
FLUID POWERKenneth J. Korane,
MANUFACTURING Leslie Gordon,
[email protected] J. Korane,
MATERIALS Jessica Shapiro,
MECHANICAL Kenneth J. Korane,
[email protected] Jessica Shapiro,
CONTRIBUTING EDITORVictoria Burt, [email protected]
EDITORIAL PRODUCTION Denise Greco,
Editorial Production Manager
Randall L. Rubenking, Art Director
1300 E. 9th St. Cleveland, OH 44114-1503
RS# 108
MAY 20, 2010MACHINE Design.com10
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RS# 109
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LETTERS
I was professionally involved as a designer and chief engineer in four light-aircraft companies, so I have some relevant knowl-edge and experience in the area.
For approximately 50 years — from 1925 through 1975 — the cost of a starter small airplane, was approximately the cost of a Cadillac or Lincoln car. And dur-ing that time, the U.S. dominated the manufacture and use of light aircraft. The country built about 25 ,000 aircra f t per year from 1965-75. And liability insurance
A dogfight over light aircraft
I generally read Mr. Berke’s safety column and find it informative. I am an aeronautical and me -chanical engineer and have been looking into doing some foren-sic-engineering work, so I’m at-tending meetings of the National Academy of Forensic Engineers.
However, I was disappointed that Mr. Berke didn’t address one of the points made by Mr. Brian Winter in his letter to the magazine (“Engineers and liabil-ity,” Letters, March 18), namely, the destruction of the American light-aircraft industry by law-suits.
Safety is important, but so is the recognition that lawsuits are sometimes settled unfairly due to lack of understanding by juries and a plaintiff ’s attorney’s overly aggressive sense of justice.
for the manufacturer was a small percentage of the cost of each unit.
But between 1975, when strict liability reform began, and 1985, the cost of that same airplane soared to 10 to 20 times the cost of a Cadillac or Lincoln while the cost of liability insurance became nearly 50% or more of the selling price. In the same period, the to-tal output of the industry went from approximately 25,000 units per year to under 1,000.
Surely 50 years of fine prod-
Does liability set up a no-fly zone?
A reader takes issue with our safety columnist’s views on whom to blame for the demise of the general aviation industry.
RS# 110
MAY 20, 2010MACHINE Design.com12
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RS# 111
The exact automation products you need, faster.
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SENSORS | NETWORKS/FIELDBUS | RFID | CONNECTIVITY | INTRINSIC SAFETY
LETTERS
tude, but I was getting concerned.
When I arrived at my home airfield,
on final approach and about 100
feet off the ground, it happened a
third time. Because I had just gone
through this twice before, I was
able to properly land the aircraft
and taxi to the hangar. I asked my
friend who has been sitting behind
me what was going on. She told
me her leg was cramping on her
and she was stretching her leg out
each time my seat was released.
I checked out my seat from the
back seat and found I could reach
under the front seat and release its
locking mechanism.
When I got home, I wrote a let-
ter to Cessna and the FAA describ-
ing the events, and recommended
a steel plate be required to cover
that opening so no one could inad-
vertently release the seat-locking
mechanism. I received letters from
both Cessna and the FAA telling
me the problem that I had identi-
It is my general opinion that the
light-airplane industry brought
their problems onto themselves by
not putting out good, safe prod-
ucts, and that the FAA let them do
that.
Let me give you an example of
my experience. I am a licensed pi-
lot with an instrument rating, even
though my medical is not up to
date.
Many years ago I flew my wife
and another couple to another
city and back. The aircraft was a
Cessna 172. Part way into the first
leg of the flight, my seat lurched
forward and I was laying against
the yoke (steering wheel for those
of you who are not familiar with
aircraft). I was at a safe altitude
so everything was all right, even
though I was startled. We landed
and I checked out my seat but
couldn’t find a problem.
On the flight home, it happened
again. Again, I was at a safe alti-
ucts didn’t become hazardous overnight. As Mr. Winter inferred, many of those same aircraft, now 35 to 60 or more years old, are still safely flying.
The same thing has happened to the medical profession. I know excellent doctors who are ready to just quit rather than fight the lawyers.
I believe in safety and safe products, but something has to be done. The only real produc-tion of wealth is manufacturing, making something of more value from something of lesser value. Transferr ing large amounts of money to the pockets of lawyers adds nothing to the well-being of the country as a whole.
As I get into forens ic eng i-neer ing, my sk ills will be used to defend manufacturers where, in my opinion, they are unfairly targeted.
Roland Friestad
RS# 112
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RS# 113
Visit our website for our complete product range: www.linak.com
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Our innovative electric systems are being used to upgrade gas spring and manual operations, and due to their simplicity and state of the art designs, are rapidly replacing hydraulic and pneumatic systems.
LINAK has a selection of reliable actuators to provide your application the movement you desire.
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LETTERS
lack of judgement on the part of pilots. Statistics bear this out.
Any such design flaws I discov-ered while in charge of aircraft manufacturing were corrected as soon as possible. I was not always popular with the front-office man-agement and “bean counters” but always had the full cooperation of the FAA in any such matters.
I, too, am a licensed pilot and owned a Cessna 172 for many years. I never ran into the situa-tion you describe, or any others that I could attribute to design deficiencies. (And Cessna was not one of the companies for which I worked).
The huge pro f i ts to wh ich you refer are only in your mind. Any light aircraft company that makes even a 5% profit considers itself very fortunate.
It is obv ious to me that we must agree to disagree.
— Roland Friestad
ation aircraft did not suddenly be-
come hazardous. They were haz-
ardous all along. — Lanny Berke
Mr. Berke:Your experience, while extremely serious and certainly deserving of immediate correction by the manufacturer, doesn’t seem to me to warrant an across-the-board statement that light aircraft were “hazardous all along.” On the other hand, flying does have inherent hazards, but to make a blanket condemnation of the industry be-cause of your single case seems pretty short-sighted.
I do know of cases of design or manufacturing flaws that have resulted in injury and fatalities and they are tragic and highly regrettable. These are far out-numbered by deaths and injuries caused by flying under the influ-ence of alcohol or drugs, “shade-tree” maintenance, and just plain
fied was not actually a problem
at all.
A few years later, the FAA issued
a directive that the open space that
let a back-seat passenger release
the front seat locking mechanism
be blocked with a steel plate.
I wonder how many people were
killed by this design flaw and the
FAA called it pilot error. This was
only one problem I ran into, but
there were others that Cessna and
their suppliers should have found
and not relied on the public to be
their test laboratory.
Now it appears the light-air-
plane manufacturers have their
act together with one possible ex-
ception. I do not see any reason
for general-aviation aircraft to be
priced at $250,000 to $500,000
other than to give the companies
huge profits on the sale of each
aircraft.
You make one very good point:
Over a 50-year span, general-avi-
RS# 114
MAY 20, 2010MACHINE Design.com16
[ MOTOR TRUTH #2 ]
Can I really save
money by installing
a smaller motor?
The truth? You just might be able to. If you look at
your entire drivetrain, you’ll probably find that if you
replace inefficient components (which can waste
up to 50% of the energy they use), you’ll be able
to install a new, smaller, high-efficiency DR motor
and still get the power output you need.
And, you’ll save energy at the same time, because
your current oversized motors may be wasting
energy to overcome the inefficiencies of your
entire drivetrain.
SEW’s new DR motor series is specifically designed
to work with a total system, including our helical
bevel gearboxes and electronic drives, to provide
you with maximum energy savings. Get the
whole story and learn how the DR motors are
the newest piece of the energy savings puzzle
at sewmotortruth.com.
sewmotortruth.com
RS# 115
SCANNING FOR IDEASEdited by Stephen J. Mraz
Mechanical filters have been around for centuries, and modern ones can keep hy-draulic and lubricating fluids clean of particles larger than 5 microns. But particles smaller than that slip by and create sludge and varnish, damage equipment, and drastically reduce the life of the fluid. Bal-anced Charge Agglomeration, a new fluid-purifying approach from ISOPur Fluid Technolo-gies, North Stonington, Conn. (www.isopur.com), helps filtration systems capture all impurities by forcing smaller particles to clump together, thus making them “more eas-ily removed by mechanical filters.” This extends the life of the fluid and equipment, and reduces maintenance, downtime, and defects due to faulty machinery. It also means companies don’t have to dispose of as much dirty oil as they once did.
The new method splits fluid flow into two streams. One stream receives a strong positive voltage, giving particles in that stream a positive charge. The other stream gets a negative charge. When the streams re-join, the positive and negative particles are attracted to each other and clump together, forming ever-larger particles that can be picked out by a mechanical fil-ter. This works on sludge and ferrous and nonferrous metal particles, as well as insoluble oxides and bio-
Using electricity to keep hydraulic and lubricating fluids clean
logical contaminants. And in the case of oil, once it is clean, it acts as a strong solvent to break down varnish and sludge, preventing valves from sticking and let-ting machinery run properly.
The company makes several models with flow rates ranging from 30 to 1,200 gph. They attach to lubricating or hydraulic lines via a kidney-loop hook-up to process fluid. It works on lubricating, hydraulic, and machine oil, EDM and dielectric flu-ids, vegetable oil, and phosphate ester, along with many other nonconductive fluids.
RS# 401
Incoming fluids contain many particles too small
to be extracted by mechanical
filters.
+Vdc
–Vdc
Particles are given a positive charge.
Particles are given a negative charge.
Negatively and positively charged particles clump
together, becoming large enough to be filtered out by
mechanical means.
Vent sample
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mix
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vesse
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vesse
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Outlet shutoff valve
0.5-in. outlet
Electrical controls and
indicators
Customer power
Overpressure bypass
Pump/motor
Inlet strainer
Inlet shutoff valve
0.5-in. inlet
Fluid flow
Drain DrainDrain
Fluid flow
MAY 20, 2010MACHINE Design.com18
Match Threaded Detent PinsWith A Variety of Knobs
Versatile threaded detent pins can befit with a wide selection of knob han-dles for your application. These solidquick-release pins have a groundshank and a threaded end. Shank di-ameters are available from 3/16" to1/2", along with metric sizes, and griplengths from 1/2" to 4". Pins come withbuilt-in locking balls, which are held inplace by spring force — push to insert,pull to remove.
ISO 9001-2008 CERTIFIED
MANUFACTURING CO.4200 Carr Lane Ct., P.O. Box 191970
St. Louis, Missouri 63119-7970Phone: 314-647-6200, FAX: 314-647-5736
Web Site: www.carrlane.com
Carr Lane has the best selection of ball lock and detent pins, aswell as dozens of other alignment pins for manufacturing.
Carr Lane offers standard components to help you increasequality and productivity. Visit CarrLane.com and searchour online catalog for alignment pins and any of our100,000 other products.
R
Toggle Clamps with Safety Locks.Carr Lane has introduced a variety ofnew toggle clamps with optionalsafety locks, including latch-action,vertical-handle, horizontal-handle, andpush/pull types. All Carr Lane toggleclamps have a comfortable handlegrip, in steel or optional stainless.
Carr Lane Mfg. Co., www.carrlane.com
Knobs, Handles, Hand Wheels. Needto take hold? A variety of knobs,handles and hand wheels, in metal orplastic, are available from Carr Lane.Many new items.
Carr Lane Mfg. Co., www.carrlane.com
Simple and Versatile...
Threaded detent pins areavailable in stainless steel.Knob handles can be or-dered in steel, stainlesssteel, or plastic.
Carr Lane has dozens ofalignment pin types
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Hoist Rings. What an assortment!Pivoting, swivel, and side-pull swivelhoist rings, along with lifting eyes.Choose from low profile versions toheavy-duty, extra large hoist ringswith load capacities up to 250,000 lbs.
Carr Lane Mfg. Co., www.carrlane.com
RS# 116
RS# 193
RS# 194
RS# 195
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Medium-pressure ball valvefor long-term service
Engineers at Swagelok, Solon Ohio (www.swagelok.
com), have expanded the company’s FKB line of medium-pressure ball valves by adding one capable of handling pressures up to 15,000 psig. The 8FKB two-way ball valve features a 316 stainless-steel body with reinforced PEEK seals. It operates in temperatures from 0 to 250°F (–17 to 121°C). And users have a choice of several O-ring ma-terials, including nitrile, fluoroelas-tomer, and perfluoroelastomer.
It takes relatively little torque to actuate the valve, and if pneumatic actua-tion is required, the company makes ISO-5211-compliant actuators. The positionable handle gives users flexibility in laying out control pan-els by reducing clearances with other components.
RS# 402
Request free information via
our Reader Service Web site at
RS# 117
End connections reduce installation time and costs. They also resist vibrations.
Bottom-loaded stem
design eliminates
stem blowout
and enhances operator
safety.
Positionable handle with
stop disk
Trunnion-style ball with direct-load design reliably seals across a
full range of pressures.
Stem and end-connection seal maintains full pressure rating
throughout operating temperature range. It also reduces seal wear.
MAY 20, 2010MACHINE Design.com20
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RS# 118
REPORTER’S NOTEBOOK
Steam treating hay
A farm manager has developed a machine, the DewPoint 6110, that frees farmers from rely-ing on Mother Nature to make their hay suitable for baling. Until Dave Staheli and his firm Staheli West, Cedar City, Utah, developed the DewPoint, farm-ers had to wait for the right dew conditions to moisten hay enough so that the nutritious leaves wouldn’t fall off during baling. Too much dew, or worse, rain, and the hay is too wet. Not enough dew, and most the leaves end up on the ground, not in the bales.
Inspired by a tortilla warmer that used steam, Staheli built a device that injects steam into the hay as it is picked up. The wheeled machine rides between the tractor and baler. It includes a low-pressure boiler to make steam, along with water and fuel tanks, a generator, water-feed system, and a DirectLogic DL06 PLC controller from Automation-Direct, Cumming, Ga. There’s also a C-More touchscreen control panel, also from Automation-Direct, in the tractor’s cab. The screen lets the driver control ev-ery aspect of the DewPoint, from start-up to shutdown.
The PLC controller accepts doz-ens of discrete and analog inputs, including boiler parameters, bale temperature, and crop flow as it moves through the DewPoint Hay Baler. Based on these vari-ables, especially bale chamber pressure, the PLC determines the right amount of steam to inject via several distribution manifolds mounted in the hay baler. The goal is to get hay to moisture levels of
12 to 15% while baling. And the pressure exerted by the walls of the baling chamber (bale-cham-ber pressure) correlates well with bale moisture levels.
Staheli chose controllers from AutomationDirect based on price,
technical support, and the wide variety of single-sourced com-ponents the firm offers that work well together. The machine also incorporates an OnCell Cellular IP modem from Moxa, Brea, Calif. It lets farm managers remotely mon-
makes it easier to bale
The DewPoint 6010, the red trailer between the tractor and the baler, injects low-pressure steam into the hay as it passed through on the way to the baler.
A touchscreen controller in the
tractor’s cab lets the driver
monitor and adjust a variety
of variables in the DewPoint
6010.
MAY 20, 2010MACHINE Design.com22
when needed.Farms equipped with a Dew-
Point 6110 can bale any time of day or night, providing it isn’t rain-ing and there isn’t too much dew on the fields. In the past, farmers had to wait for the right weather, then put a tractor and baler in the field to bale 40 to 60 acres. This means medium-sized hay farms (2,000 acres), often needed four sets of tractor and balers, with each baler rig costing $250,000. And in the course of a year, each baler might operate fewer than 100 hr. In contrast, the DewPoint lets hay farmers cut their capital costs from 1 million dollars to $400,000. It also gives them much more latitude in when they harvest and bale hay.
Not only is baling less expensive and more conve-nient, studies done at the University of Wisconsin found that leaf loss on hay baled with a Dew-Point is only about half that of hay baled at night during prime dew conditions. Using the machine costs between $1 and $1.25/ton of hay, and that includes chemicals to treat the boiler water, and diesel fuel for the generator and to tow the DewPoint. MD
itor and control several DewPoints simultaneously. This is helpful when a farmer has inexperienced operators out in the field carrying out baling operations. It lets the farmer “look over the shoulder” of new operators and offer advice
Request free information via
our Reader Service Web site at
AuomationDirect, www.
automationdirect.com
Circle 406Moxa, www.moxa.com
Circle 407Staheli West, www.staheliwest.
com Circle 408
Simulation unlocks the mysteries of crack formationResearch physicists at Northeastern Univ. in Boston using large-scale computer simulations have finally de-termined how cracks form and grow in materials such as steel, glass, nano-structures, and human bone. “The simulations help us understand what path cracks follow as they propagate in a stressed material,” says team lead Alain Karma, director of North-
eastern’s Center for Interdisci-plinary Re-search on Complex Systems. “This is
useful in developing materials for aircraft turbine blades, microelec-tronic circuits, and artificial bone that can better resist crack formation and propagation.”
Researchers began by examining the effects of two types of stress on crack propagation: shearing and ten-sion. Shearing causes two contacting layers to slide upon each other in op-posite directions and parallel to the plane of contact. It happens when material is twisted out of shape. The combination of shearing and tension initiates cracks.
Large-scale computer simulations revealed the surprising result that shearing and tension cause cracks to take the shape of a helix. Based on the results, the researchers developed a theoretical equation to predict how the helix would rotate, expand, and multiply in different materials.
This research could lead to lighter automobile and aircraft parts, and composite artificial bones that don’t fracture. The results are also providing insight into the evolution of geologic faults and fractures in the Earth’s crust. MD
Center for Interdisciplinary Research on Complex Systems, Northeastern Univ., www.circs.neu.edu
Why wet hay bales are fire hazards
It seems counterintuitive that bales of wet hay
can turn into fire hazards when packed into a barn,
but it’s true.
When hay is cut, it is not killed. The plant cells still breath
and metabolize, releasing heat into the bale. This is usually
no problem other than the bales lose nutritional value.
But if the bales’ internal temperatures are high enough,
and there’s enough moisture, bacteria on the hay can feed
and multiply, bumping up temperatures to about 135°F.
These temperatures, along with excess water, make prime
breeding grounds for another form of bacteria which can,
in turn, convert the hay into a porous carbon sponge and
raise temperatures inside bales to 170°F. If this hay is then
exposed to oxygen, it can self-ignite.
The DewPoint 6110
adds the ideal amount
of moisture to make
perfect bales of
hay anytime
MAY 20, 2010 MACHINE Design.com 23
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Alfmeier took the problem and a sample of a high-performance, high-
cost material that met their needs to Fabrico,
Kennesaw, Ga. Ultimately, Fabrico engineers recommended
encasing the existing bladders in a “bag” of polypropylene felt.The durable, silky material is commonly
used as a filter in pharmaceutical, beverage, and fuel applications. In addition to withstand-
ing inflation-deflation cycles of the bladders, the felt meets U.S. and international supply specifications for flame retardancy of interior trim materials in pas-senger cars, multipurpose passenger cars, commercial vehicles, and buses.
Fabrico engineers proposed four die-cut felt pieces be wrapped around and between the lumbar bladders and sewn into a bag that would glide over the seat-cushion foam instead of abrading it.
Currently, Fabrico procures the material, die-cuts and orients the parts, and ships kits from its plant in Ontario, Calif., to one in Monterey, Mexico, near the Alfmeier assembly facility in Apodaca where the final wrapping and sewing is done.
The arrangement gave Alfmeier a local supplier, and polypropylene felt cut the cost of protecting the lumbar support bladders while extending bladder life. Lower costs made the system more attractive to cus-tomers, including Mercedes. MD
× 54-mm assembly. It must perform reliably for 10,000 inflation-deflation cycles with a normal operating pressure of ap-proximately 4.4 psi and hold 12 psi without bursting.
Alfmeier engineers discovered bladders rubbing against the foam of the seat cushion caused prema-ture wear to both the foam and the bladder, noise, and problems adjusting the back support. They needed to isolate the bladder from the foam without affecting the inflating and deflating process and still meet customer flammability standards.
Engineers in the Seating Comfort business unit of Alf-meier Präzision AG, Treuchtlingen, Germany, ran into a problem with lumbar-support devices they supply luxury automakers like BMW. The modular subsystems give the driver electropneumatic control over the seat contour with massage and memory func-tions, but the units were failing prematurely and damaging adjacent seat foam.
The electropneumatic, valve-driven unit lets the driver de-termine the amount of air that inflates a rubber-bladder assembly, controlling softness and back support. The entire lumbar support is composed of three 18-gage-thick bladders welded into a 414
Enhanced driver’s seat comfort is in the bag — with polypropylene felt
The lumbar
subsystem developed by
Alfmeier Präzision for front seats in luxury cars uses an air-actuated polypropylene
bladder that can be inflated and
deflated at least 10,000 times.
Alfmeier Präzision, www.alfmeier.de
Fabrico, a division of EIS, www.fabrico.com
Circle 409
RS# 119
MAY 20, 2010MACHINE Design.com24
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REPORTER’S NOTEBOOK
transit buses, says Hartter.Although fuel economy is the key
driver behind hybrid technology, pro-ductivity and drivability demand equal billing, says Andreas Johansson with Parker Hannifin AB, Trollhättan, Swe-den. Parker’s RunWise hydraulic-hybrid transmission addresses those issues, he says, and reduces fuel consumption from 30 to 50% in Class 8 refuse ve-hicles, compared to baseline vehicles.
The RunWise transmission has a two-speed hydrostatic drive for ur-ban driving combined with mechani-cal direct drive for efficient operation at highway speeds. It also has high-pressure accumulators that capture braking energy and reuse it to help accelerate the vehicle. A digital con-troller handles pump/motor opera-tion, gear shifting, and accumulator charging and discharging, as well as operations of the diesel engine.
Compared with conventional trucks, tests show the RunWise trans-mission accelerates refuse trucks faster without affecting fuel savings, says Johansson. There is also less brake wear, thanks to hydraulic-energy recovery, and less noise. The RunWise should pay for itself in fuel and maintenance savings in 4 to 5 years, says Johansson.
Vincent Duray of Eaton Corp.,Eden Prairie, Minn., explained the advantages of its parallel-hydraulic hybrid called Hydraulic Launch Assist (HLA). It contains hydraulic components and controls similar to those in a series hybrid. However, it
Energy efficiency was the focus of the 7th International Fluid Power Conference, held recently in Aachen, Germany. So it’s not sur-prising that many of the technical discussions centered on hydraulic-hybrid vehicles (HHVs).
HHVs offer greater power den-sity than electric hybrids and are therefore more efficient at recover-ing and reusing braking energy, explains Larry Hartter of FEV Inc.,Auburn Hills, Mich. While electric hybrids typically return 30% or less of the braking energy back to the wheels, hydraulic hybrids can re-turn as much as 70%.
However, with R&D progress-ing on several fronts, there is no consensus on the best HHV design. FEV favors serial hybrids. These typ-ically have one or more pump/mo-tors (P/Ms) connected to the driv-ing wheels, a P/M connected to the internal-combustion engine, along with interconnected accumulators. There is no direct mechanical link between the engine and wheels.
When compared with other designs, the series hydraulic hybrid offers better fuel economy than parallel (launch-assist) hybrids that only recycle braking energy, says Hartter. And series hybrids eliminate the additional costs and weight of hydromechanical (power split) hybrids.
Though the series hybrid recov-ers braking energy, decoupling the engine from the wheels is the pri-mary reason for a series HHV’s high fuel economy, says Hartter. This lets the engine operate where it is most efficient, that is, at higher torque with fewer engine transients.
Initial road tests of a hydrau-lic-hybrid delivery vehicle work-ing a typical route in Detroit demonstrated a 45 to 50% de-crease in fuel consumption. This shows that series hybrids are a viable option for commercial ve-hicles such as delivery trucks and
Hydraulics researchers stress energy efficiency
Eaton, www.eaton.com
Circle 410
FEV, http://fev.com Circle 411
Lumex, www.lumex.biz
Milwaukee School of Engineering, www.msoe.edu
Parker Hannifin, www.parker.com
Circle 412
Voswinkel, www.voswinkel.net
RS# 121
MAY 20, 2010MACHINE Design.com26
REPORTER’S NOTEBOOK
transfer and reduces temperature dif-ferences. This increases reversibility of gas compression and expansion and, therefore, efficiency. Test results in work cycles typical of hydraulic-hybrid vehicles show the regenera-tor’s power efficiency was in the 97% range, versus about 80% for gas/oil accumulators.
Hybrids weren’t the only focus at Aachen. Engineers from Voswinkel GmbH, Meinerzhagen, Germany, introduced a new type of hydraulic-hose fitting that reportedly improves flow efficiency in hydraulic circuits. They note that standard fittings, when crimped, slightly collapse the nipple and restrict the ID. The compa-ny’s new uvos-m fittings have a cor-rugated socket that, when crimped onto hose, tightly grips the reinforce-ment without nipple ID collapse, ac-cording to the company’s Fritz-Georg Weiland.
In size DN 19, the fittings increase internal-flow area about 10%. For flow rates of 200 lpm, pressure losses drop by 24% in the DN 19 and by 34% in DN 25 fittings. On a mobile machine with just two hydraulic lines, the DN 25 uvos-m can save about 130 liters of fuel/1,000 hr of operation, says Weiland.
Even the type of fluid makes a difference. Paul Michael of the Mil-waukee School of Engineering ex-plained that although straight-grade hydraulic fluids are used in many fluid-power applications, multigrade hydraulic fluids are a better choice in commercial vehicles and mobile equipment where temperatures vary widely. Even though they cost more than straight-grade fluids, savings with these so called energy-efficient hydraulic fluids can be substantial.
At low temperatures, multigrade fluids reduce hydromechanical losses due to viscous drag. And at high temperatures, volumetric efficiency improves in many kinds of pumps. Field trials in skid steer loaders and excavators show this equates to fuel-efficiency improvements of 14 to 22%, and machine productivity improves as well. Savings are said to exceed 10,000 Euros over the life of the fluid. MD
augments, but does not replace, a truck’s existing drivetrain.
Parallel hybrids use regenera-tive braking to improve fuel econ-omy in refuse trucks by 15 to 30%, based on duty cycle, says Duray. It also reduces brake wear.
Although a series hybrid saves more fuel by managing engine speed, admits Duray, parallel hy-brids offer several advantages. For example, it readily retrofits to exist-ing vehicles. HLA’s modular design lets it install in new or existing vehicles without extensive altera-tions or design changes to other major vehicle subsystems. Parallel hybrids connect to the vehicle’s drivetrain between the transmis-sion and differential.
Parallel hybrids also improve acceleration and significantly reduce heat generation, engine-power output, and loads on the torque converter and transmission. This reduces failures in driveline components or, as an alterna-tive, permits smaller components that lower initial investment and weight. And the vehicle continues to function even if the hybrid sys-tem fails.
As noted previously, hydraulic-hybrid vehicles and many other machines rely on hydropneumatic piston or bladder accumulators to recover and reuse energy. But under a wide range of operating conditions, thermal losses in the accumulators themselves can be substantial, explains Alexander Stroganov of Lumex Ltd., St. Pe-tersburg, Russia.
His company has developed a fluid-power storage device that significantly reduces thermal losses. Called a compressible metal regenerator, it provides nearly isothermal gas compression and expansion. The design relies on a series of flexible-metal leaves di-viding the gas reservoir within an accumulator shell — a design read-ily manufactured via conventional methods, says Stroganov.
Segmenting the gas volume into thin layers with metal ele-ments, he explains, improves heat
RS# 123
REPORTER’S NOTEBOOK
was to establish equations for servomotors so the bottom end of a lapper arm moved at a constant velocity as a punch lowered. The
An engineer used Grafi-Calc simulation software to define the concept for a machine intended to punch-out dog-food bis-cuits. The software lets users “premodel” designs before CAD by drawing skeleton geometries that represent the design’s functional intent — not its form. The process has been likened to sketch-ing on the back of an envelope. GrafiCalc simu-lates and solves kinemat-ics. It also handles static and tolerance stack-up analyses and includes a geometry Goal Seek fa-cility that helps optimize designs in terms of shape, posi-tion, and fit criteria.
The initial challenge in the de-sign of the dog-biscuit machine
Wind-powered car goes for a speed recordThe world record for a wind-powered car is 126.1 mph, set last year by Brit-ish engineer Richard Jenkins on a stretch of the Mohave Desert near the California-Nevada border. But if engineering students at Lehigh Univer-sity have their way, that record won’t stand much longer.
Their design for a “land yacht” features not sails but tall, inwardly canted wings. According to the student design-ers, the yacht magnifies wind speed by keeping a narrow angle between its vertical wings and the wind direction. The smaller the angle, the more speed a yacht draws from the wind. As the
The GraphiCalc sketch captures the machine’s four-bar linkage using lines (not the complete geometry of the lapper arm). The geometry of the mechanism was back-solved using inverse kinematics to establish a constant velocity for the end of the lapper arm, point C.
Software automates back-of-the-envelope calculations
RS# 125
MAY 20, 2010MACHINE Design.com30
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engineer first sketched the skel-eton geometry and constrained it to reflect functional intents. The engineer then back-solved the geometry of the mechanism using inverse kinematics to establish a constant velocity for the end of the lapper arm. He imported transient values for the actuator’s length into Excel to develop servomo-tor equations. The software thus helped conceptualize, analyze, and validate critical engineering parameters in the earliest stages of design.
According to the engineer, the analysis took about an hour to get a solution with GrafiCalc. In con-trast, he estimates a design time of about one month using the “build-test-fix” method with a midrange CAD package and a motion-sim-ulation add-on and data-analysis software. MD
yacht moves, however, the wings generate a force perpendicular to the wind direction. The yacht’s wheels must counter this side force to keep the vehicle running straight. So students are busy designing tires and a suspension that will supply this counter force but not increase drag or friction enough to slow down the yacht.
The wings mount 15 ft from the main fuselage. This configuration should give pilots better aerody-namic control over pitch, roll, and yaw, the student designers say. MD
Lehigh University, www.
lehigh.educ
Geomate Co., www.
inventbetter.com
Circle 413
RS# 127
RS# 126
MAY 20, 2010 MACHINE Design.com 31
154 Hobart St., Hackensack, NJ 07601
TEL: 201-343-8983 ) FAX: 201-343-2132
www.masterbond.com ) [email protected]
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Vertical Motion Arms that field-adjust to any load. Any workspace. And any operator.
Hoff man® Brand SYSPEND™ Vertical Motion Arms quickly fi eld-adjust for diff erent
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Hoffman® SYSPEND™ offers:
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New Way Air Bearings,Aston, Pa., fit the bill. Com-pressed air sent to the bearing disperses between the bearing and the surface through a carbon material with thousands, perhaps millions of holes. This even dispersion of air gives the bearings almost zero friction.
The bearings are also relatively inexpensive yet durable enough to stand up to daily student use. They are also easy to use and align and can be quickly set up and broken down, a must for lab setups that change every week. The bearings also provide translation and rota-tion motion. MD
Not many engineering students have an intuitive feel for the way capaci-tors, inductors, and resistors work together in viscously damped systems. To give them that kind of understanding, a professor at the Massachusetts Institute of Tech-nology developed a lab curriculum that explains electrical components in terms of their mechanical corollaries: masses, springs, and dampers. But to make systems of mechanical and elec-trical components more analogous, the professor needed a zero-friction bearing. Using off-the-shelf roller bear-ings, even those with the lowest rolling frictions, would not work because even that small amount of friction masks the effects of damping.
Porous-media air bearings from
Air bearing gives engineering students a feel for electronics
New Way Air Bearings, www.newwayairbearings.com
Circle 414
RS# 129
Call us at 1-888-260-7466 or fax us at 516-867-5656
or Email us at [email protected]
See us at www.RinoGB.com
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REPORTER’S NOTEBOOKLOOKING BACK
10 YEARS AGO — 2000IBM rolls out a “Web” computer:IBM’s NetVista line of computers claim to be the first designed from the ground up for fast, high-bandwidth Internet access. IBM heralds it as the most dramatic and significant roll out
of desktop technology since its first PC almost 20 years
ago. The com-puter
will feature a seven-port universal serial bus, 256-bit encryption, a 15-in. flat dis-play, and wireless LAN. Also included are CD/DVD and floppy drives, built-in speakers, two slots, and three bays. The computers will cost less than $2,000.
30 YEARS AGO — 1980Tail fins may cut aircraft’s fuel use:Engineers are Lockheed-Georgia Co.estimate a newly designed twin fin for the C-130 Hercules transport will cut fuel consumption by at least 3% on long flights and 6% for low-altitude missions. Called an af-terbody strake, the device consists of two 7-ft-long alumi-num/fi-berglass fins which are attached under-neath the propjet’s tail section. The fins are designed to eliminate turbulence and reduce drag. While the strakes can achieve significant fuel savings, another option is to burn the same amount of fuel but boost the aircraft’s speed by 18 knots, from 300 to 318.
50 YEARS AGO — 1960Nuclear punch for a lightweight fighter: Head of the line of mixed mis-siles that are carried by the Air Force’s F-102 is the GAR-11 Nuclear Falcon. The first air-to-air missile with nuclear capa-bility, it is designed for use in head-on attacks on supersonic bombers. Hughes Aircraft Co. devel-oped the weapon with a radar-guidance system, which can launch it without the pilot seeing the target, and guide it to en-sure a “kill.” Described as small, consid-ering its capabilities, the Falcon is 7-ft long and weighs 200 lb. MD
MAY 20, 2010MACHINE Design.com34
REPORTER’S NOTEBOOKCOMPANY NEWS
IN-STOCK PRODUCTSElectronic-components distributor Digi-Key Corp., Thief River Falls, Minn., has expanded its inventory to offer products from the following companies: The Mini-Fit H
20 sealed
connector system from Molex, Lisle, Ill.; the Zippy2 Ethernet Combo
Board, the KSZ8851SNL-BBE-EVAL evaluation board for the KSZ885SNL Ethernet controller from Micrel Inc., San Jose; sealed power plugs and jacks from Switchcraft Inc., Chi-cago; and the PTSM Series PCB ter-minal blocks from Phoenix Contact Inc., Middletown, Pa.
RESEARCH GRANTRE2 Inc., Pittsburgh, Pa., has been awarded a Small Business Innova-tion Research grant to research and design a modular intelligent manipulation system with intuitive control for the U.S. Army’s Tank and Automotive Research, Devel-opment and Engineering Center. RE2’s design will increase the ef-fectiveness of robotic manipula-tors on UGVs by giving operators the sensation that his or her arm is actually manipulating an object. RE2 is a developer of modular ma-nipulation systems.
3D PRINTERS HIT THE MARKETStratasys Inc., Eden Prairie, Minn., has delivered its first shipments of Hewlett-Packard 3D printers to five European markets: France, Germany, Italy, Spain, and the U.K. The printers are codeveloped by HP and Stratasys, an additive-fabrication-system maker.
STOCK EXPANSIONMouser Electronics Inc., Mans-field, Tex., an electronic-compo-nent distributor, has more than doubled its stock of interconnect products from Hirose Electric Co., Simi Valley, Calif. The products include FFC / FPC connectors, wa-terproof circular connectors, and I/O connectors.
FREE VISION TECHNOLOGY SEMINARSCognex Corp., Natick, Mass., a supplier of machine vision and industrial-ID systems is offering free vision-technology seminars to be held throughout the U.S. and Canada. The half-day event dem-onstrates vision and industrial ID systems for automated inspection tasks and traceability initiatives in the automotive, pharmaceutical, food, beverage, consumer pack-aged goods, pharmaceutical, med-ical, and electronics industries. For more dates, information, and online registration, go to www.
cognex.com/seminar or call (800) 677-2646. MD
RS# 132
MAY 20, 2010MACHINE Design.com36
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REPORTER’S NOTEBOOKCOMPANY NEWS
ity, etc.), and educational facility (any organization that conducts welding education or train-ing). Deadline for submission is July 12, 2010. Go to www.aws.
org/awards/image.html for nomi-nation forms and information.
AWARDSTaiyo Yuden (U.S.A.) Inc., Schaumburg, Ill., has named Avnet Electronics Marketing Americas, Phoenix, as its 2009 Distributor of the Year. Avnet distributes Taiyo Yuden’s surface-mount and leaded passive com-ponents, Bluetooth modules, power electronics modules, power supplies and recordable digital media. Avnet distributes electronic components from leading manufacturers and asso-ciated design-chain and supply-chain services.
Bosch Rexroth, Rochester, Mich., a specialist in drive and control technologies, received an MI Earth Day Award during the MI Earth Day Fest in Roch-ester, Mich. The award recog-nizes a company operating in Michigan that is dedicated to clean technologies and prac-tices. Bosch was honored for its industry-leading, fuel-efficient and vehicle-emission-reducing technologies, such as hydraulic hybrid technology, along with its work in other areas such as solar energy, wind energy, and ocean energy development.
STRATEGIC PARTNERSHIP AGREEMENTKollmorgen, Radford, Va., a man-ufacturer of driverless-control technology, and Knapp System-integration GmbH, a warehouse automation specialist, have reached an agreement, where Knapp will license and integrate Kollmorgen’s NDC Suite technol-ogy in warehouse applications for automated order-picking and automating standard forklifts for operatorless transport applica-tions on a global basis. MD
CALL FOR ENTRIESThe American Welding Society (AWS), Miami, has issued a call for entries for the 8th Annual Image of Welding Awards. The awards are open to all welding-industry professionals.
Awards are issued in seven
categories: Individual (you or other individual), Section (AWS local chapter), large business (200 or more employees), small business (less than 200 em-ployees), distributor (welding products), educator (welding teacher at an institution, facil-
RS# 134
MAY 20, 2010MACHINE Design.com38
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RS# 135
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BERKE ON SAFETY
accidents isn’t just child’s play
A farmer seriously injured his foot, leg, and ankle when he was thrown from a hay rack. His father had been towing the rack behind a tractor and baler while his son stacked bales onto the hay rack.
When they finished, they pulled onto country roads to deliver the hay to a barn a few miles away. The father was still driving the tractor and the son was sitting on a bale in the middle of the rack.
At a four-way stop, the father slowed and made a sharp right-hand turn. Bales of hay bounced out of the rack on both sides, and the son was thrown from the vehicle to the right.
The injured man sued his father and his father’s insurance company for his injuries and damages. The court case hinged on whether the man had been doing something that caused his fall, independent of his father’s actions while driving.
Two witnesses said the hay rack’s right wheels hit one of Minnesota’s famous springtime potholes about 30 ft from the intersection. The right-hand wheels then ran onto a 25-ft-long, 6-in.-high curb that led to the intersection before bouncing off the curb with enough force to throw hay bales and the son from the hay rack.
The insurance company’s expert witness had a doctorate in physics and was a professor at a local university. His careful mathematical analysis indicated the son could not have been thrown off the hay rack by the same force that threw bales of hay in all directions. If he had been sitting as still as a bale of hay, the centrifugal force of the vehicle taking the turn would have thrown him off the left side of the hay wagon, not the right.
Therefore, the professor concluded, the man must have been doing some-thing that caused him to fall off the right side of the rack, independent of the vehicle’s path.
I was an expert witness for the plaintiff. I often use models of machines when evaluating safety during hazard analyses and when presenting cases to juries in court. However, in this case, I used toys to prove to myself and the court how the accident happened.
All of the farm implements in the case were at least 30-years old. Using the Internet, I found a manufacturer that makes toy versions of each piece of equip-ment involved in this accident, including bales of hay, at 1:48 scale.
Thanks to the accuracy of the models and an understanding wife, I recreated the accident scene on my dining-room table. After playing with the scaled-down accident scene for a while, I was able to reproduce the accident as it was described by the witnesses.
Despite the fact that I was, in fact, using toys to prove my analysis of the ac-cident, when I showed my findings to insurance-company representatives, the case settled quickly. This is just the latest example I’ve seen that pure mathemati-cal analysis is no substitute for physically recreating an accident scenario.
— Lanny Berke
Lanny Berke is a registered professional engineer and Certified Safety Professional involved in forensic engineering since 1972. Got a question about safety? You can reach Lanny at [email protected].
Edited by Jessica Shapiro
Investigating farm
RS# 136
MAY 20, 2010MACHINE Design.com40
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RS# 137
Rittal – The System.
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ways to engage, challenge, and test your knowledge while offering educational moments and some fun along the way. We wanted something deserving of your time, knowledge, and energy.
After months of brainstorming de-tails, categories, rules, and prizes, we began developing questions, writing game requirements, and bringing our Lee Teschler avatar to life.
That’s why our annual Indy 500 issue garners a lot of attention, our Web site gets particularly higher volume when we feature racing lawnmowers or the latest mountain bike, and why thousands of you are currently playing our new, online game called THE WORLD’S SMARTEST DESIGN ENGINEER.
We began work on this monumental project close to a year ago, thinking of
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MAY 20, 2010MACHINE Design.com42
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Be A LUNCH BUNCHERIf you haven’t yet signed up to play, why not check it out. We’ ve made the registration process easier and the flow of the game faster. Since many of you enjoy playing at lunchtime, we’ve just begun a “Lunch Bunch” program where you can register several engineers from your company and compete against each other. You’ll be hearing more about this in the coming weeks, but in the meantime, as Avatar Lee says “Better Study Up.” The game is a great place to learn!
tions and will alert you when those are complete.
Check out our new Game Blog at machinedesign.com under “Forums” to see what others are saying!
If you’ve been playing the game and responded to our request for feedback, we thank you. Your input is helping us refine the program. As we speak ,we are in-corporating many of your sugges-
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RS# 138
MAY 20, 2010 MACHINE Design.com 43
INDY 500
IndyCar 2012 the race is on
Auto racing is about more than getting cars to go as fast as possible. Premier groups like the Indy Racing League (IRL) also want to keep drivers safe, fans engaged, and technology relevant to real-world consumer applications. They also want more teams competing.
To that end, IRL’s IndyCar chassis is getting a refresh. Officials are hoping to choose a chassis and engine platform for the 2012 season by June 1 of this year.
Early this year, IRL President Brian Barnhart outlined what the organization is looking for in a new car, and designers were quick to respond. Five firms have entered the competition for the 2012 chassis, including current chassis construc-tor Dallara, Parma, Italy, and LeMans and ChampCar designer Lola, Huntingdon, Cambridgeshire, U.K. Swift Engineering, San Clemente, Calif., a seasoned design firm, notably of the current Formula Nippon design, is also developing an entry.
Safety, better efficiency,
and more-exciting racing
are revving up the chassis
designs competing to run at
IndyCar events in 2012.
MAY 20, 2010MACHINE Design.com44
The field’s two relative newcomers are BAT Engineering, Indianapolis, led by principals with experience at Lola and other race-car constructors such as Reynard and March, and DeltaWing Racing Cars, Indianapolis, featuring the technical head of Target Chip Ganassi Racing which took the IndyCar champi-onship in 2008 and 2009.
Car criteriaIRL clearly set out its expectations for the new car in February. The new
chassis must meet current safety standards, but winning designs need to pro-pose additional ways to prevent crashes and make them less dangerous for driv-ers, crew, and spectators.
“It is often said about the 3S of racing — safety, strength, and speed — that
DeltaWing Racing CarsDeltaWing is taking a radical approach on many fronts. In addition to being supported by key IRL
teams rather than an established chassis builder, DeltaWing has pledged an open-source design pro-
cess. Anyone can access the car’s specs and CAD drawings, and anyone can submit original design
ideas.
The concept has produced a radical design, including a 160-lb, 2.0-liter, 300-hp, four-cylinder, turbo-
charged engine, that is projected to weigh 1,030 lb with a driver and cost around $600,000. The engine
and transmission are nonstressed members of the chassis, so the car can accommodate diff erent pow-
ertrains. DeltaWing is pushing for IRL to restrict fuel-delivery rate to the engines and leave other engine
specs up to teams.
The smaller powerplant and mass are made possible in part by bodywork that nearly encloses both
sets of wheels. Distance between front wheels is 24 in. while in back it is 70 in. Cutting the drag of open
wheels, narrowing the track, and beefi ng up the front fairing, let DeltaWing cut the drag coeffi cient 60%
to 0.24. Replacing the rear wing with a vertical fi n keeps the car stable in turns but doesn’t add drag
on straightaways. And the absence of front and rear wings makes the car less sensitive to “dirty” air
when following closely and leaves a cleaner wake.
Simulation and full-size wind-tunnel testing confi rm that 80% of the aerodynamic downforce acts
on the rear of the car, which also supports 72.5% of the mass. This aero and mass balance give better
traction to the 12.5-in.-wide rear tires during acceleration without adding weight. Stability is also en-
hanced by a six-speed, driver-controlled diff erential with full torque vectoring and active stagger that
eliminates the need for diff erent diameters on the inner and outer tires on oval tracks.
Bodywork in front of the front wheels and behind the engine absorbs crash energy to further pro-
tect the driver. Tegris polypropylene composite from Milliken & Co., Spartanburg, S.C., will add impact
and intrusion resistance without adding weight to DeltaWing’s prototype. Compared to glass and
carbon-fi ber composites, Tegris resists two to fi ve times the impact energy, has comparable
stiff ness, and is easier to manufacture and recycle.
Authored by:
Jessica ShapiroAssociate [email protected]
Key points:t��'JWF�DPNQBOJFT�IBWF�QSPQPTFE�
designs for the 2012 IndyCar Chassis, to be selected by June 1.
t��/FX�EFTJHOT�BSF�NFBOU�UP�CF�TBGFS �encourage close racing, save fuel, and keep the series affordable for teams.
t��1SPQPTFE�EFTJHOT�JODMVEF�VQEBUFE�versions of the current chassis and radical new concepts.
ResourcesBAT Engineering, nextindycar.
wordpress.com
Dallara, www.dallara.it
DeltaWing Racing Cars, deltawingracing.com
Honda Performance Development, racing.honda.com/hpd/
Indy Racing League, www.indycar.com
Lola Group, www.lola-group.com
Swift Engineering, www.
swiftengineering.com
MAY 20, 2010 MACHINE Design.com 45
INDY 500
turbulence generated by competing vehicles or have cars leave cleaner air in their wakes.
The car has to be able to hit a lap speed of 235 mph with less engine power than the current 630 hp. It will have to generate less drag to do so, while at the same time creat-ing enough stable downforce to permit safe cornering in traffic.
Third, the league wants these changes, and racing in general, to be affordable for teams. Officials are hoping
you need safety first,” says Andrea Toso of Dallara. “If you are fine with safety, then you move to logistical and engi-neering strength, including reliability, economics, support, and distribution. If you are fine with strength, then you go to speed or performance. And anytime you have an issue in the safety or strength department, you have to address it right away, even by conceding on speed.”
IRL’s second priority is keeping IndyCar races inter-esting. Specifically, they want cars to be less sensitive to
BAT EngineeringFormer Lola chief designer and
Reynard North America president
Bruce Ashmore, former March
chief designer and engineer Alan
Mertens, and longtime open-
wheel racing engineer Tim
Wardrop made a safe cockpit
the top priority of their clean-sheet
design. They consulted with IRL safety and technical
directors Jeff Horton and Les Mactaggart and Indianapolis surgeon Dr. Terry Trammell.
A stiff er suspension, stronger suspension mounts, and less fragile body work promote fast,
close racing with less chance of having race-ending contact with other cars. More-crushable
structure, bodywork that extends to the outer edges of the tires, and a stressed engine that
helps hold the car together in a crash will protect racers and spectators.
Although some of these stiff ening and crashworthiness improvements add weight, Ashmore
says the new car’s weight will be “very similar” to that of the current model. Enhanced effi cien-
cy comes from smoother, more-aerodynamic contours. The current chassis has a lot of angular
bodywork specifi cally designed to reduce downforce and slow the overpowered cars down.
Although the engine will ultimately be IRL’s decision, Ashmore would like to see a V6 twin
turbo. Such a car would be slightly cheaper to build and have fewer parts that could break dur-
ing long races. League organizers could bleed off turbo-induction pressure so cars could run a
safe 500 hp on ovals and get the 750 hp they need to perform on road courses. Twin turbos have
better cooling performance than a centrally located single unit.
“Turbos are relevant technology for modern vehicles,” Ashmore says. “In a truck or SUV that is
mostly driven on fl at roads with a single
occupant, a V6 gives enough power;
you don’t need a V8. When you are tow-
ing a boat and transporting six people,
a turbo could nearly double your horse-
power.”
BAT Engineering proposes to build
its chassis within a 30-mile radius of the
Indianapolis Motor Speedway. The com-
pany says it is already forming partner-
ships with local fi rms and organizations
to prepare for the production of a 2012
chassis that will cost about half what the
current model does.
MAY 20, 2010MACHINE Design.com46
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RS# 139
See us at MD&M East, Booth #551.
INDY 500
the new car will cost 40 to 50% less than the current model. IRL predicts costs savings will come mainly from reducing the inventory teams need to compete on both oval and road or street courses.
According to Toso, this means a car with all the options, including oval and road course suspension, aero, and differential packages; sensors, electronics, and data acquisition; and fuel hardware, should cost less than $400,000. A fully loaded car currently costs around $700,000.
Also on the economic front, IRL has specified that the new chassis must be built in the U.S., preferably in Indiana. And most entrants have pledged to base manufacturing around the Brickyard in Speedway, Ind., near Indianapolis.
According to Bernard, a U.S.-built car would let the league “take advantage of more-competitive pric-ing and the existing American supplier network for parts,” as well as protecting teams from currency fluctuations.
The fifth requirement is for a lighter chassis that will have aerodynamic effects similar to the current model. A lighter car would need less power to meet target speeds and have better fuel efficiency.
Team’s strategies for building lighter cars would
DallaraDallara designed the current, 2003-vintage IndyCar. The
Italian fi rm says any of its three proposed 2012 chassis would
be built near Speedway, Ind., and cost 55% less than the cur-
rent design. The cars weigh 1,390 lb without a driver or fuel.
This compares to 1,530 lb for the current design.
A 570-hp in-line four-cylinder turbocharged engine could
take the car up to 225 mph on laps at the Brickyard, or the
cars could sport a turbo V6. Either engine would be a stressed
member which lightens the cars by eliminating the frame.
Bodywork slightly wider than the tire tracks keeps wheels
from interlocking. The cars are also shaped so that aerody-
namics keep them on the ground in a rear-end collision or a
crash into the wall. Updated aero packages make the cars less
sensitive to the wakes of nearby racers.
Design decision-makersDecision day is June 1, and hitting that deadline is a must,
as IRL President Brian Barnhart estimates IRL will need 18 to
20 months to build, test, and begin making chassis for the
start of the 2012 season.
The fi nal decision will be made by IRL CEO Randy Bernard,
who took over from Tony George March 1. Bernard will have
help from an advisory committee, dubbed ICONIC for its goal
of fi nding an innovative, competitive, open-wheel, new, in-
dustry-relevant, and cost-eff ective design.
The committee is chaired by retired Air Force Gen. William
R. Looney III, and IRL team owners elected Gil de Ferran, co-
owner of Luczo Dragon Racing/de Ferran Motorsports, In-
dianapolis, to represent them.
Bernard named Barnhart, former IRL vice president of com-
petition Tony Cotman, and promoter and Texas Motor Speed-
way president Eddie Gossage to the committee.
Technical experts include Rick Long, a high-performance
engine developer, Tony Purnell, a former technical consul-
tant to FIA, the European motorsport organization, and Neil
Ressler, former chairman of Jaguar Racing in Formula One
and former vice president and chief technical offi cer of re-
search and vehicle technology at Ford.
MAY 20, 2010MACHINE Design.com48
RS# 140
INDY 500
a leader in environmentally friendly initiatives with this chassis,” states the league’s press release establishing car criteria.
Prospects for some items that have long been on the wish list of some fans and commentators, like a multichas-sis or multiengine series, are slim.
“Intense competition and battles with other race-car manufacturers is a fantastic spectacle and a rich environ-ment for our engineers,” says Lola head of special proj-
also play into the sixth requirement: IRL wants the new chassis to be relevant to the consumer auto industry.
Seventh on the list is an updated aesthetic. Specifically, IRL wants more space for sponsor logos. They also want it to be easier for fans to identify cars and drivers they are rooting for.
The final requirement is one of the vaguest: The car should be “green.” “The IRL prides itself on its role in the greening of racing and wants to maintain its position as
Swift EngineeringCalifornia-based Swift Engineering focused its aerodynamics study on the wings, seek-
ing to reduce downforce and the turbulence they create. Designers at Swift have come
up with two diff erent chassis designs, although the company only
intends to build a single winning model. The
sharp-nosed “23” model has fully exposed
wheels, a sculpted front wing, and a
substantial back wing with end-
plates. Bodywork on the “32” in-
cludes front and side pods that
protect both sets of wheels
and rear-wing end plates that
are continuations of the rear
bodywork.
Both models dis-
pense with cowlings cov-
ering parts of the engine. “We saw
an opportunity to showcase the en-
gine and other ‘jewelry’ while preserv-
ing effi ciency with a much smaller
fairing,” said Casper Van der Schoot,
Swift’s director of motorsports. The change has little aerodynamic impact, but cuts down on
sponsorship space.
A tilted rear underwing borrowed from the company’s Formula Nippon racer is said to
sweep up the car’s wake, leaving cleaner air behind it that should promote closer racing
and passing. Swift also intends to place LED lights on the roll hoop, side pods, and upper
bodywork to signal spectators the car’s position, fuel level, and throttle and brake positions
throughout the race.
Although producing the cars in Swift’s California facilities meets IRL’s US-manufacturing
requirement, it may knock down the fi rm’s feel-good points for not locating in Indiana.
Race position
Fuel level
Throttle and
brake position
MAY 20, 2010MACHINE Design.com50
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INDY 500
kind of powerplant they will provide remains unclear. Discussions last year leaned toward switching from a four-camshaft, normally aspirated V8 to a turbocharged, four or six-cylinder engine with dual overhead cams. So the 2012 car might sport a fuel-effi-cient, turbocharged, four-cylinder engine. MD
ects Peter McCool. “However, it is not conducive to keeping cost down, which has been a key criteria. But a return to multichassis grids may well be an option in stronger economic times.”
It appears IRL will stick with its single-engine format and its current engine supplier, Honda. But what
come up with two visually diff erent cars to add variety to the grid and accommo-
date two engine manufacturers, if IRL chooses to go that way. The company plans
to wind-tunnel test both 1,380-lb confi gurations in the wind tunnel across the
entire ride height range to ensure parity.
One body style might have a slight edge on oval courses while the other is
better for road races, so Lola engineers are designing a series of sized and con-
fi gured aero blockers for the underbodies of the cars. The blockers would detract
slightly from the cars’ aerodynamic effi ciency and keep the two body styles on a
level playing fi eld.
A large central underbody panel boosts downforce and let designers shrink
front and rear wings that can leave turbulence in a car’s wake. Rear-wing end-
plates also minimize vortex rings that form over the back of the car at race speeds
and inhibit passing. The front and lower rear wings also serve as bumpers to limit
wheel-to-wheel contact if cars collide.
The bones of Lola’s designs will work for both IndyCar races and IndyLights
development series with slight changes to the upper body work, a concept Lola
engineers say makes both series safer for drivers and keeps teams’ costs down.
“The crossover will encourage new teams to enter both IRL and Indy Lights,” says
Peter McCool, Lola head of special projects.
LolaDesigners at British
fi rm Lola, known for their Le-
Mans Prototype (LMP) 1 and 2
chassis and ChampCars, have
RS# 142
MAY 20, 2010MACHINE Design.com52
RS# 143
FASTENING & JOINING
Engineering tricks make
parts stickPolypropylene (PP), polyethylene (PE), and other thermoplastic olefins attract designers because of their low cost and excellent physical properties. The poly-mers are durable, flexible, and resist moisture, heat, and solvents. Unfortunately, some of these properties also make the plastics difficult to bond with conven-tional adhesives.
PP, PE, Teflon, and other hard-to-bond polymers are called low-surface-energy (LSE) plastics, and engineers typically turn to mechanical fasteners and ultrasonic welding to assemble LSE plastic structural components. But these ap-proaches can affect cost, service life, and aesthetics. As designers specify more LSE plastics, they need more-efficient, reliable, and economical ways to join LSE plastics.
Mechanical fasteners constrain components, increasing the risk of cracking and failure at attachment points from material expansion and contraction, flex-ing, and vibration. Ultrasonic welding is time consuming and often dimples the surface, harming product appearance.
Adhesives, on the other hand, distribute loads evenly, reducing joint stress. They resist flexing, vibration, and impact. Adhesives seal joints to minimize corrosion and fill in surface gaps that mechanical fasteners or ultrasonic meth-ods can’t fix.
Practical and economical adhesives for joining LSE plastics were not avail-able until recently, however. New liquid and viscoelastic adhesives are changing the outlook for adhesive-based assembly of LSE plastics.
Surface dynamicsPolymer surface energy is important because it determines if adhesives can
spread out over the bonding surface, a process called wetting out that is neces-sary to create strong bonds. The surface energy, or wettability, of a material is measured in dynes per centimeter. Plastics with relatively high surface energy — acrylonitrile butadiene styrene (ABS) and polycarbonate, for example — bond readily because they are easily wet by conventional adhesives.
Properly prepared aluminum with a surface energy of 840 dynes/cm strongly bonds with adhesives, which explains why modern aluminum-skinned aircraft are relying more on adhesives and less on rivets for structural assembly.
At the lower end of the spectrum, PP and PE have surface energies around 30 dynes/cm. Polytetrafluoroethylene (PTFE), the original coating for nonstick cookware, is the LSE champ at 19 dynes/cm.
Measuring the contact angle of a water droplet on the surface of a material deter-mines surface energy. Contact angles greater than 90° indicate lower surface energy and a surface that is more difficult to wet. When the contact angle approaches 180°, the surface is very difficult to wet and water “beads up” as on a waxed car.
Adhesive bonding
improves the looks
and durability of
low-surface-
energy plastics,
but pretreatment
or special adhesive
formulations
are a must.
Authored by:
Jeremy CoolerTechnical SpecialistFabricoKennesaw, Ga.
Edited by Jessica [email protected]
Key points:t��-PX�TVSGBDF�FOFSHZ�QPMZNFST�BSF�
EVSBCMF �GMFYJCMF �BOE�MPX�DPTU �CVU�hard to bond with conventional adhesives.
t��4VSGBDF�FOFSHZ�JT�B�SFMBUJWF�RVBOUJUZ�UIBU�BGGFDUT�BO�BEIFTJWF�T�BCJMJUZ�UP�XFU�UIF�TVSGBDF�
t��3BJTJOH�UIF�QPMZNFS�TVSGBDF�FOFSHZ�UISPVHI�QSFUSFBUNFOU�PS�MPXFSJOH�UIF�BEIFTJWF�T�TVSGBDF�FOFSHZ�QSPNPUFT�CPOEJOH�
Resources:Fabrico, www.fabrico.com
i#BTJDT�PG�%FTJHO�&OHJOFFSJOH��Adhesives,” machinedesign.com/
article/adhesives-1115
i#BTJDT�PG�%FTJHO�&OHJOFFSJOH��+PJOJOH�QMBTUJD w�machinedesign.com/
article/joining-plastic-1115
MAY 20, 2010MACHINE Design.com54
Conversely, contact angles less than 90° indicate higher surface energy and a surface that is easier to wet. On a surface producing a contact angle approaching 0° water forms a sheet.
The better a liquid adhesive wets a material surface, the more area it can cover. This has two beneficial results: a stronger chemical bond and stronger mechanical bond.
The chemical bonds get a boost from more attraction and interaction of re-active groups in the adhesive and the substrate. Mechanical bonds form when adhesive penetrates the surface, filling in microscopic irregularities and pro-ducing adhesive interlocks.
Better bondingAbsolute surface energy numbers are of less interest to engineers than the
relative magnitude of the plastic’s surface energy and that of the adhesive. Ide-ally, the surface energy of a plastic should be 7 to 10 dynes/cm higher than the surface energy of an adhesive. A liquid or pressure-sensitive adhesive with a surface energy of 20 dynes/cm will spontaneously wet out LSE plastics with sur-face energies of 30 dynes/cm or more.
Therefore, engineers can make LSE plastics easier to bond by either raising the surface energy of the plastic or lowering the surface energy of the adhesive.
To boost a plastic’s surface energy, engineers usually pretreat the plastic with primers, flame, plasma, or corona-discharge processes. These change the sur-face chemistry and render the plastic wettable by conventional adhesives.
Plastic pretreatments add cost and time to production processes. In addi-tion, the surface energy effects of flame, plasma, and corona-discharge treat-ments may only last minutes, days, or weeks depending on the plastic. Primers may pose environmental issues that engineers must weigh.
The other approach, lowering the surface energy of the adhesive to attain an aggressive bond, involves adding tackifiers to the adhesive formulation. In some cases, engineers use double-coated or transfer tapes to improve tackiness.
Newly formulated acrylic-liquid adhesives and pressure-sensitive-adhesive tapes strongly bond with many LSE plastics without priming or other pretreat-ments. One approach uses a two-part, solvent-free, room-temperature-curing acrylic adhesive that skips curing ovens, UV lamps, and heaters. The resulting structural bonds resist chemical attack, water, humidity, and corrosion and have overlap shear strength over 1,000 psi.
When substrates are thin, lightweight, or flexible, a thin bonding product ad-heres as well or better than liquid adhesives. For such parts, a pressure-sensitive, double-coated or transfer tape gives LSE materials bonds that resist temperature extremes and solvents and have peel strength comparable to those of liquid
RS# 144
FASTENING & JOINING
Thin bonding systems must withstand extreme temperatures and UV exposure to attach low-surface-energy plastics in automotive interiors. The adhesives replace mechanical fasteners that would compromise vehicle aesthetics.
New adhesive formulations let manufacturers attach labels, ID tags, insulation, and internal parts to appliances with low-surface-energy powder-coat finishes.
Help for hard-to-bond surfaces
TransportationThe high performance and lower
cost of low-surface-energy (LSE)
plastics makes them attractive ma-
terials in the transportation sector.
Designers use LSE-specifi c liquid
adhesives and thin-fi lm-bonding
systems instead of mechanical fas-
teners or welding to attach polypro-
pylene fenders, bumpers, body trim,
body panels, and other items in ve-
hicles and recreational trailers.
Most automobile interior trim
pieces are now LSE plastics. Thin
bonding systems can handle the ex-
treme temperatures in auto interiors
and hold these parts in place for the
life of the vehicle without unsightly
mechanical fasteners.
Flexible LSE-rubber gaskets laminated with die-cut, thin bonding fi lms, let assem-
blers peel and stick the gaskets where they are needed. These gaskets bond to ad-
vanced LSE paint systems that are impervious to conventional adhesives.
Die-cut, thin bonding fi lms also permit peel-and-stick attachment of heat-shield
materials and sound-dampening foams in all-terrain recreational and work vehicles
with hoods and other body panels made from LSE plastics or blends. This approach
eliminates time-consuming, labor-intensive, and environmentally hazardous liquid-
contact-adhesive processes.
AppliancesPowder coating provides a last-
ing, durable, LSE fi nish for house-
hold and industrial appliances. New
thin bonding fi lm formulations
let manufacturers securely attach
sound-deadening insulation, metal
identifi cation and serial labels, and
internal LSE plastic components
that operate at elevated tempera-
tures to the hard-to-bond paint.
This eliminates conventional fas-
teners that detract from modern
design aesthetics and may promote
corrosion and stress cracking.
Electronic and MedicalPolypropylene fi lm’s dielectric
properties make it the insulation of
choice for many electric and elec-
tronic applications. Thin bonding
systems create a durable, cost-eff ec-
tive bond for this LSE plastic.
In the competitive medical disposables market, thin bondings fi lm laminate low-
cost LSE plastic into diagnostic strips.
RS# 145
MAY 20, 2010MACHINE Design.com56
HELI-CAL® Flexure Technology:Gives more design possibilities
to fit your application!
For the whole picture, visit www. Heli-Cal.com
Machined Springs U-Joints
Standard Couplings Custom Couplings
PRODUCTS COMPANY, INC.AS9100B
ISO 9001:2000
�� �"&���� �(� ���������"'���!��(���!$����#������ ��
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RS# 146
FASTENING & JOINING
and assembly using less-skilled labor. Adhesives add little additional weight to assemblies, cause no change in part dimensions or geometry, and readily bond dissimilar substrates and heat-sensitive materials. And because the limitations of conventional fasten-ing techniques are not an issue, engi-neers have more latitude in specify-ing component thickness and shape.
Designers are using new liquid-adhesive, thin-film/foam bonding systems instead of mechanical fasten-ers and ultrasonic welding to attach polypropylene fenders, bumpers, body trim, body panels, and other items on vehicles and recreational trailers. They attach name plates, protective windows, and warning la-bels to industrial equipment and are finding specialized niches in diag-nostic medical products. MD
structural adhesives.O t h e r a d h e -
sives for LSE plas-tics use cyanoacry-late chemistry. The high-strength, one-part adhesives cure at room temperature and produce strong bonds on LSE plas-tics without olefin primers. Accelerators can be added to the formulation to speed cure in low-humid-ity environments.
RELATIVE SURFACE ENERGY OF MATERIALS
MaterialSurface Energy
(dynes/cm)
Contact Angle
(°)
Copper 1,103
Aluminum 840
Glass 250 to 500
Polycarbonate (PC) 46 75
Acrylonitrile butadiene styrene (ABS)
35 82
Polypropylene (PP) 30 88
Polyethylene (PE) 30 88
Polytetrafluoroethylene (PTFE)
19 120
A contact angle less than 90° (top) indicates the substrate material has higher surface energy and is readily wet out by the adhesive. Good wetting promotes stronger adhesive-substrate bonds through chem-ical and mechanical interaction.
A contact angle greater than 90° (bottom) is indicative of a low-surface-energy (LSE) substrate. Such substrates are difficult to wet out with conventional adhesives. Pretreatments, spe-cialty adhesive formulations, or both can let LSE substrates form strong bonds with similar and dissimilar materials.
Some cyanoacrylate adhesives permit light-accelerated curing to increase bond depth and strength. The short cure times let manufac-turers process relatively small plastic parts in seconds rather than minutes in high-volume applications. Cure strength can be boosted further with plasma, primer, or corona discharge pretreatment of the LSE plastic.
LSE-adhesive advantagesThis new generation of liquid
adhesives, adhesive tapes, and thin-film/foam bonding systems create strong bonds with LSE plastics that resist impact, shock, and fatigue bet-ter than conventional mechanical and ultrasonic fastening.
The availability of reliable adhe-sive-bonding alternatives for LSE plastics promises faster production
RS# 147
Adhesive
NONWETTING
WETTINGAdhesive
Substrate
Substrate
MAY 20, 201058 MACHINE Design.com
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DMC-40x0 Accelera Controller & Drives
RS# 148
HYDRAULICS
Sizingtube lines for efficient hydraulics
Temperature derating factorsMaximum
operating
temperature, °F
Steel, C-1010
and C-4130
Stainless steel Copper
Aluminum,
6061-T6
Monel,
Type
400304 316
100 1.00 1.00 1.00 1.00 1.00 1.00150 1.00 0.91 1.00 0.85 1.00 0.97200 1.00 0.84 1.00 0.80 1.00 0.94250 1.00 0.79 1.00 0.80 0.94 0.91300 1.00 0.75 1.00 0.78 0.80 0.88350 0.99 0.72 0.99 0.67 0.60 0.86400 0.98 0.69 0.97 0.50 0.43 0.85500 0.96 0.65 0.90 0.84600 0.61 0.85 0.84700 0.59 0.82 0.84800 0.57 0.80 0.83900 0.54 0.78
1,000 0.52 0.771,100 0.47 0.62
1.200 0.32 0.37
Derating factors are based on allowable design stresses at various temperatures per ASME B31.1.
thickness. Here’s a simple procedure for sizing tubes.
Flow diameterThe first step is to determine required flow diameter.
The accompanying “Recommended flow diameter” table gives guidelines for specific flow rates and types of line.
The table is based on the following recommended flow velocities:t��1SFTTVSF�MJOFT������GQT�PS������NFUFST�TFD�t��3FUVSO�MJOFT������GQT�PS������NFUFST�TFD�t��4VDUJPO�MJOFT�����GQT�PS������NFUFST�TFD�
If flow velocities differ from these, calculate the re-quired flow diameter based on:
The right tubing and fittings are critical for trouble-free PQFSBUJPO�PG�GMVJE�QPXFS�TZTUFNT��1SPQFSMZ�TJ[FE�UVCFT �which may differ for various parts of a hydraulic system, also give the best combination of efficient and cost-effec-tive performance.
A tube that is too small raises fluid velocity, which has many detrimental effects. In suction lines, it leads to cavi-tation that starves and damages pumps. In pressure lines, it causes excessive friction losses and turbulence, both re-sulting in high pressure drops and heat generation. High heat, in turn, accelerates wear in moving parts and ages seals and hoses. The end results are shorter component life and wasted energy and, therefore, low levels of efficiency.
On the other hand, tubing that’s too large unnecessar-ily increases costs. It can also consume valuable real estate that makes it more difficult to fit tubing into confined spaces and restricts engineers in configuring adjacent equipment and components. And oversized tubing can simply be harder and more time consuming to install. It also weighs more than necessary, and that hurts fuel con-sumption on mobile equipment.
Matching tubing to an application involves selecting the right material and determining optimum OD and wall
The right size
tubing limits
fluid-friction
losses that cause
pressure drop,
heat generation
and, in case of
suction lines,
pump-damaging
cavitation.
WHAT’S THIS?When you see a code like this, take a photo of it with your smart phone (iPhone 3G-S gives best results) and, using software from www.neoreader.
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MAY 20, 2010MACHINE Design.com60
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Standard or Custom Designsfor Virtually Any Application
Torque Ratings From1 oz.in. to 3,000 lb.ft.
Single or Multiple Disc Designs
Power On or Spring-Set
Cost Effective and Value Engineered
Electric, Mechanical, Airor Hydraulic Actuation
Leading Edge Clutches & Brakes
Design and derating factorsSeverity of
serviceDescription
Design
factor
Derating
factor
A (Normal)Moderate mechanical and
hydraulic shocks4.00 1.00
B (Severe)Severe hydraulic shocks and
mechanical strain6.00 0.67
C (Hazardous)Hazardous application with
severe service conditions8.0 0.50
Derating factors provide a measure of safety against unknowns in materials and operating conditions.
Design stress ratingsMaterial and type
Allowable design stress, psi
(Design factor of 4 at 72°F)Tube specification
Steel C-1010 12,500SAE J356, J524,
J525Steel C-1021 15,000 SAE J2435, J2467Steel, HSLA 18,000 SAE J2613, J2614
Stainless steel, 304
& 31618,800
ASTM A213, A249,
A269Alloy steel C-4130 18,800 ASTM A519
Copper, K or Y 6,000 SAE J528, ASTM B75Aluminum 6061-T6 10,500 ASTM B210
Monel, 400 17,500 ASTM B165
Allowable stress levels shown here are for fully annealed tubing.
d = 0.64(Q/V)0.5
where d = tube ID, in.; Q = flow, gpm; and V = velocity, fps.
For metric units:d
m = 4.61(Q
m/V
m)0.5
where dm
= tube ID, mm; Q
m = flow, lpm; and V
m =
velocity, meters/sec.
Diameter and thickness
Next determine tube OD and wall thickness. Using the “Pressure rat-ings” table, find the diam-eter and thickness com-bination that satisfies the following two conditions:1. Has recommended
design pressure that equals or exceeds maximum operating pressure.
Rigid tubing is rugged and handles high pressures. Sizing it properly gives the best combination of cost and performance.
2. Provides tube ID that equals or exceeds the required flow diameter deter-mined earlier.Design pressures in the table are based on a severity of service rating “A” (de-
sign or safety factor of 4) as listed in the “Design and derating factors” table.In more-severe operating conditions, multiply values in the pressure-ratings
Authored by:
Burleigh BaileyResearch & Development ManagerTube Fittings Div.Parker Hannifin Corp.Columbus, Ohio
Edited by Kenneth J. [email protected]
Key points:t���5VCJOH�UIBU�T�UPP�TNBMM�
causes excessive flow velocity, turbulence, and cavitation.
t���5VCJOH�UIBU�T�UPP�CJH�increases cost, space requirements, and weight.
t���4J[F�UVCJOH�CBTFE�PO�material, diameter, and wall thickness to meet pressure and flow requirements.
Resources:Parker Hannifin, www.
parker.com
RS# 149
Also Available from Nippon Pulse
tin-can steppers, hybrid motors,
linear steppers, drivers, controllers,
prototyping, system engineering, and
product/application support
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dep
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HYDRAULICS
Recommended flow diameters
Ma
xim
um
flo
w r
ate
,
gp
m
Recommended flow
diameter, in.
Pre
ssu
re li
ne
s
Re
turn
lin
es
Su
ctio
n li
ne
s
0.25 0.064 0.101 0.1600.50 0.091 0.143 0.2260.75 0.111 0.175 0.2771.00 0.128 0.202 0.3201.25 0.143 0.226 0.3581.50 0.157 0.247 0.3921.75 0.169 0.267 0.4232.00 0.181 0.286 0.4532.50 0.202 0.319 0.5063.00 0.222 0.350 0.5543.50 0.239 0.378 0.5994.00 0.256 0.404 0.6404.50 0.272 0.429 0.6795.00 0.286 0.452 0.7165.50 0.300 0.474 0.7506.00 0.314 0.495 0.7846.50 0.326 0.515 0.8167.00 0.339 0.534 0.8477.50 0.351 0.553 0.8768.00 0.362 0.571 0.9058.50 0.373 0.589 0.9339.00 0.384 0.606 0.9609.50 0.395 0.623 0.986
10.00 0.405 0.639 1.01211.00 0.425 0.670 1.06112.00 0.443 0.700 1.10913.00 0.462 0.728 1.15414.00 0.479 0.756 1.19715.00 0.496 0.782 1.23916.00 0.512 0.808 1.28017.00 0.528 0.833 1.31918.00 0.543 0.857 1.35819.00 0.558 0.880 1.39520.00 0.572 0.903 1.43122.00 0.600 0.947 1.50124.00 0.627 0.990 1.56826.00 0.653 1.030 1.63228.00 0.677 1.069 1.69330.00 0.701 1.106 1.75332.00 0.724 1.143 1.81034.00 0.746 1.178 1.86636.00 0.768 1.212 1.92038.00 0.789 1.245 1.97340.00 0.810 1.278 2.02442.00 0.830 1.309 2.07444.00 0.849 1.340 2.12346.00 0.868 1.370 2.17048.00 0.887 1.399 2.21750.00 0.905 1.428 2.26355.00 0.949 1.498 2.37360.00 0.991 1.565 2.47965.00 1.032 1.629 2.58070.00 1.071 1.690 2.67775.00 1.109 1.749 2.77180.00 1.145 1.807 2.86285.00 1.180 1.862 2.95090.00 1.214 1.916 3.03695.00 1.248 1.969 3.119
100.00 1.280 2.020 3.200110.00 1.342 2.119 3.356120.00 1.402 2.213 3.505130.00 1.459 2.303 3.649140.00 1.515 2.390 3.786150.00 1.568 2.474 3.919160.00 1.619 2.555 4.048170.00 1.669 2.634 4.172180.00 1.717 2.710 4.293190.00 1.764 2.784 4.411200.00 1.810 2.857 4.525
Flow diameters listed here are based on maximum allowable velocity of fluid through the line.
table by the appropriate derating factors before determining the tube OD and wall thickness combination. Contact a reputable tubing sup-plier when in doubt.
Allowable stress levels and the underlying specifications used to arrive at the pressure ratings are given in the “Design stress ratings” chart. Values are for fully annealed tubing.
Or calculate design pressure based on Lame’s equation,
P = S((D2 – d2)/(D2 + d2))where D = tube OD, in.; d = tube ID, in. (D – 2T); P = recommended design pressure, psi; S= allowable stress for a design factor of 4, psi; and T = tube wall thickness, in.
For thin wall tubes (D/T ≥ 10) the following equation may be used:
P = 2ST/D.The design factor is generally applied to the
material’s ultimate strength (or tubing burst pressure) to provide a margin of safety against unknowns in material and operating condi-tions. Apply the derating factors listed here di-rectly to values in the pressure ratings table to determine maximum recommended working pressures. That is, multiply values in the table by the derating factors.
Besides severity of service, high operating temperatures also reduce allowable working pressure in tubing. Temperature-derating fac-tors for various tube materials are given in the accompanying table. Where applicable, apply derating factors for severity of service and tem-perature to the design pressure values (from the table) to calculate the maximum recommended working pressure. For example, the combined derating factor for 316SS tubing for B (severe) service and 500°F operation is 0.67 × 0.9 = 0.60.
Selection exampleHere’s an example of the tube-sizing pro-
cess for pressure, return, and suction lines for a hydraulic power unit using petroleum-based hydraulic fluid. Operating temperature range is –20 to 140°F, maximum operating pressure is 3,500 psi, maximum flow rate through each line is 10 gpm, and severity of service is A (normal).1. Select tube material. Carbon steel, C-1010,
is an economical choice. It is suitable for petroleum fluids, has an operating tem-perature range of –65 to 500°F, and meets maximum operating pressure requirements. Tubing suppliers provide data on many other materials, such as alloy and stainless steels, copper, aluminum and Monel, as well as plastics such as nylon and PVC.
2. Size the tube. According to the Flow diam-RS# 150
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Encoder
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RS# 151
HYDRAULICS
eter table, recommended IDs for lines at 10 gpm flow rate are: 0.405 in. for the pressure line, 0.639 in. for the return line, and 1.012 in. for the suction line.
3. Pressure rating. Now, using the pressure-rating table, find tubes with IDs equal to or greater than the above flow diameters, and wall thicknesses appropriate for design pressures of 3,500-psi minimum for the pressure line and about 500 psi for return and suction lines. Because derating factors for severity of service and maximum operating temperature are both 1.0, design pressure values in the tables do not need to be reduced.
Next, match tube IDs and pres-sures in the tables for these condi-tions. For the pressure line, select 0.62-in. OD × 0.083-in. wall tubing. The 0.095 and 0.109-in.-thick wall would also be satisfactory if 0.083-in. wall is not readily available.
For the return line, either 0.75 × 0.035 in. or 0.75 × 0.049 in. would meet requirements. Also note that the type of fitting can affect tub-ing selection. Here, for instance, SAE J514 flareless fittings (Parker Ferulok) would require 0.75 × 0.065 in. because 0.065 in. is the thinnest wall recommended for this fitting with 0.75-in. tubing. This would reduce flow diameter about 3% below recommended, but is still in the acceptable range. The alter-native would be 0.87 OD × 0.072-in. wall tubing, which is excessively large. Fitting manufacturers provide tube thickness recommendations for various fittings and sizes.
For the suction line, use 1.25 OD × 0.049 to 0.083-in. wall tube for SAE J514 37° flare (Parker Triple-Lok) or SAE J1453 O-ring face seal (Parker Seal-Lok) fittings and 1.25 OD × 0.095-in. wall tube for flareless fittings.
One final consideration is choos-ing the right wall thickness for bent tubing. If bending without a mandrel, then wall thickness of less than 7% of tube OD is not recommended. MD
Pressure ratings
Tub
e O
D, i
n.
Wa
ll t
hic
kn
ess
, in
.
Tub
e ID
, in
.
Design pressure, psi
(4:1 design factor)
Ste
el 1
01
0
Ste
el 1
02
1
Sta
inle
ss s
tee
l
(30
4, 3
16
, 41
30
,
HS
LA
)
Co
pp
er
0.250 0.020 0.210 2,150 2,600 3,250 1,0500.250 0.028 0.194 3,100 3,700 4,650 1,5000.250 0.035 0.180 3,950 4,750 5,950 1,9000.250 0.049 0.152 5,750 6,900 8,650 2,7500.250 0.058 0.134 6,900 8,300 10,400 3,3000.250 0.065 0.120 7,800 9,350 11,750 3,7500.250 0.083 0.084 9,950 11,950 15,000 4,800
0.500 0.028 0.444 1,500 1,800 2,200 7000.500 0.035 0.430 1,850 2,200 2,800 9000.500 0.049 0.402 2,700 3,250 4,050 1,3000.500 0.058 0.384 3,250 3,900 4,850 1,5500.500 0.065 0.370 3,650 4,400 5,500 1,7500.500 0.072 0.356 4,100 4,900 6,150 1,9500.500 0.083 0.334 4,800 5,750 7,200 2,3000.500 0.095 0.310 5,550 6,650 8,350 2,6500.500 0.109 0.282 6,450 7,750 9,750 3,1000.500 0.120 0.260 7,200 8,650 10,800 3,4500.500 0.134 0.232 8,050 9,650 12,150 3,8500.500 0.148 0.204 8,950 10,750 13,450 4,3000.500 0.188 0.124 11,050 13,250 16,600 5,300
0.625 0.072 0.481 3,200 3,850 4,800 1,5500.625 0.083 0.459 3,750 4,500 5,650 1,8000.625 0.095 0.435 4,350 5,200 6,550 2,1000.625 0.109 0.407 5,050 6,050 7,600 2,4500.625 0.120 0.385 5,600 6,700 8,450 2,7000.625 0.134 0.357 6,350 7,600 9,550 3,0500.750 0.035 0.680 1,200 1,450 1,850 6000.750 0.049 0.652 1,750 2,100 2,600 8500.750 0.058 0.634 2,100 2,500 3,150 1,0000.750 0.065 0.620 2,350 2,800 3,550 1,1500.750 0.072 0.606 2,650 3,200 3,950 1,2500.750 0.083 0.584 3,050 3,650 4,600 1,4500.750 0.095 0.560 3,550 4,250 5,350 1,700
0.875 0.065 0.745 2,000 2,400 3,000 9500.875 0.072 0.731 2,200 2,650 3,350 1,0500.875 0.083 0.709 2,600 3,100 3,900 1,2500.875 0.095 0.685 3,000 3,600 4,500 1,4500.875 0.109 0.657 3,500 4,200 5,250 1,6500.875 0.120 0.635 3,900 4,700 5,850 1,8500.875 0.134 0.607 4,400 5,300 6,600 2,1000.875 0.148 0.579 4,900 5,900 7,350 2,3501.000 0.035 0.930 900 1,100 1,350 4501.000 0.049 0.902 1,300 1,550 1,950 6001.000 0.058 0.884 1,550 1,850 2,300 7501.000 0.065 0.870 1,750 2,100 2,600 8501.000 0.072 0.856 1,950 2,350 2,900 9501.000 0.083 0.834 2,250 2,700 3,400 1,1001.000 0.095 0.810 2,600 3,100 3,900 1,2501.000 0.109 0.782 3,000 3,600 4,550 1,4501.000 0.120 0.760 3,350 4,000 5,050 1,6001.000 0.134 0.732 3,800 4,550 5,700 1,8001.000 0.148 0.704 4,200 5,050 6,350 2,0001.000 0.156 0.688 4,450 5,350 6,700 2,1501.000 0.188 0.624 5,500 6,600 8,250 2,6501.000 0.220 0.560 6,550 7,850 9,800 3,1501.250 0.049 1.152 1,000 1,200 1,550 5001.250 0.058 1.134 1,200 1,450 1,850 6001.250 0.065 1.120 1,350 1,600 2,050 6501.250 0.072 1.106 1,500 1,800 2,300 7501.250 0.083 1.084 1,750 2,100 2,650 8501.250 0.095 1.060 2,050 2,450 3,050 1,0001.250 0.109 1.032 2,350 2,800 3,550 1,1501.250 0.120 1.010 2,650 3,200 3,950 1,2501.250 0.134 0.982 2,950 3,550 4,450 1,4001.250 0.148 0.954 3,300 3,950 4,950 1,6001.250 0.156 0.938 3,500 4,200 5,250 1,7001.250 0.188 0.874 4,300 5,150 6,450 2,0501.250 0.22 0.810 5,100 6,100 7,700 2,450
This table shows the recommended OD and thickness for tube that meets an application’s required flow velocity and strength. For a more complete listing, visit http://www.parker.com/literature/Tube%20Fittings%20Division/General%20Technical.pdf
RS# 152
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RS# 154RS# 153
RS# 138
RS# 155
MEDICAL INDUSTRY FOCUS
Connecting with
portable medical devices
mountings that measure just 74 × 19.4 × 18.5 mm. Having more pins lets engineers choose from a variety of ground-ing schemes to maintain signal integrity, and this makes these connectors well suited for portable ultrasound ma-chines, patient monitors, and test equipment.
Engineers have devised several approaches to extend-ing connector life, including new materials and entirely new designs. For example, modern connectors with rug-ged nickel-plated aluminum housings can have minimum rated lives of 20,000 mating cycles with no performance loss. Such connectors can also be mated and unmated in less than 2 sec and cost 25% less per mated line than high-density rack-and-panel versions.
Designers have also come up with a quick-disconnect breakaway connector that includes a simple push/pull
Here’s a closer look at mechanical, electrical, and safety requirements, as well as customer concerns.
Mechanical considerationsConnectors must often be small but have high pin
counts. Customers are also demanding more mating cy-cles (connect-disconnect) along with consistent and reli-able connections. In many cased, customers also want zero-insertion-force (ZIF) designs.
To meet demands for smaller connectors with more pins, designers are working to cut pin spacing to less than 1 mm. This can shrink the size of the connector by more than 60% compared to older connectors with the same number of pins. As a result, some connectors boast 260 contacts, each with a 0.8-mm contact pitch, in PC-board
By shrinking the distance between pins to less than 1 mm, small connectors such as this QLC model for portable medical equipment can house 260 pins.
As medical
equipment becomes
more portable and
is used in small
clinics and homes,
connectors must
be safe, simple, and
reliable.
Engineers designing connectors for portable medical equipment must take several factors into consider-ation, including size and insertion force, shielding from interference, and preventing electrical shocks.
MAY 20, 2010MACHINE Design.com66
Tools for getting the perfect connector
Design-failure-mode-eff ects analysis (DFMEA) and
process-failure-mode-eff ects analysis (PFMEA) play sig-
nifi cant roles in meeting the mechanical and electrical
design challenges of building the right connector for
a specifi c application. DFMEA explores ways products
might fail during real-world use, while PFMEA investi-
gates whether manufacturing process will be able to
handle a given design.
Another tool, 3D modeling, often via stereo-lithogra-
phy (SLA) or selective-layered sintering (SLS), is also cru-
cial to successful medical-connector designs. It has be-
come the preferred way to make connector prototypes.
Manufacturers can also drop a 3D model of a connector
into a model of the customer’s equipment to verify that
it will meet design specifi cations.
well in patient monitors and portable imaging equipment like ultrasound devices. ZIF connectors often use landed contacts, which eliminate engagement forces and reduce wear on the contacts to the short time they are pressed together and lightly wiped past each other during cam-and-lock operations. As a result, contacts in the plug and receptacle do not touch each other while connector halves are being engaged. Not only do these connectors have minimum rated lives of 10,000 mating cycles, they can be mated in less than 2 sec.
Electrical considerationsOnce engineers determine a connector’s mechanical
characteristics, electrical issues come into play, including contact resistance and shielding requirements.
Contact resistance impedes current flowing through the connector. One way to decrease this resistance is by choosing the right material. For example, gold plating over contacts made of high-conductivity copper alloys lowers resistance. If strength is a concern, consider using beryl-lium copper as the base material. Beryllium copper also has low stress relaxation which boosts the number of mat-
mating mechanism rated at more than 5,000 cycles. And the coupling mechanism’s canted spring cuts the time it takes to hook up medical gear.
Breakaway features that remove the danger of tearing connectors off equipment or out of walls are another recent innovation. Breakaway connectors are often used in portable medical imaging and diagnostic equipment because they are rugged and reliable enough to withstand field use. Some breakaway connectors feature a spring probe pin and pad contacts for durability and to withstand harsh environments. The probe pin in the plug connector works across multiple sizes. An internal clip ensures individual pins and sockets remain electrically connected and accommo-date misalignments. The spring probe lets the connector receptacle house individual touch-pad areas, providing reliable electrical contacts. Further, the spring probe and touch pads make connectors easy to clean in the field. The individual touch pads, for instance, contain no crevices that let contaminants accumulate.
ZIF connectors, besides being easy to engage and disengage, also rate high in terms of mating cycles, durability, and minimizing cross-talk. This lets them serve
Zero-insertion-force connectors extend life cycles and reduce cross-talk.
Authored by:
Carl BunkeProject Engineer, Advanced TechnologyITT Interconnect SolutionsWhite Plains, N.Y.
Edited by Stephen J. [email protected]
Resources:ITT Interconnect Solutions, www.ittcannon.
com
MAY 20, 2010 MACHINE Design.com 67
MEDICAL INDUSTRY FOCUS
than 85 dB at frequencies from 40 MHz to 10 GHz.Another method of minimizing effects of EMI/RFI is to
overmold the connector cable. This is often accomplished by attaching a stainless-steel shield over the shell (the shielding lies between the wires and connector jacket), and then premolding or overmolding the end of the cable to the connector. So when there is EMI/RFI, it is absorbed by the overmolded cable, thus minimizing insertion loss and any electrical variations. The overmold also adds tensile strength to the cable.
Some connectors use springs and shield-locking mechanisms to ensure pressure around the perimeter of the mated connector is uniform and creates an EMI/RFI shield. By eliminating EMI/RFI disruptions, signal noise
ing cycles the connectors will withstand.
Spring-probe-and pin-pad designs
Quick-disconnect breakaway connectors from ITT feature a spring probe pin and pad contacts that accommodate misalignments.
mentioned earlier also reduce electrical resistance, thanks to the internal clip that always provides a highly conduc-tive path.
Shielding against EMI and RFI signals, another consid-eration, is critical for devices such as pacemakers and pa-tient monitors. Signal noise can affect a pacemaker’s oper-ation and corrupt data in monitors. In these applications, it is also vital that connectors use nonmagnetic materials because magnetic emissions degrade image clarity and increase signal noise. As a result, connector manufacturers rely on stainless steel, alloys, and brasses, as they offer non or low-magnetic fields, thus keeping EMI/RFI from inter-fering with equipment. Shielding effectiveness lets some connector manufacturers offer EMI performance greater
RS# 156
TOTAL MOTION CONTROL
800.921.3332 www.HarmonicDrive.net
Hollow Shaft Brushless Actuators feature a through-bore up to
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Drive coupled to a performance-matched brushless motor and a high-resolu-
tion encoder. Maximum torque of 250 in-lb and positional accuracy better than
1.5 arc-minute is achieved. The FHA Mini Series is available in three frame sizes
ranging from 50mm to 75mm square and 48mm to 66mm in length.
Precision Motion Control
CSF-2UH Series
The CSF-2UH Series is a housed Harmonic
Drive Gear utilizing a cross roller output bearing
to support high-load capacities. The CSF-2UH
offers a gear reduction ratio of 30:1 through
160:1 and provides peak torque ranging from
9 Nm to 2,630 Nm, with zero backlash and
positional accuracy better than 1 arc-minute.
Precision Hollow Shaft Gearhead
The SHF-2UH is a zero-backlash Harmonic
Drive Gear which offers a compact design,
an integral cross roller output bearing and a
large hollow shaft. Peak torques ranging from
9.0 Nm through 1,840 Nm and hollow shaft I.D.
ranging from 14mm through 80mm are available
depending on the unit size.
Zero Backlash Gearhead
The CSF-GH is a precision, zero-backlash
gearhead designed to easily mount to any
servo motor. A high-capacity cross roller
output bearing provides option for flange or
shaft output. The CSF-GH has a peak torque
ranging from 18 Nm through 2,630 Nm,
depending on the unit size. Gear reduction
ratios of 50:1 through 160:1 are available.
High Precision HD Gear
CSF Component Sets provide
unparalleled torque-to-weight ratio
and high precision. Harmonic Drive
provides zero backlash with accuracy
better than 1 arc-minute. Gear-reduc-
tion ratios of 30:1 through 160:1 are
available without change in weight
or form factor. Peak output torques
range from 1.8 Nm to 9,180 Nm, de-
pending on unit size and ratio. CSF
Component Sets are designed for
integration into equipment for a
performance-optimized design.
Call to speak with an
applications engineer
to be repaired in the field, touchproof connectors pre-vent health-care professionals and patients from getting shocked when they touch a connector. Touchproof con-struction often involves placing a plastic plunger over male pins, letting only the female contacts touch the male pin. Making pins on the active side of the connector touch-proof using any means eliminates the risk of shocks. MD
can’t affect pacemakers, nor can it corrupt data or images traveling from or stored in patient monitors and diagnos-tic equipment. And shield cans placed on PC boards pro-tect circuits from signal interference.
Filter connectors also play a critical role in manag-ing and controlling EMI and RFI. Some connectors have standard filtering features, including individual isolat-ed-pin filtering for high-frequency noise, built-in ground plane barri-ers in connector inserts, and shield cans on PC boards to protect circuits from signal interference.
But the filter-design approach is more effective. It lets engineers de-fine and change individual circuit capacitance, ground, and electro-magnetic-pulse (EMP) performance during development.
To ensure medical devices work, especially in critical applications, engineers must design intercon-nects that are reliable and maintain signal fidelity. This can be done by using breakaway connectors, EMI-shielding, and grounding-electron-ics cables. Such designs allow for shell-to-shell grounding at less than 10 mΩ, as well as EMI performance of greater than 85dB at frequencies from 40 MHz to 10 GHz. Perfor-mance is further enhanced by ter-mination processes which allow for 360° shield/connector coverage.
Complex EMI/RFI electronic is-sues have driven connector manu-facturers to develop higher-per-formance and more-cost-effective EMI-suppression methods, includ-ing spring-probe contacts a chip-on-flex (CoF) filter. CoF filters, using a flex circuit with chip capacitors, are surface-mounted to a pad on the feed-thru contact. This replaces tra-ditional planar-array block capaci-tors and while provides reliable fil-tering. In addition, the filters per-form well despite thermal shocks and vibrations.
Safety considerationsFrom a safety aspect, portable
medical devices need finger protec-tion and touchproof connectors. IP2X, a finger-protection standard, requires that a connector’s live or electrified parts cannot be touched by a human finger. Because por-table medical equipment may need
RS# 157
MAY 20, 2010 MACHINE Design.com 69
11715 Main Street, Roscoe, IL 61073 866-623-2168
Forest City Gear helps customers in an extremely diverse group of industrial, medical, aerospace, sporting goods,
research lab and high-performance racing markets, plus many others. Some might foolishly suggest this makes us
“a jack of all trades, master of none,” as that old adage goes.
Boy, are they wrong.
Exactly the opposite is true. Forest City Gear is the longtime market leader in special gear solutions, precisely because
we’ve seen and solved problems in virtually any application you can name that requires the highest geometrical integrity,
superior repeatable performance, accuracy that’s often off-the-charts for other gear companies and a secure, reliable
line of supply. O yes, and all at an affordable price that helps keep customers competitive and viable in their markets.
Who says you can’t be all things to all people? Well, we suppose
the size of our machining centers is a limit, if you can call what you
see here limited?
Call Forest City Gear and hear about all we can be…
on your next gear challenge! Go to www.forestcitygear.com today.
Who Says You Can’t Be All Things To All People?
"For high-precision gears,
we certainly can!"
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Star gear for racecar fuel pumpArticulating gear for the Utah Arm Internal spline gear for a
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diffractometer positioning
Circle 158
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Some of these offerings include:
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RS# 162RS# 161
RS# 159 RS# 160
MOTORS & DRIVES TECH GUIDE
Medical-device makers warm up to piezomotors
Piezoelectric motors and actuators have many advantages over conventional electromagnetic (EM) motors for med-ical equipment. Current medical applications for piezoelec-tric devices include ultrasonic emitters, artificial fertiliza-tion, medical nanomicroliter pumps, micromonitoring, surgery devices, and MRI-compatible robots. They are particularly useful for pick-n-place systems as used for microdose dispensing, cell penetration and cell imaging in cytopathology, and medical material handling.
Piezoelectric actuatorsA piezoelectric (or just piezo) actuator is a solid-state de-
vice that uses the change in shape of a piezoelectric material when an electric field is applied to create motion. A piezoelectric-ceramic element produces mechanical energy in response to electrical signals, and conversely, is capable of producing electrical signals in response to mechanical stimulus.
The use of piezoelectric materials dates back to 1881 when Pierre and Jacques Curie observed that quartz crystals generated an electric field when stressed along a primary axis. The term piezoelectric derives from the Greek word “piezein,” meaning to squeeze or press, relating to the electricity that re-sults from pressure applied to a quartz crystal.
Piezoelectric ceramics consist of ferroelectric materials and quartz. Piezo-ceramic elements typically start as high-purity powders of piezo materials such as PZT (plumbum, zirconate, titanate) that are pressed to shape, fired, elec-troded, and polarized. Polarization uses high electric fields to align the material
Piezoceramic
motors and actuators
avoid several problems
that beset ordinary
motors in medical uses.
Authored by:
Jim McMahonPresidentZebra CommunicationsSimi Valley, Calif.
Edited by Robert [email protected]
Key points:t��1JF[PFMFDUSJD�NPUPST�BOE�BDUVBUPST�BSF�
not affected by electromagnetic fields.
t��1JF[P�EFWJDFT�DBO�SFBDI�BDDFMFSBUJPOT�of more than 10,000 g and response times of less than 0.01 msec.
t��5IF�FGGJDJFODZ�PG�QJF[PFMFDUSJD�NPUPST�JT�OPU�SFEVDFE�CZ�NJOJBUVSJ[BUJPO�
Resources:
Pari Pharma, www.paripharma.com
Physik Instrumente L.P., www.pi-usa.us Circle 621Zebra Communications, www.zebracom.net
Tiny Motors Make Big Moves, tinyurl.
com/38p4yym
Micro Moves, tinyurl.com/3xnc5h4
[Open in new window]
A miniature piezo-linear motor mounted on the left side of the circuit board can reach velocities of 200 mm/sec. The right side of the board holds the motor-drive electronics.
MAY 20, 2010MACHINE Design.com72
MOTORS & DRIVES TECH GUIDE
oscillation creates only a few nanometers of move-ment, but the number of vibrations per second is so high that the rotor appears to move with a smooth mo-tion over a virtually unlim-ited travel range.
Today’s ultrasonic reso-nant motors, such as the PILine model developed by Physik Instrumente,Auburn, Mass., are char-acterized by speeds to 500 mm/sec. Such mo-tors can produce acceler-ations to 10 g. The motor mechanisms are also stiff, a prerequisite for their fast step-and-settle times of a few milliseconds with res-olutions to 0.05 μm.
Piezo-stepper-linear mo-tors usually consist of sev-
eral individual piezoactuators and generate motion through a succession of coordinated clamp/unclamp and expand/
contract cycles. Like the resonant motor, each extension cycle provides only a few microns of movement. Continu-ous motion arises from the high operating frequency that can create speeds up to 10 mm/sec.
Unlike the ultrasonic piezomotors that function through vibrations, piezo-stepper motors like Physik’s PiezoWalk can achieve forces of up to 700 N (155 lb) with picometer (ρm or 1 × 10-12-m) resolution. A resolution of 50 ρm (0.00005 μm) has been demonstrated. The motor can perform extremely high-precision positioning over long travel ranges. When it reaches position, it can switch
domains along a primary axis. Piezoelectric actuators in their basic form produce small dis-placements, but generate huge forces. The minute size of the displacement is the basis for the high precision motion they can deliver.
Long travel ranges use a clever arrangement of multiple actuators or the operation of a single piezo element at its reso-nant frequency. These types of piezomotion devices are called piezomotors.
Two piezomotors in par-ticular seem to work best for medical applications. The first is an ultrasonic piezo-linear motor, also called a resonant motor. The second is a piezo-stepper motor. Both versions provide unlimited travel or movement, yet both are differ-ent in their design, specifica-tions, and performance.
How it movesUltrasonic piezoelectric motors use ultrahigh-fre-
quency acoustic vibrations on a nanometer scale to cre-ate linear or rotary motion. Though identified as acoustic energy, the frequency of the vibration is far beyond human hearing. Large travel ranges at high speeds typically use ultrasonic linear drives. The 50-nm resolutions they ex-hibit makes them a better alternative to electromagnetic motor-spindle combinations. The ultrasonic drives are substantially smaller than conventional EM motors, and they don’t need the drivetrain elements that convert rotary to linear motion.
Piezoelectric linear motors use a rectangular monolithic pi-ezoceramic plate as the stator ele-ment, segmented on one side by two electrodes. Depending on the desired direction of motion, one of the electrodes is excited to pro-duce high-frequency eigenmode oscillations (one of the normal vi-brational modes of an oscillating system) from tens to hundreds of kilohertz. Attached to the plate is an alumina friction tip called a pusher that presses against the moving portion, the rotor of the motor. As the piezo plate vibrates, the pusher produces microim-pulses against the rotor and drives it either forward or backward. Each
Various-shaped piezo devices serve specific purposes. Two linear stages (bottom and right) flank a circular rotary stage that uses three pushers that rotate the center collar.
The atomizer head of a Pari Pharma eFlow Rapid Electronic Nebulizer uses an annular piezotransducer to atomize liquids for aerosol delivery of medications.
MAY 20, 2010MACHINE Design.com74
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Automation House
IndraMotion MTX CNC System
Answer
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to a highly dynamic motion system for tracking, scanning, or active-vibration suppression. Both the ultrasonic piezo-motors and piezo-stepper motor can operate in the pres-ence of strong magnetic fields or at low temperatures.
Types of actuatorsThere are a number of different piezoactuators and
motor types currently available. Simple piezoactuators expand proportionally in relation to the drive voltage and are typically classified as stacked, shear, tube, or bender. The stacked actuator is the most common type. It devel-ops a high force with fast response over a short travel. The shear actuator works best for lateral motions, such as fast, XY systems. It develops high force at high frequencies, but travel is typically limited to 20 μm. Tube actuators mostly serve in microdispensing applications and AFM scanners. Although the bender actuator can reach several millime-ters of travel, its low force and low frequency limits its use.
The virtually frictionless flexures and motion ampli-fiers used with flexure-guided piezoactuators give longer travel with an extremely straight motion. The motion is basically proportional to the drive voltage and integrated multiaxis systems are available. The “frictionless” opera-tion minimizes wear and tear over an extended motion range of 2 mm or more.
As referenced earlier, ultrasonic-friction motors are based on high-frequency oscillation of a piezoplate (sta-tor) to give unlimited high-speed motion with response times in the tens of milliseconds. This oscillation transfers to a slide or rotor via friction but this limits resolution typically to 50 nm.
Likewise, piezo-stepping motors basically possess un-limited motion range by an accumulation of small control-lable steps. Direct piezo actuation can develop picometer resolution using a dither mode while generating forces to 155 lb for off-the-shelf units. This motor has a fast re-sponse of less than 1 msec with high stiffness.
UItrasonic transducers use plate or disk-driven piezo elements with a high frequency at resonance. These ac-
Stacks of encapsulated piezoceramic material will drive a rod actuator arm through the circular hole at the top of the stack.
RS# 164
MOTORS & DRIVES TECH GUIDE
A piezo stack does just that, stacks different piezo material to extend the overall length and motion.
This miniature ultrasonic motor has only four parts, an ultrasonic piezoresonator and two lateral sliders pressed against it by a spring doubling as the moving carriage. The load is mounted directly to the carriage spring.
In one type of piezoactuator, the PZT material consists of two levels that move at right angles. In a typical operation, the base material extends to push the tip against a ceramic runner. The tip is them powered to push the runner in the desired direction. Voltage is removed from the base to release the runner, and the tip them returns to its normal position.
accuracy even when powered down.
P i e z o d e -vices provide faster accelera-tion and so can react in a mat-ter of micro-seconds . Ac-celeration rates of more than 10,000 g with response times of 0.01 msec are possible.
Piezoelec-tric motors are useful for medi-cal and biotech-nology applica-tions as they do not create elec-tromagnetic in-terference — nor are they influenced by it — eliminating the need for magnetic shielding. This is particularly im-portant for motors within strong magnetic fields, such as those in MRI equipment. Small piezomotors find use in MRI-monitored microsurgery while larger piezomotors rotate patients and equipment. The magnetic fields and metal components in conventional electric motors make it impossible for motorized medical devices to function within MRI equipment.
Because piezomotion depends on crystalline effects and not rotating parts like gears or bearings, piezomotors are virtually maintenance-free and do not need lubrica-tion. Additionally, they can be sterilized at high tempera-tures, a significant advantage in medical applications.
Static operation, even while holding heavy loads for long periods, consumes practi-cally no power. Also, because miniaturization does not reduce the efficiency of piezoelectric motors, they are still effective in power ranges below 30 W. This makes piezomotors prime can-didates for use in battery-op-erated, portable, and wearable medical devices because they can extend the life of a battery as much as 10×.
When at rest, piezomotors do not generate heat. They also eliminate servo dither and the heat that accompanies it.
In principle, piezomotors are vacuum compatible, a need for many applications in the medi-
tuators are typically used as sensors, transducers, or in nebulizers.
Improved performancePiezoelectric motors make medical devices smaller,
more precise, lighter, and easier to control. For example, piezomotors are smaller and more compact than elec-tromagnetic motors, yet can provide a greater force. The efficiency of electromagnetic motors falls as their dimen-sions shrink because more of their electrical power gets converted to heat. The efficiency of piezoelectric mo-tors stays virtually constant. For the same volume and weight, the stored energy density of a piezomotor is 10× greater than that of an electromagnetic motor. The most advanced piezomotors are found in compact, high-speed micropositioning stages smaller than a matchbox. The smallest piezomotor-driven stages are currently found in autofocus devices for cell-phone cameras.
The higher force-to-size ratio of piezomotors lets en-gineers design smaller equipment and instrumentation devices while maintaining or improv-ing performance through a number of different factors. For example, the direct-drive principle of piezomotors eliminates the need for supplemen-tary transmissions or gear trains found with conventional electromagnetic motors. The mechanical-coupling el-ements otherwise needed to convert the rotary motion of classical mo-tors to linear motion are unnecessary. Elimination of mechanical coupling avoids the usual backlash effects that limit accurate positioning. The intrin-sic steady-state autolocking capabil-ity of piezoelectric motors also does away with servo dither inherent in electromagnetic motors. Piezomotors can hold their positions to nanometer
Miniature ultrasonic motor
Piezoelectric actuator
Spring
Slider
PiezoWalk Principle
Preload
Ceramic runner
Preload
Piezo stack
L
ΔLPolarization
MAY 20, 2010MACHINE Design.com76
The ironless maxon winding.
High efficiency, no magnetic
cogging.
maxon DC motor
Close to 100%.
maxon motor is the world’s leading supplier of high-preci-
sion drives and systems of up to 500 watts power output.
maxon motor stands for customer specific solutions, high
quality, innovation, competitive prices and a worldwide dis-
tribution network. See what we can do for you:
www.maxonmotorusa.com
When energy-efficient drives are called for, maxon DC
motor provides the answer: the premium DC motors with
ironless rotor come in a comprehensive selection – Ø 6 to
65 mm, 0.3 to 250 watts – and feature high power density
and a more than 90% efficiency factor. Feedback devices,
gearheads and control electronics are also available for a
complete drive system.
A compact piezomotor linear-translation stage uses a single actuator to push a bearing along a mounting-platform guide.
cal industry. They can also continue to operate at cryo-genic temperatures close to 0°K.
Piezomotors are also not flammable and, therefore, safer in the event of an overload or short circuit at the output terminal, a considerable advantage for portable and wearable medical devices.
Medical applicationsFinally, it is useful to consider medical uses where pi-
ezoactuators excel. In Optical Coherence Tomography, piezoelectric motors impart rapid periodic motion to the unit’s reference mirror and imaging optics. To create 2D and 3D images from optical-interference patterns, opti-cal fibers must move both axially and laterally during the scan. Piezomotors provide more-precise movements im-proving image resolution over conventional electromag-netic motors.
Piezoelectric actuators are finding use in transdermal-drug delivery and systems for needle-free insulin injec-tion. End-effect manipulation of endoscope and gastro-scope devices also employ piezoelectric devices.
The microrobot bases used with biomedical microtools such as tweezers, scissors, and drills are powered by piezo-motors. Confocal microscopy in ophthalmology also uses piezoelectric motors for quality assurance of implants. The optics must move precisely to adjust the focal plane and for surface scanning. Piezoelectric positioning systems are integrated directly into the optics.
As shown, the growing need for accuracy in the micron and nanometer range, miniaturization of components, the dynamics of streamlining, and immunity from electrical interference push the physical limits for electromagnetic drive systems. Piezoelectric motors look to fill the gaps when the older technology hits its limitations. MD
RS# 165
Linear piezomotor
Mounting platform
Bearing
Glued friction bar
Excitation electrode
Piezoactuator (stationary
Friction tip
MAY 20, 2010 MACHINE Design.com 77
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MOTORS & DRVES TECH GUIDE PRODUCTS
Ethernet-based servodriveThe Ethernet-based Advanced Koll-morgen Drive (AKD) is available for 120/240-Vac or 480-Vac operation, with a power range of 3 to 24-Arms continu-ous current, 9 to 48-Arms peak. The unit supports a variety of feedback devices — mart feedback devices (SFD), Endat,
BiSS, Analog sine/cos encoders, incremental encoders, Hiperface, and resolvers — and Ethernet Motion buses — EtherCAT, CANopen, and Modbus/TCP.
The AKD’s autotuning algorithms automatically adjust all gains, including patent-pending observers. This func-
tion also provides immediate and adaptive responses to dynamic loads and promises precise control of all motor types.
The AKD features 27-bit resolution, a powerful dual processor system that executes servoalgorithms with high resolu-tion for very-fast settling times, torque loop updates in 0.67 μsec, 6.25-μsec velocity, and 125-μsec position loops.
Additional features optically isolated I/O that reduces noise and eliminates the need for additional hardware; SIL-qualified, over-voltage, current, and temperature detection; option cards that increase available I/O and add NVRAM; and multiaxis machine-control capability.Kollmorgen, 203A West Rock Rd., Rad-ford, VA 24141, (540) 633-3545, www.kollmorgen.com
RS# 622
Permanent-magnet motorsThe IronHorse permanent-magnet dc 56C-frame motors feature totally enclosed nonvented (TENV) and totally enclosed fan-cooled (TEFC) models. Constructed of a rolled-steel frame with cast-aluminum end bell, the motors are available in 0.33 to 2 hp.
With a base 1,800 rpm, the motors are designed for use on unfil-tered SCR (thyristor) Type 115 or 230-V rectified ac inputs, when used with an appropriate SCR drive or with PWM-type dc adjustable-speed drives.
Additional features include linear speed/torque characteristics over the entire speed range, high starting torques for heavy-load applications, reversible rotation, and dynamic-braking capability for faster stops. Large brushes provide for longer brush life.AutomationDirect, 3505 Hutchinson Rd., Cumming, GA 30040, (800) 633-0405, www.automationdirect.com/dc-motors
RS# 623
RS# 166
MAY 20, 2010MACHINE Design.com78
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RS# 175
RS# 173
RS# 174
SOFTWARE REVIEW
The straight-forward
shaft design is
made up of standard
shaft features.
duced-stiffness matrix from a finite-element model) or as a finite-element model solved in an advanced mod-ule. Users can define a bear-ing simply as a rotatable support with specified flex-ibility; a catalog-level de-sign with ISO capacities and macrogeometry; or with full microgeometry, life ad-justment factors, and high-speed inertial effects. As the model develops, users can
add further detail to each component.
The software then simulates the effect of a duty cycle or series of loads on the entire system, with multiple conditions of speed, load, and temperature defined, allowing simultane-ous cumulative dam-age analysis of all components. Users can define and apply multiple duty cycles,
reflecting different applications.RomaxDesigner models shafts for deflection and
stress using closed-form equations for beam seg-ments. Advanced modules provide the capability to use FE models for more-complex shaft geometry. Us-ers can choose from predefined materials and stress concentration factors, or develop their own. The base package can model parallel and concentric shafts. Per-pendicular shafts and moving axis (planetary) shafts are modeled with extended modules. An additional
RomaxDesigner is modular software, with a base package allow-ing system-level design and analysis, and with modules that allow the detailed analysis of indi-vidual components. The base software can analyze systems on parallel axes, with extensions available to analyze perpendicu-lar shafts and planetary systems. Even in the base package, users can build and analyze complex sys-tems, including nonlinear and 3D effects.
Users define each system component with a level of complexity ap-propriate to the needed analysis. Base modules let users define each compo-nent using an industry-standard closed-form equation. With more-advanced modules, indi-vidual components can be converted to models with finite-element attributes. For example, a housing can be defined according to its stiffness, (using a re-
RomaxDesigner provides a suite of tools for mechani-cal analysis of rotating structural components such as gears, shafts, bearings, clutches and synchronizers, and spline connections and housings. Engineers de-signing gearboxes, transmissions, vehicle drivelines at a system level, as well as providers of components, will find value in the consolidated analysis approach this software provides. The unified approach is es-pecially valuable when there are multiple nonlinear interactions contributing to load, component stress, and misalignment. When components are operating near to their limits, the increased accuracy provided by the detailed analysis modules lets users maintain adequate safety factors while avoiding defensive overdesigns.
Scalable software for gearbox and driveline engineering
The gearbox model with helical and hypoid gears
provides an example of the complex designs
RomaxDesigner supports.
An analysis in RomaxDesigner shows the deflection of the gears and shafts under load.
WHAT’S THIS?When you see a code like this, take a photo of it with your smart phone (iPhone 3G-S gives best results) and, using software from www.neoreader.
com, you will be connected to relevant content on machinedesign.com
MAY 20, 2010MACHINE Design.com80
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of localized housing distortion on bearing roundness, nor a direct way to calculate the effects of ther-mal expansion on bearing fit and preload. These features have been proposed for a future release.
Advanced bearing-analysis modules provide detailed analyses
bearing life, the models include the effects of misalignments de-veloped through the flexibility of any coupled components. A bearing preload tool automates studies of bearing life as a function of preload. RomaxDesigner does not currently include the effects
module analyzes shaft fatigue. The software can define and analyze shafts that are connected at non-90° angles, though the gear defini-tions for these systems are limited.
The base package provides standard bearing-life and load-ca-pacity analysis using ISO 281:1990 or ISO 291:2007. The program also includes a modified rating with a closed-form calculation of effects of misalignment. A built-in data-base includes data from four bear-ing manufacturers’ catalogs. Users can define and save additional bearings. A bearing search tool allows quick access to all four cata-logs and user-defined bearings.
Bearing models provide non-linear stiffness interactions with adjacent components, which can be critical when calculating gear-support stiffness, gear-mesh misalignments and preload re-quirements. When calculating
A New Part wizard makes it simple to select assemblies and components.
Jonathan AdlerEngineer – Specialist in product design and systems analysisMcLaren Performance Technologies Inc.Livonia, Mich.www.mclarenperformance.com
Edited by:Leslie Gordon,[email protected]
RS# 171
MAY 20, 2010 MACHINE Design.com 81
For over 40 years Thomas has been providing leading edge pump and
compressor solutions to medical original equipment manufacturers
around the world. Whatever the medical application, Thomas has a
proven track record of providing on-target solutions that not only meet
the application’s requirements, but also routinely add value in terms
of performance, size, weight and effi ciency that time and again make
our customer’s products better and more successful.
For more information, visit gd-thomas.com
Leading Edge Solutions
PUMP AND COMPRESSOR SOLUTIONS FOR OEMS WORLDWIDE
SOFTWARE REVIEW
standards. For parallel-axis gears, additional modules permit macro-geometry definition and optimiza-tion for manufacturability as well as detailed analysis of microgeom-etry for contact stress and trans-mission error. RomaxDesigner graphics are suitable for a variety of reporting illustrations, such as system topology and component deflection.
For parallel and perpendicular-axis gears, modules provide in-terfaces to more detailed analysis software, such as Simpack, LDP, and AnSol. They act as a “front end” for even more-computationally intensive formulations of bending and contact stress. The combina-tion of these software packages is particularly powerful, as it permits cumulative damage-life analysis including the nonlinear effects of gear-tooth deflection and bearing stiffness, acting on a fully devel-oped tooth profile. Additional modules focus on NVH and dy-namic characteristics, such as gear rattle and whine, system modal analysis, and clutch analysis. Mod-ules are also available to automate optimization and for the sensitivity analysis of system and component designs.
The developer does not include self-directed tutorials with the software, but the company does provide user training directly. The trainers customize course content and duration to meet the needs of each organization. A one-week training session would be suf-ficient to cover the basic modules and a few advanced topics. Many highly specialized software pack-ages require constant use to become and stay proficient. I find that RomaxDesigner does not require this level of attention. En-gineers with other responsibilities will find this software functional even if not used on a regular basis.
The software comes from Ro-max Technology, based in Not-tingham, U.K., with offices in Asia, Europe, and North America (www.
romaxtech.com). MD
include spur and helical gears, and with the perpendicular-axis module, bevel and hypoid gears. The base software models gears with enough detail to analyze their effects on the rest of the system. Additional modules allow design and rating to AGMA, DIN and ISO
(ISO 281 Supplement 4), including contact stress, fluid-film thickness, and stress-based life calculation. Advanced bearings can be defined with an assortment of predefined roller and raceway crowns, or with a measured crown.
RomaxDesigner models may
RS# 172
MAY 20, 2010MACHINE Design.com82
SPOTLIGHT SAFETY SENSORS & NETWORKS
Modular
safety controlThe samosPro modular safety control processes up to 96 safety inputs and 48 safety outputs simul-taneously. The control monitors safety sensors such as emergency stop pushbuttons, light curtains, and interlocking installations on
guard doors. The short reaction time lets protective measures mount closer to dangerous areas of a machine. Measuring just 22.5-mm wide, the control lets the units be used in construction widths starting from 45 mm.
Gateways, such as Ethernet/IP, Modbus/TCP, Profibus-DP, and Profinet IO, transmit more than 50 bytes bidirectionally between a PLC or HMI and the samosPro safety control, ensur-ing fast and comprehensive diag-nosis and visualization of control data. Using samosPlan, users program the control. Replaceable programming memory, called sa-
mosMemory, holds the relevant application program for the ma-chine or system.Wieland Electric Inc., 49 Inter-national Rd., Burgaw, NC 28425, (910) 259-5050, www.wielandinc.
com RS# 446
Rotary encoders with
integrated safety technologyThe RVS58S incremental rotary encoders, with integrated
safety technology, are designed for use in safety-aligned systems up to SIL3 in accordance with IEC 61508, perfor-mance Level “E” in accordance with IEC 13849, and Cat-egory 4 in accordance with DIN EN 954-1. The encoders,
with self-diagnostics, are also suitable as a motor feedback system for safe drives in accordance with IEC 61800-5-2.
The encoders have a sin/cos interface, 1,024 or 2,048 signal periods, and are thermally stabilized for high-resolution interpolation. The encoders operate at 5 Vdc ±5% and 200-kHz maximum output frequency in temperatures ranging from –20 to 80°C. They are rated to handle 40-N axial shaft loads at 6,000 rpm (maximum) or 10 N at 12,000 rpm (maximum), and 60-N radial shaft loads at 6,000 rpm (maxi-mum) or 20 N at 12,000 rpm (maximum).Pepperl+Fuchs, 1600 Enterprise Pkwy., Twinsburg, OH 44087; (330) 486-0001, www.pepperl-fuchs.com
RS# 447
Safety network controllerThe NE0A-SCPU01 safety network controller provides 12 safety inputs, two test outputs, and six safety outputs, and can be used as a stand-alone controller, a safety slave, or a DeviceNet standard slave. The controller’s preconfigured and TUV-certified program templates make the selection process easy. Designers can create safety circuits and save them as reusable templates for fast and simple standardization.
The NE0A includes safety function blocks for E-stop, door switch, external-device moni-toring (EDM), safety light curtain, limit switch, enabling switch, and mode selector.Omron Scientific Technologies, 6550 Dumbarton Circle, Fremont, CA 94555, (888) 510-4357, www.sti.
com/controllers/NE0A/index.htm
RS# 448
Request free information via
our Reader Service Web site at
Absolute encoders fulfill
safety requirementsThe Posital Optocode Series of absolute en-coders are now available as a safety version. The encoders comply with the new Machin-ery Directive by fulfilling the requirements of IEC 61508 and EN 62061. Operated with
protective extra low voltage (PELV), the encoders are for use in drive technology, lift applications, mobile machines, construction machinery, and machine tools.Fraba Inc., 1800 E. State St., Suite 148, Hamilton, NJ 08609, (609) 750-8705, www.posital.com RS# 449
MAY 20, 2010 MACHINE Design.com 83
www.machinedesign.com/rsc
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Sealed compressor housing provides quiet operation
Internal
Clean, corrosion-resistant oil-free transfer of your media
For analyzers, medical devices, imaging, pneumatics
Motors include DC, low EMI/RFI BLDC or ironless-core
Small quantities are available for prototyping use
head connections configured for reduced pulsation
KNF applied its 60+ years of diaphragm pump experience to bring you
a new pump designed to provide increased pneumatic performance
and compact size.The 2-head design with leak-tight internal
connectors features low pulsation and minimum noise emissions.
Trenton, New Jersey609-890-8600
datasheets at www.KNF.com/usa P U M P S
Your special OEM projects are always welcome
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Profinet connectorsThe Hummel M23-based Profi-net high-speed industrial Ethernet connector, combines Ethernet, data, or power lines in one single interconnect package. The con-nector carries up to five individual EMI-shielded circuits and guarantees safe transmission up to Gigabit range without interference. Connecting com-ponents are HF-technically matched to a resistance of 100 Ω at 100 Mbit, eliminat-ing cross-talking.
The brass-alloy-cast connectors are flame resistant (Twinax-inserts are V0 rated according to UL-94); vibration safe, and have crimp contacts. Available options include straight, elbow, and panel mounts (front and rear); crimp and PCB-mount connectors, I/O modules, adapter, flange, and conduit adapter. The unit has four shielded Twinax-inserts for data transfers, 12 additional contacts
Machined springsMachined springs provide linear de-flection rates and, unlike traditional wire wound springs, virtually all re-sidual stresses are absent. There are no internal stresses to overcome before deflection occurs. All coils deflect under load.
Machined springs with two or more integral coils have redundant elastic elements should a failure occur, and the failed coil will be physically trapped by a second coil (or multiple coils). In many cases, a broken spring will continue to function.
With machined springs, perpen-dicularity, parallelism, lateral bend-ing, and axial and torsional rates are guaranteed.Helical Products Co. Inc., Box 1069, Santa Maria, CA 93456, (877) 353-9873, www.heli-cal.com
RS# 466
for transmission of signal and power achieve maximum power density/effectiveness within the M23 housing (Sig-
nal 4 × 2 each 0.6-mm contacts) 0.08 to 0.34 sq mm – 28 to 22 awg (CAT6 - 0.25 sq mm) and 12 × 1 (0.25 to 1.5 sq mm).
Sealcon, 14853 E. Hinsdale Ave., Suite D, Centennial, CO 80112, (800) 456-9012, www.sealconusa.com RS# 465
Request free information via
our Reader Service Web site at
RS# 176
MAY 20, 2010 MACHINE Design.com 85
www.machinedesign.com/rsc
PRODUCTS
SUPERTEAM
"--�4&/4034n
X X X � B M M T F O T P S T � D P N
Pressure ranges are available from 1/4 to 30 inch H2O full
scale. Offset voltage errors are significantly reduced by
electrical cross coupling technology.
www.allsensors.com/mad/amp.htm
ni Low Pressure Sensor
2O full
superior output offset characteristics.
www.allsensors.com/mad/mini.htm
ssure Sensor
2O
calibrated to zero. www.allsensors.com/mad/mv.htm
Surface Mount Basic Pressure Sensor
Surface mount basic pressure sensors provide a low-cost solu-
www.allsensors.com/mad/smt.htm
ALL SENSORS®
High accuracy. Low pressure. We are pressure sensors.
408.225.4314 (P) 408.225.2079 (F) [email protected]
PRODUCTS
Pneumatic assembly
tools
Pneumatic assembly tools perform numerous manufacturing func-tions, improve product quality, and increase productivity. Available as hand or bench models, the tools make plumbing assemblies; splice wire rope and cable; crimp electrical components; swage mechanical fas-
teners; stake, punch, pierce, and flare; seal, emboss, and notch; and clamp and hold assemblies.Fabco-Air Inc., 3716 NE 49th Ave., Gainesville, FL 32609, (352) 373-3578, www.fabco-air.com
RS# 467
Data acquisition and display stationsThe DXAdvanced R4 is latest version of the Daqstation data-acquisition and display stations with high-capac-ity memory and an option for strin-gent pharmaceutical applications. An Advanced Security option delivers full compliance with FDA regulation 21 CFR Part 11. This is complimented by a multibatch option that allows chan-nels to be grouped and recorded to discrete batch records with indepen-dent start and stop control.
Standard features include 400 Mbyte of internal Flash mem-ory, with an optional USB interface. Custom graphics let users design custom display screens. An alarm-annunciator display mode uses ISA sequencing, which replaces common annunciator lamp panels.
Two models are offered — the DX1000 with two to 12 universal inputs, 5.5-in. color display; and the larger DX2000 with 4 to 48 universal inputs and 10.4-in. color display.
Modbus RTU and TCP, EtherNet/IP, and Profibus DP protocols aid instal-lation on control networks, and the DXAdvanced R4 can interface with PLCs and other control products as a data source or to add graphical data display and recording functions. An external input option lets the DX2000 handle up to 300 additional inputs from external I/O for a total system capacity of 348 inputs.Yokogawa Corporation of America, 2 Dart Rd., Newnan, GA 30256, (770) 254-0400, www.yokogawa.com/us
RS# 468
RS# 177
MAY 20, 2010MACHINE Design.com86
Available in pressure ranges of 1, 5, 10, 20, and 30 inch H
scale. Output is available as a calibrated amplified signal with
Amplified Very Low Pressure Sensor
Includes a PCB mountable feature with dual pressure ports.
Amplified Mi
tion in a small footprint. Pressure ranges include 1, 15, 30, and
100 PSI. In addition, an unprecedented 10 inch device is also
available with position sensitivity better than 0.03% full scale.
Millivolt Low Pre
Available in pressure ranges of 1, 5, 10, 20, and 30 inch H
full scale. Millivolt output is temperature compensated and
Request our latest sensor Databook today!
Build the Perfect Beast of a LineWith Visumatic
Robotic Fastening
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Visumatic’s automatic
fastening components.
Ready to drop in place,
configured to your specs,
AND every Visumatic
product is backed with our
unmatched Human Touch
customer service.
Smarter Machinesfrom Creative Engineers
for Smart Customers
$ 0 / 4 * % & 3
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Machines
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FOR SCARA ROBOTS
World Encoders, Inc. Hoffman Estates, IL 60169
formerly Koyo Encoder, Inc. Toll Free: 1-800-903-9093
The World Encoders!Proven Reliability for over 53 years. Super-Durability & Absolute Dependability.
Distributors Wanted! Online Shoppingwww.worldencoders.com
Compare Pricing S.R.P. (List Price) Basis
World Encoders Dynapar BEI EPC
Modular Size 12 $ 47.00 E5/E2 $164.00 M15 $ N/A $ N/A
Size 15-Shaft (Std.) $132.00 TRDA-2E $349.00 E14 $ N/A $184.00 15S-1024
Size 20-Shaft (Std.) $205.00 TRDA-20N $384.00 H23 $305.00 H20D $336.00 702-1024R
Size 25-Shaft (Std.) $235.00 TRDA-25N $493.00 HA625 $515.00 H25D $361.00 725N-1024R
Size 15-Hollow (Std.) $120.00 TRDA-VA $230.00 F14/F18 $ N/A $201.00 15H-2500
Qube 2.25" $120.00 RS $238.00 21/22 $ N/A $190.00 711
Size 35-Hollow-Hub 1" $360.00 HS31 $473.00 HS35 $655.00 HS35 $358.00 25T
NEMA4 IP66 w/Cover w/Metal Body w/Metal Body w/Metal Body w/Plastic Body
LISTED 87ML
IND. CONT. EQ.
C US
Brand Encoders
Value & Technology
Linear Fully Enclosed
Modular / KitWheeled & Qube
NEW!
Small Wheeled
HS20
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Heavy-duty HS31 Hollow
Incredible Features and Super-Low Prices!
NEW!
Small Size 20 MPG
Handwheel & Pendants
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RS# 180
RS# 178
RS# 179
MEETING YOUR NEEDS FOR PRECISION STAINLESS STEEL
ISO 9001:2000 ISO 13485:2003 AS 9100 B
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EAGLE STAINLESS Tube & Fabrication Inc.
10 Discovery Way Franklin Massachusetts
phone 800-528-8650 fax. 800-520-1954
MD&M West Booth 3025
www.eagletube.com
PRODUCT LIT
TensionersThe Multi-Jackbolt Tension-ers make large-diameter bolting safer for workers, re-duces installation and removal times, and requires only hand/air tools. The DVD, “The Simple Solution to Bolting Problems,” explains the technol-
ogy in detail, com-pares this bolting method to others, and covers common
applications in a wide variety of industries.
Superbolt Inc., Box 683, 1000 Gregg St., Carnegie, PA 15106,
(800) 345-2658, www.superbolt.comRS# 469
Motion-control components and systemsThe 56-page Advanced Motion Sys-tems for Defense, Aerospace, and National Security includes multiaxis motion simulators, pedestals, precise two-axis azimuth/elevation gimbals, vacuum-rated motion systems, advanced system controls, and high-performance linear and rotary stages and gantries. The brochure covers single, two, and three-axis motion simulators, advanced motion-simulator controls, electro-optics test systems, high load-capacity linear and rotary stages, high-vacuum and clean-room-ready systems, prototype laser and micro-wave-beam steering systems, and solar tracking and telescope systems. One section covers high-performance components that include rotary stages, linear stages, and gantries.Aerotech Inc., 101 Zeta Dr., Pitts-burgh, PA 15238, (412) 963-7470, www.aerotech.com/PDFfiles/CA0410BMil_Aero.pdf RS# 470
Metal stampingThe eight-page 2010 Metal Stamp-ing Brochure details the company’s high-quality metal-stamping capabili-ties. Stampings are available in sizes including flat blank-ing and piercings up to 12 × 12 in., metal forming in thicknesses from 0.005 to .134 in., and draws up to 3-in. deep and 8 in. in diameter. Also covered are the company’s “Dock-to-Stock” and “Just-in-Time” programs.Boker’s Inc., 3104 Snelling Ave., Min-neapolis, MN 55406, (800) 927-4377, www.bokers.com RS# 471
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MAY 20, 2010MACHINE Design.com88
To advertise in the DATA FILE sections
call 216.696.7000 or e-mail
ATA FILED Literature Advertising Section
New Loctite® Threadlockers
Loctite® 243™ Medium Strength
Blue Threadlocker and Loctite® 263™
High Strength Red Threadlocker provide:
'� upgraded temperature resistance –
up to 360°F
'� oil tolerant curing on as-received
fasteners without cleaning
'� primerless performance on both
inactive and active metals
For a free sample and more info,
go to www.useloctite.com/MA23Galil Motion Control
Galil’s “Pocket PLC”Has Lots of I/O
RIO Pocket PLC is smart,
compact, low-cost, and packed
with I/O. 32 digital and 16 analog
I/O in 3.9 x 4.3 x 1.3” package.
Ethernet/RS232, RISC processor,
PID process loops, counters, timers, data logging, email
alerts. Network multiple RIOs. $295 qty 1/$195 qty 100.
Call Galil at 800-377-6329 or http://www.galilmc.com/
pocketplc for specs and free tutorials.
Custom Integral Style Studded DualVee®
Guide Wheels
Affordable, swaged integral style studded DualVee guide wheels in concentric and eccentric versions are now available from Bishop-Wisecarver. Studded wheels are offered in stainless steel with low temperature, high temperature or custom grease, and in sizes 0-4.
No minimum order quantities and short lead times. Consult our Applications Engineers for custom stud lengths. 888.580.8272; www.bwc.com
CounterBalance Corporation
Motion Control with CounterBalance Corporation
CounterBalance Corporation has many solutions for heavy lid applications. Designed to provide precise balancing of delicate or heavy
loads. CounterBalances can be designed to integrate hinge and attaching features…a complete system. CounterBalance engineers offer design assistance to improve quality and reliability of balancing systems. Call or contact us at 215-957-9260 or http://www.cbal.com.
Boker’s, Inc.
Boker’s Free 2010 Washer CatalogWasher Catalog features over 24,000 non-standard flat washer sizes avail-able with no tooling charges. ODs of 0.080” to 5.140”, a range of IDs and thicknesses, as well as 2,000 material options provide endless washer pos-sibilities. Materials include numerous carbon steels, stainless steels, alumi-nums, brasses, coppers and non-me-tallics. ISO 9001:2008 Registered.
(888) 927-4377, FAX: (800) 321-3462Email: [email protected]: www.bokers.com/mdd
EDGE WELDED BELLOWS
BellowsTech, LLC de-
signs & manufactures
precision bellows in a
full range of diameters
and thicknesses rang-
ing from .394” (10 mm)
to 26” (660 mm) in
diameter. Available in
an array of dimensional
configurations & alloys including Titanium, 316LSS, AM350 SS,
Aluminum, and Inconel/Hastelloy.
Email: [email protected], for NEW 12 page brochure.
BellowsTech, LLC / PMG, LLC
BEI Sensors
BEI Industrial Encoders Design & Specifying Guide
65 full color pages of product specifications, design examples, drawings and accessories - all dedicated to encoder feedback solutions. Includes rotary and linear encoders, electronic mod-ules, wireless interfaces, cables, connectors and accessories. Special sections include hazard-ous and extreme environments.
Call 800-ENCODER or visit www.beiied.com/catalog
Apple Rubber Products
Sealing Solutions to Suit Your NeedsFrom engineering to manu-facturing and inspection, Apple Rubber Products sup-plies high performance seals and parts directly from their USA plant. Choose from Standard O-Rings, Miniature Seals, Housing (Face) Seals, Medical Seals, Silicone Parts, Custom Shapes, FilterSeals®,
and Composite Seals. Pick the sealing category that’s right for you: www.applerubber.com/products
Animatics
Get SmartMotor™ driven Actuators FAST New OEMDynamics Catalog shows Thrust Curves for a vast array of belt and ball-screw driven actuators pre-assembled with Animatics SmartMotors and their built-in control systems. Just Apply Power, communicate serially, or download a simple program to complete your Automation task. Log onto www.oemdynamics.com for complete information.
All Motion
4 Axis Driver + Controller Measures Just 2.25” Square
The product is a miniature 4 axis stepper motor controller and driver measuring 2.25” x 2.25” x 0.6”. The controller-driver is capable of driv-ing each motor at 1 Amp of current at 1/16th micro-step resolution. The controller performs fully profiled moves and accepts high level com-
mands from RS232, RS485 or USB. On boards program stor-age allows stand alone operation. Connections for limit / home switches for each channel , and dual encoders for position monitoring and correction are supported.
www.allmotion.com (408) 460-1345
ACE Controls Inc
Decelerate loads, prevent im-pact damage, improve product performance, increase cycle speeds and reduce noise. New ACE Controls Main Catalog includes industrial and safety shock absorbers, as well as models for the PET & GLASS industries. Additional motion control catalog products include: gas springs, hydraulic dampers, velocity and feed controllers.
Farmington Hills, MI(800) 521-3320 (248) 476-0213Fax (248) 476-2470Email: [email protected]
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AutomationDirect’s Volume 13 Free Catalog now availableAutomationDirect’s volume 13 cata-
log offers over 8,500 industrial auto-
mation products for a wide range of
applications. The latest two-volume
edition features product descriptions,
technical data, and photos for PLCs,
touch screen monitors, AC and DC
motors, text panels, sensors, encod-
ers, pushbuttons, switches, drives,
and more. Printed separately from the
“Desk Reference” are a complete prod-
uct price list and a product overview.
For a free copy, in print or on CD, or more information, visit
www.automationdirect.com or call 800-633-0405.
Caplugs
Caplugs Offers Comprehensive Catalog
Caplugs offers a new 144-page,
full-color catalog. This comprehen-
sive catalog features a complete
line of product protection devices
with more than 5,000 caps, plugs,
tubes, netting, containers, edge lin-
ers and wraps.
To request a copy of Caplugs new
catalog visit www.caplugs.com. To
speak with a customer service rep-
resentative, call 1-888-CAPLUGS
or e-mail our sales department at
RS# 258
Gems Sensors & Controls
Gems Fluid Sensors & Controls Master CatalogThis 340-page Master Catalog details the broad portfolio of Gems liquid level, flow, and pres-sure sensors, miniature solenoid valves, and pre-assembled flu-idic systems designed for OEMs across a wide range of indus-tries. Provides full specifications, dimensions and part numbers.
800-378-1600www.GemsSensors.com
MACHINE Design.com 89MAY 20, 2010
TURCK Sensors Catalog Includes 17 New Product Types
TURCK’s extensive Sensors Cata-
log details the company’s full sen-
sors line, including 17 recently
introduced product varieties. The
catalog also features a new section
dedicated to specialty sensors and
harsh duty sensors, designed to
withstand the most challenging ap-
plication environments. It addition-
ally details related sensor cordsets
and accessories.
Phone: (800) 544-7769
URL: www.turck.us
860-542-5543www.nemb.com
From .007" to 1" diameter.Most machinable materials.
SELF-LUBRICATING GEAR
SOLUTIONS CALCULATED FOR LIFE
The Intech Power-Core™ gears are precision
machined and offer solutions to applications
in which lubrication, wear, noise, vibration,
inertia, shock load, moisture and chemicals
present a problem for nylon, Delrin or metal
gears. Metal Core provides for a secure at-
tachment to the shaft and higher torque trans-
mission. Gear design and sizing is backed
by durability calculation using proprietary
software.
Intech Corp., 250 Herbert Ave., Closter, NJ
07624. (201) 767-8066; Fax: (201) 767-7797.
www.intechpower.com
Wittenstein
New Motion Control Website
Experience the new look
and feel of Wittenstein. In-
cluding alpha gearboxes,
custom servo solutions
and simulation systems
- the world of motion is
only a mouse click away.
Put your web in motion
with Wittenstein.
Visit us today at www.wittenstein-us.com
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Trim-Lok Inc., Buena Park, CA
Vinyl & Rubber ExtrusionsTrim-Lok Inc. releases a brand new
FREE “Catalog 500” featuring “How
to Order” steps for the first time
customer, along with an expanded
line of complete trims and seals.
FREE samples may be requested.
Latest additions include our Flap
Seal, Fire Retardanct Trim, adn
Hatch Seal. Contact us toll fee at
1-888-874-6565, e-mail us at info@
trimlok.com or visit us on-line at
www.trimlok.com
P/M Structural PartsThe use of powder metal parts
can result in substantial sav-
ings. Symmco P/M parts offer
high quality and high precision,
with possible savings of 90%
or more over machined parts.
Helical gears available. Short
runs are our specialty. Press
capacity from 2.5 to 750 tons.
Huge inventory of stock sin-
tered bronze bearings, bar and
rectangular plate also available. 24 hour service. (814)
894-2461, fax (814) 894-5272. www.symmco.com
Symmco, Inc., Sykesville, PASeal Master Corp., Kent, OH
SEALS, ACTUATORS,GRIPPERS AND BAGS
Solve difficult closure prob-lems with custom-built, fab-ric-reinforced, fully molded elastomeric Seal Master® inflatable seals. With close tolerance capability and re-sistance to compression,
they’re ideal for imaginative production and processing applications too. Engineered specialties include fabric-reinforced bags, bladders, plugs and other custom rubber products. Design assistance offered.
Omega Engineering, Inc.
Miniature RFID Data Loggers and Readers OM-84 Matchbook™ SeriesOmega’s new CE compliant OM-80
series of data loggers and readers
are economical, accurate and
provide a reliable solution
for cold chain environmental
monitoring. The OM-84 model
features a miniature weather-
resistant design with a factory
replaceable battery. Each logger
can store up to 10,000 readings
and is reusable. Stored data can be downloaded and saved to
your computer using the reader and software that is included. Each package
of data loggers comes with a certificate stating NIST-Traceability (No Points).
Built-in LEDs display high and low alarm verification indicating whether or
not measured temperatures have remained within the user programmable
alarm window throughout deployment. This product is ideal for produce, sea-
food, dairy, supermarkets, or any applications where temperature monitor-
ing is needed. Price starts at $90 for a pack of 5.
Northwire
Tough As Nails, CoilBoss™ Retractile Cords Northwire’s CoilBoss Retractile Cords literature outlines in-stock and custom-configured options offered to exceed your requirements. Guaranteed to perform, CoilBoss improves the wiring life of applications requiring movement. Shipped fast with no minimums. 715.294.2121; www.northwire.com/brochure
High- PerformanceMagnetsNew catalog features h igh
performance magnet materials
such as NdFeB and SmCo,
molded magnets, ceramic and
alnico magnets. MCE offers
magnet c ircu it des ign,
custom fabrication, assembly,
and advanced coat ings.
Complete traceability is offered.
P h o n e : ( 3 1 0 ) 7 8 4 - 3 1 0 0 ,
Fax:(310)784-3192; [email protected];
www.mceproducts.com
Magnetic Component Engineering
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EPOXIES MADE TO ORDER
For specialized needs, Master Bond can custom formulate an epoxy adhesive, sealant, coating,, potting, and encapsulation compound to meet your specifications. We offer unsurpassed technical expertise and have years of experience in solving complex problems. Special formulations can be made in small to large quantities. These formulations can increase productivity, eliminate waste and improve product reliability. Additionally, our products can be supplied in simple, easy to use packaging.
Master Bond, Inc.
Phone: (201)343-8983Fax: (201)343-2132E-mail: [email protected]
IBOCO®
Introducing IBOCO’s new full-line catalogIBOCO’s new catalog features more of
the products you asked for:
· TS Solid Duct
· TSH solid duct with mounting holes
· NEW Din Rail Cutter
· Liquid-tight conduit and connectors
PLUS
· Wire duct and conduit cutting tools
And ask for our New Brochure featuring our full line of polycar-bonate enclosures.
Fax: 732-417-1166
www.iboco.com
e-mail: [email protected]
Integrated Panel Management
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Smalley Steel Ring Company
Spiral Retaining Rings & Wave SpringsSmalley’s complete product line is now available in one easy to navigate catalog. The new cata-log includes over 7,000 standard wave springs, spiral retaining rings and snap rings. Smalley’s new catalog offers simplified part selection, special design and engineering tools and the latest applications of Smalley products. (847) 719-5900.
E-mail: [email protected], Web: www.smalley.com/getcatalog
HOTWATT, INC.
NEW REVISED 2010 ELECTRIC HEATER CATALOG
Hotwatt manufactures electric heat-ers including cartridge, air process, immersion, strip and finned strip, tubular and finned tubular, band, crankcase, foil, flexible glasrope and ceramic heaters. We have been manufacturing resistance heating el-ements since 1952 and offer a wide variety of heaters for OEM, industrial, medical, commercial and military ap-plications.
E-mail: [email protected] Page: www.hotwatt.com
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MACHINE Design.com90 MAY 20, 2010
LET US GIVE YOU A HAND
WITH YOUR CUSTOM
WIRE FORMS!
We have greatly expanded our capabilities
with multiple CNC machines! Our fully
automated CNC bending center allows us to
custom fabricate wire forms with
up to 5/8” diameter.
Send us your shape
today. With a
sketch, blueprint
or sample we will
supply a prompt
quote to your
specifications.
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RS# 184RS# 185
RS# 182 RS# 183
BUSINESS INDEX
This index includes all significant references to parent companies mentioned in feature editorial material within this issue of MACHINE DESIGN. It doesn’t cite companies listed solely in the Products and Lit Section. Page numbers listed refer to the pages where the articles begin.
Ensinger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Fabrico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24, 54FEV Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26FIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Ford. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Forest City Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Fortus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Fraba Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83, 96Geomate Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Gerwah . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Hewlett-Packard. . . . . . . . . . . . . . . . . . . . . . . . . . .36, 96Hirose Electric Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Honda Performance Development . . . . . . . . . . . . 52Hughes Aircraft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34IBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34ISOPur Fluid Technologies . . . . . . . . . . . . . . . . . . . . 18ITT Interconnect Solutions . . . . . . . . . . . . . . . . . . . . 67Indy Racing League . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Jaguar Racing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48KNF Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Knapp Systemintegration GmbH . . . . . . . . . . . . . . 38Kollmorgen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38, 78LehIgh University . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Lemo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Lockheed-Georgia Co. . . . . . . . . . . . . . . . . . . . . . . . . 34Lola . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Luczo Dragon Racing/de Ferran Motorsports . . 48Lumex Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28March . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Massachusetts Institute of Technology . . . . . . . . 33McLaren Performance Technologies Inc. . . . . . . . 81Mercedes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Micrel Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Milliken & Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Milwaukee School of Engineering . . . . . . . . . . . . . 28Minco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Molex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Moxa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22New Way Air Bearings. . . . . . . . . . . . . . . . . . . . . . . . . 33Nippon Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Northeastern Univ. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Omron Scientific Technologies . . . . . . . . . . . . . . . . 83Pari Pharma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Parker Hannifin AB. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Parker Hannifin Corp., Tube Fittings Div. . . . . . . . 61Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Phoenix Contact Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 36Physik Instrumente L.P.. . . . . . . . . . . . . . . . . . . . . . . . 74Pneumatech Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95R&W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96RE2 Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Reynard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Ringfeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Rittal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Rollon Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Romax Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Shimpo Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . 70Smalley Steel Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Solid Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Staheli West . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Stratasys Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Swagelok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Swift Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Switchcraft Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Taiyo Yuden (U.S.A.) Inc. . . . . . . . . . . . . . . . . . . . . . . . 38U.S. Army. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Voswinkel GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Wago Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Wieland Electric Inc. . . . . . . . . . . . . . . . . . . . . . . .83, 95Wittgenstein . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Zebra Communications . . . . . . . . . . . . . . . . . . . . . . . 72
Air Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Alfmeier Prazision AG . . . . . . . . . . . . . . . . . . . . . . . . . 24All Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Altech. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96American Welding Society . . . . . . . . . . . . . . . . . . . . 36AutomationDirect . . . . . . . . . . . . . . . . . . . 6, 22, 70, 78Avago Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . 70Avnet Electronics Marketing Americas. . . . . . . . . 38B&R Industrial Automation . . . . . . . . . . . . . . . . . . . . . 6BAT Engineering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45BMW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Balluff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Bishop-Wisecarver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Bosch Rexroth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Cameron Compression . . . . . . . . . . . . . . . . . . . . . . . 95Cognex Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Dallara . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44DeltaWing Racing Cars. . . . . . . . . . . . . . . . . . . . . . . . 45Digi-Key Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36, 70Dynaflo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Eaton Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Ecoloc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
RS# 186
MAY 20, 2010MACHINE Design.com92
ADVERTISER INDEX
RS# . . . COMPANY. . . . . . . . . . .PAGE
142 . . . . . ACE Controls, Inc.. . . . . . . . . . . . . 52
110 . . . . . Aerotech, Inc.. . . . . . . . . . . . . . . . . 12
188 . . . . . All Motion, Inc. . . . . . . . . . . . . . . . 94
177 . . . . . All Sensors. . . . . . . . . . . . . . . . . . . . 86
155 . . . . . Ametek Inc . . . . . . . . . . . . . . . . . . . 65
152 . . . . . Animatics Corporation . . . . . . . 64
111 . . . . . Apple Rubber Products . . . . . . 13
103 . . . . . Automation Direct . . . . . . . . . . . . .3
145 . . . . . Balluff Inc. . . . . . . . . . . . . . . . . . . . . 56
127 . . . . . BEI Industrial Encoder Div . . . . 31
192 . . . . . Bimba Manufacturing Co . . . . BC
154 . . . . . Boker’s Inc. . . . . . . . . . . . . . . . . . . . 65
164 . . . . . Bosch Rexroth. . . . . . . . . . . . . . . . 75
108 . . . . . Caplugs . . . . . . . . . . . . . . . . . . . . . . 10
149 . . . . . Carlyle Johnson Machine Company, LLC . . . . . . . . . . . . . . . . 61
116 . . . . . Carr Lane Mfg Co.. . . . . . . . . . . . . 19
190 . . . . . Cicoil Corp. . . . . . . . . . . . . . . . . . . . 96
107 . . . . . Clippard Instrument Lab Inc. . . . . . 9
122 . . . . . Contitech. . . . . . . . . . . . . . . . . . . . . 27
189 . . . . . CounterBalance Corp . . . . . . . . 95
151 . . . . . CUI Inc. . . . . . . . . . . . . . . . . . . . . . . . 63
175 . . . . . D&R Products . . . . . . . . . . . . . . . . 79
105 . . . . . Digi Key . . . . . . . . . . . . . . . . . . . . . . . .7
106 . . . . . Dynetic Systems. . . . . . . . . . . . . . . .8
181 . . . . . Eagle Stainless & Fabrication, Inc. 88
104 . . . . . ebm-papst . . . . . . . . . . . . . . . . . . . . .5
134 . . . . . Fabrico . . . . . . . . . . . . . . . . . . . . . . . 38
158 . . . . . Forest City Gear . . . . . . . . . . . . . . 70
148 . . . . . Galil Motion Control Inc . . . . . . 59
136 . . . . . Gates . . . . . . . . . . . . . . . . . . . . . . . . . 40
137 . . . . . Gates . . . . . . . . . . . . . . . . . . . . . . . . . 41
176 . . . . . H.A. Guden Company . . . . . . . . 85
157 . . . . . Harmonic Drive LLC . . . . . . . . . . 69
133 . . . . . Haydon Kerk Motion Solutions 37
146 . . . . . Helical Products Company, Inc. 57
161 . . . . . Igarashi Motor Sales. . . . . . . . . . 71
174 . . . . . igus, inc. . . . . . . . . . . . . . . . . . . . . . . 79
171 . . . . . Keystone Electronics Corporation . . . . . . . . . . . . . . . . . . 81
169 . . . . . KNF Neuberger, Inc. . . . . . . . . . . 84
139 . . . . . Lee Company . . . . . . . . . . . . . . . . 47
143 . . . . . Lin Engineering . . . . . . . . . . . . . . 53
114 . . . . . LINAK. . . . . . . . . . . . . . . . . . . . . . . . . 16
118 . . . . . Loctite Corp.. . . . . . . . . . . . . . . . . . 21
173 . . . . . Magnetic Component Engineering, Inc. . . . . . . . . . . . . . 79
128 . . . . . Master Bond, Inc. . . . . . . . . . . . . . 32
178 . . . . . Master Bond, Inc. . . . . . . . . . . . . . 87
165 . . . . . Maxon Motor Usa . . . . . . . . . . . . 77
126 . . . . . MITRPAK. . . . . . . . . . . . . . . . . . . . . . 31
109 . . . . . Moog Components Group . . . 11
135 . . . . . Moog Inc . . . . . . . . . . . . . . . . . . . . . 39
119 . . . . . National Precision Bearing . . . 24
141 . . . . . NB Corp . . . . . . . . . . . . . . . . . . . . . . 51
113 . . . . . Newark. . . . . . . . . . . . . . . . . . . . . . . 15
150 . . . . . Nippon Pulse America Inc . . . . 62
153 . . . . . Ogura Industrial Corp.. . . . . . . . 65
101 . . . . . Omega Engineering Inc . . . . . IFC
167 . . . . . One Planet . . . . . . . . . . . . . . . . . . . 84
124 . . . . . Parker Hannifin. . . . . . . . . . . . . . . 29
129 . . . . . Pentair. . . . . . . . . . . . . . . . . . . . . . . . 33
102 . . . . . Phillips Plastics Corporation . . . .1
117 . . . . . Physik Instruments Lp. . . . . . . . 20
185 . . . . . Precision Paper Tube Company 91
162 . . . . . Protex Fasteners Ltd . . . . . . . . . . 71
191 . . . . . Proto Labs, Inc. . . . . . . . . . . . . . . IBC
160 . . . . . Quality Bearings & Components 71
156 . . . . . Quickparts.com Inc. . . . . . . . . . . 68
125 . . . . . Reid Supply Company. . . . . . . . 30
. . . . . . . . . Rino Mechanical Components Inc 34
138 . . . . . Rittal Corporation . . . . . . . . .42-43
147 . . . . . Rotor Clip Company. . . . . . . . . . 58
166 . . . . . SAB North America. . . . . . . . . . . 78
187 . . . . . Sealeze Corp . . . . . . . . . . . . . . . . . 93
183 . . . . . Sepac. . . . . . . . . . . . . . . . . . . . . . . . . 91
168 . . . . . Servometer /Precision Mfg. Group, LLC. . . . . . . . . . . . . . . . . . . . 84
115 . . . . . SEW Eurodrive. . . . . . . . . . . . . . . . 17
131 . . . . . Shenzhen Power Motor Industrial Co., Limited . . . . . . . . 35
132 . . . . . Smalley Steel Ring Company . 36
123 . . . . . Spirol International Corp . . . . . 28
121 . . . . . Symmco Inc.. . . . . . . . . . . . . . . . . . 26
140 . . . . . TDK Lambda Americas Inc . . . 49
159 . . . . . Techno Inc. . . . . . . . . . . . . . . . . . . . 71
172 . . . . . Thomas Products Div. . . . . . . . . 82
92 . . . . . . Trim-Lok Company . . . . . . . . . .186
112 . . . . . Turck Incorporated . . . . . . . . . . . 14
170 . . . . . Ultra Motion Company. . . . . . . 84
184 . . . . . Universe Kogaku Inc . . . . . . . . . 91
179 . . . . . Visumatic. . . . . . . . . . . . . . . . . . . . . 87
182 . . . . . Western Wire Products Co . . . . 91
163 . . . . . Wolong Electric Group Co., Ltd. 73
180 . . . . . World Encoders, Inc . . . . . . . . . . 87
144 . . . . . World Success International Dev Ltd. . . . . . . . . . . . . . . . . . . . . . . 55
120 . . . . . ZERO-MAX . . . . . . . . . . . . . . . . . . . 25
While every effort has been made to
ensure the accuracy of this index, the
publisher cannot be held responsible for
any errors or omissions.
Static Control
800.787.7325e-mail: [email protected]
www.sealeze.com
SOLUTIONS
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Brushes
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RS# 187
MACHINE Design.com 93MAY 20, 2010
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BACKTALK
CAGI award winnersA team of engineering students from the University of Wisconsin-Madison walked away with this year’s top prize in the 2009-2010 National Innovation Award contest sponsored by the Compressed Air & Gas Institute (CAGI).
Team WALKS design uses compressed air to power a “Weight-assisted lifting and kinesthesia system” (WALKS) to assist physical therapy and re-habilitation patients by supporting up to 90% of their body weight while promoting a natural walking motion. Mentored by CAGI member Titus Mathews of Pneumatech Inc., students Axel Dahlberg, Jonny Jordan, Stefanie Knauf, Pat Verstegen received a $2,500 prize, and $8,000 went to their advisor Heidi-Lynn Ploeg for the school’s mechanical-engineering department.
According to the judging panel, Team WALKS design “recognizes the need and opportunity for this type of device to help reduce the escalating costs of health care.”
Second place went to Team Spin Zone from Buffalo State College for their “Onboard vehicle-compression storage system,” which uses a double-acting cylinder to capture and store energy from a vehicle’s suspension system. The $1,500 prize went to team members Brad Wargula, Kenny Stafford, Matt Geil, Jason Zaepfel, Sara Ward and Miles Williamson, and faculty advisor Dr. David Kukulka received $4,000 for the school’s mechan-ical-engineering department. CAGI member, Ed Czechowski, of Cameron Compression, mentored the team.
The invitation-only Innovation Awards are designed to honor under-graduates for innovative use of compressed air. MD
Centennial celebration
Wieland Electric is celebrat-ing its 100th year of develop-ing plug-and-play electrical in-terconnect products. Friedrich Wieland founded the family run business in October 1910 in Bamberg, Germany. In 1990, a U.S. subsidiary, Wieland Elec-tric Inc., began operating in Burgaw, N.C. The company ’s “Contacts are Green” motto demonstrates their commit-ment to innovative environ-mental practices. MD
RS# 189
MAY 20, 2010 MACHINE Design.com 95
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