Machine Design

October 6, 2011 A Penton Media Publication Tune in to EngineeringTV.com

WHEN TO GO WITH CUSTOM LEADSCREWS, page 50 CAD MODELERS: MORE THAN JUST NURBS AND B-SPLINES, page 56 HOW OEMS JUSTIFY ENERGYEFFICIENT TECHNOLOGY, page 64

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VOLUME 83 ISSUE 17 OCTOBER 6, 2011

MECHANICAL An integrated gear profile enhances nut performance, simplifies manufacturing, and reduces total cost.

Motor and drive

Key points:

• Custom-designed leadscrew assemblies don’t necessarily cost more or have longer lead times.

get the most from

Leadscrew

customized leadscrews Some companies offer a few options on a device and say tor comprising an integrated motor, leadscrew, and nut in some applications, but considering a custom design that they have custom products; unlike Henry Ford’s dictum: “any color as long as it’s black,” they also offer white and takes all application factors and costs into account often has better overall cost of ownership. red. But true custom components are limited only by imagination and manufacturing technology. Custom parts are also thought to have long lead This is particularly true for leadscrews. Engineers Custom leadscrew turn to these devices when accuracy and reliability are times. But manufacturers assemblies let parts do double duty. This assembly critical. And custom leadscrews make sense whenever of custom parts can adincludes a leadscrew and vise engineers on processes price and cost of ownership matter. nut, motor, and drive. A that can meet schedule restructural aluminum rail What if ... straints. For example, many serves as a guide. From a manufacturer’s perspective, custom leadengineers mistakenly bescrews are those built to customer specifications rather lieve injection molding only than those of the manufacturer. A true custom supplier makes sense for large quantities due to the complexity of challenges engineering customers to answer “What if …” the mold, but this is no longer always the case. questions to define exactly what they want. Likewise, the technology for prototyping parts has adFor instance: If cost was no object, what would the pervanced to the point where it is not necessarily cost prohibifect component look like? What would the motion profile tive and may actually save money in the long run. be in the absence of friction? What if the screw could be as By talking over the application with a manufacturer, long or short as needed? And what if the nut could be any engineers can quickly assess the supplier’s ability to proshape or size? How could the device perform better? How vide custom parts. At the outset, it’s important to avoid the could we simplify assembly or use fewer parts? urge to rule out options. No supplier is going to offer a deThe keys to success are imagination and avoiding consign direction that increases his own risk of failing. straints at the outset. Both are often hindered by common misconceptions. How to go custom Many believe custom parts always cost more. In fact, Many engineers accustomed to the constraints of stanthe ability to combine components and cut assembly and dard leadscrews find exploiting the benefits of custom maintenance may make custom parts more affordable. An alternatives challenging. For most engineers not familiar assembly of specialized parts might outperform an actuawith the range of customization possibilities, the best place

sizes, shapes, and designs to safely handle most any product.

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• Consolidating functions into fewer custom-designed parts can simplify assembly, cut maintenance, and even lower part cost.

Encoder strip

Resources: Nut Consolidating functions with custom nuts can save assembly time and part costs. For instance, the custom nut in this assembly is self-lubricating and includes an insertmolded encoder strip while the leadscrew has a low-friction, PTFE coating.

to start is with performance specifications including motion, environment, and location. Business considerations such as life cycle, production schedule, and budget also come into play. (See “Custom leadscrew checklist.”) Motion. How will the component move? Specifically, what distance will it cover and in what direction? How fast should it cover that distance? What is the frequency of travel? How precise does the motion or final position need to be? Finally, how much load will be moved? Environment. What conditions will the component work under? What are the expected maximum, minimum, and average temperatures? Will it encounter radiation, moisture, or chemicals that require careful materials selection? How about vacuum or pressure? Are there cleanliness standards that must be met? What contaminants, if any, are expected? Location. Where is the component going to be? How much room is available? What support structures and mounting provisions are available? How visible or hidden should it be to operators or customers? Does it need to mate to other components? Life cycle. How many cycles should it complete between maintenance intervals and over its lifetime? Alternately, what period of time is it expected to last? Production schedule. How many are required? When are the first and last components needed? Budget. What is an acceptable unit price for the component? What start-up and tooling costs are acceptable given the length of the production run?

Haydon Kerk, www.haydonkerk.com “Don’t Settle for Standard Parts,” MACHINE DESIGN, June 23, 2011, machinedesign. com/article/the-benefits-of-customcomponents-0623 “Introduction to Linear Actuators,” Webinar hosted by Haydon Kerk and MACHINE DESIGN, Nov. 13, 2008, machinedesign.com/ node/87018

After defining as many of these parameters as possible, an engineer should intelligently choose component specifications. For instance, quantity, budget, and timing will influence manufacturing methods and tooling investment. Analyzing speed, loading, and duty cycle will establish the minimum PV — the product of load and velocity — the component needs. It will also help the engineer determine the acceptable friction. Both PV and friction affect material selection. Material choices also depend on corrosion risk and chemical and thermal compatibility.

Open options Manufacturers customize leadscrews by specially machining screws, nuts, and other components. They can make the parts with user-defined materials or processes. And they can incorporate guide features or ensure seamless integration with downstream components like motors. The screws themselves can be machined to accommodate bearings, couplings, pulleys, and other attachments. Custom machinWANT MORE? ing also lets deFocus on this code image signers add special using your smartphone and leads or specify free software from www. neoreader.com, and you will be thread forms that connected to related content work best for their on machinedesign.com. motion profiles. http://tinyurl.com/6f538h5 The manufacOCTOBER 6, 2011

CAD

Recent engineering software uses much more than Nurbs. Here is a guide to the best approach.

The model of a human head is made up of voxels.

How to select the best CAD modeler

How to

The latest engineering software uses much more than Nurbs. Here is a guide to the best approach.

best CAD modeler

select the

Most engineers are familiar with geometric modelers with their solids and surfaces and Nurbs-based curves. Yet there are many cases where traditional geometric modelers are too slow or not a good fit for the design task at hand. Examples include modeling textures; shelling complex models; modifying and using scan data; designing complex organic shapes and artistic, aesthetic forms for manufacturing; adding highly sculptural detail to parametric CAD models; and combining hand-modeled and computer-generated forms. Increasingly over time, the lines between different types of geometric modeling software have blurred, as each combines similar approaches and tools from the others. Newer, nontraditional approaches have accelerated this trend. For example, “hybrid” software from 3D-Coat combines what are called polygonal and voxel modeling. And PowerShape from Delcam, Salt Lake City, lets users model with solids, surfaces, and polygons. In addition, Freeform, 3D organic design software from Sensable, Wilmington, Mass., combines voxels, solids, surfaces, and polygons. The combination of multiple geometry types in one package shortens design time and eliminates the need to learn multiple pieces of software with different user interfaces and ways of working. It also reduces the number of challenges inherent in getting separate pieces of software to efficiently talk to each other. These modelers complement traditional CAD packages. As this blending of modeling approaches continues, engineers and designers need a working understanding of the advantages of each geometry format, when and how to com-

pumps perform 64 Proving To justify the installation of an energyefficient pumping system, engineers must note the efficiency of the system, pump, and motor.

• Detailed performance specifications are a good starting point for talking with leadscrew manufacturers about design.

50

to get the most from 50 How customized leadscrews Custom leadscrew assemblies do not necessarily cost more or have longer lead times. Engineers who know what they want out of the part and have a good manufacturing partner can design assemblies that save money and time.

Leadscrew

How to

Nut

to lift almost anything 44 How Suction pads come in a vast range of

Tom Solon, PE

Edited by Jessica Shapiro [email protected]

Nut guide / structural rail

FEATURES

Authored by: Engineering Manager Haydon Kerk Motion Solutions Hollis, N. H.

Start with ideal specifications and keep an open mind.

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OCTOBER 6, 2011

56 Access our Reader Service Web site to quickly find and request information on the products and services found in the pages of MACHINE DESIGN. www.machinedesign.com/rsc

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C-more operator touch panels offer: • Clear TFT 65K color displays (6-inch STN models also available) • Analog touch screen for maximum flexibility • Easy-to-use software

CONNECT TO CONTROLLERS WITH DRIVERS FOR: • All AutomationDirect PLCs/PACs • Allen-Bradley ControlLogix® CompactLogix® MicroLogix™ 1100/1400 Ethernet ENI Adapter for SLC Series FlexLogix SLC® 5/05 Ethernet™ MicroLogix™

C-more touch panels in 6" to 15" sizes are a practical way to give plant personnel easy access to controls and data. Check out the powerful yet easy-to-use configuration software by downloading a demo version at: http://support.automationdirect.com/demos.html ALL C-MORE PANELS INCLUDE: • Analog resistive touch screen with unlimited touch areas • One USB A-type and one USB B-type port • Serial communications interface FULL-FEATURED MODELS ADD: • 10/100Base-T Ethernet communications • CompactFlash slot for data logging

• Modbus RTU and TCP/IP Ethernet • GE SNPX • Omron Host Link Adapter (C200/C500), FINS Serial and Ethernet • Selected Mitsubishi FX Series, Q Series • Siemens S7-200 PPI and S7-200/300 Ethernet (ISO over TCP/IP)

www.automationdirect.com/c-more

REMOTE ACCESS AND CONTROL BUILT-IN No Additional Hardware required. The C-more Remote Access feature resides in all panels with Ethernet support, and requires no option modules. Access real-time data or initiate an action on a control system from anywhere, any time. (Requires software and firmware version 2.4 or later*, and an

www.automationdirect.com Go online or call to get complete information, request your free catalog, or place an order.

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Ethernet C-more panel)

C-more touch panel line-up: * Software and firmware are downloadable for authorized customers from: www.automationdirect.com

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DEPARTMENTS

ON THE COVER The Schmalz SPB4 suction pad

8 EDITORIAL R&D doesn’t mean innovation

10 EDITORIAL STAFF 12 LETTERS 18 SCANNING FOR IDEAS Gear drive for tough applications IP67-rated M16 connector for ac/dc motors

22 REPORTER’S NOTEBOOK 30 LOOKING BACK 36 SENSOR SENSE Position alignment using vision sensors

38 FROM THE SAFETY FILES No interlock: missing guard factors into hay-grinder accident

40 VANTAGE POINT Reshoring requires skilled workers – Glenn Marshall

42 INVENTOR’S CORNER Simple blow-out preventer cuts and seals oil-well drill pipe

70 FE UPDATE Simulation software helps boost the bottom line at foundries.

74 PRODUCT SPOTLIGHT Plastics & elastomers

76 84 85 86 86 87

PRODUCTS BUSINESS INDEX AD INDEX CLASSIFIEDS BUSINESS STAFF BACKTALK

For customized article reprints and permissions please contact: Penton Reprints, 1-888-858-8851, e-mail at [email protected] or visit pentonreprints.com. Editorial content is indexed in the Applied Science Technology Index, the Engineering Index, SciSearch and Research Alert. Microfilm copies available from National Archive Publishing Company (NAPC), 300 N. Zeeb Rd., P.O. Box 998, Ann Arbor, MI 48106-0998, Ph: 734-302-6500 or 800-420-NAPC (6272), extension 6578. Permission to photocopy is granted for users registered with the Copyright Clearance Center (CCC) Inc. to photocopy any article, with the exception of those for which separate ownership is indicated on the first page of the article, provided that the base fee of $1.25 per copy of the article, plus $.60 per page is paid to CCC, 222 Rosewood Dr., Danvers, MA 01923 (Code No. 0024-9114/11 $1.25 + .60). Subscription Policy: MACHINE DESIGN is circulated to research, development, and design engineers primarily engaged in the design and manufacture of machinery, electrical/electronic equipment, and mechanical equipment. To obtain a complimentary subscription see our Web page at submag.com/sub/ mn. For change of address fill out a new qualification form at submag.com/sub/mn. Printed in U.S.A., Copyright © 2011. Penton Media, Inc. All rights reserved. MACHINE DESIGN (ISSN 0024-9114) is published semimonthly except for a single issue in January and July by Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66212. Paid subscriptions include issues 1-21. Issue No. 22 (OEM Handbook and Supplier Directory) is available at additional cost. Rates: U.S.: one year, $139; two years, $199;. Canada: one year, $159; two years, $239; All other countries: one year, $199; two years, $299. Cost for back issues are U.S. $10.00 per copy plus tax, Canada $15.00 per issue plus tax, and Int’l $20.00 per issue. Product Locator, $50.00 plus tax. Prepaid subscription: Penton Media (MACHINE DESIGN), P.O. Box 2100, Skokie IL 600767800. Periodicals Postage Paid at Shawnee Mission, Kans., and at additional mailing offices. Can GST #R126431964. Canadian Post Publications Mail Agreement No.40612608. Canada return address: Bleuchip International, P.O. Box 25542, London, Ont., N6C 6B2. Digital subscription rates: U.S.: one year, $69; two years, $99;. Canada: one year, $79; two years, $119; All other countries: one year, $99; two years, $149. POSTMASTER: Send change of address notice to Customer Service, MACHINE DESIGN, P.O. Box 2100, Skokie, IL 60076-7800.

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Low Cost Vacuum Generators For Lifting, Clamping, Mounting, Vessel Evacuation and “Pick and Place”! E-Vac® Vacuum Generators are compressed air powered vacuum pumps that provide instantaneous response and are most commonly used for pick and place operations. These single stage vacuum pumps are a low cost venturi available in a variety of sizes and flows along with a selection of vacuum cups suitable for a wide range of applications.

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Compact, portable Instantaneous vacuum up to 27"Hg Easy to mount at point of use Engineered for high efficiency to minimize compressed air usage

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Adjustable E-Vac vacuum generators permit easy adjustment by simply loosening the locknut and turning the exhaust to increase or decrease the level of vacuum and vacuum flow. Four models are ideal for porous and non-porous applications.

Modular E-Vac vacuum generators use a compact block design for convenient mounting which is ideal for use on existing machinery. Fourteen models for porous and non-porous applications are available.

In-Line E-Vac vacuum generators are cylindrical and compact. They can be threaded directly onto a compressed air line or held in place with a mounting clip. Fourteen models for porous and non-porous applications are available.

Vacuum Cups, Fittings, Tubing, & More WATCH THE VIDEO! www.exair.com/45/48045.htm

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What’s new online machinedesign.com New eBook: Guide to high-performance brushless servosystems This updated handbook from ElectroCraft provides a technical overview of the theory behind brushless motion-control systems, the key components, and how they interact. Plus a helpful application guide outlines design considerations, engineering calculations, conversion tables, and how to apply brushless servosystems. Download a copy at http://machinedesign.com/ebook.

Largest autonomous vehicle deploys The largest autonomous vehicle ever deployed with infantry is headed to Afghanistan. Lockheed Martin’s 11-ft-long SMSS can carry more than a half ton of a squad’s equipment over rugged terrain. It has a 125-mile range and can follow a soldier or navigate on its own via GPS waypoints. It can also be teleoperated or manually driven. See it at www.engineeringtv.com.

Webinars on injectionmolding simulation Sigma Plastic Services will host Webinars on Sigmasoft software on October 12 and 13. Topics include 3D simulation of polymer injection molding, and analyzing molds to make accurate decisions about tooling design and process parameters. Learn more and register at www.3dsigma.com.

EDITOR’S WEB PICKS

Helical machined springs

6

A new series of videos from Helical Products explains the engineering details behind machined springs. The custom flexures, machined from a single piece of material, solve complex motioncontrol problems by providing precise compression, extension, and torsion, and no rotation during compression. Learn more at www.heli-cal.com.

Ethernet for machine builders Rockwell Automation has a 75-page addition to its Ethernet Design and Implementation Guide to aid machine builders using Ethernet/IP networks for real-time, closed-loop motion control. The new chapter, developed with Cisco, provides design guidance, recommendations, and best practices for control-system engineers synchronizing motion applications within a plant’s IT infrastructure. Download a free copy at http:// tinyurl.com/6a8gmch.

Safety goes social

Design guide for bonding plastics Henkel has updated its Loctite Design Guide for Bonding Plastics. The 96-page guide provides detailed technical information, such as bondstrength data for 30 substrates and shear-strength data on 23 adhesives,

MACHINE Design.com

including cyanoacrylates, epoxies, hot melts, and polyurethanes. Special sections discuss surface treatments, joint design guidelines, and process costs versus overall strength. Download a copy at www. henkelna.com/loctitestructurals.

TÜV SÜD America has launched profile pages on Twitter, LinkedIn, and Youtube to provide the latest technical compliance, safety, and certification updates, as well as news on inspection, testing, training, and upcoming events. Learn more at www.tuvamerica.com.

OCTOBER 6, 2011

FREE WEBINARS ON INDUSTRIAL AUTOMATION PRODUCTS Ethernet communications This 30-min seminar covers all of the devices that allow your automation equipment to communicate faster and more reliably with Ethernet. Learn advantages of Ethernet over serial communications, and see brief overviews of Ethernet products, including hubs, switches, Ethernet PLC modules, Ethernet Remote IO, touch panels, and Ethernet acdrive modules. October 5, 2011, 2:00 ET

Productivity3000 update This 30-min show is an overview of the Productivity3000 automation controller, focusing on updates and new features of the powerful instruction set. Learn where to get a copy of the FREE full version of software. A live question and answer session closes the session. October 26, 2011, 2:00 ET

Motor controls Applying ac or dc drives requires understanding the application so that the correct size drive, motor, and control scheme are used. Applications that don’t require drives can use soft starters or motor contactors. This recently recorded, 30-min review covers all these motor control options. Visit www.automationtalk.com to register and view Webinars, or watch previously recorded presentations. Or visit http://learn. automationdirect.com to view dozens of short video tutorials on PLCs, HMI, and more.

Name Peter Simonsen Job Title Design Engineer, Embedded Software Area of Expertise Renewable Energy LabVIEW Helped Me Perform real-world simulations with total control of the application Latest Project Develop a test architecture for verification of wind turbine control systems

NI LabVIEW

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EDITORIAL R&D doesn’t mean innovation Research and development is a hot topic, judging by the response to our recent editorial on the subject. So it might be interesting to see where research dollars really come from, according to figures from the National Science Foundation. The NSF says a little less than 70% of all research funding in the U. S. comes from private industry. Federal government funds another 26%, with colleges and universities paying for a little less than 3%. Even more interesting is that the U. S. accounts for about 33% of global R&D spending. In fact, the U. S. is the biggest R&D spender on the planet by far. Japan and China are second and third with about 13% and 9% of the world’s total, respectively. But something doesn’t add up in this picture. With all the money flowing into R&D, you might wonder why there is so much hand-wringing among politicians and business leaders about a lack of innovation. One sign of the trend: For the first time, the Global Risk Management Survey compiled by the risk management firm Aon Corp. found business leaders put a failure to innovate on the list of top-10 global risks. So if 33% of the world’s R&D funds don’t buy innovation, what do they buy? Insight into the answer comes from Matt Ridley, a zoologist-turnedscience-writer for The Economist magazine. Ridley says that company R&D budgets “get captured by increasingly defensive and complacent corporate bureaucrats, who spend them on low-risk, dull projects and fail to notice gigantic new opportunities, which, thereby, turn into threats.” More to the point, the evidence is that an increasing amount of R&D goes into erecting a thicket of patents to protect existing technologies rather than to perfect new ideas. You can get a sense of this effort from the NSF statistics which show that “R&D” is really small “R” and big “D”: About 60% of all R&D work in the U. S. is “development.” Applied research accounts for just 22% of the total, and basic research another 17%. It’s been argued that much of the work now put into coming up with mundane-yet-patentable technology will have the unintended consequences of hindering innovation. This is especially likely if it falls into the hands of patent trolls buying up inconsequential patents simply so they can sue those who infringe them. The often-cited example of the potential damage is that of the smartphone industry. An estimated 250,000 patents cover this technology in one country or another. If a court finds just one infringed patent, it will force the offending handsets to be pulled off shelves. Is there a way to make R&D more fruitful without spending more? Prescriptions for innovation often advocate thinking out of the box, so here is some out-of-the-box thinking about R&D, suggested by the work of George Basalla, Professor Emeritus of the University of Delaware’s Dept. of History: Eliminate patents. In the second half of the 19th century neither Holland nor Switzerland had a patent system, but that didn’t stop those countries from thriving economically. In fact, the lack of patents acted as a stimulus for two Dutch industries back then, margarine and incandescent light-bulb production. And Swiss industry of the time was successful enough to attract foreign capitalists willing to invest despite lack of patent protection. — Leland Teschler, Editor RS# 107 OCTOBER 6, 2011

Sooner or later, we all need to start playing with the big toys...

When that time arrives, check out our line of EC centrifugal fans! s Packaged air movers up to 39.4” (one meter) in diameter s Maximum 22,000 CFM or 7.5” static pressure, fully speed controllable s Direct driven by very efficient EC external rotor motors with up to 8HP capacity s Direct digital control, most sizes equipped with RS485 MODBUS RTU interface

ebm-papst, growing our products to meet the larger needs of our global customers www.ebmpapst.us

RS# 108

We made the i’s even bigger! increased speed

EDITORIAL STAFF

increased load Leland E. Teschler, Editor, [email protected] Kenneth J. Korane, Managing Editor, [email protected]

SENIOR EDITORS Leslie Gordon, Stephen J. Mraz

increased controls

increased size

The NEW 3200 iDrive and 2200 iDrive — internal, innovative, integrated — moving smarter.

iDrive 2200 & 3200 SERIES

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RS# 109

Last Brake Standing.

AUTOMOTIVE & NEWS FEATURES Stephen J. Mraz, [email protected]

CAD/CAM Leslie Gordon, [email protected]

ELECTRICAL, ELECTRONICS Robert J. Repas, Jr., [email protected]

FASTENING, JOINING Jessica Shapiro, [email protected]

FLUID POWER Kenneth J. Korane, [email protected]

MANUFACTURING Leslie Gordon, [email protected] Kenneth J. Korane, [email protected]

MATERIALS Jessica Shapiro, [email protected]

MECHANICAL Kenneth J. Korane, [email protected] Jessica Shapiro, [email protected]

CONTRIBUTING EDITOR Victoria Burt, [email protected]

EDITORIAL PRODUCTION

Nexen brakes and clutches outperform and outlast. Our rugged brakes and clutches deliver high torques and cycle rates, withstanding heat, corrosion and are washdown available. Select yours at nexengroup.com or call 1.800.843.7445 and ask about our Twice the Life program for clutch-brake applications.

Denise Greco, Editorial Production Manager Randall L. Rubenking, Art Director

Quality you can depend on. Delivery you can rely on. 1300 E. 9th St. Cleveland, OH 44114-1503 RS# 110 10

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SolidWorks is a registered trademark of Dassault Systèmes. ©2011 Dassault Systèmes. All rights reserved.

LOOKING FOR DESIGNERS TO PUSH THIS BABY PROJECT �: HOT ROD BABY BUGGY Help host Jeremy Luchini design the first hardcore baby buggy using SolidWorks®. You’ll share ideas, comment on designs and vote on key decisions throughout the project. If you think you’re ready, let’s go design. Watch. Share. Vote. LetsGoDesign.tv

RS# 111

LETTERS Immigrants? Not now, thank you.

I am one of the skilled immigrants that is talked about in a recent Vantage Point (“Let’s Open the Door to Skilled Immigrants,” Aug. 11). But I had to wait in a long line and pay good money to earn my green card. Illegal immigrants, basically criminals, broke the law to get into the U. S. And U. S. companies love to use their cheap workforce and, thus, become accomplices. As a legal immigrant, I must protest the stupid voices calling for amnesty for illegal immigrants. Keep the rule of law and punish all criminals, otherwise you become accomplices as well. Jiri Polivka H-1B should be entirely revoked until unemployment in this country is below 5%. Employers do not want foreign workers be -

cause they are more educated or skilled; they want them because they are less expensive. T. J. McDermott If I lose my job because someone else is willing to do it for less money, then good for them and shame on me. We are in a world economy and continued selfishness on our part is not going to get us out of the financial mess we are in. Don Solanace

I’m all in favor of opening the doors to highly skilled immigrants who can work as corporate officers and heads of research and policy. It’s obvious that American institutions are not producing the caliber of talent these positions demand. And immigrants would improve our competitiveness because they would be willing to work for lower salaries and probably without expensive bonuses. Name withheld at writer’s request

Direct-Drive Linear ACTuators Features: • Acceleration to 5 g

ACT Linear Actuator

• Velocity to 5 m/s • Travel to 1.5 m • Maximum continuous force output to 270 N • Maintenance free, direct drive, zero-cogging motor and noncontact optical linear encoder • Couple with an Aerotech controller for highest performance

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Dedicated to the Science of Motion Aerotech, Inc., 101 Zeta Drive, Pittsburgh, PA 15238 Ph: 412-963-7470 • Fax: 412-963-7459 • Email: [email protected]

www.aerotech.com

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We’ve got the perfect package to fight contamination in washdown applications: 304 stainless steel helical (bevel or inline) gear reducer: • 95.5%–97% efficiency • C-face or IEC input • PTFE seals on output shaft • smooth body minimizes particle and bacteria collection • highly resistant to most acids, alkalis and corrosion 304 stainless steel C-face motor: • encapsulated stator and conduit box • antibacterial treatment • premium 6200 series stainless steel bearings • double-lip FKM seals Movitrac LTE-B inverter: • IP66/NEMA 4X enclosure • SBus (CAN based) communicates with PLC • single or three-phase input

seweurodrive.com RS# 113

LETTERS What about U. S. citizens graduating from engineering schools? They are not being hired because they have no experience. Meanwhile, more-experienced engineers are being ignored because their skill sets are too old. Companies should take the long view and train people for jobs in the U. S. Ann Marie Walters I am a permanent U. S. resident with a masters in mechanical engineering from a U. S. university with over 16 years of design and manufacturing experience, and I can’t get a job here even at a very low pay. All because U. S. firms are outsourcing design to countries like India and China. So, stop this H-1 visa program and train and develop people here. We have lots of good brains. And there is no brain drain here. Instead we have a technology drain powered by the greed of

the U. S. companies. Charles Osko Citizen engineers like myself are unemployed due to companies farming out the work to China and India. Now you want to bring so-called “skilled immigrants” here? Forget it. We have qualified engineers who won’t be hired because companies can hire a green-card engineer for half the cost. Larry Presky American workers don’t have jobs and you want to bring in foreign workers in larger numbers? Are you daft or just one of the most insensitive people on the planet? This would be a bad idea even if we weren’t in a recession because older workers have been unemployed and underemployed for years. When American’s have ‘full’ employment, then maybe we can

talk about hiring foreign workers. And if I were M ACHINE D ESIGN, I would be more thoughtful about leading with an article like this. The Vantage Point column features editorial and opinion from outside the magazine on a variety of topics. There is no guarantee readers will agree with all viewpoints expressed there. — Leland Teschler Is there a shortage of highly skilled American citizens that requires we open the floodgates and let immigrants pour in? We have the highest unemployment in decades. The last thing this country needs is to increase competition among graduates and unemployed skilled citizens. We cannot afford this. D. Speller I strongly disagree with the idea of bringing in skilled foreign engi-

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RS# 114 14

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OCTOBER 6, 2011

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RS# 115

LETTERS neers and scientists to help spur the American economy. Those jobs rightly belong to Americans. And foreign students should not be taught in our universities and take spaces away from American students. This article is highly insulting to American engineers and scientists. American engineers are capable of “spawning new products that create wealth and advance our standard of living.” Given the serious economic recession that we have been in for the past three years with high levels of unemployment, the last thing we need is to flood this country with more H1-Bs. I have gone to school and worked with these people and it has been my experience that American engineers can more than hold their own against foreign engineers. Bill Herkel

Unemployment in certain skilled fields, especially science, technology, engineering and math (STEM), is already very low, and businesses need more people skilled in those areas if they are to grow. Legions of unemployed construction workers affect the unemployment rate, but they don’t make it any easier for me to hire a top notch engineer. People in STEM fields are already competing in a global marketplace. So we can either compete with foreigners living in foreign countries and paying foreign taxes, or we can let those people come to the U. S., pay U. S. taxes, create U. S. jobs, and compete with us in our own country. Both alternatives involve competition, but letting foreigners pay U. S. taxes helps our budget deficit. Dolores Parund

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Showing their age Most mature engineers I work with don’t have the time to socialize electronically. Sure, we may visit each others’ cubes occasionally. But it seems the only coworkers who have a lot of time for this and similar activity (like Facebooking and Tweeting) are the younger set who always seem to be looking at their smart phones and PDAs. I guess I’m showing my age. Pete Suttmeier Here’s what I always say to new engineers looking for just the right program to handle their current design problem: “If you can’t do it by hand, don’t use a computer.” The slide rule era was helpful, at least for knowledgeable engineers, because you had to approximate the answer. (I know I am showing my age by mentioning the slipstick.) Ed Leahy

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RS# 117

SCANNING FOR IDEAS Edited by Stephen J. Mraz

Gear drive for tough applications Steel shims ensure bearing settings are maintained for the life of the drive. Spherical and tapered roller bearings handle heavier loads for greater torque.

Gear teeth peened for strength and long life.

Ductile-iron housing withstands shock loads.

Casehardened and ground teeth have beveled and helical tooth forms.

Horizontally split housing simplifies disassembly/ assembly for maintenance.

Seals prevent oil leaks. Bolt-on feet are adjustable. Optional cooling subsystem uses no water or electricity.

Shaft-driven pump

The Falk V-Class gear drives from Rexnord Industries, Milwaukee (www. rexnord.com), can handle up to 341,000 Nm of torque and are available with single, double, and triple gear reductions. They can also transmit from 15 to 10,000 hp, depending on size and whether they have a parallelshaft or right-angle configuration. To keep oil in the sump at 180°F, which extends the life of the oil and drive, there are cooling fins on the cast-iron housing and oil-feed passages throughout the housing. Rexnord engineers also used computational fluid dynamics in designing the housing to improve its heat-dissipation capabilities. Cast-in oil dams in the housing and seals with purgeable grease chambers reduce the chance of leaks. Drainbacks on axial and radial seals also prevent oil leaks and contact between lubricated surfaces. RS# 401 18

MACHINE Design.com

OCTOBER 6, 2011

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RS# 118

SCANNING FOR IDEAS IP67-rated M16 connector for ac/dc motors The low-profile (0.867-in.-tall) M16 and M16/12 Twintus connectors from Sealcon LLC, Centennial, Colo. (www.sealconusa.com), meet IP67 requirements for ac and dc motors, and when retrofitted with an M23 footprint, can handle M22 applications as well. The M12 side mates to common M12 signal feedback cord sets. Power and signal inputs are color coded to prevent connection errors. The connectors work in temperatures from –40 to 257°F. The housing can M12 signal be nickel (8 or 12 pos) plated or have a blackchromate coating. An optional EMI shield helps eliminate EMI/RFI. Optional EMI And the entire connector is said to shield cost 50% less than standard M16 connectors. RS# 402

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Smal Size. Big Stpig Powe. Need more lateral stopping power, but don’t have the space? Nason thought you might. This compact, SC series stop cylinder is the most powerful pneumatic cylinder available in its size. With five bore sizes available, piston position sensing, side or face mounting, a selection of mounting flanges, as well as a variety of customizable stroke and rod options, you’re guaranteed a perfect fit for each application. Think smaller, stronger and smarter. Think Nason. 800.229.4955 • www.nasonptc.com

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RS# 119

M16 power

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powerful, intelligent online tools RS# 120

REPORTER’S NOTEBOOK Mailers fly through handling equipment thanks to servos When postal regulation changes mandated the placement of a third piece of tape on mass mailings, a manufacturer of paper-handling equipment had to economically meet the new requirements quickly. A switch from stepper motors to servodrives did the trick. Postal paper handling has changed in the past 40 years. Machines today must accommodate sample packets, CDs, plastic cards, and other items not traditionally associated with mail. A few years ago, the USPS updated its specifications for tabbing — how tape goes on mailers such as brochures, newsletters, flyers, and so forth. Previous rules placed two tabs at the top of the mailer. The new specifications call for tabs on the leading and trailing edge of the paper to avoid jams during handling. Mailers now needed three tabs instead of two. Adding that third tab on the trailing edge of the paper made the process more difficult. Paper being fed with an open edge for inkjet printing of the address has to be turned 90° to add the back tab. This action must be done as the mailer travels in a straight line at up to 350 fpm. The first and most-obvious solution was to simply add another tabbing machine. However, both 22

MACHINE Design.com

These networked servoamplifiers and associated servomotors replace the original stepper-motor control system.

Resources: Kirk-Rudy Inc., www.kirkrudy.com

RS# 406

Red Lion Controls, www.redlion.net RS# 407

big and small mailing services didn’t like the idea of buying a new machine or finding the space for a table to hold it. They wanted a single, compact system that could attach the new back tab without slowing the workflow. Paper-handling equipment maker Kirk-Rudy in Atlanta came up with the KR545T Tabber, a machine that can apply multiple tabs or labels on three sides in a single pass. The tabber needs only one transport table. It then folds it underneath while the mailer continues to move. Earlier machines with this design used stepper motors. But attaching three tabs in a morecomplicated arrangement while

OCTOBER 6, 2011

Yaskawa America Inc., www.yaskawa.com RS# 408

keeping up speed necessitated the move to servomotors. Kirk-Rudy’s first servo-equipped machine handled speeds up to 350 fpm, but even faster operation, along with greater accuracy, became the redesign target. Another design goal was to simplify the current control system of four individual PLCs with an HMI control panel. The original design needed extensive programming. Servos for the new design came from Yaskawa America Inc., Waukegan, Ill. The Yaskawa team had to get the label dispensing to

This tabbing machine, or tabber, uses servocoordinated motion to apply multiple tabs or labels in a single pass.

start and stop accurately at high speeds. With that goal met, the next phase aimed at implementing the new tab kicker. Yaskawa Sigma-5 servomotors and amplifiers implement the feed and kicker tasks. The Sigma-5

These servomotors drive the label feed heads on the tabber, which accurately place labels on mailers traveling at up to 500 fpm.

amplifier accommodates highresolution encoders, along with advanced tuning algorithms for responsive and stable performance. These factors helped boost the machine speed by more than 20% while keeping near-

perfect accuracy. The new system places and seals a 1-in. tab in just 10 msec at linear speeds up to 500 fpm. Tolerance of tab placement also improved from 1/16th of an inch to within 1/32nd of an inch or less. In tests where the same mailer passes through the tabber several times, the new tab so closely aligns with the old that the eye sees only one tab. To further simplify the design, the four servomotor amplifiers now connect to a single Yaskawa MP2310iec networked controller. The single controller replaced the four individual PLCs in the old design. The Yaskawa controller uses an IEC-61131-3 programming environment. Programming time is reduced by downloading prewritten software libraries from the Internet. Minor programming changes are now a simple task. The Yaskawa controller includes a built-in Web server, accessible via any browser, that lets programmers update programs or firmware at a distance. Alternately, customers can receive updates through e-mail. The new HMI control panel from Red Lion Controls, York, Pa., includes a unified alarm that eliminates the need to transmit alarm information directly from the controller. All alarms now display in one spot, allowing for quick identification of the warning or fault condition. Alarms may also be accessed via the Web interface, letting Kirk-Rudy remotely identify the source of the alarm or fault and resolve it quickly without the need of a field service call. MD

OCTOBER 6, 2011

MACHINE Design.com

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REPORTER’S NOTEBOOK

Magnet generates largest magnetic pulse It might not look like much, It took a 1.45-GW but the electrogenerator to power magnet at the this record-setting, Pulsed Field Fanondestructive cility at Los Alamagnet, along with an electric current of more mos National than 100 MJ. Laboratory set a record when it generated a 97.4-tesla field without destroying itself in the process. (High-powered magnets routinely rip themselves apart due to the large forces they create.) For comparison, the magnetic field of the Earth is about 0.0004 T, the field of a junkyard magnet measures 1 T, and magnets in MRI machines generate 3 T. The Los Alamos magnet will let researchers from around the world explore the properties and quantum nature of materials. MD

Resources:

Los Alamos National Laboratory, www.lanl.gov

makes perfect sense to choose over Pneumatics 6 GOOD REASONS: • • • • • •

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Greater Flexibility Greater Control Longer Life Better for the Environment Zero Maintenance Watch the video: Lower Total Cost www.IntelligentActuator.com/reasons

California: 800-736-1712 Illinois: 800-944-0333 Georgia: 888-354-9470 RS# 121

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OCTOBER 6, 2011

MORE NEW TECHNOLOGY PRODUCTS ADDED DAILY. AND SHIPPED THE SAME DAY.

We are thrilled to announce the coming together of element14 and Newark into one powerful entity—the all-new element14. We will continue to provide the great products and personal service we’re known for, plus a significant new product expansion, and much more. The vision is a single destination that offers an unprecedented range of technical data, innovative tools and services, meaningful community and expert engagement, and the best component shopping experience ever. Learn more about our combined vision at www.newark.com/together

RS# 122

REPORTER’S NOTEBOOK

VTOL UAV that fits in a backpack After four years of R&D, engineers at AeroVironment Inc., Monrovia, Calif., have successfully test flown their Shrike UAV, a 5-lb drone that can fit in a backpack and take off and land vertically. Built under contract from DARPA, the Shrike can hover or fly for more than 40 min while transmitting high-resolution encrypted video back to a home base. It also has enough battery power to land on the top of a building or cliff, for example, and transmit several hours of video of what it is looking at, a capability the Pentagon calls “perch and stare.” The battery-powered aircraft is remotely flown using the same ground-control system used to pilot the company’s other UAVs, including the Raven, Wasp, and Puma. MD

Power distribution from XS to 3XL

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OCTOBER 6, 2011

Resources:

AeroVironment, www.avinc.com For more information on the company’s other military UAVs, check out http:// tinyurl.com/3sn4o7q

Image courtesy of AeroVironment Inc.

Job-hunting engineers get FEA training for free Kellie Valentine had been employed as a senior mechanical engineer at General Dynamics for the last seven years. She became unemployed when the Bloomington, Minn., facility closed. Valentine says that while employed, she did not receive any training in finite-element analysis (FEA) because there were a few individuals in her group who specialized in simulation and analysis using Ansys software. So to stay on Resources: top of her career, Ansys, www.ansys.com RS# 409 she signed up for classes at engiLink to classes through Dec., neering-software http://www.ansys.com/Support/ reseller, Applied Training+Center Engineering Inc. in According to Ansys, it is best to Maple Grove, Minn. start with classes that begin with Valentine says that “Introduction” or “Ansys.” Just go to Minnesota pays the link, type in your information, and then in the Purchase Order box unemployed workWhen unemployed engineer Kellie Valentine type “displaced worker.” ers up to $3,000 for requested state funding to get FEA training, she their training. Howwas turned down. Ansys then stepped in and ever, it turned out has offered free training in any of its offices for that the state’s program requires the participating any displaced U. S. engineer. facility to obtain a “WF-1 code,” something no Ansys training-accredited facility has. The state, therefore, denied her the funds. But there is a happy ending: According to Ansys, Canonsburg, Pa., it now offers free training in any of its offices (as space permits) for any unemployed U. S. engineer. “This is wonderful,” says Valentine. “Most large companies in this area use Ansys. So when firms start hiring new employees, it seems likely they might start with workers who have taken the initiative to get themselves trained. The Ansys Web site makes it simple to sign up. And the staff is great to work with!” MD

RS# 123

www.rittal-thesystem.com

REPORTER’S NOTEBOOK

Resources:

Coming: Self-powered integrated circuits

The IEDM conference, www. ieee-iedm.org

The National Nano Device Lab in Taiwan has developed a manufacturing process that can build integrated circuits combining a two-sided solar cell and thin-film transistors (TFTs). The underlying process is said to be environment-friendly and is billed as a step toward selfAt left, a hybrid uniform 6-in. CIGS solar cell. The silicon solar cell on its reverse side is powered chips. One side of the visible in the mirror. At right is an artists’s conception of the cell integrated with TFTs on resulting chip features both a the same silicon solar-cell substrate. solar cell and TFTs made from CIGS (CuInGaSe2). These devices are on the back of a mobility of 0.22 cm2/V. The relatively low-temperature silicon-based solar cell. The chips are made without (400 to 500°C) and sodium-free manufacturing using environmentally harmful cadmium, or sodium, process used could make the CIGS fabrication which is typically found in CIGS solar-cells. Cells technique compatible with CMOS processing. The often incorporate these materials to boost light researchers will describe their work at the upcoming conversion efficiency. To compensate, the CIGS layer IEEE International Electron Devices Meeting (IEDM) in was deposited on a textured surface, bringing the Washington, D. C., in December (“Bifacial CIGS [11% CIGS cell conversion efficiency up to 11%. The TFTs set Efficiency]/Si Solar Cells By Cd-Free And Sodium-Free a record for CIGS technology, demonstrating a hole Green Process Integrated With CIGS TFTs,”). MD

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RS# 124 28

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Introducing the first 22 mm stand-alone biometric switch for the industrial environment.

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It is easy to install because it fits in a standard 22 mm push-button cutout with quick connections using M12 connectors. No special tools are required, reducing machine setup time and cost. Your customers will love the Harmony biometric switch for its state-of-the-art technology and for the secure access it provides to sensitive zones and machine functions — without keys, badges, or passcodes that can be borrowed, forgotten, or lost. Designed for the industrial environment, it offers excellent resistance to mechanical shock and vibration and can remember up to 200 fingerprints, recognizing each in less than a second. Plus, with built-in configuration software, it’s easy to configure and use too.

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RS# 125

REPORTER’S NOTEBOOK

LOOKING BACK

10 YEARS AGO — 2001 Stirred, not shaken: Solar panels power a 1/8-hp gearmotor to stir up settling ponds in a water treatment process devised by Pump Systems Inc. Stirring the pond pushes oxygen into the water, boosting the rate at which waste decomposes.

The result: no smell. Besides making the air fit to breathe, mosqui-

1:1 Gearbox, Uniquely rated so you can:

Balance Torque to RPM to Life

toes stay away because the water is always moving, and wildlife is returning as the nearby habitat becomes more pleasant. The stirring motors from Groschopp of Sioux City, Iowa, were tested last winter, left to spin and churn through subzero waters without maintenance or repair. When water-treatment engineers pulled them out this spring, they were still running. The permanentmagnet motors work through a parallel-shaft speed reducer with a 20:1 ratio.

30 YEARS AGO — 1981

Made in USA

because:

Choose + + + + + + + + +

Application rated for optimum operation and cost You can balance Torque to RPM and Operating Life 3 torque ratings in each gearbox to fit your needs 3/16”, 1/4” and 3/8” shaft diameter gearboxes Machined Aluminum housings, 4 ball bearings Backlash 1°, with option of 1/2° Weight reduced by 30% over comparable units RPM to 5,000 Made in USA with American CNC machines

Ground tests ending for Satcom III-R: Technicians at RCA AstroElectronics are shown preparing the RCA Satcom III-R communications satellite for a series of tests in a giant thermal/ vacuum chamber. The tests will assure the spacecraft can operate reliably in Earth’s orbit. The satellite will furnish communications for all 50 states, serving the cable-TV industry and providing commercial and government communications.

50 YEARS AGO — 1961 Undersea research— to 6,000 ft — can be carried out in the twoman Seapup VI designed by General Mills Inc., Minneapolis.

Exclusive 24 Month warranty! Call us at 1-888-260-7466 or fax us at 516-771-6444 or Email us at [email protected] See us at www.ondrives.us/BG.htm

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.US Corp.

OCTOBER 6, 2011

The 12,600-lb vehicle is less than 19-ft long and 8-ft wide. It is highly maneuverable in vertical, horizontal, and inclined planes. A mechanical arm performs tasks while the Seapup hovers or rests on the ocean floor. MD

Here today.

Here tomorrow.

The RittalXpress stocking program ensures next day shipping for more than 2,200 of our most popular Industrial and IT enclosures, accessories and climate control products. Visit www.rittal-corp.com/rittalxpress for a complete selection of in-stock products.

RS# 126

www.rittal-thesystem.com

REPORTER’S NOTEBOOK AGREEMENT Electronic-components distributor Digi-Key Corp., Thief River Falls, Minn., has signed distribution agreements with the following companies: Nuventix Inc., Austin. Tex., to supply its SynJet thermal-management products; Intematix Corp., Fremont, Calif., a maker of remote phosphor components for high-quality LED lighting; Swissbit, Bronschhofen, Switzerland, a

COMPANY NEWS manufacturer of independent DRAM modules and Flash storage; and Delta Products Group, Fremont, Calif., a provider of dc/dc products. Fabrico, Kennesaw, Ga., a provider of design and manufacturing services for flexible materials and adhesives, and AOS Thermal Compounds, Eatontown. N. J., a manufacturer of thermal-management materials, will work together to leverage their expertise in these areas. Garlock Sealing Technologies LLC (GST), Palmyra, N.Y., has agreed to acquire the One-Up Pump Diaphragm business from W. L. Gore & Associates Inc. Elkton, Md. The One-Up Pump Diaphragm manufacturing business will relocate to GST’s facility in Palmyra, and will continue to use Gore’s high-performance PTFE material in the pump diaphragm. GST designs, manufactures, and sells fluidsealing products.

PATENT AWARDED New Way Air Bearings, Aston, Pa., an independent manufacturer of porous-media air-bearing products, has been issued U. S. Patent No. 7,908,885-B2 for its Non-Contact Porous Air Bearing and Glass Flattening Device.

PROTOTYPING SERVICE Robinson Rubber Products, Minneapolis, a designer, developer, and manufacturer of custom-molded rubber products, extruded rubber products and precision rollers, is offering a new prototyping service that tests customers’ designs and ideas in actual working environments before they invest in production molds and tooling. Prototypes can be completed in 5 to 25 working days, depending on part complexity.

ADVISORY COUNCIL

RS# 127 32

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OCTOBER 6, 2011

Rockwell Automation, Milwaukee, has launched a Biofuels Customer Advisory Council (CAC) to provide customers with a forum to discuss their needs, challenges, and industry opportunities. Rockwell will use customer feedback to guide and validate future strategies and product road maps for its Pavilion8 model predictive control and plantwide optimization solutions.

ENERGY EFFICIENCY

TECHNOLOGY Conference & Expo

SHOW PREVIEW Pg. 31 A Penton Publication

MARCH / APRIL

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THE TECHNOLOGIST’S TOOL FOR ENERGY-EFFICIENT PRODUCT DESIGN

…WELL ALMOST Super low-power circuitry makes it possible to run remote, hard-to-reach applications INSIDE THIS ISSUE

Computer simulation gets a bigger role in wind power design Pg. 14

Do energy efficient induction motors always pay for themselves? Pg. 20

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Tricky! The difficulties of driving high-brightness LEDs Pg. 36

School is back in Session

Designing out electronic failures Page 22

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Designing in lithium-ion batteries Page 25

Canopen can do Page 29

THE SOURCE FOR THE DESIGN AND MANUFACTURING OF MEDICAL DEVICES

Focus on

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Inside

Rotary actuators take their turn Page 24

Comparing servo to proportional valves Page 30

Where to place that hydraulic filter Page 36

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Let the Learning begin!

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REPORTER’S NOTEBOOK

MEETINGS & SHOWS SHPE CONFERENCE 2011

COMSOL CONFERENCE Oct. 13-15 — The 7th annual Comsol Conference brings together engineers from a broad spectrum of industries to see the latest in state-of-the-art multiphysics simulation. The program includes user presentations, hands-on

minicourses, tutorials, an exhibition, a poster session, keynotes, an awards banquet, and more. The event will take place at the Boston Marriott Newton in Newton, Mass. For more information, go to http://www. comsol.com/conference2011/usa/.

HS35 – It’s rugged, accurate and programmable – an industry first

Oct. 26-30 — The Society of Hispanic Professional Engineers (SHPE) will hold its annual conference at the Anaheim Convention Center in California. The multifaceted conference offers a wide range of programs for middle and high-school youth, university students and professionals in STEM fields. Highlights of the conference include the following: Career Expo; Professional Program features certification courses and concentrated tracks in business development and green engineering; Graduate Program includes seminars designed to nurture the development of future faculty and researchers; Undergraduate Program filled with technical and experiential learning opportunities for university students; and Pre-College Symposia — An extensive program that exposes Hispanic youth in grades six through 12 to STEM subjects and career opportunities. For more information, go to http://conference.shpe.org/ shpe2011. Schools or individual middle or high-school students interested in attending the PreCollege Symposia can register at www.shpefoundation.org.

TUBE BENDING CONFERENCE Robust meets precision – Our versatile new HS35 incremental hollow shaft encoder for your toughest applications: IP 67 rated, -40 to 212 °F service range, 200 g shock resistant

n

Position accuracy of < 60 arcsec (superior to competition); high resolution programmable from 1 to 8192 ppr

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Baumer shaftlock bearing design (using dual ABEC 5) withstands higher shaft runouts; our reinforced inserts isolate shaft currents

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Encoder resolution, index and output configured with your PC

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www.baumer.com/HS35 Contact: 800 937 9336 x335 Baumer Ltd. 122 Spring Street Unit C-6 Southington · CT 06489 [email protected] · www.baumer.com

34

MACHINE Design.com

RS# 128 OCTOBER 6, 2011

Nov. 24-25 — The 4th Dortmund Tube and Profile Bending Colloquium DORP2011 will be held at the Dortmunder Westfalenhallen in Germany. The conference covers the increasing demands on bent parts — 3D profile bending with very small radii, complicated geometries, and use of high-strength materials. The forum lets attendees exchange experiences between users, machine manufacturers, and university researchers. There will be lectures, stimulating discussions, and an intense exchange of experiences and views between industry and science on an international level. More information visit www.iul.eu/dorp2011. MD

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RS# 129

ASSUMPTIONS: 10 HP @ 1800 RPM 150 Hz, 215 T Frame

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The abILITy To wIThsTaND puNIshmeNT Is gooD...buT avoIDINg IT Is eveN beTTer

SENSOR SENSE Position alignment using vision sensors Just-in-time manufacturing and a demand for reduced inventory have pushed the adoption of automated storage-and-retrieval systems (ASRSs). These complex systems contain a series of bays for product storage that can stack up to 20-units high. A smart vision sensor monitors the location of a small hole to properly align the forks of an automated storage and retrieval system.

Registration hole

Durability vs Distance – It’s No Longer a Decision When selecting the best proximity sensor for abusive environments, the decision has always carried a difficult tradeoff – durability vs sensing distance. The 100% stainless steel X-series Pile Driver is the first sensor to deliver both. How durable? Impact withstandability is 20X beyond traditional plastic-face products. How far? Sensing ranges exceed industry standards by up to 2.5X. So what does this 1-2 combination mean to you? n Fewer sensor-target impacts n Increased machine uptime n Reduced maintenance and

troubleshooting n Fewer rejects and increased quality n Lower spare parts inventory

www.sensing.net/xpd

RS# 130

Pepperl+Fuchs, Inc. • Twinsburg, Ohio • 330.486.0001

Vision sensor

Tracks located in the aisle between bays steer an automated car as it moves to a desired bin location. To monitor drive position, an encoder or other measurement device guides the vehicle to the destination. Because of belt wear, wheel slippage, or chain expansion over time, the retrieval unit may not end up at the exact location. It may be off by only a fraction of an inch, but that’s enough for the system to malfunction. A new line of vision sensors has been designed to solve this type of problem. A hole drilled in the horizontal or vertical support member of the storage rack at each bin location acts as a position register. A camera system installed on the ASRS detects the hole position within the camera’s field of view. If it is off center, four digital outputs, +X, -X, +Y, and -Y, tell the system how far and in what direction to travel to center the camera precisely over the hole. Once centered, the bin can be pulled without damage to the rack structure. The ASRS can also use the corrected position to recalibrate itself. Of course, applications using vision positioning aren’t limited to highbay warehouses. For example, low-temperature cameras designed for cold storage can track perishable products as they move through a chiller. More-specialized applications can include determining the roundness, diameter, or location of holes in an object without the expense of a full vision system. MD Pepperl+Fuchs (www.pepperl-fuchs.us) supplied information for this column. Edited by Robert Repas OCTOBER 6, 2011

EVERY PLANT NEEDS A PARTNER TO KEEP THINGS BUZZING We’ll work hard to keep your plant buzzing using the most advanced sensing technology…all from a single-source partner. We’ve stayed busy as a bee for over half a century developing innovative products that take the sting out of applying sensors. Our sensors are crafted using state-ofthe-art components and the latest technologies to ensure precision, reliability, and functionality. In addition, we offer a wide selection of accessories to meet all your application needs. Go to www.sensing.net/buzz1 or give us a buzz at 330.486.0001 and we’ll devote a swarm of technical experts to go to work for you.

Pepperl+Fuchs Inc. Twinsburg, Ohio 330.486.0001 www.pepperl-fuchs.com

RS# 131

FROM THE SAFETY

FILES

No interlock: missing guard factors into hay-grinder accident A man was injured when part of the hay grinder he was operating broke free and struck him in the chest. The grinder was running without a drivetrain guard at the time of the accident. The hay grinder developed a worrisome vibration in its drivetrain 14 months after getting a new engine and flywheel cover. The grinder’s operator removed the guard over the Engine and Grinding drivetrain between the engine and the grinding flywheel housing mechanism mechanism and took the machine to the mechanic who had installed the engine to have the vibration diagnosed and repaired. The mechanic wasn’t able to complete the repair that day, so the operator took the machine back to grind large, round bales of hay at a farmer’s field as scheduled, leaving the guard off. The farmer was working about 50 ft from the grinder when it stuttered and stopped. He subsequently Drivetrain guard found the operator face down on the ground and (missing at time called 911. of accident) Investigators determined a bent driveshaft caused the severe vibration. During grinding operations, the hammer mechanism of the grinder Warning hit something hard that sent a shock through the decals driveline. The shock, combined with the stress from the bent shaft, fractured a universal joint. Without a guard to stop it, a knuckle of the joint flew out of the machine and struck the operator in the chest. At the same time, the engine overloaded and stalled. The investigation determined that the previous installation of the engine and flywheel cover had nothing to do with the accident. It also d let found the guard, had it been installed, would have been substantial A missing guar l sa er iv un enough to stop the U-joint knuckle from flying out of the machine. The part of a a hay machine also contained warnings alerting users that parts could fly out joint fly out of re grinder to inju als of the drivetrain and that a guard was needed for safe operation. ec D the operator. However, the guard was not large enough or extensive enough to fully protect opors warned operat erators who could reasonably be expected to be working around the drivetrain while in s to keep shield ard the machine was running. Because it was not hinged to the machine, it was reasongu e th t place, bu or ably foreseeable that the machine could be operated without the guard; there were ed ng hi t no as w e th to no interlocks to prevent this. d ke interloc The hay grinder manual could have discussed the operation of the machine’s commachine. ponents — including the engine, flywheel and housings, clutches, drivetrain, and guards — in greater detail along with their potential hazards. A list of sympPart of a hay grinder’s toms indicating serious mechanical problems and a toll-free universal joint broke off under vibration and sho number where users could contact the manufacturer could ck loading. Without a drivetrain guard, it flew also have helped the operator avoid the accident. MD out of the machine and injured the operator.

This month’s safety violation comes from the files of Lanny Berke, a registered professional engineer and Certified Safety Professional involved in forensic engineering since 1972. Got a safety violation to share? Send your images and explanations to jessica.shapiro@ penton.com.

WANT MORE?

Focus on this code image using your smartphone and free software from www. neoreader.com, and you will be connected to related content on machinedesign.com.

Edited by Jessica Shapiro

http://tinyurl.com/3mntlvq 38

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OCTOBER 6, 2011

MODULAR POWER IS NO LONGER A PIPE DREAM. Installs as fast as it delivers. powerfast™ takes the rigidity out of wiring for power. TURCK’s modular cordset power distribution system saves up to 40% of labor, time and contractor installation costs. Not only is it easier to install, it’s easily scalable and changeable. Made-to-length, quick connect IP67, IP68 and IP69K molded cordsets are available in four connector sizes rated up to 30 amps. Plus receptacles, tees, reducers and cable drops, to deliver power as you need to motors, drives, sensors and a host of electrical devices.

NFPA 79 compliant

Made in North America and in stock for immediate availability. 1-800-544-7769 www.turck.us SENSORS | NET WORKS/FIELDBUS | RFID | CONNECTIVITY | INTRINSIC SAFETY RS# 132 ©2011 TURCK Inc. NFPA is a trademark of the National Fire Protection Agency.

VANTAGE POINT Reshoring requires skilled workers For the past two years, the Association for Manufacturing Excellence (AME) has been leading the Rebirth of Glenn Marshall Manufacturing Jobs initiative. This Initiative is designed Director-at-Large to boost employment and business opportunities for The Association North American manufacturers through collaboration for Manufacturing with federal, state, and local government agencies and Excellence educational institutions. The aim is to make businesses Rolling Meadows, more globally competitive, drive demand for skilled Ill. workers, accelerate the economic recovery, and improve America’s quality of life. Paul Kuchuris, AME’s new president, and Harry Moser, founder of the Reshoring Initiative, want to bring jobs back to North America and guide schools to produce skilled workers trained to tackle the newly created openings. To raise awareness, Kuchuris and Moser have been pooling their resources to promote the Initiative and attract support from industry and community leaders and policymakers. Current projects include expanding the Total Cost of Ownership (TCO) Estimator tool, which now covers 17 countries; delivering more than 100 presentations nationwide in 2011; recruiting volunteers for local reshoring projects; and getting buy-in from various government offices. The Initiative is gaining visibility but has a long way to go when it comes to bringing work back to North America, says Moser. “Companies must learn to use TCO to improve their profitability. Eventually, the U. S. has to balance its $600 billion per year trade deficit, and government must realize that reshoring is a much-more efficient and feasible solution than exporting for most companies.” Challenges that lie ahead include gaining the attention of major corporations, and getting them to reevaluate off-shoring and reward supply chain managers on TCO rather than price, says Moser. Reaching these goals will make it easier to recruit skilled workers to the manufacturing community. However, educating these workers also presents challenges. Even during the recession, 32% of manufacturers could not fill jobs because applicants did not have the proper skills. “The Roadmap to Education Reform for Manufacturing,” a report released earlier this year by The Manufacturing Institute, provides six principles for education reform: • Move to competency-based education. • Establish and expand industry-education partnerships. • Infuse technology in education. • Create excitement for manufacturing careers. • Apply manufacturing principles like “lean” to reduce education costs. • Expand successful youth development programs. To gain skilled workers, we need to improve our educational system through an outcome-based mentality and performance accountability of our teachers, says Kuchuris. Because the needs of the business community change all the time, we must also develop personnel programs that focus on the ever-changing skill gaps, as well as cultivate an environment based on innovation and empowerment. Off-shoring began at least 50 years ago and is driven by thousands of consultants and the price-based bonus plans of many supply chain managers, says Moser. Efforts like the Reshoring Initiative and Rebirth of Manufacturing Jobs are far outnumbered. However, the first step — gaining awareness — is well on its way. Glenn Marshall is a Benchmarking Champion at Newport News Shipbuilding. For more information on reshoring initiatives, visit www.ame.org and www.reshorenow.org.

Edited by Kenneth J. Korane RS# 133 40

MACHINE Design.com

OCTOBER 6, 2011

Technology You Can Trust

Gate Drive Optocouplers and Isolation Amplifiers for IGBT and MOSFET Protection The ACPL-C79B/C79A/C790 isolation amplifiers were designed for current and voltage sensing in electronic power converters in applications including motor drives and renewable energy systems.

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Your design requires quality you can count on Protection features are important for ensuring safe and stable power converter operation in power inverter applications such as solar and wind power generation systems and motor drive. IGBTs and other power devices used in these applications require full protection to avoid damage resulting from conditions such as: t
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RS# 134

DC

Inverter

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The ACPL-796J
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INVENTOR’S CORNER Edited by Leslie Gordon

Simple blow-out preventer cuts and seals oil-well drill pipe

Payne holds a ½-in.-diameter pipe that his BOP cut in half.

42

According to inventor Karl Payne, deadly after 60 years.” last year’s Macondo Well disaster in A sudden back the Gulf was either the result of a failpressure in the drill ure of the blow-out-preventer (BOP) pipe would trigger the or, more probably, a failure of the charge. The explosive power source for the BOP because charge for his model is it partially worked. Traditionally, a powered by a 12-gauge BOP is designed to shotgun shell (withcut and seal the drill out buckshot). “It took pipe and is powsome experimentaered by hydraulic tion to determine the pressure, which is amount of powder to provided by an eleccut a ½-in. pipe,” says trical pump through Payne. “The thickest hydraulic hoses. and largest-diameter “All of this is a mile pipe that could be under the ocean cut with my invention in the most-hostile would depend on the environment imagsize of the explosive Payne holds the blowinable,” he says. “My charge and have to be deout valve itself. idea is to replace the termined experimentally.” hydraulic system Payne says he is not trying to with a measured reinvent the wheel, maybe just one explosive charge, of the spokes. He got his idea after which would acseeing the ejection device on a picomplish the same lot’s seat. Payne can be reached at result but be faster [email protected]. MD and more dependable.” He claims his invention is pretty simple. “In a singleram BOP of this configuration, explosive force would power the cutter in place of hydraulic pressure,” says Payne. “An explosive charge is a selfcontained power source not affected by pressure, temperature, or how long it’s been in place. It is also cost effective, easy to manufacture and, because of its simplicity, more A dismantled dependable. Consider the BOP shows all its World War II bombs still being components. found in Europe and are just as

MACHINE Design.com

OCTOBER 6, 2011

All Gearmotors are

Created Equal.

Just because different companies’ washdown gearmotors may appear similar from the outside doesn’t mean they’re built the same on the inside. The Bison 230V inverter duty, IP69K rated SANIMotor™ is unique from other gearmotors, since it completely encapsulates all electrical components in thermally conductive epoxy resin, is sealed with EPDM rubber o-rings and secured with hex bolts to guarantee against leaking. CERTIFIED Q U

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RS# 135 To learn more: 1-800-AT-BISON • [email protected] • www.bisongear.com

*HDU (QJLQHHULQJ&RUS

FLUID POWER

How to

lift almost

anything Designing a vacuum-handling system involves many factors. On one hand, engineers must contend with the size, weight, and type of material to be handled, and how fast and precisely it must be moved. On the other, there’s the size and type of vacuum generator, system operating pressure, as well as components such as valves, hoses, and connectors. But it all comes together at the suction cup or pad. This seemingly simple device must firmly and safely support the load, resist gravitational and acceleration forces, minimize air consumption, and not mar or damage the workpiece. And, of course, it must resist fatigue and abrasion, withstand dirt, contaminants, and temperature extremes, and provide long, economical life with little or no maintenance.

Selection criteria

Obviously, a lot goes into selecting a suction pad. Leading manufacturers offer extensive data on various types of pads and the advantages of each, along with load capacity, temperature limits, chemical compatibility, and so on. Engineers normally select suction pads based on the following criteria: Operating conditions. Cycle rates, expected life, aggres44

MACHINE Design.com

OCTOBER 6, 2011

Suction pads come in a vast range of sizes, shapes, and designs to safely handle most any product. sive surroundings, temperature, and other environmental factors are all considerations when selecting suction pads. Material. Suction pads come in a wide range of materials to meet specific application requirements. Common materials include nitrile, silicone, and natural rubbers, fluoroelastomers, and polyurethanes. Some materials, for example, are particularly suited for smooth, rough, or oily surfaces, or easily damaged workpieces. There are also special antistatic suction pads for handling electronic components, and pads which won’t mark plastic parts. Environmental conditions can affect the material choice when the pads must resist ozone, chemicals, extreme temperatures, or operate silicone-free. Surface. The workpiece surface may make certain types of suction pads more suitable than others. The wide range of available products includes flat and bellows suction pads in many sizes and shapes with various types of sealing lips and sealing edges.

Physical factors

Engineers should determine certain physical parameters as part of the selection process. Coefficient of friction. It is usually not wise to assign a ballpark value for the coefficient of friction, µ, between the

With the force applied horizontally: SPB4 bellows suction pads grip tough-to-handle soft packages.

d = 1.12 i

mS PU n

With the force applied vertically: d = 1.12 i

m S PU n  µ

Authored by:

Justin Katz Applications Engineer Schmalz Inc. Raleigh, N. C. Edited by Kenneth J. Korane [email protected]

Key points:

• Flat pads, for flat or slightly curved parts, offer quick evacuation and good stability. • Bellows pads adapt well to curved or uneven workpieces. •Special-duty pads are designed for specific applications, such as handling wood, sheet metal, or candy.

Resources:

Schmalz Inc., www.schmalz.com

suction pad and workpiece. This means designers must determine µ beforehand through testing. However, as a general guide, approximate values for various workpiece surfaces include: • Oily surfaces: µ = 0.1. • Moist or wet surfaces: µ = 0.2 to 0.4. • Glass, stone, plastic (dry): µ = 0.5. • Wood and metal: µ = 0.5. • Rough surfaces: µ = 0.6. • Sandpaper (dry): µ = 1.1. Holding forces. Calculated holding forces can never exceed the theoretical maximums. In practice, many factors, such as the size and shape of the suction pad and the surface finish and rigidity (deformation) of the workpiece play an important role. For this reason, we recommend that engineers include a safety factor, S, of at least 2. The German accident-prevention regulations demand a minimum safety factor of 1.5. In operations which swivel or turn over the workpiece, use a safety factor of 2.5 or higher to cope with the resulting forces. Suction pad diameter. The absolute holding force depends on the suction-pad diameter and the workpiece surface finish. Determine the required diameter with the following equations.

Here, d = suction diameter, cm. (For suction pads with a double lip, d = the internal diameter; for bellows suction pads, it’s the minimum internal diameter of the sealing lip.) Also, m = mass of the Thin and flexible workpiece, kg; PU = vacuum, sealing lips hold bar; n = number of suction chocolates without pads; S = safety factor; and μ = damage. coefficient of friction. Suction capacity. The required vacuum level and circuit volume are critical for calculating the necessary suction capacity. However, keep in mind that the workpiece material is the decisive factor which determines suction capacity. For porous parts, always carry out suction tests to ascertain actual capacity requirements. Additional factors. In addition to the factors mentioned here, vacuum-system manufacturers often list other data for individual suction pads to aid in the selection process. For example, data for Schmalz suction pads include: Theoretical suction force. The theoretical holding force of a suction pad is calculated from the pressure differential and the surface area: F = ΔpA. Schmaltz bases this value on a –0.6 bar vacuum (at sea level) with a smooth, dry workpiece surface. Depending on operating conditions, this value may have to be reduced to account for the safety factor, friction losses, or a lower vacuum level — for example, due to a porous workpiece. Internal volume. This is used when calculating the total volume of the gripper system and, thus, total evacuation time and equipment cycle rate. Minimum radius of curvature. This specifies the minimum radius which a suction pad can securely grip, important for curved workpieces. Suction-pad stroke. This is the lifting effect during evacuation of a suction pad. It typically applies to bellows-type pads. It also allows for height compensation and gentle cup placement.

Universal pads Manufacturers generally classify suction pads as universal or special purpose. Universal pads cover a wide range of requirements, while specific-duty pads are designed to meet special requirements such as handling thin OCTOBER 6, 2011

MACHINE Design.com

45

FLUID POWER

RS# 136

automotive bodywork parts or porous workpieces in the woodworking industry. The two most-common types of universal products are flat and bellows suction pads. Flat suction pads are particularly suited for handling objects with flat or slightly curved surfaces. They come in a wide range of materials, sizes, and shapes, including round and oval, with steep or flat sealing lips. A low overall height and small internal volume means short evacuation times, letting them grip workpieces quickly. The flat shape ensures good stability when attached to a load and they withstand high lateral forces during fast movements. Flat suction pads are typically used for handling smooth or slightly rough workpieces such as metal, glass, or wood sheets, cardboard boxes, and plastic parts. Wear-resistant versions can handle higher loads and give up to 10 times the life of standard NBR (nitrile-rubber) units. The pads are recommended for demanding applications with quick cycle times, such as handling oily metal sheets in automobile production or extremely abrasive workpieces, like rough cardboard. Suction plates are a variation of flat pads. One type, for instance, has a flexible sealing ring attached to a metal base plate. Like suction pads, they come in a wide range of sizes and materials and have low internal volume for fast cycling. They are designed for handling rough or structured surfaces, such as ornamental glass, checker plate, and broken natural stone. Users can quickly change the sealing ring without tools. Flat, oval suction pads produce high forces despite relatively small dimensions. In fact, they can generate considerably higher forces than round, flat pads when handling narrow workpieces. They’re best suited for thin and curved objects, such as extrusions, pipes, and sections of door and window frames. Bellows suction pads compensate for varying workpiece heights and can handle parts with uneven surfaces or that easily damage. Like flat pads, they come in many shapes, sizes, and materials. Bellows suction pads adapt well to curved or irregular workpiece surfaces and can lift products when vacuum is applied. Typical versions have bellows with 1.5, 2.5, or 3.5 folds. More folds are generally better for handling workpieces with extremely uneven surfaces, or when a longer suction-pad lifting stroke is necessary. The upper bellows are often stiffer for stability during horizontal acceleration, while the lower bellows and sealing lips are softer and more flexible to conform to curved and uneven surfaces and give good sealing, even on nonrigid workpieces. The bellows also provides damping when it contacts the workpiece, beneficial when handling fragile parts. Bellows pads are typically used on curved or uneven parts such as car-body components and pipes; cardboard boxes and blister-packs; and easily damaged items such as electronic components and injection-molded plastic parts. They OCTOBER 6, 2011

Automated vacuum-handling systems for metal parts must deal with fast cycle times and a variety of part shapes and sizes.

are also used to move cardboard, sheet metal, wood, glass, and ceramics.

Recent innovations

Manufacturers also offer many suction pads designed for specific applications. These include flat and bellows pads for handling sheet metal and metal tubing; wood products ranging from furniture parts and parquet flooring to laminated chipboard and rough-sawn lumber; packaged goods such as film-packed and blister-packed products, cardboard boxes, and soft bags; plastic film and paper; and CDs and DVDs. Here’s a look at some recent innovations from Schmalz. Sheet metal. Metal-stamping and automotive assembly operations are growing more complex as automation processes deal with quicker cycle times and a wider variety of part shapes and sizes. A new type of round, bell-shaped suction pad (called the SAXM) with a flexible sealing lip, a reinforced structure, and special oil grooves is built for OCTOBER 6, 2011

RS# 137

FLUID POWER

Wear-resistant suction pads are suited for high-speed handling of cardboard boxes and rigid packaging.

high-speed operations. The shape offers a longer suction-pad stroke, letting it deftly adjust to contoured workpieces. And an inner support prevents deep-drawing of thin metal sheets. It evacuates quickly, produces high holding forces, and withstands extreme lateral acceleration even on oily surfaces. And it’s made of wear-resistant material that gives triple the life of standard NBR pads. The pads are designed for handling sheet-metal and car-body parts, loading CNC and lasercutting machines, and handling blanks at destackers. Structural shapes. SAOK suction pads grip structural sheet-metal components with round edges and small radii, including pipes, stiffening plates, and frame parts. A soft sealing lip ensures a good fit to securely hold the workpiece in fast-cycling machines. Edge-gripper suction pads are available in NBR for smooth metal parts, and in a high-temperature material for handling hot-formed components and hot sheet metal up to 250°C. Chocolates. The SPG suction pad has an extremely thin and supple sealing lip that seals against smooth, glazed chocolates. The tapered suction pad completely encloses and securely holds without breaking round and square chocolates moving at high process speeds. High nominal flow ensures that the pad reaches required operating vacuum quickly and compensates for any leaks. The SPG is manufactured from FDA-approved silicone for direct contact with food. It can also be steam sterilized and washed using standard cleaning agents. It handles round chocolates up to 35 mm diameter and oval and square chocolates with a maximum diagonal measurement of 30 mm. 48

MACHINE Design.com

OCTOBER 6, 2011

Soft packaging. Automated handling of flexible-form packaging is one of the biggest challenges in handling technology. This is due, in part, to the broad spectrum of different bag designs and materials. But it is also due to the non-rigid nature of the packaging and loose contents, such as powders or liquids, that must be picked at high speeds. A bellows suction pad with 4.5 corrugations, the new SPB4 Series, reliably handles such packages at process speeds up to 100 cycles/min. The long, stable bellows has a thin and flexible sealing lip with integrated flow vanes. This lets the pad adjust to the bag and hold it with maximum surface coverage. Large nominal diameters ensure high-volume flows and accommodate any air leakage between the suction pads and the product. And an integrated joint in the pad

Modular VEE units let users configure vacuum feeds, connection elements, and suction pads to suit an application.

Calculating g forces To determine the necessary holding forces for a suction pad, consider more than just the workpiece mass. The suction pads must also handle acceleration forces which, in fully automatic systems, are by no means negligible. To simplify calculations, let’s look at the three most important and frequent load cases. 1. Horizontal suction pads, vertical force. In this case, suction pads are placed on a horizontal workpiece which is lifted vertically. Calculate the theoretical holding force FT (N) from: FT = m × (g + a) × S where m = mass (kg), g = acceleration due to gravity (9.81 m/sec2), a = system acceleration (m/sec2), and S = safety factor.

SAOK suction pads grip structural sheet-metal components with round edges and small radii.

compensates for any deformation from the contents shifting during movements. A roughened surface and raised portion on the bellows corrugations prevents an “adhesive effect” where the folds stick to each other, providing additional process reliability even when the bellows are fully compressed. The series uses food-safe silicone and conforms to FDA guidelines, and can be used in toploader, multipack, blister packaging, and form-and-seal equipment. Package handling. A new series of suction pads is for heavy-duty applications handling cardboard and plastic boxes and high-gloss printed packages. Made of proprietary Elastodur material, it gives triple the life of NBR. They include flat suction pads (SPF) and round (SPB1) and oval (SPOB1) bellows suction pads with 1.5 corrugations. The wear-resistant pads have adaptable lips for good sealing on porous surfaces. Support ribs on the suction surface ensure stability and high gripping force, letting them withstand the high lateral loads of fast-moving cardboard-box aligners. An optional prefilter integrated into the suction pads prevents contamination of the vacuum system. High temperature. Pads made with fluorocarbon-based materials resist temperatures up to 400°C for short periods with little marking of the workpieces — making them well suited for the glass industry. The suction pad attaches to a large metal base for good heat dissipation and quick cooling. They are for handling hot workpieces, such as removing glass from molds and gripping hot metal parts. Schmalz makes a special version (SPL-HT) with a stainless-steel body and textile seal that withstands tem-

2. Horizontal suction pads, horizontal force. The suction pads are placed on a horizontal workpiece which must move laterally. FT = m × (g + a/µ) × S where µ = coefficient of friction. Typical values for µ are listed under “Coefficient of friction” in the main article. 3. Vertical suction pads, vertical force. The suction pads move a vertical workpiece, or shift a horizontal workpiece to another orientation. FT = m/µ × (g + a) × S. Always use the worst case with the highest theoretical holding force that applies to the application.

peratures to 600°C. It’s for flat workpieces, such as in floatglass manufacturing, glass-tempering processes, and hot forming in the metal industry. Modular end-effectors. A new modular system for quickly configuring vacuum end effectors (VEE) is for use in pick-and-place processes, case packers, carton and tray erecting machines, and other packaging machines with frequent format changes. The VEE elements give system integrators and machine and robot manufacturers a new way to set up or reconfigure flexible end effectors, including a wide selection of vacuum feeds, connection elements, and suction pads. CAD models of all the modular elements can be downloaded from the company’s Web site and quickly combined into the required configuration. Users can construct a system with one to 12 suction pads, including flat and bellows pads for handling fragile foil and blister packaging, cardboard boxes, and filled bags or flow-wrap packaging. The VEE handles loads up to 2 kg and process accelerations up to 10 g, for fast pickand-place processes typical for the packaging industry. All VEE elements are made of FDA-approved polysulfone. They resist alkaline and acidic cleaning agents and can be steam sterilized, making them particularly suitable for use in food processing. MD OCTOBER 6, 2011

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MECHANICAL Motor and drive

Start with ideal specifications and keep an open mind. Nut guide / structural rail

How to

Nut

get the most from

Leadscrew

customized leadscrews

Some companies offer a few options on a device and say they have custom products; unlike Henry Ford’s dictum: “any color as long as it’s black,” they also offer white and red. But true custom components are limited only by imagination and manufacturing technology. This is particularly true for leadscrews. Engineers turn to these devices when accuracy and reliability are critical. And custom leadscrews make sense whenever price and cost of ownership matter.

What if ...

From a manufacturer’s perspective, custom leadscrews are those built to customer specifications rather than those of the manufacturer. A true custom supplier challenges engineering customers to answer “What if …” questions to define exactly what they want. For instance: If cost was no object, what would the perfect component look like? What would the motion profile be in the absence of friction? What if the screw could be as long or short as needed? And what if the nut could be any shape or size? How could the device perform better? How could we simplify assembly or use fewer parts? The keys to success are imagination and avoiding constraints at the outset. Both are often hindered by common misconceptions. Many believe custom parts always cost more. In fact, the ability to combine components and cut assembly and maintenance may make custom parts more affordable. An assembly of specialized parts might outperform an actua50

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OCTOBER 6, 2011

tor comprising an integrated motor, leadscrew, and nut in some applications, but considering a custom design that takes all application factors and costs into account often has better overall cost of ownership. Custom parts are also thought to have long lead Custom leadscrew times. But manufacturers assemblies let parts do double duty. This assembly of custom parts can adincludes a leadscrew and vise engineers on processes nut, motor, and drive. A that can meet schedule restructural aluminum rail straints. For example, many serves as a guide. engineers mistakenly believe injection molding only makes sense for large quantities due to the complexity of the mold, but this is no longer always the case. Likewise, the technology for prototyping parts has advanced to the point where it is not necessarily cost prohibitive and may actually save money in the long run. By talking over the application with a manufacturer, engineers can quickly assess the supplier’s ability to provide custom parts. At the outset, it’s important to avoid the urge to rule out options. No supplier is going to offer a design direction that increases his own risk of failing.

How to go custom

Many engineers accustomed to the constraints of standard leadscrews find exploiting the benefits of custom alternatives challenging. For most engineers not familiar with the range of customization possibilities, the best place

An integrated gear profile enhances nut performance, simplifies manufacturing, and reduces total cost.

Authored by:

Tom Solon, PE Engineering Manager Haydon Kerk Motion Solutions Hollis, N. H. Edited by Jessica Shapiro [email protected]

Key points:

• Custom-designed leadscrew assemblies don’t necessarily cost more or have longer lead times.

Leadscrew

• Detailed performance specifications are a good starting point for talking with leadscrew manufacturers about design. • Consolidating functions into fewer custom-designed parts can simplify assembly, cut maintenance, and even lower part cost.

Encoder strip

Resources: Nut Consolidating functions with custom nuts can save assembly time and part costs. For instance, the custom nut in this assembly is self-lubricating and includes an insertmolded encoder strip while the leadscrew has a low-friction, PTFE coating.

to start is with performance specifications including motion, environment, and location. Business considerations such as life cycle, production schedule, and budget also come into play. (See “Custom leadscrew checklist.”) Motion. How will the component move? Specifically, what distance will it cover and in what direction? How fast should it cover that distance? What is the frequency of travel? How precise does the motion or final position need to be? Finally, how much load will be moved? Environment. What conditions will the component work under? What are the expected maximum, minimum, and average temperatures? Will it encounter radiation, moisture, or chemicals that require careful materials selection? How about vacuum or pressure? Are there cleanliness standards that must be met? What contaminants, if any, are expected? Location. Where is the component going to be? How much room is available? What support structures and mounting provisions are available? How visible or hidden should it be to operators or customers? Does it need to mate to other components? Life cycle. How many cycles should it complete between maintenance intervals and over its lifetime? Alternately, what period of time is it expected to last? Production schedule. How many are required? When are the first and last components needed? Budget. What is an acceptable unit price for the component? What start-up and tooling costs are acceptable given the length of the production run?

Haydon Kerk, www.haydonkerk.com “Don’t Settle for Standard Parts,” MACHINE DESIGN, June 23, 2011, machinedesign. com/article/the-benefits-of-customcomponents-0623 “Introduction to Linear Actuators,” Webinar hosted by Haydon Kerk and MACHINE DESIGN, Nov. 13, 2008, machinedesign.com/ node/87018

After defining as many of these parameters as possible, an engineer should intelligently choose component specifications. For instance, quantity, budget, and timing will influence manufacturing methods and tooling investment. Analyzing speed, loading, and duty cycle will establish the minimum PV — the product of load and velocity — the component needs. It will also help the engineer determine the acceptable friction. Both PV and friction affect material selection. Material choices also depend on corrosion risk and chemical and thermal compatibility.

Open options Manufacturers customize leadscrews by specially machining screws, nuts, and other components. They can make the parts with user-defined materials or processes. And they can incorporate guide features or ensure seamless integration with downstream components like motors. The screws themselves can be machined to accommodate bearings, couplings, pulleys, and other attachments. Custom machinWANT MORE? ing also lets deFocus on this code image signers add special using your smartphone and leads or specify free software from www. neoreader.com, and you will be thread forms that connected to related content work best for their on machinedesign.com. motion profiles. http://tinyurl.com/6f538h5 The manufacOCTOBER 6, 2011

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MECHANICAL Example 1: Portable medical pump turer can also machine custom-mounting features into leadscrew nuts, size the nuts to fit tight space, or incorporate performance enhancements such as compliant mounts or vibration damping into the nuts. In some cases, injection molding nuts from powdered metals or plastics gives manufacturers the flexibility to add features like encoder flags, points, metal housings, and mounting brackets to the nuts. Custom design also opens up a range of materials for both screws and nuts. Leadscrews are commonly made from stainless steels and nuts are of te n acetal or bronze. But screws can also be aluminum, titanium, or specialty steels, and nuts can be made from carbon-fiber composites; engineering polymers like fluoropolymers, polyetheretherketone (PEEK), and polyamide-imide; or a wide variety of bearing-grade metals and polymers. Leadscrew manufacturers offering customer-specific designs usually work with designers to incorporate guide features. Some designs will take into account the relationship to external guide mechanisms like slides or rails. Some will actively engage the guide.

Consolidation adds value An important step on the path to custom leadscrews is to evaluate overall assembly. This means looking at the components connected to the leadscrew. For instance, it is often possible to turn the components attached to the nut into the nut itself. And combining motors and guides saves space, reduces component count, simplifies assembly, and lowers total cost. To look at where consolidating a design makes sense, an engineer should ask: • How will the screw be supported? • How is the screw driven? • What attaches to the nut? • Can the leadscrew assembly work as a structural element? Answering these 52

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OCTOBER 6, 2011

REQUIREMENT

CUSTOM DESIGN

Match syringe diameter and Special thread design, including encoder to motion profile high-accuracy rolled thread, and for required dispense rate rolling dies achieve required lead. Low-friction TFE leadscrew Operate for two weeks on coating and low-friction nut one AA battery material maximize efficiency. Seal against leaks in or out, Special surface finish lets nut including submerged when mate with commercial seal. swimming Quick engagement and Custom quarter-turn locking release between nut and thread on nut syringe plunger Knurled screw accepts pressSecure drive gear to screw fit gear without adhesive or additional components

Example 2: Train-door actuator REQUIREMENT

CUSTOM DESIGN

A 2-m screw with right-hand and left-hand threads permits simultaneous actuation. Doors open manually if Thread lead at 2.4 in./rev allows power is lost easy back driving. High-strength, maintenance- Self-lubricating carbon-fiberfree operation in dirty composite nuts run on a environment stainless-steel leadscrew. Quick-change, replaceable Custom-molded nut configured nuts for easy replacement. Dual sliding doors

Example 3: Lift mechanism for hands-free telephone operation REQUIREMENT Operate with low power from telephone line Minimum component cost Minimum assembly cost

CUSTOM DESIGN A 0.3-mm lead gives maximum mechanical advantage, TFE leadscrew coating and low-friction nut material improve efficiency, and precision-rolled thread maintains consistent load. Multicavity, automated nut tooling and simplified screw design reduce labor and machine costs. Precision screw features and custom nut design permit automated assembly.

Example 4: Auto-sample mechanism in medical diagnostic instrument REQUIREMENT

CUSTOM DESIGN

Minimum size to let more test stations Custom nut combines carriage, nut, and fit in same lab guidance system. footprint High-helix (long-lead) leadscrew with High linear velocity minimal axial thread clearance between with precise nut and screw permit high-speed position control precision. Floating centralizers eliminate radial clearance and damp vibration. TFE Quiet operation coating and polymer guide surface cut friction and noise.

Machined Springs 6ROXWLRQ No Rotation During Compression Springs based on a helix in a single direction, whether wire-wound or machined, will rotate about their centerline when compressed. At Helical we have the ability to stack both a right and left hand Flexure in a single piece and prevent end-to-end rotation during compression or extension.

Learn more about RSSRVLQJÀH[XUHV

Video! KWWSELWO\TV

Compression, Extension, Torsion, and Lateral Bending are some of the spring load cases that can be provided with Helical’s machined spring. Integrating attachment features into a single-piece machined spring allows for endless innovative design solutions. Helical Products Company, Inc. and its engineering team have over 50 years of experience designing and manufacturing innovative products for controlling mechanical movement, specializLQJLQPDFKLQHGVSULQJVDQGÀH[LEOHFRXSOLQJV

www.heli-cal.com 32%R[:HVW0F&R\/DQH 6DQWD0DULD&DOLIRUQLD )D[ Made in USA Est. 1958

$6% ,62&HUWL¿HGDQG52+6&RPSOLDQW

RS# 138

MECHANICAL

Custom leadscrew checklist Get the most out of custom-designed leadscrews by creating a complete performance specification. Knowing the following requirements is a good starting point for a discussion with manufacturers: ☐ Load – Static and dynamic, axial and radial ☐ Motion profile – Speeds, accelerations, distances, and/or times ☐ Total stroke ☐ Positional accuracy requirement ☐ Orientation (Vertical, horizontal, or other) ☐ Duty cycle ☐ Operating life ☐ Temperature — Operating and storage ☐ Environmental exposure — Weather, chemicals, radiation, dirt, etc. ☐ Location and space considerations ☐ Drive method – Screw or nut, direct or indirect, motor type (if applicable) ☐ Attachment and support details – screw and nut ☐ Quantity required – Prototypes, production, lifetime ☐ Cost target

questions can reveal new opportunities. For example, rather than attaching a nut to a carriage, the carriage, nut, guide bushings, and sensor flags can all be a single component. If a design calls for a timing pulley or gear, the nut can be designed to perform these functions which can make assembly and maintenance easier and improve reliability. The entire leadscrew assembly — leadscrew, nut, bearings, coupling, and rotary motor — can be converted to a motorized axis. This can be done by attaching the leadscrew directly to the motor’s rotor or integrating the nut into the rotor and passing the leadscrew through the motor’s center. A custom leadscrew assembly can even incorporate the entire guiding structure. For instance, Haydon Kerk’s ScrewRails, RGS, LRS, and MotoSplines run guide rails concentrically around the leadscrews. And while standard leadscrew assemblies rarely carry structural loads, custom designs can. Using a leadscrew as a stressed element can simplify frame structures. Not only do consolidation strategies reduce part counts and assembly times, they can also cut individual component costs. Compared to component assemblies, these integrated solutions eliminate the need for couplings and duplicate bearings. Once these duplicate bearings are out of the design, mounts can be simpler because they no longer need to

Material match-ups REQUIREMENT precisely support the eliminated bearings. The structural framework previously needed to ensure alignment of individual components can then be replaced with less precise — and less expensive — sheet-metal or polymer elements. And once nuts incorporate simplified attachment points, sensor mounts, and guide bushing replacements, they can eliminate carriages that required complex machining.

The supply side

Even when engineers specify leadscrews with custom parts in mind from the get-go, they still might have misgivings about cost effectiveness and delivery schedules. Many designers base these opinions on experience, and it would be misleading to suggest all manufacturers are equally positioned to provide custom leadscrews. However, it would be equally misleading to suggest that engineers have to pay a penalty to get custom parts. CAD/CAM, CNC machining, rapid prototyping, and lean manufacturing let suppliers use the same manufacturing processes for moderate runs of custom products as for huge standard-part runs. By asking the following simple questions, engineers can get a feel for whether their chosen suppliers understand true custom design and have the ability to deliver. • Does the company actively promote customized leadscrews?

NORD SURFACE PROTECTION REINVENTED!

POSSIBLE CHOICE

Corrosion resistance 316 stainless-steel — saltwater screw Autoclave PEEK or PPS nut compatibility Nut machined from Low volumes bar stock High volumes Injection-molded nut Self-lubricating nut, Long life TFE-coated screw Aluminum or Nonmagnetic titanium screw

• Does the company have strong applicationsengineering support? • Are lead times for custom parts similar Application requirements often to those for determine material choices for leadscrew standard ones? components. Both the basic materials • Does the chosen and component-fabrication company methods affect how components perform actually and how much they cost. manufacture parts instead of repackaging components available from other firms? • Do company representatives pay attention to performance specifications instead of simply assigning part numbers? Each company has its strengths and weaknesses, but all contenders will exhibit similar approaches to defining custom products. The right manufacturing partner can put a custom-design project on the road to both high performance and good value without the need to settle for off-the-shelf parts. MD

NSD TupHTM, A bREAkTHROUgH IN PROTECTION AT A MOlECUlAR lEVEl. At last it’s here, a cost-effective and weight-saving alternative to stainless steel for use in the harshest environments. NORD has redefined surface protection. NSD TupHTM is a true innovation in corrosion resistant cleanable sealed surfaces. Molecular conversion of the aluminum alloy provides our drive equipment with all the protection your application demands. All of this at a fraction of the price you have been forced to pay for stainless steel. Introducing NSD TupHTM, the better solution you have been asking for is finally here. you can immediately start saving big money on protection without compromising quality. Contact us today and find out how you can profit from NORD reinvention.

www.nord.com INNOVATION bEyOND THE ORDINARy RS# 139

CAD

Recent engineering software uses much more than Nurbs. Here is a guide to the best approach.

The model of a human head is made up of voxels.

How to

select the

best CAD modeler Most engineers are familiar with geometric modelers with their solids and surfaces and Nurbs-based curves. Yet there are many cases where traditional geometric modelers are too slow or not a good fit for the design task at hand. Examples include modeling textures; shelling complex models; modifying and using scan data; designing complex organic shapes and artistic, aesthetic forms for manufacturing; adding highly sculptural detail to parametric CAD models; and combining hand-modeled and computer-generated forms. Increasingly over time, the lines between different types of geometric modeling software have blurred, as each combines similar approaches and tools from the others. Newer, nontraditional approaches have accelerated this trend. For example, “hybrid” software from 3D-Coat combines what are called polygonal and voxel modeling. And PowerShape from Delcam, Salt Lake City, lets users model with solids, surfaces, and polygons. In addition, Freeform, 3D organic design software from Sensable, Wilmington, Mass., combines voxels, solids, surfaces, and polygons. The combination of multiple geometry types in one package shortens design time and eliminates the need to learn multiple pieces of software with different user interfaces and ways of working. It also reduces the number of challenges inherent in getting separate pieces of software to efficiently talk to each other. These modelers complement traditional CAD packages. As this blending of modeling approaches continues, engineers and designers need a working understanding of the advantages of each geometry format, when and how to com56

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OCTOBER 6, 2011

A Bezier curve is defined using control points.

Authored by:

Kevin Atkins Corporate Applications Engineer Sensable Wilmington, Mass. Edited by Leslie Gordon

Resources: 3D-Coat, www.3d-coat.com Delcam, www.delcam.com Sensable, www.sensable.com Other resources for basic CAD tutorials: An Alternative to Nurbs, http:// tinyurl.com/3r28cs3 Computers for MCAD, http:// tinyurl.com/43738z8 The Changing Face of Model Annotation, http://tinyurl. com/43slrxw

Control points directly on the surface define its curve.

bine them, and where to best apply them. Of course, the capability to model efficiently is crucial to streamlining the design and manufacturing of new products.

Different geometries solve different problems Let’s take a look at four different geometry types, their pros and cons, the workflows they facilitate, and the types of products they suit. Nurbs is short for “nonuniform rational B-splines,” with “B-splines” being the important bit. Years ago, manufacturing companies needed a way to mathematically capture the nonrectilinear shapes found in car exteriors, ships hulls, and airplanes in a way that was accurate and could be reliably repeated. It was easy to define straight lines and arcs, but a freely defined curve was another thing. In 1959, French engineer Pierre Bezier and French physicist and mathematician Paul de Casteljau, working independently, came up with a way of using control points to define and control a free curve.

Methods were also invented to control the curve with control points directly on the curve as opposed to on a control net. This made the definition and control of these curves more intuitive. The method works well to define straight lines, arcs, and circles as well as curvy shapes. Defining a 3D surface just extends this principle. Extrapolating these simple examples into a fully finished design requires that the model follow the abstract rules inherent in Nurbs modeling. Mostly, the CAD software controls these rules, working behind the scene. The upside is that as long as the software follows the rules carefully, it can generate models that won’t fail. The downside: Sometimes the rules become so limiting or so time consuming to follow, the designer is forced to compromise his or her design, or give control to others later in the manufacturing workflow, for example, in applying textures. When you need rectilinear, typical engineering models, Nurbs are great. Nurbs are best suited for products that have well-defined edges, are inherently smooth, rectilinear in nature, or can be parametrically defined. However, in OCTOBER 6, 2011

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CAD

situations where double compound curvature surfaces must join together such that the transition between them is aesthetically smooth, with the joint invisible, this can be a particularly tricky modeling task with Nurbs. Polygons are another way to model a 3D object by creating 2D triangles and then connecting the triangles together. Increasing the number of polygons and reducing their size allows the accurate modeling of any shape below any reasonable manufacturing tolerance. Polygons are also common in design and manufacturing work that relies on additive manufacturing (AM) for production. In AM workflows, polygons are used as the translation language that lets the CAD software “talk” to the AM machine. Another common use of polygons is in scanning. Scanners export pointcloud data, but this is almost immediately translated into polygons for import into CAD software. Polygons generate a shape which will later be converted into a Nurbs model for further use in a traditional CAD system. However polygons have numerous downsides. They are less accurate and less precise than Nurbs, although boosting the resolution can partly resolve this. In addition, files can get so large that models become unusable. Polygons are not easily and randomly created on-the-fly, which limits applications such as scan cleanup. And polygon models are not necessarily manifold or watertight solid models. They can have overlapping open shells, which can cause problems in downstream processes such as additive manufacturing and must typically be fixed before the workflow can continue. Lastly, converting polygon models into Nurbs is often the only way to reuse these models later. The act of converting polygons to Nurbs is not trivial, giving rise to the need for specialty software, such as Geomagic Studio or Rapidform XOR. Voxels — Just about everyone is familiar with how 2D pixels define a photograph. Voxels can be thought of as 3D, volumetric pixels. They are inherently three dimensional and can be arranged randomly in 3D space — like shifting grains of sand — to create different shapes. This inherent dimensionality means that designers modeling with voxels are not limited by the same rules that apply to Nurbs 58

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modeling, for instance, by the constraints of topology. As with polygons, when voxels get smaller and smaller, the relative accuracy of a sphere represented by voxels will rise to the point that any deviation is smaller than the tolerances of the manufacturing technique being used to produce the product. Voxels let users perform a 3D version of the antialiasing commonly found with 2D pixel images such as adding triangles to the diagonals of a block model. The net result is that users can generate smoother models without taking the voxels down to micron sizes. An additional benefit of 3D antialiasing is that the software wraps the voxel model in polygons for import into additive manufacturing machines. Voxel models are also inherently solid, manifold, and watertight. All the checking required when using polygon models — to ensure downstream manufacturing

An increasing number of polygons defines a sphere.

RS# 140

CAD

processes will not fail — is not required with voxel models. Also voxel models let users randomly add (or subtract) voxels on-the-fly, giving designers the creative freedom to simply push, pull, smooth, and carve models of “virtual clay.” In addition, voxels work well for modeling textures. This is rarely done in traditional CAD software because the complexity of the Nurbs model would slow the software and make the model unusable. Because voxels are not bound by the same solid-modeling and surface limitations as Nurbs, creating textures is simple. And these textures are not just visual in nature, they are actually part of the model. Voxels are well suited for modeling highly organic-shaped products and performing complex modeling operations such as shelling intricate shapes — operations which typically fail in Nurbs or polygons. Like any modeling approach, voxels also have downsides. For example, currently available voxel modelers do not support sharp edges well. And because accuracy and smoothness is driven by the size of the voxel, dimensionally precise and smooth models can get large in data size. In addition, voxel modelers are not history-based or parametrically driven, so some design changes can take longer than when done on a correctly defined Nurbs parametric model. Subdivisional surfaces — The Catmull– Clark algorithm for subdividing surfaces (subD) was developed in 1978. It was primarily used for models in games, movies, and computer graphics. But recently, CAD modelers including Creo and Rhino have put subD techniques into their toolsets. At the basic level, subD is a method for representing a smooth surface by continually refining a mesh. By continually subdividing the control net, the software increasingly smooths the model. As the localized subdivision continues, it is possible to model details such as pockets. This 60

MACHINE Design.com

lets subD modelers make smooth continuous models faster and more easily than traditional Nurbs-based CAD. In addition, subD modeling lets users take the model back and forth through the various levels of subdivision without losing detail. Users can make gross changes to the overall shape at earlier stages of subdivision, while details added at later levels can be automatically regenerated. Another benefit, especially over Nurbs models, is that users can create complex models without trimming. Subdivisional technology is best suited to smooth flowing shapes and concept creation. However, it, too, has its downsides. When designers want more rigid control over a portion of the model, it can be argued that Nurbs modeling is better. Also, subD forces users to undertake abstract thought processes to define and control the model, unlike polygons or voxels which are

OCTOBER 6, 2011

These are examples of voxel models of a cell-phone cover with and without textures. Textures can be used for rapid prototyping to produce realistic-looking samples, and also to produce the texture on the final product.

RS# 141

CAD

much more unordered in their definition.

Poly-Rep gets you there faster No modeling technology is capable of addressing every modeling scenario for every workflow necessary to get a product to market. Fortunately CAD/CAM companies are adding more representations to their core functions to overcome the fundamental limitations of the different technologies. For example, not long ago, most CAM software could only use Nurbs. Now, most programs can create toolpaths on top of polygons as well, effectively eliminating the need to convert a finished polygon model to a Nurbs model. PowerShape software gives designers the capability of Nurbs to model, for example, a glass bottle, and then leverage the advantages of polygons to create a complex organic sculpt, such as a bunch of grapes with vines and leaves. It then wraps the sculpt around the Nurbs surface and passes the whole model downstream to machining. In another example, Sensable’s Freeform is an organic voxel modeler which has evolved to provide poly-representational modeling. This lets designers move freely between surfaces, solids, polygons, and voxels. For example, a designer could scan a manually sculpted design that cannot be modeled in Nurbs, import the .STL file into Freeform for clean up, integrate CAD components and further modify the model as needed, and then either create mold inserts or export directly for manufacturing. Poly-representational products help bridge the gap between the different types of 3D modeling tasks. This lets design teams choose the best format for each part of the design process, from concept modeling to detail engineering and on to manufacturing, minimizing the number of different programs used and streamlining design.

The result: better design Interoperability between and within products is constantly improving, including their approaches to modeling. This is good news for everyone involved in product design. Polyrepresentational modeling software gives designers flexibility and creative freedom. In addition, newer, nonexpert CAD users can exploit inherent capabilities that only “super users”, or those competent in multiple design systems, were previously able to employ. MD 62

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The smooth surface came from using subD techniques.

ThomasNet.com’s new semantic search technology will transform your product and supplier discovery process. Our revolutionary product finder understands syntax patterns—so unlike most search engines, it not only gives you product results containing specified attributes, but also further defines your need with the help of its pre-navigation feature.

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ThomasNet.com/ProdSearch RS# 142

OEM/MOTION CONTROL

Proving pumps OEM engineers who devise equipment that saves energy have it pretty good these days. They have the satisfaction of knowing that their work both saves their customers money and, on some level, helps the planet. This is particularly true for engineers working on industrial projects that feature energy efficiency. Some utilities will give industrial customers financial incentives paying up to 70% of costs for efficiency projects (based on annual kilowatt-hour savings). Items covered under such policies typically include variable-speed drives (VSDs), controls, premium efficiency motors, and most other measures that can save electricity. However, there is a catch. The utility expects to see verification of energy savings. Like all well-managed businesses, they (utilities) want to see the energy reductions before they cut checks. The end users, on the other hand, are looking at the bottom line (show me the money). While the concern is primarily energy savings, management looks at the big picture beyond energy savings. Upper managers typically want to make investments that increase productivity, reduce the costs of environmental compliance, lower production and waste-disposal costs, boost product quality and reliability, improve capacity, and make workers safer. There is a benefit to this big picture methodology. In many cases, energy savings alone may be insufficient to justify a project. Though it should be understood that the primary objective is energy savings, management must look at what they are getting for the money. There are numerous cases where company management denied projects because the “energy specialist” failed to look beyond energy savings. And it is sometimes the case that the cost of downtime far outweighs the energy savings. Centrifugal pumps are prime candidates for major energy savings, because their power use varies as the cube of the speed ratio (i.e., cut the speed in half and you reduce the power to one-eighth of the original value). They are the second most widely used type of mechanical equipment in the world, outnumbered only by the electric motor. The

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Motor

Eddy current drive

The original installation and the solid-shaft retrofit (right) mentioned in the example. Note that the VFD and premium-efficiency motor combo is much shorter than the original equipment.

Operating cost analysis per pump rpm

Operating cost $/year

Savings

Original

Proposed

1,717 rpm

$57,670

$26, 496

$31,174

1,500 rpm

$31,309

$13,941

$17,368

1,200 rpm

$14,188

$8,075

$6,113

Maintenance

$16,244

$0

$16,244

Total savings

$70,899

perform

There is an old adage that you can’t manage or justify what you can’t measure. That’s especially true for equipment installed to save energy. Authored by:

use of VSDs with centrifugal pumps, when properly applied, has a tremendous potential for cost and energy savings by reducing friction in the system. In relative terms, pumps Significant are efficient machines. Most reduction of overall height typically operate near 75% and mass of efficiency (best efficiency point, or BEP). Because unit of this relatively high efficiency, it is easy to dismiss the potential energy savings available by optimizing pumping systems. But a pump is sensitive to how it is operated and it is the pumping system that has the greatest influence on pump energy use. Energy can account for as much as

William Livoti Senior Principal Engineer Baldor/ABB Baldor Electric Co. Little Rock, Ark. Edited by Leland Teschler [email protected]

Key points:

• In many cases, energy savings alone may not be sufficient to justify an energy-efficiency project. • The most common reasons company management won’t fund energy projects include lack of a detailed energy assessment and a failure to evaluate the entire system. • Energy-savings projects demand a “big-picture” methodology.

Resources: Baldor energy savings app for smart phones, itunes.apple. com/us/app/be$t-baldor-energy-$avings/id357984703?mt=8 Readers interested in the Baldor Energy Dashboard program can contact the author directly at [email protected].

Example: 1,717-rpm spreadsheet Flow required Head required Additional system friction loss Motor efficiency VFD efficiency factor Mechanical-drive efficiency Pump efficiency Energy cost per kilowatt hour Operating hours per year

1,500 375 64 ft 90% 88% 100% 72% $0.10 2,651

Factor

Base

System efficiency System input power required for process Power required for additional friction Total power required Total cost per year Cost savings

49% 249.1 bhp 42.5 bhp 291.6 bhp $57,670

1,500 gpm 1,500 gpm 1,500 gpm 311 ft 311 ft 375 ft 0 ft 64 ft 64 ft 90% 90% 96% 88% 98% 88% 100% 100% 100% 82% 72% 72% $0.10 $0.10 $0.10 2,651 2,651 2,651 Reduce friction Increase drive efficiency Increase motor by 59 ft by 10 points. efficiency by 5 points. 65% 54% 52% 181.4 bhp

223.7 bhp

234.0 bhp

0.0 bhp

38.2 bhp

39.9 bhp

181.4 bhp

261.9 bhp

274.0 bhp

$35,873 $21,797

$51,785 $5,885

$54,179 $3,492

OCTOBER 6, 2011

MACHINE Design.com

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OEM/MOTION CONTROL

Head, %

Head, ft

500 75% of a pump’s total cost of the pump operating point moves Example: Centrifugal ownership. A pump can be away (to the right or left) from BEP, pump flow versus head efficiently designed yet can the efficiency and reliability drop off. 400 be operated in an inefficient While this sounds like a no-brainer manner. As a result, many approach, it is often bypassed when 300 pumping systems operate at making a simple energy-savings efficiencies far below their analysis. The typical rationale for 1,717 rpm 200 BEPs. not using the more-detailed analysis: C entrifugal pumps Poor historical documentation, lack 100 1,500 rpm should be selected and norof expertise/manpower, and lack of 1,200 rpm mally operated at or near monitoring equipment or funds to 0 the manufacturer’s designincorporate these details. 0 500 1,000 1,500 2,000 2,500 3,000 rated conditions of head Now consider the most common Flow, gallons/min and flow. This is usually at reasons for management denying Calculated operating conditions at the three the BEP. Pump-impeller funding for energy projects: Energy pump speed ranges the customer defined. vane angles and the size and assessment lacks sufficient detail inshape of the internal liquidaccurate estimates of potential cost flow passages are fixed and can only be designed for one savings and a failure to evaluate the entire system. The point of optimum operation. For any other flow condiCatch 22 is that before one can apply for incentives/fundtions, these angles and liquid channels are either too large ing from the utility, state and/or local government, one or too small. must obtain management approval by developing a solid Any pump operated at excess capacity — that is, at a business case. flow significantly greater than BEP and at a lower head — will surge and vibrate, creating potential bearing and shaftA real example seal problems while requiring excessive power. When The following case study is an excellent example in pumps operate at reduced capacity, i.e., at a flow signifiwhich the big-picture methodology helped justify an encantly less than BEP and at a higher head, the fixed vane ergy project. The original well-water system was installed angles will cause eddy flows within the impeller, casing, in May 1975 and comprised two separate installations. and between the wear rings. The radial thrust on the rotor Both were critical to the plant operation. The loss of one will rise, causing higher shaft stresses, more shaft deflecpump diminished plant operations, and loss of both forced tion, and potential bearing and mechanical-seal problems. a production shutdown. The units in question were verThere will also be more radial vibration and shaft axial tical six-stage turbine-style pumps coupled to 250-hp movement. Continued operation in this mode will accelhollow-shaft motors. An eddy-current drive controlled erate the deterioration of the mechanical and hydraulic pump speed. performance and may ultimately make the pump fail. The pumps developed a 310-ft head at about 1,700 galEfficiency and reliability are complementary; the closer lons/min when operating at a base speed of 1,717 rpm. the pump operates to BEP the more reliable the unit. As The system generally operated in the 1,200 to 1,700-rpm range. However, the pumps could run at a higher rpm under extreme condiANSI pump-curve sensitivity for pump reliability Weibull tions. The well pumps fed water into characteristic Lower several areas of the plant. life ~ MTBF impeller life Discharge The plant piping and instrumenOptimum recirculation η Hightation diagram showed that the well temperature pumps sent water into a treatment facil0.92*η rise Suction Best practice = ity. Upon entering the facility, the presLow-flow Low bearing recirculation –10 to 5% of BEP cavitation and seal life Best sure was dropped to 25 psi via a pres0.53*η efficiency sure-reducing valve. Water then flowed Reconsider! point Low bearing and seal life to the clear-well, flush-water, and chloBetter practice = –20 to 10% Cavitation rination systems. Engineers verified the treatment plant only require a maxiGood (commercial) 0.1*η practice = –30 to 15% Avoid! mum of 25 psi through the 8-in. line feeding the plant. Pump curve Reliability curve The maintenance history on both well systems showed the pumping sysFlow, % tems were considered “bad actors.” The pumps, along with the eddy-current The impact on reliability of a pump operating away from its BEP becomes clear in a flow versus head diagram. (Source: Barringer & Associates Inc.) drive and motor, experienced high vibration and frequent failures. Mean-

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OCTOBER 6, 2011

DYNAMIC SOLUTIONS

TEFLON® COATINGS

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Cable and hose management systems are easy enough for you to design when you have the time. When you don’t, Gortrac has the solution.

To enhance product performance Donwell Company is a licensed DuPont applicator for all TEFLON® Coatings. These coatings can improve the performance of your parts by providing them with one or more beneficial properties.

s

Solutions designed to drop into your existing dimensional envelope s 2D and 3D CAD files available from our website anytime, finished drawings and models available from our engineers every time s Replaceable wear surfaces, long travel support with minimal tow forces, options for quiet operation and unlimited cavity widths promote design flexibility s Modular components support complete, turnkey solutions delivered quickly and cost-effectively

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We coat both small and large parts to close tolerances in quantities from 1 to 1,000,000. Call Donwell for custom TEFLON® coating services to meet your specifications. A Division of A&A Manufacturing www.Gortrac.com Email: [email protected] Toll Free: 800-394-1547 Fax: 262-786-3280

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OEM/MOTION CONTROL

time-between-repair for the drive was just one year; for the pump, 2.5 years; and for the motor, 2.5 years. The accompanying pump and system head versus flow curve displays calculated operating conditions at the three speed ranges defined by customer. The accompanying spreadsheet display breaks down the energy consumption and savings. Vertical columns indicate savings based on reduced friction, drive efficiency, and motor efficiency,

respectively. All savings calculations were based on operating at specified points 33% of the time at 10 cents/kW/hr. Shown here are calculations for the 1,717-rpm case. There were similar spreadsheet calculations for the 1,500 and 1,200-rpm speeds. A point to note is that head loss across the pressure-reducing valve was deduced using an analog gage upstream and downstream of the valve.

CUSTOM ENGINEERED SPINDLES & SLIDES DESIGNED & MANUFACTURED TO YOUR SPECIFICATIONS

www.setco.com/design Let Us Help You 1-800-543-0470 RS# 147 68

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OCTOBER 6, 2011

To use the Baldor Energy Dashboard program, users supply information about transducers, suction, discharge, and flow. Users enter pump data that include at least six operating points (flow versus head) from the OEM pump curve and transducer multiplier data (suction/discharge), as well as operating hours and cost of energy per kilowatt per hour. The program then calculates system efficiency, pump efficiency, calculated head, and calculated BHP.

The customer chose not to share the cost of downtime data from the Baldor SP Drive. It works with three transwhen the pump system was out of service. But the comducers that monitor suction pressure, discharge pressure, pany did indicate the downtime substantially affected its and flow. It processes the necessary data and delivers it bottom line and was the primary reason for evaluating the to a PC, laptop, DCS, or PLC via Ethernet. The informasystem. When looking at the total cost of maintenance for tion it supplies includes the pump-performance curve, one pump system from installation (1975) to date, the comsystem curve, pump efficiency, flow, head, calculated BHP, pany spent approximately $295,040. This is a staggering real-time voltage and current, energy-usage trends over number considering that the pump should operate reliably months and years, and the cost per kilowatt/hour. MD for 15+ years between repair cycles. The solution that addressed these problems was the replacement of the existing hollow motor with a solidshaft premium-efficient design. Designers modified the pump shaft to accept a solid-shaft motor/coupling and provided detailed instructions for implementation. They also leveled the sole plate to insure the pump was plumb and level, and to eliminate pipe stress on the pump discharge per Hydraulic Institute Standards. A lowcoefficient-of-friction polymer material replaced the existing cutlass rubber pump line shaft bearings. A PWM variable-frequency drive (VFD) replaced the old eddy-current drive, and designers installed feedback control to automatically modulate the system on demand (to reduce friction and improve process control). All in all, the energy-assessment team identified not just energy savings. They also identified and documented additional benefits from reduced maintenance and downtime, improved reliability, and better productivity, to name a few. When you need rugged and reliable monitoring solutions for your toughest machine On this particular project, a VFD environments, go with proven, solid-state temperature transmitters and shaft tachometers modulated the pump flow. It is genfrom Electro-Sensors. erally taken for granted that a VFD TT420 Temperature Transmitters: • NO CALIBRATION— Ready to go! will provide energy savings. But there • Surface-mount and 1/8" or 1/4" NPT taps is no standard way to document the • 2-wire loop powered models with or without grease zerk savings or prove you are getting the • Outputs standard 4-20mA signal ST420 Shaft Tachometers: savings you expected. Ditto for the • Intrinsically safe design time it will take to see results of cor• Applies to virtually any machinery and PLC • M18 stainless steel, NEMA 4X/IP67 rective action, and whether or not the • Uses shaft mounted pulser disc or wrap • Simple installation and retrofitting system saves money in areas besides energy. The affordable, easy-to-install monitoring solution for: Industry is beginning to address Conveyors • Bucket Elevators • Motors • Gearboxes • Pumps • Turbines the need for such proof with software • Fans • Curing Ovens • Centrifuges • Agitators • Hammermills tools. The Energy Dashboard is one such tool that provides this informaFREE CATALOG & tion. It also brings built-in knowlAPPLICATION ASSISTANCE: edge, skills, and techniques for track1-800-328-6170 ing and controlling energy consumpwww.electro-sensors.com tion while improving, monitoring, The original machine monitoring experts and validating system reliability. ©2011 ELECTRO-SENSORS INC. • 6111 BLUE CIRCLE DRIVE • MINNETONKA, MN 55343 The Energy Dashboard gets its

Rugged p speed and t temp p temperature sensing se e

Pre-calibrated, P re-ccalibrated, pproven rove solutions install install fast fast and and perform pperfo erfo anywhere

RS# 148

OCTOBER 6, 2011

MACHINE Design.com

69

FE UPDATE

Simulation software helps boost foundries’ bottom line Casting process In general, foundries simulation is an effectively recycle established tool in their materials. More the foundry industry than 90% of all cast parts in Germany are made from remelted scrap metal. And the reuse of molding materials such as sand and water means almost no waste. However, foundries spend a lot on energy and materials — on average 40% of all costs. Physical laws dictate that an average energy input of 2,000 kW-hr per metric ton of final casting product is needed. This adds risks because they can predict the results of changes up to a total energy consumption of 11 billion kW-hr they make. Engineers are free to make unusual design in the German foundry industry per year. Over 50% of changes and see what will happen virtually without this energy is used just to fill gates and risers. waiting until multiple different castings are poured. Fortunately, casting-simulation software helps For example, one company detected a shrinkage foundry engineers optimize casting parameters, often defect in its complex ductile-iron carriers late in the before the first part is poured. Simulation helps to machining process. Simulation showed the root cause: minimize the amount of material cast and, thereby, The pass feeding molten metal to the critical area was the amount of energy needed for the melting process. getting cut off prematurely. Engineers changed the Simulation also plays a role in cutting CO2 emissions by helping users slash process and cycle times riser layout to eliminate the defect. for high-production castings. Engineers can use They also took design chances by making unusual simulation to optimize heat-up and temperature dischanges to the gating system. This slashed the pourtribution in permanent molds, plan ing weight by 13 kg, a savings of 13 metAuthored by: layouts that maximize the number ric tons of melt and 12,272 kW-hr energy Jörg C. Sturm of parts molded at one time, and used to melt the raw material per year. Magma Giessereitechnologie reduce or eliminate preproduction The redesign also reduced the riser neck GmbH trial-and-error runs. cross section by 25%, resulting in lower Aachen, Germany Here are a few example of how riser-removal costs. The modified layout Christof Heisser simulation software such as Magshortened pouring time by 2.5 sec and Magma Foundry Technologies masoft can help optimize casting slashed solidification time by 11 min, Inc. operations. increasing productivity by 15%. The origiSchaumburg, Ill. nal job was to eliminate the defect. The fiOutside-of-the-box casting Edited by Leslie Gordon nal design, based on simulation, resulted techniques in significantly lower production costs. Resources: New ways of doing things usually In another example, simulation results Magma Foundry Technologies pose potential risks and rewards. encouraged pump manufacturer Otto Inc., www.magmasoft.de Simulation lets engineers take more Junker in Germany to cast a steel pump 70

MACHINE Design.com

OCTOBER 6, 2011

Staple Set Brush by Sealeze

Gates are being optimized using casting process simulation to eliminate defect.

housing that had direct-pour top risers instead of the typical side risers. This lowered the amount of liquid metal needed by 81%, reduced molding time by 79%, and minimized the time needed to burn-off the risers by 87%. The company reduced its total production costs for the part by 12%. Additionally, a South American iron foundry increased the casting yield for a ductile-iron differential-case housing from 62 to 67% by using simulation to develop a nontraditional gating system. The design lowered the overall scrap rate from 17 to 7%, saved 700,000 kW-hr/yr to produce 24,000 parts and slashed total costs by $500,000.

Simulation boosts quality

Equipment manufacturer John Deere, Moline, Ill., cut the scrap rate of a gray-iron part from 10.3 to 1.4% and saved $66,936/yr by modifying the part and gating system. The company also boosted its casting yield from 58 to 64% for an additional savings of $66,600/yr. The foundry claimed that if it had used simulation at an earlier stage, it could have potentially saved $140,000 more in the first year of production and would have avoided casting design and pattern changes that cost $120,000.

• Conveyor and Material handling • Packaging Lines • Food Processing • Water and wastewater processing

Custom staple set brushes in a variety of sizes and configurations For more than 25 years, Sealeze has manufactured the widest variety of custom strip brush products. Now, we introduce custom staple set brushes in a variety of sizes and configurations designed to meet your application needs. Our experienced Sales Representatives, in-house engineering staff and design services are available to help you find the right brush solution for your application.

Heat-treatment times are reduced through the use of casting process simulation.

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RS# 149 OCTOBER 6, 2011

MACHINE Design.com

71

FE UPDATE

Castingprocess simulation covers the entire process.

In another case, mechanical-engineering company Heidelberger Druck AG in Germany relocated a mold gate based on simulation results and thereby significantly reduced the amount of repair welding it had to perform on a cover. Temperature losses in the original part had led to incomplete filling of a rib. Simulation let engineers see how material flow was affected by moving the gate to different locations.

Energy savings in heat treatment Many castings obtain their final mechanical properties after the casting process during heat treatment. The optimal layout and energy input during heat treatment strongly relates to when a necessary microstructure develops. Magmasoft lets users model the entire heat-treatment process and the resulting microstructures. The software also lets users simulate residual stresses. Designers previously added large safety margins to each heat-treatment step because the way heat-treatment furnaces transmit energy to parts was not well understood. Simulation does away with these safety margins. New models even let users predict the amount of local carbon saturation in cast iron and steel. Say the total austenitization time for a wind-energy part was 6 hr. Reducing this time by 1.5 hr saves 128 kW-hr/ metric ton of product without sacrificing final properties or microstructure. For 500 heat-treated parts, savings add up to 100,000 KW-hr/yr.

Aluminum molds

RS# 150

Energy savings in mass-produced castings that use metal molds rather than sand molds are comparatively high because metal molds can be used for more parts. The number of degrees of freedom in permanent molds is much lower than in sand casting, but it is still possible to cut costs using simulation. In one case, the original gating system for a motorcycle fork produced using the tilt-pour casting process

Castingprocess simulation is being used to optimize a high-pressure die-casting gating system.

resulted in several quality issues. Worse yet, casting yield was only 49%. Simulation helped engineers eliminate filling turbulence, and a hotspot and its related defect. They used smaller gates, which boosted the casting yield by 18.5%. In addition, the faster filling of thin walls shortened solidification time to cut cycle times by 10%.

Savings in high-pressure die casting In high-pressure die casting, 40 to 60% of process energy goes to melting metal. The remainder is used for the actual casting process. The energy input needed for melting depends on the amount of scrap (typically 5 to 7%), melting losses (2 to 5%), and casting yield, the ratio between casting weight and total pouring weight (30 to 70%). Raw metal is usually melted with natural gas, but the amount needed can vary by a factor of seven, depending on the equipment and environmental policies of different foundries. And the amount of electricity used can vary by a factor of two, for an average value of 5,603 kW-hr per metric ton of final castings. With these uncertainties, simulation can help designers better design and place gating systems, which can significantly reduce the amount of energy needed.

Optimizing gating systems and remelt Using a gearbox housing as an example, a research project evaluated the energy savings possible by switching from an oil-based die-cooling technique to a water-based technology without affecting casting quality. A comprehensive design of experiments study (DOE) was conducted using casting simulation to evaluate the effect of several process parameters and gating designs. The software compared all of the calculated trial runs and showed the best solutions. Here, simulation netted a 25% reduction in runner volume, which meant that 12% less material was needed per shot. The better design, in combination with the lower pouring weight, slashed cycle time by 8%. MD

RS# 151

SPOTLIGHT PLASTICS

& ELASTOMERS

PVC/TPU jacketing compounds The Apex P-55003 and P-55004 jacketing compounds for industrial data and control cables are based on blends of polyvinyl chloride (PVC) and thermoplastic polyurethane (TPU). Applications include use in factory-automation networks, industrial robots, and other plant systems requiring data or control cable. The compounds provide resistance to oil and chemicals, toughness at low temperatures, and oxygen indices comparable to those of standard PVC jacketing compounds. Teknor Apex Co., 505 Central Ave., Pawtucket, RI 02861, (800) 554-9892, www.teknorapex.com RS# 446

ation via e informWeb site at e r f t s e Requ der Service sc o u r Re a n.com/r w w w.m

achine

desig

Rigid and flexible vinyl products The Geon HC rigid and flexible vinyl products include nonphthalate formulations, including hemocompatible, nonphthalate materials for critical health-care applications that contact blood. The company’s line of certified USP Class VI products have been expanded to include materials that have passed the ISO 10993-5 standard for in vitro cytotoxicity for medical devices. The new Geon vinyl products for medical-device housings and enclosures meet requirements for flame and chemical resistance to hospital cleaners and disinfectants. PolyOne Corp., 3587 Walker Rd., Avon Lake, OH 44012, (866) 7659663, www.polyone.com RS# 447

High-temperaturegrade TPU The high-temperature-grade Elastollan 785 A 10 HPM polyester TPU withstands temperatures to 300°F (150°C) for up to 3,000 hr and required mandrel tests without showing cracks or deformations, stickiness, or excessive color change. It offers lower compression set, good wear and chemical resistance, high tear and tensile strength, and has a typical Shore A hardness of 85. Alliance Polymers & Services LLC, 30735 Cypress Rd., Suite 400, Romulus, MI 48174, (734) 710-6700, www.apstpe.com RS# 448 74

MACHINE Design.com

OCTOBER 6, 2011

versatility by design Bond Porous and Non-Porous Surfaces Adhesive/Sealant EP21 Epoxy System

ë Forgiving one to one mix ratio ë Outstanding physical strength properties ë Chemically resistant ë Superior durability

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0ERMANENT -AGNET "RAKE &ROM THE WORLDSLARGEST MANUFACTUREROFWORLD CLASS ELECTROMAGNETICCLUTCHES ANDBRAKES

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L (IGH TORQUE COMPACT  DESIGNLIGHTWEIGHT 6ISITOURWEBSITEAT HTTPOGURA CLUTCHCOM L :EROBACKLASH FORMOREINFORMATION L .ODRAGTORQUE ANDREQUESTA L #ONTROLLEDSTOP &2%%#$ 2/- L #ANOPERATEINHIGH CATALOG TEMPERATURES 2ANDOLPH2OADs3OMERSET .* 0HONE  s&AX   7EBSITEHTTPOGURA CLUTCHCOM %MAILINFO OGURA CLUTCHCOM RS# 153

SOLVE DIFFICULT SEALING PROBLEMS CUSTOM

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When inflated it expands to the striking surface creating a positive seal. When deflated it returns to its original configuration allowing free movement of one or both surfaces.

Fabric-reinforced for strength and structural integrity for optimum inflation/deflating operations, they are not subject to the compression set of ordinary seals. Strong, versatile and flexible, Seal Master seals have been solving troublesome problems for industry since 1974.

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RS# 155

© 2010 Seal Master Corporation

PRODUCTS

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Clutches The Model HC/CH clutch, designed for use in marine applications, features a patent-pending key seal that allows for the use of standard O-rings and makes installation in current

The Driving Force. Worldwide. configurations easier by using a double keyway and single drilled actuation hole. The key seal simplifies the sealing and minimizes damage to expensive seal arrangements. The clutches have forced oil-cooling provisions for highenergy engagements. Disc-Pac cores are designed using extra heavy plate thicknesses to maximize torque and heat capacity while minimizing spline wear to both the disc cores and hub. Hubs are manufactured from high-quality alloy steel and include induction-hardened teeth for maximum spline life. Two styles are available: EWA model for oil-immersed application and EDA units designed to run as dry friction clutches. Industrial Clutch, 1701-3 Pearl St., Waukesha, WI 53186, (262) 547-3357, RS# 465 www.indclutch.com

High-efficiency dc-dc converters The VYB Series of high-efficiency 4:1 input dc-dc converters provide output power ranging from 10 to 20 W. Packaged in a 2 × 1-in. footprint, the converters are suitable for batterydriven applications where charging and discharging conditions require an ultrawide input range. Available in 3.3, 5, 12, or 15-Vdc single output models and ±5, ±12, or ±15-Vdc dual out-

put models, the converters accept input voltages of 9 to 36 Vdc or 18 to 75 Vdc. Outputs are fully regulated to within ±0.5% over all line-input conditions and ±1.0% for all load conditions. Input to output isolation of 1,500 Vdc is provided across the range. Operating temperature range is –40 to 85°C. Single-output 15 and 20-W models offer an output trim that allows adjustment within ±10% of nominal output. Additional features include short-circuit, overcurrent, and overvoltage protection. CUI Inc., 20050 S.W. 112th Ave., Tualatin, OR 97062, (800) 275-4899, www. cui.com RS# 466

70-W brushless dc motor

www.imsgear.com 440 Viking Dr. (Suite 110) Virginia Beach, VA 23452

PH: (757) 227-5553 Fax: (757) 227-5543

A newly designed 70-W flat brushless dc motor delivers 130-nMn maximum continuous torque at 85% efficiency. The 45-mm-diameter motor is available with Hall sensors; comes in four windings — 24, 30, 36, and 48 V; and can be combined with more than 54 different planetary and spur gearheads. For motion control, a wide variety of servocontrollers and positioning controllers are available. maxon precision motors inc., 101 Waldron Rd., Fall River, MA 02720, (508) 677-0520, www.maxonmotorusa.com RS# 467

RS# 156 76

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OCTOBER 6, 2011

DYNAMIC SOLUTIONS CUSTOM ENGINEERED FOR YOUR APPLICATION A&A Manufacturing Company is your single-source provider of innovative protective cover products for: Ball screws Precision slides s Robots s Linear rails & motors s Machine ways s s

The widest variety of technologies and materials are used to protect in any environmental condition. A&A can design and deliver exactly what you need to keep your equipment in motion.

A Division of A&A Manufacturing www.Gortite.com Email: [email protected] Toll Free: 800-298-2066 Fax: 262-786-3280

RS# 157

RS# 159

RS# 158 RS# 160

PRODUCTS Hollow-shaft rotary encoder A new hollow-shaft version of the company’s MCD rotary encoder makes it easy to mount the device on shafts up to 20 mm in diameter. They have a permanently lubricated steel and brass gear set for trouble-free life. The encoders come with analog (voltage/current) or digital electrical interfaces. Measurement is based on a rotating magnet and a Hall-effect sensor. There is no contact between components and no loss of accuracy due to wear or surface contamination. A flexible range-setting feature lets the installer “teach” the device the limits of mechanical motion that will be experienced during operation. Once these limits have been defined — which can involve multiple rotations — the device will automatically self-calibrate so the full range of the electrical output will exactly match that of the mechanical movement. The encoders are suitable for applications requiring extended multiturn capabilities (up to 8,192 rev). A self-powered rotation-counter (based on Wiegand wire technology) records the number of rotations — even if these occur when there is no power supplied to the sensor. Fraba Inc., 1800 E. State St., Suite 148, Hamilton, NJ 08609, (609) 750-8705, www. fraba.com RS# 468

AC Motor Drives for OEM Applications *VU]L`VYZ7\TWZ7HJRHNPUN4HJOPULZ6]LUZ4P_LYZ )SV^LYZ-HUZ+VVY .H[L6WLULYZ;YLHKTPSSZ

Chassis/IP-20, Nema 1/IP-40 and Nema 4X/IP65 models

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KB Electronics, Inc.

 5> [O:[YLL[*VYHS:WYPUNZ-3  -H_! 6\[ZPKL-3 ^^^RILSLJ[YVUPJZJVTLTHPS!PUMV'RILSLJ[YVUPJZJVT

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$55! *

“A Complete Line of Motor Drives”

LED lighting for freezers, fridges Low-maintenance LF1E Lumifa LED light strips are for use in freezer or refrigerated display cases with temperatures as low as –40°C. They can also be used in testing chambers where temperatures are below freezing. The strips providing uniform lighting while producing low levels of heat, thereby saving energy. The lights operate on 24-Vdc voltage and retain 70% of their initial luminance at 40,000 hr. The Series is available in cool white (temperature: 5,000 K) or warm white (3,000 K), four lengths with a maximum length of 1,450 mm (4.75 ft), and three types: no lens, condensing lens, and dual lens. IDEC Corp., 1175 Elko Dr., Sunnyvale, CA 94089, (800) 262-4332, www.IDEC.com/usa/LUMIFA RS# 469

Micro diaphragm gassampling pump The NMS010 micro diaphragm gassampling pump transfers, evacuates, or compresses gases for portable monitors, medical, and other gas-sampling instruments applications. This pump measures 13.2 × 26 × 39 mm, weighs 20 gm, and can deliver flow rates up to 0.75 lpm, vacuum up to 12 in.-Hg, and pressure up to 7.5 psig.

The pump has a newly designed oval-shaped diaphragm that uses the space over the motor to increase the size of the pumping chamber, which leads to a higher flow rate. Oilless operation allows uncontaminated flow of the pumped medium and contributes to safe and virtually no-maintenance pump operation. A new valve system promotes low aerodynamic loss and the pump exhibits minimal noise over a long service life. KNF Neuberger Inc., 2 Black Forest Rd., Trenton, NJ 08691, (609) 890-8600, www.knfOEM.com RS# 470

RS# 163 OCTOBER 6, 2011

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PRODUCTS Stop-request pushbutton The Series 84 stop request pushbutton for public transportation meets the PRM TSI directive (Persons of Reduced Mobility Technical Specification for Interoperability). The pushbutton has raised symbols for passengers who are visually im-

paired, and an LED-illuminated halo that provides a visual indication for hard-of-hearing passengers. LEDs are available in red, orange, yellow, green, blue, or white. The device can be pole or panel mounted in a contoured housing.

Revolutionizing Encoder Technology

The tactile feedback of the shorttravel switching system operates at the slightest touch (typically six to 12 Newtons) and provides positive tactile feedback to passengers. Symbols are raised 1 mm from the aluminum lens surface and are greater than 18 mm wide. The shock, vibration, and climateresistant pushbutton is sealed to IP67. It uses a high-quality, normally open contact of gold-plated silver alloy rated 10 µA – 100 mA, 50 m Vac/Vdc – 42 Vac/Vdc. Under optimal operating conditions, it will last for at least 1 million activations. EAO Corp., 98 Washington St., Milford, CT 06460, (203) 877-4577, www. eao.com RS# 471

The Benefits of Capacitive Technology Flexible- interchangeable shaft adapters and programmable resolutions Rugged- resilient to dust & dirt, temperature & vibration Green- less than 10 mA current consumption Simple- quick & easy to assemble on a motor

24-Bit USB DAQ

AMT100 Incremental Encoder Series

AMT203 Absolute Encoder Series

AMT303 Commutation Encoder Series

www.amtencoder.com RS# 164 80

MACHINE Design.com

OCTOBER 6, 2011

The USB-2408 Series 24-bit multifunction USB DAQ measure temperature or voltage. The unit offers 16 voltage or eight thermocouple outputs, up to two analog outputs, eight digital I/O, and two counter inputs. The USB-2408 provides up to 1-kS/sec sampling, suitable for capturing low or medium-speed signals. The unit features a 24-bit ADC, which provides accuracy and noise performance. Measurement Computing Corp., 10 Commerce Way, Norton, MA 02766, (508) 946-5100, RS# 472 www.mccdaq.com

Tin-can-type linear actuator The PFL35T Linearstep Series tin-can-type linear actuator offers direct linear motion without the need of mechanical transformers. The actuator has a 35-mm OD and features neodymium magnets, which allow for a high driving force. The PFL35T comes in three leadscrew pitches (0.48, 0.96, and 1.2 mm), both bipolar and unipolar windings, a force rating up to 39.5 N (at 200 pps), rated voltages of 5 and 12V, and 48 steps/rev. Nippon Pulse America Inc., 4 Corporate Dr., Radford, VA 24141, (540) 633-1677, www.nipponpulse.com RS# 473

The easy-to-operate DOH-SD1 Series dissolved-oxygen meter has a realtime SD-card data logger. The meter features an LCD with green light backlighting, altitude and salt adjustments, RS-232/USB interface (with optional cable), and automatic temperature compensation. Omega Engineering Inc., One Omega Dr., Stamford, CT 06907, (203) 359-1660, www.omega. com RS# 474

Pumps and compressors The 660/668 and 2660/2668 Series of pumps and compressors are feature airflows to 5.25 cfm (149 lpm), pressures to 160 psi (11 bar), and maximum vacuum to 99% of local barometer (990 mbar). The pumps and compressors are constructed of die-cast aluminum parts. In addition to low vibration and reduced sound level, the devices’ oilless WOB-L technology extends operating life. Thomas Div., 1419 Illinois Ave., Sheboygan, WI 53081, (920) 457-4891, gd-thomas.com RS# 475

THE TOUGHEST REQUIREMENTS

OF TODAY’S BREAKTHROUGH APPLICATIONS TAKE THE FLEXIBILITY OF SAB SPECIALTY CABLES.

UV Resistant Marine & International Approvals Fuel & Oil Resistant

Shielded & Unshielded Chemical Resistant

Heat Resistant

For over 60 years, SAB has been the proven leader in the development and manufacturing of superior specialty flexible cables built for special needs and approvals for the most demanding applications. Available in various configurations and combinations for control, power, data and signal in shielded versions and abrasive resistant jackets turning cable customers into satisfied customers. SAB flexible specialty cables help you engineer solutions to the toughest problems and our twisted thinking has led to some of the greatest innovations in perfect flexible specialty cables setting new standards in the flexible cable market. Call your local representative today

U

Dissolved oxygen meter

S B North America

344 Kaplan Drive, Fairfield, New Jersey 07004 • Tel: 973.276.0500 • Fax: 973.276.1515 Toll free: 1-866-722-2974 • www.sabcable.com • [email protected] RS# 165 OCTOBER 6, 2011

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BUSINESS INDEX

3D-Coat . . . . . . . . . . . . . . . . . . . . . . . 56

Nuventix Inc. . . . . . . . . . . . . . . . . . . 32

AOS Thermal Compounds. . . . . . 32 AeroVironment . . . . . . . . . . . . . . . . 26 Alliance Polymers & Services LLC74 Altech. . . . . . . . . . . . . . . . . . . . . . . . . 88 Ansys . . . . . . . . . . . . . . . . . . . . . . . . . 27 Aon Corp. . . . . . . . . . . . . . . . . . . . . . . .8 Applied Engineering Inc.. . . . . . . 27 Association for Manufacturing Excellence, The . . . . . . . . . . . . . 40 AutomationDirect . . . . . . . . . . . . . . .6

Objet Inc.. . . . . . . . . . . . . . . . . . . . . . 87

Baldor/ABB, Baldor Electric Co. . 65 Cisco . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Comsol. . . . . . . . . . . . . . . . . . . . . . . . 34 DARPA . . . . . . . . . . . . . . . . . . . . . . . . 26 Delcam . . . . . . . . . . . . . . . . . . . . . . . 56 Delta Products Group. . . . . . . . . . 32 Deublin . . . . . . . . . . . . . . . . . . . . . . . 88 Digi-Key Corp. . . . . . . . . . . . . . . 32, 88 ElectroCraft . . . . . . . . . . . . . . . . . . . . .6 Fabrico. . . . . . . . . . . . . . . . . . . . . . . . 32 Garlock Sealing Technologies LLC. . . . . . . . . . . . . . . . . . . . . . . . . General Dynamics . . . . . . . . . . . . . General Mills Inc. . . . . . . . . . . . . . . Groschopp . . . . . . . . . . . . . . . . . . . .

32 27 30 30

Haydon Kerk Motion Solutions . 51 Helical Products . . . . . . . . . . . . . . . . .6 Henkel . . . . . . . . . . . . . . . . . . . . . . . . . .6

Pepperl+Fuchs . . . . . . . . . . . . . . . . Phoenix Contact. . . . . . . . . . . . . . . PolyOne Corp. . . . . . . . . . . . . . . . . . Pump Systems Inc.. . . . . . . . . . . . .

R+W America. . . . . . . . . . . . . . . . . . 88 RCA Electronics. . . . . . . . . . . . . . . . 30 Red Lion Controls. . . . . . . . . . . . . . 23 Rexnord Industries . . . . . . . . . . . . 18 Robinson Rubber Products. . . . . 32 Rockwell Automation. . . . . . . . 6, 32 Schmalz Inc. . . . . . . . . . . . . . . . . . . . 45 Seal Master. . . . . . . . . . . . . . . . . . . . 88 Sealcon LLC . . . . . . . . . . . . . . . . . . . 20 Sensable . . . . . . . . . . . . . . . . . . . . . . 56 Sigma Plastics Services. . . . . . . . . . .6 Simrit . . . . . . . . . . . . . . . . . . . . . . . . . 88 Smalley Steel Ring . . . . . . . . . . . . . 88 Society of Hispanic Professional Engineers, The . . . . . . . . . . . . . . 34 Solvay Specialty Polymers. . . . . . 74 Swissbit . . . . . . . . . . . . . . . . . . . . . . . 32 TÜV SÜD America. . . . . . . . . . . . . . . .6 Teknor Apex Co. . . . . . . . . . . . . . . . 74 University of Delaware, Dept. of History . . . . . . . . . . . . . . . . . . . . . . .8 W. L. Gore & Associates Inc.. . . . . 32 Yaskawa America Inc. . . . . . . . . . . 23

Intematix Corp. . . . . . . . . . . . . . . . . 32 Kirk-Rudy . . . . . . . . . . . . . . . . . . . . . 22 Lockheed Martin . . . . . . . . . . . . . . . .6 Los Alamos National Laboratory 24 Magma Foundry Technologies Inc.. . . . . . . . . . . . . . . . . . . . . . . . . 70 Magma Giessereitechnologie GmbH. . . . . . . . . . . . . . . . . . . . . . 70 maxon precision motors inc. . . . 88 National Nano Device Lab. . . . . . 28 National Science Foundation. . . . .8 New Way Air Bearings. . . . . . . . . . 32 Northwire . . . . . . . . . . . . . . . . . . . . . 88 RS# 166 84

MACHINE Design.com

OCTOBER 6, 2011

36 87 74 30

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.

ADVERTISER INDEX RS#. . . . COMPANY . . . . . . . . . . . . . .PAGE

130 . . . . .Pepperl+Fuchs . . . . . . . . . . . . . . . . . 36

111 . . . . .SolidWorks Corporation. . . . . . . . 11

112 . . . . .Aerotech Inc. . . . . . . . . . . . . . . . . . . . 12

131 . . . . .Pepperl+Fuchs . . . . . . . . . . . . . . . . . 37

107 . . . . .Spirol International Corporation .8

161 . . . . .All Motion, Inc. . . . . . . . . . . . . . . . . . 78

102 . . . . .Phillips Plastics Corporation. . . . . .1

159 . . . . .Stock Drive Products . . . . . . . . . . . 77

118 . . . . .Altech Corp . . . . . . . . . . . . . . . . . . . . 19

116 . . . . .Pyramid Inc. . . . . . . . . . . . . . . . . . . . . 16

168 . . . . .Techno Inc . . . . . . . . . . . . . . . . . . . . . 87

117 . . . . .Associated Spring/Raymond . . 17

154 . . . . .Quality Bearings & Components. . . . . . . . . . . . . . . . . 75

170 . . . . .Trim-Lok Company. . . . . . . . . . . . . 88

103 . . . . .Automationdirect.com . . . . . . . . . .3 105 . . . . .Automationdirect.com . . . . . . . . . .6 140 . . . . .Autonics USA Inc. . . . . . . . . . . . . . . 59 134 . . . . .Avago Technologies U.S. Inc . . . 41

160 . . . . .Quality Transmission Components. . . . . . . . . . . . . . . . . . . 77 133 . . . . .Reid Supply Company . . . . . . . . . 40

170 . . . . .Baldor Electric Co. . . . . . . . . . . . . . .IBC

. . . . . . . . . .Rino Mechanical Components Inc . . . . . . . . . . . . . . . 30

128 . . . . .Baumer Electric, Ltd.. . . . . . . . . . . . 34

126 . . . . .Rittal Corporation . . . . . . . . . . . . . . 31

167 . . . . .BEI Sensors . . . . . . . . . . . . . . . . . . . . . 85

123 . . . . .Rittal Corporation . . . . . . . . . . . 26-27

135 . . . . .Bison Gear & Engineering . . . . . . 43

165 . . . . .SAB North America. . . . . . . . . . . . . 81

171 . . . . .Clippard . . . . . . . . . . . . . . . . . . . . . . . . BC

124 . . . . .Schneider Electric . . . . . . . . . . . . . . 28

164 . . . . .Cui Inc . . . . . . . . . . . . . . . . . . . . . . . . . . 80

125 . . . . .Schneider Electric . . . . . . . . . . . . . . 29

145 . . . . .Donwell Co. . . . . . . . . . . . . . . . . . . . . 67

155 . . . . .Seal Master . . . . . . . . . . . . . . . . . . . . . 75

109 . . . . .Dorner Mfg Corp. . . . . . . . . . . . . . . 10

149 . . . . .Sealeze Corp . . . . . . . . . . . . . . . . . . . 71

108 . . . . .EBM-Papst. . . . . . . . . . . . . . . . . . . . . . . .9

147 . . . . .Setco USA . . . . . . . . . . . . . . . . . . . . . . 68

148 . . . . .Electro Sensors . . . . . . . . . . . . . . . . . 69

113 . . . . .Sew Eurodrive. . . . . . . . . . . . . . . . . . 13

122 . . . . .Element 14 . . . . . . . . . . . . . . . . . . . . . 25

127 . . . . .Smalley Steel Ring Company . . 32

142 . . . . .ThomasNet. . . . . . . . . . . . . . . . . . . . . 63 132 . . . . .Turck Incorporated. . . . . . . . . . . . . 39 144 . . . . .Vecoplan, LLC . . . . . . . . . . . . . . . . . . 67 141 . . . . .Wittenstein. . . . . . . . . . . . . . . . . . . . . 61 115 . . . . .ZERO-MAX . . . . . . . . . . . . . . . . . . . . . 15 ader Service Access our Re kly find and ic qu Website to ion on the at request inform ices found serv products and ACHINE DESIGN. M in the pages of c design.com/rs w w w.machine

While every effort has been made to ensure the accuracy of this index, the publisher cannot be held responsible for any errors or omissions.

104 . . . . .Exair Corporation. . . . . . . . . . . . . . . . .5 114 . . . . .Exlar Corporation. . . . . . . . . . . . . . . 14 150 . . . . .Galil Motion Control Inc. . . . . . . . 72 151 . . . . .Galil Motion Control Inc. . . . . . . . 73 157 . . . . .Gortite, Division of A&A Mfg Co., Inc. . . . . . . . . . . . . . . . 67 143 . . . . .Gortrac, Division of A&A Mfg. Co., Inc.. . . . . . . . . . . . . . . 63 120 . . . . .Groschopp . . . . . . . . . . . . . . . . . . . . . 21 163 . . . . .H.A. Guden Company. . . . . . . . . . 79 138 . . . . .Helical Products Company, Inc. 53 121 . . . . .IAI America Inc . . . . . . . . . . . . . . . . . 24 158 . . . . .Igarashi Motor Sales. . . . . . . . . . . . 77 156 . . . . .IMS Gear. . . . . . . . . . . . . . . . . . . . . . . . 76 167 . . . . .Intech Corporation. . . . . . . . . . . . . 84 136 . . . . .Intelligent Motion Systems, Inc. 46 137 . . . . .Intelligent Motion Systems, Inc. 47 162 . . . . .KB Electronics Inc. . . . . . . . . . . . . . . 78 129 . . . . .Leeson Electric Corp . . . . . . . . . . . 35 152 . . . . .Master Bond, Inc. . . . . . . . . . . . . . . . 75 119 . . . . .Nason Co. . . . . . . . . . . . . . . . . . . . . . . 20 106 . . . . .National Instruments Corp. . . . . . .7 110 . . . . .Nexen Group Inc . . . . . . . . . . . . . . . 10 139 . . . . .Nord Gear Corp . . . . . . . . . . . . . 54-55 146 . . . . .Ogura Industrial Corp.. . . . . . . . . . 67 153 . . . . .Ogura Industrial Corp.. . . . . . . . . . 75 101 . . . . .Omega Engineering Inc . . . . . . .IFC

RS# 167 OCTOBER 6, 2011

MACHINE Design.com

85

CLASSIFIEDS

BUSINESS STAFF

PRODUCTS/SERVICES THE ORIGINAL

INSTANT

THUMBSCREW

Dennis Jensen, Associate Publisher Larry Berardinis, Business Development Director Virginia Goulding, Online Sales & Marketing Manager Julie Ritchie, Research Manager Jane Maloney Cooper, Marketing Manager Debbie Brady, Audience Development Manager

Michelle Modtland, Production Manager, 913-967-7292 Courtney Denison, Production Coordinator, 913-967-1738 Denise Donaldson, Administrative Manager

Advertising Sales

Mike Hancock International Sales Director, [email protected] Ph: 011-44-1372-824284, Fax: 011-44-1372-824322

Inside Sales: Mary J. Brown, [email protected] Phone: 866-821-0318, ext. 60945 Fax: 800-440-1760 Inside Sales: Leslie Travis , [email protected] Phone: 866-821-0318, ext. 60938 Fax: 800-440-1760 In most cases, advertisements contained in MACHINE DESIGN employment section indicate that the companies are equal opportunity employers. The Federal Civil Rights Act of 1964, and other laws, prohibit discrimination in employment based on race, color, religion, national origin, sex, or for any reason other than lack of professional qualification for the position being offered. It should be noted that employment advertisements in MACHINE DESIGN are published for the readers convenience and, in no way, to the best of our knowledge, promote unlawful discrimination.

To Advertise in MACHINE DESIGN’S Classifieds Section,

[email protected], Ph: 847-784-9825, Fax: 847-784-9826 N. IN, N. OH, MI, NY, PA, Ontario: Bill Rodman, [email protected], Ph: 216-931-9636, Fax: 216-621-8469

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[email protected]

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AZ, CA, ID, OR, NV, UT, WA, British Columbia: Belgium, Netherlands, Luxemburg: Jim Theriault, Rodric Leerling, rodric.leerling@ [email protected], husonmedia.com, Ph:011-31-229-841882 , Ph: 408-857-0322, Fax: 925-736-8705 Mobile 31-683-232625, AL, AR, GA, KS, LA, NM, MS, MO, OK, TX: Germany, Austria, and Switzerland: Franny Singleton, Christian Hoelscher, [email protected], [email protected] Ph: 678-947-8563, Fax: 913-514-6884 Ph: 011-49-89-95002778, CO, IA, S. IN, KY, MN, MT, NE, ND, Fax: 011-49-89-95002779 S. OH, SD, TN, WI, WV, WY: Dennis Jensen, Italy: Cesare Casiraghi, [email protected], Casiraghi Pubblicitá Estera, Ph: 952-368-0018, Fax: 913-514-6627 Ph: 011-390-31-261407, Fax: 011-390-31-261380 IL: Melinda Hurley,

DE, DC, MD, NJ, NC, SC, VA: Brandy Bissell, [email protected], Ph: 919-773-1875, Fax: 913-514-6357

contact Larry Berardinis at (216) 931-9393,

Corporate Officers Bob MacArthur, Senior Vice President Nicola Allais MacArthur, CFO Sharon Rowlands, CEO

India, New Delhi: Shivaji Bhattacharjee, Information & Education, Ph: 011-91-11-6867005, Telex: 953-31-72278, Fax: 011-91-11-6526055 Korea: Young Sang Jo, Business Com., Inc., Ph: 011-82-2-739-7840, Fax: 011-82-2-732-3662 Tokyo, Japan: Yoshinori Ikeda, Pacific Business, Inc., Ph: 011-81-03-3661-6138, Fax: 011-81-03-3661-6139 1300 E. 9th St. Cleveland, OH 44114-1503, Ph: 216-696-7000 — Fax: 216-696-0177

OCTOBER 6, 2011

BACKTALK If you’ve got game, bring it on The fourth annual Nanoline Contest, sponsored by Phoenix Contact, Middletown, Pa., is underway. The contest challenges middle-school, high-school, and technicalschool students to design an original control system using the company’s Nanoline controller. The winning team receives an all-expenses-paid trip to the Hannover Fair

“Modular” 3D printed shoes Imagine designing a shoe and having it ready to wear in less than 24 hr. Thanks to the Objet Inc., Billerica, Mass., it is a reality. The “Rapidprototypedshoe” from avant-garde shoe designer Marloes ten Bhömer will be part of an exhibition entitled Power of Making at the Victoria and Albert Museum in London. The shoe is modularly designed and manufactured so it can be dismantled and reassembled to replace parts. The shoes were created using Objet’s Connex 3D Printer – a multimaterial 3D printing

in Germany next spring. An intelligent and compact controller that automates basic tasks, Nanoline is programmed with the intuitive nanoNavigator software. Phoenix Contact supplies participating teams with the Nanoline controller, nanoNavigator software, and technical support. “In previous years, the project had to fit into one of several specific categories.But this year, we’ve eliminated the categories. There are no limits, so be creative and have fun,” said Jack Nehlig, president of Phoenix Contact USA. “We designed this contest to promote math and science education, but the participants get much more out of it. It teaches teamwork, presentation skills, creative problem-solving and much more. And the winning team gets a bonus lesson in European culture as well.” For more details or to register, contact Patty Marrero at (717) 944-1300, ext. 3022; e-mail pmarrero@ phoenixcon.com, or visit www.phoenixcontact.com/ nanoline2012. MD

technology that combines rubberlike and rigid materials. “My work is very much about liberating design — I use new materials and methods because this helps to break away from conventional approaches,” Marloes ten Bhömer explains. “The rapid-prototyping process stimulated the idea for this shoe, as the name suggests. I explored the technology and saw that rapid prototyping — adding material in layers rather than traditional shoe-manufacturing methods — could help me create something entirely new within just a few hours. “The shoe is printed as a single entity so the parts come off the printer already assembled, and you can still take the shoe apart later on. It is inspiring and opens up the possibility of interchangeable heels and creating customized designs. Also, the possibility of repairs allows for a more-realistic product and changes the idea of rapid prototyping into rapid manufacturing.” MD RS# 168 OCTOBER 6, 2011

MACHINE Design.com

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BACKTALK

THANKS TO THE FOLLOWING GAME SPONSORS:

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. Mail: Letters, MACHINE DESIGN, 1300 E. 9th St., Cleveland, OH 44114-1503, Fax: 216-621-8469 E-mail, Editorial: [email protected] Online forums: To comment on articles, editorials, and other engineering topics, go to http:// community.machinedesign.com/ forums/157/ShowForum.aspx and log in. Questions about articles: Denise Greco, 216-931-9402, [email protected], Fax questions about releases & literature to 913-514-6694 Subscriptions: For a subscription qualification form, see our Web page at submag.com/sub/mn. Subscription problems or questions: Contact a customer service representative at 866-505-7173 or e-mail: [email protected]. Order a paid subscription: 847-763-9670 Circulation: [email protected]. Editorial reprints: Contact Joel Kirk, 216-931-9324, [email protected] or visit pentonreprints.com List rentals: Marie Briganti, 877-796-6947, [email protected]

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RS# 169 OCTOBER 6, 2011

The Industrial Choice

When it comes to industrial electric motors, power transmission products and drives, no other manufacturer offers more than Baldor...that is why Baldor is The Industrial Choice! Whether your application requires a fractional or 15,000 Hp motor, a variable frequency drive, mounted bearings or gearing, a pulley or sheave or even a standby generator, Baldor is the choice most preferred by industry. When your next project demands the most reliable and energy efficient products available, look to Baldor as your one source for more industrial solutions. baldor.com

• Superior Reliability • Unmatched Quality • Local Sales and Support • Quickest Delivery Available

479-646-4711

©2011 Baldor Electric Company

RS# 170

Providing custom products and value-added assemblies based on the most successful miniature pneumatic line in the world!

Wire leads to be 7” + 1/8” with crimped terminal 10258333-2

“Cleaned for Oxygen Service” internal components

Stainless Steel coil housing 5-volt coil less than 0.5 watt

Brass base (no plating needed)

FKM seals

Mounting holes

1/2” max

Toggle-operated manual by-pass valve in base

Integrated needle valve for precise flow control

CUSTOM er

s n o i t u l o s RS# 171

Clippard Instrument Laboratory, Inc. Cincinnati, OH

1-877-245-6247 www.clippard.com/customsolutions