Machine Design Magazine

November 22, 2012
A Penton Media Publication

Tune in to EngineeringTV.com
Reengineering
the
SNOWMOBILE
page 34
HANDLING EMI
WITH INDUSTRIAL
FIBER OPTICS,
page 38
ENERGY-EFFICIENT
CASTINGS,
page 42
BETTER HEAT
SINKS WITH
MULTIPHYSICS,
page 45
APPLIANCE WIRE
GETS A ROLE
IN MACHINE
BUILDING,
page 48
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RS# 101
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RS# 102
FEATURES
CAD/CAM/CAE/FEA
Its no secret that
carmakers are under
a lot of pressure to reduce
the number, size, and weight of
engine components for better fuel
economy. In one case, we were tasked with
designing a smaller and more-efficient heat
sink to thermally regulate the electronic
components in Toyota hybrid vehicles.
Instead of using typical analytical design
methods and trial-and-error physical prototyping, we first used mul-
tiphysics software to design and test possible prototypes.
Hot under the hood
Toyota hybrid vehicles have sophisticated electrical systems in
which many power diodes and power semiconductors such as in-
sulated-gate bipolar transistors handle power conversion and other
applications. These components are standard planar silicon devices
measuring a few centimeters on each side. The devices mount on alu-
minumheat sinks, or cold plates, with channels in which a water-and-
HowToyota designed
a small, efficient heat
sink to cool electronic
components in its
future hybrid vehicles
Authored by:
Ercan (Eric) Dede
Principal Scientist
Toyota Research Institute of North America
Ann Arbor, Mich.
Edited by Leslie Gordon
leslie.gordon@penton.com, Twitter @
LeslieGordon
Key Points:
Engineers designed a smaller and more-
efficient heat sink to thermally regulate the
electronic components in futureToyota hybrid
vehicles.
Numeric simulations generated an optimal
cooling channel topology with fluid streamlines
in branching channels.
The dual configuration prototype provided
higher-performance cooling in an ultracompact
package.
Resources:
Toyota Research Institute of North America,
http://tinyurl.com/8kdkq3r
MULTIPHYSICS SOFTWARE
builds a
better heat sink
These
isometric
views showthe
derivedhierarchical
microchannel coldplate
without a jet plate (top)
andwitha jet plate
showntransparent for
clarity (bottom).
NOVEMBER 22, 2012 MACHINE DESIGN.com 45
ELECTRICAL/ELECTRONIC TECHNOLOGY GUIDE
High-endAWM-style cables are
makinga comeback inmachine
wiringprovidingover 20 years
of reliable performance.
AWMandNFPAcompliance
One company successfully navigating the shoals of the recent
NFPA-79 revisions is Krones Inc., Franklin, Wis., a manufacturer
and integrator of packaging lines for food and beverage compa-
nies. The companys engineering team recently found that com-
pliant AWM usage does require a bit of extra eort compared to
the automatic compliance found with UL-listed MTW.
Whenever you must implement changes because of an elec-
trical-code change, theres denitely an engineering-labor factor,
says Mike Nelson, the Krones engineer charged with NFPA-79
compliance.
Some of that engineering labor went into researching spe-
cic AWM products to see whether they meet the compliance
restrictions. Even proper jacket labeling doesnt answer every
compliance question regarding AWM. You cant tell whether a
product complies just by looking at the cable, says Nelson. And
even more engineering labor went to NFPA-79s documentation
requirements.
In all, Nelson estimates that Krones has spent more than 150
engineering man-hours complying with the requirements relat-
ed to AWMuse. And that gure represents just the work done to
formulate a compliance strategy. It does not include the technical
documentation and drawing changes needed to incorporate the
wire into each and every machine.
If you find electrical safety standards confusing, youre not alone. Many
machine builders recently grappled with an ambiguous round of changes to
NFPA-79. This is the National Fire Protection Association code that outlines
electrical standards for industrial machinery that protects operators, equip-
ment, and facilities from fire and electrical hazards. NFPA-79 is cited exten-
sively in the National Electrical Code (NEC) that governs the electrical wiring
of industrial machines.
The standard cuts a broad swath across the industrial machinery landscape.
It applies to a comprehensive range of machines everything frommachine
tools and injection-molding presses to testing machines and packaging lines. It
encompasses all of a machines electrical and electronic elements operating at
600 V or less. This means that a vast majority of machine power, control, and
lighting circuits fall under the scope of NFPA-79.
Machine builders complied with the dictates of NFPA-79 for years. But ear-
lier this year the standard underwent revisions that make it more difficult to
specify compliant electrical cabling.
Appliance wire OKd
The key change to NFPA-79 for 2012 involves the ability to use appliance
wiring material (AWM), which had been banned since 2007. AWMcan be an
economical wiring choice compared to higher-performing UL-listed machine-
tool wire (MTW). But there were several sound reasons behind the AWMban.
For one, some contractors were using AWMincorrectly as part of the build-
ing infrastructure. The NECdoes not recognize AWMfor this type of use.
Also, not all AWMproducts are created equal when it comes to the quality
of their insulation layer. The insulation thickness of low-quality commodity
cabling varied such that the wire, while meeting its electrical insulation require-
ments, was not sufficiently flame resistant for use in industrial machines.
Its important to stress that not all AWM suffers from these quality issues.
Lapp and other reputable cable manufacturers can and do produce AWMprod-
ucts whose insulation wall thickness is both consistent and adequate for the
voltage rating of the cable. High-quality AWM can pass the specified vertical
flame tests (FT 1) and can safely be used in industrial machines. Keep in mind,
however, that AWM lacks the extra layers of PVC-nylon insulation found in
Appliance wire
is back, but
regulations may
limit its use.
Authored by:
Rick Orsini
Senior product manager
Lapp USA
Florham Park, N. J.
Edited by Robert Repas
robert.repas@penton.com
Key points:
NFPA-79 outlines electrical standards for
industrial machinery to protect operators,
equipment, and facilities from fire and
electrical hazards.
Banned in 2007, AWMmay now be used in
machine wiring, restrictions permitting.
New permissions may let MTW products that
carry a UL TC-ER listing slash installation costs,
even over AWM.
Resources:
Lapp USA, www.lappusa.com
NFPA79 Standard, bit.ly/Rbblbv
ULWire and cable flammability testing, bit.
ly/TxHTv2
For a white paper on the NFPA 79 electrical
code, scan this code or go
to: http://machinedesign.
com/whitepaper/
understanding-the-
electrical-code-to-be-
compliant-0501
NFPArestrictions. In the case of extremely large machines
such as bottling lines, machine builders and installation
contractors can spend dozens of engineering hours and
thousands of dollars complying with the documentation
requirements.
These documentation needs, while not insurmount-
able, must be factored into the cost of wiring the machine.
In some cases, the added documentation costs can erode
the minor price advantages of some AWMcables.
One way around the concern of documentation is to
favor listed MTW. Because it inherently complies with
NFPA-79, MTW cabling alleviates the documentation
requirement and eliminates any residual confusion over
whether a given AWMproduct is approved and properly
labeled. MTWalso has a host of technical advantages that
derive fromits superior flexibility and resistance to flame,
MTW. This extra insulation allows some types of MTWto
pass flame tests (FT 4) more rigorous than those for even
the best AWM.
Reversing the AWM ban reflected the realities of the
global machinery marketplace in which AWMremains a
widely used cabling choice. The restrictions imposed by
the new NFPA standard attempts to negate the potential
drawbacks of AWM.
The first restriction states that the AWMmust be iden-
tified as suitable for the application at hand and must be
used in accordance with the machine-manufacturers in-
structions. Other restrictions detail cable construction in-
cluding minimumconductor count, flame resistance, and
wall thickness. Compliant AWMcable must carry a jacket
print legend that spells out the AWMstyle number, volt-
age, temperature rating, and flame rating.
The reversal on AWM
usage also requires more
documentation. For ex-
ampl e, manuf act urers
must provide field-instal-
lation information related
to the AWM wi re with
each machines technical
documentation.
Easy compliance
Given all the cable runs
on and around todays com-
plex industrial machines,
t he need to document
AWM usage for each and
every machine represents
the most onerous of all the
Exposedcable runs for fast installation
Another change in the 2012 NFPA-
79 standard allows exposed cable runs
along the structure of the equipment or
in the machine chassis. As long as the ex-
posed cables closely follow the surface
and structural members of the machine,
the installation does not require conduit,
raceways, or any special hardware. Thanks
to reductions in installation time and la-
bor, exposed cable runs can reduce costs
dramatically compared to traditional in-
stallation methods that need conduit or
special mounting hardware.
Certain UL-listed cables meet exposed
run (-ER) specications, which provide an
additional level of protection for these
types of applications. Cables meeting -ER
requirements are subjected to the same
crush and impact tests as armored-type
or metal-clad (MC) cables, that lets cables
leave the machine area and enter a cable
tray without conduit.
Keep in mind, though, that not all UL-
listed cables meet NFPA requirements,
especially lower-priced commodity and
rigid products.
Safety standard
gives
APPLIANCE WIRE
a new lease on life
AKrones techniciandocuments the use of AWMin
compliance withNFPA-79.
NOVEMBER 22, 2012 MACHINE DESIGN.com 48 NOVEMBER 22, 2012 MACHINE DESIGN.com 49
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VOLUME 84
ISSUE 18
NOVEMBER 22, 2012
45
Multiphysics
software builds a
better heat sink
Toyota used multiphysics
software to build a better
heat sink for its future
hybrid vehicles.
Safety standard gives
appliance wire a new lease
on life
Appliance wiring material, banned
in 2007, is now back in service owing
to the realities of todays global
machine marketplace. But, its use
comes with restrictions.
48
Rethinking the
snowmobile
Technology borrowed from
motorcycles, snowmobiles,
mountainbikes, and snowboards
leads to a lighter, more-nimble
Personal Snow Vehicle.
Better economics for
industrial fiber optics
Plastic optic fiber is a better option
than copper wiring for applications
plagued by electrical noise.
Casting with quartz
The casting of synthetic-quartz-
composite mixtures to tolerance uses
lessenergythan casting iron.
34
42
38
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Visit www.automationdirect.com/stepper-systems for specications and prices.
Step Motor
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RS# 103
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ON THE COVER
An SR-85 Snow Runner
from Sierra Snow
EDITORIAL
Silliness at 40 below
EDITORIAL STAFF
LETTERS
SCANNING FOR IDEAS
Spindle drive moves with accuracy
Filter vent equalizes pressure inside and out
REPORTERS NOTEBOOK
LOOKING BACK
COMMENTARY
Whats up with model-based engineering?
ORR ON ENGINEERING
The death of e-mail?
SOFTWARE REVIEW
SolidWorks 2013 makes 3D modeling easier
PRODUCT SPOTLIGHT
Adhesives & fasteners
PRODUCTS
DATA FILES
BUSINESS INDEX
AD INDEX
BUSINESS STAFF
BACKTALK
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1.800.433.5700
Allied Electronics, Inc 2012. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.
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RS# 104
E
D
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R
S

W
E
B

P
I
C
K
S
Whats new online machinedesign.com
NEW EBOOKS
Smart machines: Delivering intelligent maintenance capabilities
Rapid technological innovation, demand for customized products, and requirements for more reliably maintained systems
are spurring the rise of smart machines. This eBook from National Instruments discusses the different approaches used to
track and maintain machine health.
New technology for control-panel design
This eBook from Eaton offers insights on how to simplify control panel wiring and design. Topics include an overview of
traditional panel design; key industry standards; protocols used in industrial networks; and how the SmartWire-DT system
speeds commissioning of next-generation machines and control panels.
Download these eBooks at http://machinedesign.com/ebook.
Simple, low-cost robot
The CEO of Rethink Robotics gives an overview of the Baxter robotic platform. The
inexpensive, easy-to-use robot is designed for small manufacturers who do short production
runs of many different parts. It can be programmed
by shop-floor workers and offers humanlike speed,
precision, and strength. Learn more at www.
engineeringtv.com/video/The-Baxter-Robotic-
Platform-for;Only-Engineering-TV-Videos.
Selecting potting compounds
Electronic and electrical equipment needs potting
compound to secure, protect, and insulate components.
A Fabrico site, www.fabrico.com/markets-electrical-
equipment.htm, looks at considerations for evaluating
potting materials, including device characteristics,
environment, adhesive cure time and expansion rates,
and overall costs. It also discusses benefits of materials
such as epoxy, polyester, urethane, and silicone.
Actuator-sizing software
A new online sizing program from Tolomatic helps
engineers design and specify electric actuators based
on motion requirements like length, velocity, and
acceleration, as well as orientation, loads, and applied
forces. It also lets users select a motor based on
parameters such as continuous/peak torque and speed,
and add features to the actuator like mounts and switches.
Its compatible with PCs, tablets, and smartphones. Learn
more at http://sizeit.tolomatic.com.
Oil-cleanliness booklet
More than 75% of all hydraulics problems can be linked to
dirty oil. Bosch Rexroth has published a 44-page booklet,
on oil-resistant paper, that outlines common contaminant
sources, the basics of contamination control, key filter
properties, tolerances of hydraulic components, and
recommended oil-cleanliness levels according to ISO 4406.
It also covers monitoring and maintenance strategies to
proactively diagnose problems before a failure. Order a
free copy at www.boschrexroth-us.com/filter.
Enclosure selector
Rittals Web site (www.rittal-corp.com) helps engineers
quickly design, size, and quote enclosures and climate-
control products. The SmartSelect tool lets users select
the type of product and then specify dimensions, ratings,
materials, and other parameters. Results include exact
matches and close alternatives, along with product
details, drawings, installation videos, and related info.
The companys QuickQuote application creates a bill of
material and price estimate. Users can also access the
tools on most smartphones and mobile devices.
Controls catalog
OTTO has published an interactive, 226-page magazine-
style PDF catalog on its switches, grips, joysticks, and
control panels. Content includes product data, technical
specs, drawings and photos, and a comprehensive
military cross-reference. Download a copy, or request a
print version, at www.ottoexcellence.com.
Structural simulation
Ansys will host a free, 1-hr Webinar on November 29 on
how to improve simulation processes. The discussion
covers large and complex model performance, modeling
3D-composite shapes, customizing processes for
structural mechanics, crack modeling, mapping of
external data, and contact modeling, as well as better
ways to handle finite-element models. Learn more at
http://tinyurl.com/cknkp9x.
Fastener app
PennEngineering has launched the PEMspec app for
iPhones and iPads. It lets users access critical installation
dimensions for self-clinching, flaring, broaching, surface
mount, and weld fasteners. Data includes mounting-hole
size, minimum sheet thickness, and installed height above
sheet, among other criteria. Users can search by fastener
parameters or part number, and the app also contains
pertinent links and contact information. Learn more at
www.pemnet.com.
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RS# 105
EDITORIAL
Silliness at 40 below
Many years ago a college classmate of mine told a funny story
about his summer job testing communications gear for a defense
contractor. He spent his time alternately freezing the radios to
40C and heating them to 85C, while operating them to make
sure theyd work at these extreme temperatures.
Trouble was, most of the radios wouldnt pass this test. To fix
the problem, the contractor had to go through a redesign, which
took more than a month, putting the project behind schedule.
Once the electronics had been fixed, my buddy drew a lot of over-
time running radios in temperature chambers, trying to catch up.
In fact, the pace was so hectic that nobody bothered to check the
radios at room temperature.
You may be able to guess what happened. It was only as things
slowed down that QA discovered the revamped radios often sput-
tered out when operating in ambient temperatures.
With that situation in mind, I was amused at a tale told in the
memoirs of former General Motors Corp. Vice Chairman Bob
Lutz to illustrate some of the whacky design practices he encoun-
tered when he joined GM in 2001. He discovered the ashtray of a
new Cadillac STS had a lot of spring pressure. When opened, it
shot out as though launched from a cannon, and once deployed,
was tough to push in with just one finger. This was in contrast to
the ashtray on an Acura, which glided open and took a single ef-
fortless push to close.
Lutz figured the ashtray design in the Cadillac had to be a mis-
take, so he was flabbergasted when a senior interior-trim engineer
said it operated that way on purpose. The reason: So it could meet
an internal GM standard that dictated ashtrays had to function
after a night spent at 40F.
Lutz says loopy situations like the Cadillac ashtray were not at
all uncommon in those days. They arose because GM had a habit
of engineering its vehicles for extreme situations. That was a noble
idea, but it came at the expense of alienating thousands of GM
owners on a daily basis.
You might wonder what happened to the 40F ashtray spec.
Lutz says his team eventually eliminated it and 90% of the other
sacred but silly engineering dos and donts that had somehow be-
come embedded in GM culture. He also opined that the existence
of these disconnected-from-the-real-world practices was a testi-
mony to a culture that was inwardly focused in pursuit of its own
goals, with the customer left out of the equation.
I would put it a little differently than Lutz did. Both in the case
of the bad radios and with the ashtrays that operated superbly
only at 40C, the designers had lost sight of the trade-offs they
were making. There is a lesson here for any engineer whod like
to avoid having something they designed be the butt of jokes, or
who doesnt want their work to wind up as a humorous incident in
someone elses memoir.
Leland Teschler, Editor
RS# 106
NOVEMBER 22, 2012
Actuatorline has all the precision you need and wont keep you waiting
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RS# 107
MITRPAK
Power Transmission Products
38 River Road, Uxbridge, MA 01569
Tel: 508-278-2422 Fax: 800-346-0018 800-648-7725
www.mitrpak.com
Does your gear drive mesh properly? Not all do.
MITRPAK drives are precision made. You can feel the difference.
MITRPAK features include:
Stainless steel shafts Double-shielded ball bearings Factory optimized gear mesh
Hardened spiral Adjustable locknuts in place of Completely sealed
bevel gears spacers and retaining rings Lubricated for life
U.S. and metric right angle, three-way, and counter-rotating gear drives in stock and
guaranteed to ship in 24 hours.
For complete specifications and CAD files, log onto www.mitrpak.com, or call
toll free, 800-648-7725.
EDITORIAL STAFF
1300 E. 9th St. Cleveland, OH 44114-1503
EDITOR
Leland E. Teschler
leland.teschler@penton.com
MANAGING EDITOR
Kenneth J. Korane
ken.korane@penton.com
SENIOR EDITORS
Leslie Gordon
leslie.gordon@penton.com
Stephen J. Mraz
stephen.mraz@penton.com
ASSOCIATE EDITORS
Lindsey Frick
lindsey.frick@penton.com
Robert J. Repas, Jr.
INDUSTRY COVERAGE:
AUTOMOTIVE, PACKAGING,
MEDICAL
Stephen J. Mraz
CAD/CAM, MANUFACTURING
Leslie Gordon
ELECTRICAL, ELECTRONICS
Robert J. Repas, Jr.
FASTENING & JOINING,
MATERIALS
Lindsey Frick
FLUID POWER
Kenneth J. Korane
MECHANICAL
Lindsey Frick
Kenneth J. Korane
EDITORIAL PRODUCTION
Denise Greco
Editorial Production Manager
Randall L. Rubenking
Art Director
RS# 108
RS# 109
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RS# 110
LETTERS
ized tests without the enormous
budgets of public schools and in
spite of (or perhaps because of )
most parents lacking education
degrees.
Not all home-schooling parents
are in it just to get their children a
good education. Some parents are
more interested in religious indoc-
trination and some appear to be
ducking the responsibility of get-
ting their kids to school every day.
I became a home-schooling parent
when I saw that children in many
overseas schools, especially in Asia,
were about two years ahead of
American kids in math by 4th grade.
I figured that my children were go-
ing to have to compete with those
kids when they grew up, so I took
on the rather large responsibility of
teaching them at home. I remember
asking a public-school teacher why
they didnt assign more homework.
The response was that the parents
would complain.
Funding ever more assistants
and fewer students per school is
not going to fix the problems of
public education. Plus, it ignores
two extremely serious problems:
The lack of parental involvement,
which would change if all parents
paid part of the cost out of pocket;
and the cultural sense of entitle-
ment that everyone deserves an
easy, effortless life courtesy of the
government.
When the government subsi-
dizes something we get more of
it. Subsidizing idleness, teenage
motherhood, and recreational de-
grees that dont lead to produc-
Anyone for ethics?
Unfortunately, ethics went out the
window in the U.S. many years ago
with the advent of our instant so-
ciety (Where Did Ethics Go? Sept.
6). Everyone wants everything they
can possibly need and dream of
without waiting or working for it,
all at the expense of others.
This problem is more prevalent
here in the U.S. than in Europe,
Asia, or the Caribbean countries.
It is most likely the fault of parents
who let others raise their kids and
advertising wonks.
And it doesnt matter what the
profession is, it is all about greed.
Randy Scott
I have worked in the engineering
field for more than 40 years. I am
now in business for myself as a
forensic mechanical engineer do-
ing accident reconstruction for at-
torneys and insurance companies.
Part of my job involves testifying
in court on civil and criminal cases
where I have been amazed at what
some engineers will say under oath
to prove a case for their clients.
Sometimes they testify to accident
scenarios that violate the laws of
physics. Some engineers testifying
are registered professional engi-
neers and are theoretically bound
to follow the Engineers Code of
Ethics. But they dont. How can
they look in the mirror and not
cringe at what they see?
Why do people try to beat the
system? Do they really think the
easy way is the best way? Its pretty
simple, and somewhat trite, but
honesty is always the best policy.
Harold A. Schwartz
Smaller can be better
Yes, small sample sizes have more
outliers, but there is more to the
story (Bad Math for Fixing Bad
Math Scores, Aug. 23).
Home schooling represents the
smallest of schools, and home-
schooled kids have average scores
in the 88th percentile on standard-
tive jobs erases the work ethic that
made this country great.
Karl Oberstramm
Get off of my cloud
Im concerned over privacy in the
cloud. I am no expert on this topic,
just someone who has seen Face-
book, Google, and other e-mail
providers data mine everything
that passes through their hands.
Supposedly no personally identi-
fying data is ever mined, but how
many pieces of a jigsaw puzzle
have to be present before the fi-
nal piece can easily be deduced?
Its already frightening how much
Google knows and what adver-
tising clout they have attained. I
use Google as an example, but the
same principle applies to similar
online organizations and to gov-
ernments. If I have heard correctly,
the U.S. government, for example,
is building an ambitious project to
record everything in the U.S. that
goes on in the Internet. So am I
right to be downright frightened of
storing my employers engineering
information in the cloud, where I
will have no real control over who
might see it?
David Rensle
Running NASA Apple-style
By your example, Steve Jobs let
the project run off the rails and
then chewed out the develop-
ment team after development
had reached a crisis (If Steve Jobs
Ethics are dead?
A couple of readers bemoan the lack
of ethics in practically every facet
of Ameri can l i fe. Others debate
whether Steve Jobs management
style would work at NASA. And
one reader wonders about our
privacy and cloud computing.
RS# 111
TM
in the Spring when I found that
the float valve on my lawnmower
rusted, even after draining it for the
winter.
Fortunately, I found a station that
sells ethanol-free gas. These can be
found at www.puregas.org. And
Washington state now lets marine
stations sell only ethanol-free gas.
The real surprise came when
I started using ethanol-free gas
in my car and truck. The truck (a
2005 F 150) was getting 13 mpg
around town and the spark plugs
were black. In Feb. of this year,
I started using ethanol-free gas
in the truck. Within two tanks, it
was getting 14.5 mpg, and the
new plugs are running tan. Since
then, the mileage has been 14.5
to 15mpg, which is an 11 to 15%
improvement.
This might be an isolated case,
but it seems a rigorous test needs
to be done.
Erik A. Larsen
Had Run the Mars Rover Project,
Sept. 20). Only then did he take
corrective action.
The NASA results might have
been the same with Steve Jobs pres-
ent. It depends on how much mi-
cromanaging (or project oversight)
Jobs was capable of. NASA made its
decisions and lived with the conse-
quences. Managers there thought
they had managed the risks.
It takes proactive checks to pre-
vent projects from running off the
rails. Even Steve Jobs didnt do that.
I think your analogy is faulty.
Stephen McDonald
A wise manager taught me early in
my career that if you fire everyone
who makes a mistake you are soon
left with only those folks who are
not doing anything at all.
David Leahy
I agree with whoever said Steve
Jobs was the last American busi-
nessman who knew what he was
doing, so I doubt he would have
any interest in landing an SUV on
Mars. But if he did, hed have the
right people in the right places at
the right times.
You dont keep underachieving
employees on your payroll. Get
rid of the people who do it wrong
and promote/hire those who do it
right. The replacements automati-
cally learn from their predecessors
mistakes. Or they, too, become pre-
decessors.
Frank Blankenship
Curing those ethanol blues
My problem with ethanol started
out with my RV and some equip-
ment I store for winter. The 10%
ethanol/gas blend attracts water in
the atmosphere. This fact was ham-
mered home as I pumped 2 gallons
of water from my 200-gallon fuel
tank on my boat. It was also evident
LETTERS
RS# 112
TRANSVERSE
VIBRATION COMPARISON
25
20
15
10
5
0
C
L
A
M
P

(
L
B
F
-
T
H
O
U
S
A
N
D
S
)
0 50 100 150 200 250
time (SECONDS)
HUCK 360
OTHER VIBRATION-
RESISTANT
NUT DESIGNS
SOLUTION
:
HUCK 360
BOLT NUT
BOLT NUT
PROBLEM
:
CONVENTIONAL THREAD
TRANSVERSE
VIBRATION
Anatomy of the
HUCK 360
Once vibration begins,
clamp load quickly
decays with nuts and
bolts, while it holds
constant with the Huck 360.
No gap exists.
Threads are locked
preventing any
movement.
Gap between the threads allows
for transverse movement.
RS# 113
SCANNING FOR IDEAS
Edited by Stephen J. Mraz
For a white paper on
gearhead construction
and use, scan this
code or go to: http://
machinedesign.com/
whitepaper/gearhead-
construction-and-use-0911
Spindle drive moves
with accuracy
Request free information via our
Reader Service Web site at
The BS22-1.5 spindle drive from
MICROMO, Clearwater, Fla. (www.
micromo.com), a member of
the Faulhaber Group, uses ball
screws to generate highly accurate
linear motion. The stainless-steel
drive is accurate to within 5 m
or less over its entire length of
travel. The motor connects to the
ball screw through a backlash-free
coupling that is part of the ball
screw.
The screw is 126.5-mm long,
and the standard stroke measures
94mm. Pitch is 1.5 mm. Axial load
capacities are to 519 N (dynamic)
and 475 N (static). The device
can handle input speeds up to
5,000rpm and still maintain its
accuracy.
RS# 401
Motor
Motor flange
Clutch housing
with duplex ball
bearings
Spindle thread
Spindle nut with
fastening screw
thread
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RS# 114
SCANNING FOR IDEAS
Filter vent equalizes pressure inside and out
Electronic enclosures are often sealed against
water and contaminants, but this can lead to
pressure differentials between the interior and
exterior that cause problems. For example,
lower pressure inside the enclosure can pull
water and air in, damage the seals, and wreak
havoc on the electronics. To prevent this prob-
lem, engineers at W.L. Gore & Associates Inc.,
Elton, Md. (www.gore.com/protectivevents),
developed a protective vent, the PolyVent D3,
that lets air pass in and out, but keeps water,
dust, insects, and debris from getting in.
The vent has a press-fit width of 2.5 mm
and gas-flow capacity of 7 ml/min. The hous-
ing is polypropylene and contains an ePTFE
membrane. This membrane lets gases pass
through while keeping out contaminants. The
vent works in temperatures from 4 to 212F.
The vent takes up no space inside enclosures
and its low-profile exterior portion reduces
the risk of damage from technicians who ser-
vice the enclosure. RS# 402
RS# 116 RS# 115
Liquid and
particles kept out
Polypropylene
housing
Air and gas
molecules pass in
and out through
the membrane
ePTFE membrane
Polyester backing
Simplicity
s
Zip tie bars integrated into
mounting brackets
s
Tiered structure for easy access
s
Easily removable clamping bars
Better Clamping and Reduced
Cable/Hose Slippage
s
Double rows of large fingers
hold more zip ties
s
Anti-slip ridges on bar prevent
cable slippage
NEW ZIP TIE
MOUNTING
BRACKET
REVOLUTIONIZES
CABLE/HOSECLAMPING
A Division of A&A Manufacturing
www.Gortrac.com
Email: sales@aaman.com
Toll Free: 800-298-2066
Fax: 262-786-3280
RS# 117
REPORTERS NOTEBOOK
carries one person, the driver, who should weigh less
than 260 lb. Though developed in the U.S., U.K., and
New Zealand, Quadskis will be built Michigan and
should be available next month. MD
The Quadski from
Gibbs Sports Am-
phibians Inc., Auburn
Hills, Mich., can travel
45 mph over land
or water, and transi-
tions between the
two modes at the push
of a button. The 1,180-lb
(dry) amphibian vehicle is
equipped with a 1,300-cc
175-hp BMW engine
that either powers the
rear wheels on land or a
Gibbs-designed and built
jet drive for speeding over
the water. On land, the
Quadskis four wheels are
supported by independent
coil springs and hydraulic
dampers. Once the opera-
tor drives it into the water,
he pushes a button and
the wheels retract within
4 sec for a smoother,
more-streamlined hull. The
composite hull is made
from a single-piece mold. In the water, the hull lets the
craft plane but still has the lateral grip needed for tight
maneuvers. The vehicles low center of gravity makes
it stable on the road and in the water. The $40k vehicle
Amphibian jet ski hits 45 mph on land and sea
Resources:
Gibbs Sports Amphibian Inc.,
gibbssports.com
MACHINE DESIGN article on Gibbs
amphibian sports car,
tinyurl.com/d9mwnsm
The amphibious Quadski gets is power from
a four-cylinder, water-cooled BMW engine.
The engine features electronic fuel injection,
a double-overhead camshaft, and dry-sump
lubrication. Engineers at Gibbs spent more
than 18 months and 75,000 engineering man-
hours adapting the engine to the Quadski.
Forklift motor lets
eMotorcycle take the
checkered flag
Engineering students at Virginia Tech University designed an
electric motorcycle that ran in the TTXGP, a series of 20-mile races.
The motorcycle, dubbed the VT Bolt, competed in the 75 class, in
which bikes are limited to a 7.5-kW-hr battery pack. The bike took
first place in all three of its races, consistently hitting top speeds
over 100 mph.
The VT team worked with engineers from Kollmorgen, Rad-
ford, Va., the company that supplied the motor, a permanent-
magnet, low-voltage AKM 74, and the controller, an ACS80XL 80V
Gen6. The motor was modified to accept a motorcycle sprocket
and was outfitted with a custom side bearing that let it withstand
higher-than-normal loads exerted on the shaft by the chain. The
motor was also rewound to operate on the battery-packs rela-
tively low voltage. The controller, usually used with motors having
a maximum of 54 hp (40 kW), was delimited to let it control mo-
tors with up to 73 hp (57.6 kW). This
let the controller and motor better
handle the short-duty cycles and
power demands of TTXGP races. The
controller was also modified to con-
trol speed, torque, and regenerative
braking. The drive usually controls
traction in 4 to 5-ton fork lifts. Both
the motor and controller are sealed to IP68 levels, so they can
withstand vibrations common in race cars.
The VT Bolt won all three of its races, making it this years North
American TTX75 Cup winner. MD
Low-density
sealant cuts
weight in aircraft
No materials are left be-
hind in the race to reduce
weight in aircraft, not even
sealants. Simrit, Elgin, Ill.,
the industrial sealing prod-
ucts division of the Freudenberg and NOK
Group companies, developed a low-density
silicone material that reduces weight by 15
to 20% compared to other sealants. With a
specific gravity of less than one, the material
has the same physical properties of tradi-
tional silicone materials, but weighs less.
These low-density silicones operate at
temperatures anywhere from 85 to 401F
(65 to 205C), and set at a durometer of
around 50 to 60+ Shore A. Like most sili-
cones, they resist common aircraft fluids and
will work in fireproof constructions.
Simrits silicone meets SAE Aerospace
Material Specification (AMS) 3302 and 3303.
The material is produced at Simrits Nad-
cap-approved Tillsonburg, Ontario, Canada,
plant. The plant is certified to AS9100 Revi-
sion C quality management, including de-
sign for the aerospace industry. MD
Resources:
Kollmorgen,
www.kollmorgen.com
RS# 406
Virginia Tech University,
www.vt.edu
Resources:
Simrit, simrit.com
RS# 407
The VT Bolt is an all-
electric motorbike
designed and built by
students at Virginia
Tech University to
race in the TTXGP. Its
7.5-kW-hr battery pack
powers a Kollmorgen
permanent-magnet
motor, which gives
the bike a top speed in
excess of 100 mph.
Thousands of enclosures
Hundreds of sizes
Next-day shipping
REPORTERS NOTEBOOK
Navy tries turning seawater into fuel
Engineers at the U.S. Naval
Research Laboratory are de-
veloping a way to turn seawater
into fuel. The multistep process
first extracts CO
2
and H
2
from
seawater, then catalytically
converts the two into jet fuel
in a gas-to-liquid transforma-
tion. The fuel could be used for
aircraft, ships, and amphibious
vehicles. Giving naval ships the
ability to make fuel from sea-
water would eliminate the need
to deploy ships and manpower
to deliver fuel to ships at sea.
And a lot of Navy resources go
into delivering fuel. In 2011,
for example, 15 replenishment
ships loaded 600 million gal-
lons of fuel onto Navy vessels
underway.
So far, naval researchers have
developed and demonstrated
technologies for recovering CO
2

and H
2
from seawater using an
electrochemical acidification cell.
Theyve also converted the CO
2
and H
2
into hydro-
carbons. The Navy estimates that once tweaked and
scaled up, the process
could produce fuel for
$3 to $6/gallon. MD
Resources:
U.S. Naval Research
Laboratory, nrl.navy.mil
The acidification cell used to draw CO
2
out of seawater fits on a
portable skid. It includes a reverse osmosis unit, power supply,
pump, and a CO
2
recovery unit. The cell has the benefit of
producing hydrogen at its cathode as a by-product.
www.rittal-thesystem.com
3D printing for charity
techfortrade, a London-based charity, revealed the
winners of its 3D4D Challenge for the best 3D print-
ing technology that would improve the incomes and
livelihoods of people in developing countries.
The 3D4D Challenge finalists included: Bethany
Weeks and Luke Iseman, U.S., for an off-grid 3D
printer that recycles plastic bags into tools for local
farmers; Boris Kogan, Israel, for a small-scale, easy-to-
manufacture and assemble robotic greenhouse that
will help communities grow good food, even in the
most-difficult environments; and Edmund Bell-King
and Cornell Jackson, U.K., for solar lamps created
from recycled plastic Coke bottles. The lights replace
the costly and dangerous kerosene lanterns com-
mon in rural India.
Other winners included Tom Fripp and Steve
Roberts, U.K., for 3D printing soft-tissue prostheses;
JF Brandon, Canada, for a simple, 3D-printed solar
tracker that can provide solar
electricity to communities; Roy
Ombatti, Kenya, for 3D-printed
shoes made from recycled plastic
that can be worn by individuals
with deformed feet resulting from
jigger-fly infestation; and Suchis-
mita and Jayant Pai, India, for providing young en-
trepreneurs and students access to 3D printers and
material based on discarded plastic bottles.
Winners each receive $1,000 and access to ex-
perts who will help them develop their projects for
a follow-up competition to take place at this years
3D Printshow in London. The final winner will get
$100,000 to further develop his or her project. MD
Software
strengthens
3D-printed parts
Researchers at Purdue University, are working
with Advanced Technology Labs of Adobe Inc.,
San Jose, to develop a computer program that
strengthens objects created us-
ing 3D printing. Bedrich Benes,
an associate professor of com-
puter graphics at Purdue, says
the software targets online users
who pay $300 to create an object
with 3D printers, only to have it
break along areas of high stress
during shipping.
The software strengthens objects by making
structural elements thicker or adding struts. It
also reduces the stresses on structural elements
by hollowing-out overweight areas.
The software first uses mesh-based simula-
tion to identifygrip positions, where users are
likely to grasp the object. The solver requires less
computing power than traditional FEA packages,
which are used in high-precision work such as
designing jet-engine turbine blades.
The software not only makes objects lighter,
it also cuts part costs by 80%, says Benes.
In the future, researchers plan to write soft-
ware that will help users better understand how
structural strength is affected by 3D printed
objects layered composition. They might also ex-
pand the software algorithms to include printed
models with moving parts. MD
Resources:
Advanced Technology
Labs of Adobe Inc.,
www.adobe.com/
technology.html
Purdue University,
www.purdue.edu
Resources:
3D4D Challenge,
www.3d4dchallenge.org
techfortrade, www.
techfortrade.org
RS# 118
REPORTERS NOTEBOOK
The Scion iQ proves that small cars
neednt be Spartan. For example,
though the car measures just
10-ft long and 5.5-ft wide, theres
plenty of room for two adults in
the comfortable front seats. It was
the perfect vehicle for driving (and
parking) in and around Boston for
a week.
The hatchback is powered by
a 1.43-liter four-cylinder engine
with an 11.5:1 compression ratio
that cranks out 94 hp and 89 lb-ft
of torque, enough to get the car
in and out of traffic whether on
Bostons skinny downtown streets
or its many freeways. The iQ could
even pull a U-turn on some fairly
narrow streets, thanks to its 26.4-ft
turning circle (curb to curb).
The engine also gets an honest
30mpg, city or highway, with the
help of its continuously variable
transmission. Though the fuel
tank only holds 8.5 gallons, thats
enough to cover over 255 miles.
And the transmission is sealed;
Toyota claims drivers will never
need to replenish the transmission
fluid.
The roomy front seats come
courtesy of a few nifty design
tricks. For example, to
make more space for the
front-seat passenger,
Toyota designers left
out the glove compart-
ment. To replace that
cargo space, they added
a drawer under the pas-
senger seat. They also
pushed the passenger
seat a tad forward for a
bit more legroom in the
back seat. Also absent is
the spare tire. Instead,
unlucky drivers must use a repair
kit in case of a flat.
Steering is crisp and precise on
the front-wheel-drive iQ with the
6.5-ft wheelbase and electric-assist
steering. The steering module
is smaller than a conventional
power-steering unit, so it takes
up less room under hood. The
front-mounted differential is also
designed for compactness because
room under the hood is so limited.
The short wheelbase makes the ride
a bit rough over bumpy roads but
the car handles and corners well.
Those worried about safety
when driving a small car can ap-
preciate the iQs numerous safety
2012 Scion iQ Hatchback:
Compact and comfortable
features. They include stability
and traction control, antilock disc
brakes with assist, and electronic
brake-force distribution. The car
even carries 11 air bags, including
one that pops up between the rear
seat headrests. When inflated, it
helps keep out broken glass and
debris common in collisions.
The iQ also carries a full array of
electronics: a 160-W, six-speaker
stereo with HD radio and a CD
player, Bluetooth, and a USB port
for plugging in your iPod. There
are also power door locks, mirrors,
and windows, air conditioning,
keyless entry, and even a tachom-
eter (an odd instrument for a car
Resources:
Scion, www.scion.com/
cars/iQ
RS# 119
with CVT). As expected,
cargo room is tight,
3.5ft
3
with the back
seats in place. But thats
enough for groceries
or a briefcase or two.
Folding the back seats
flat opens up 16.7 ft
3
of
storage, which will hold
easily hold a couple
suitcases.
The car is easy to
drive, easier to park,
comfortable, and gets
great mileage. If Toyota
engineers designed the
iQ with the same dura-
bility and reliability of
their other cars, the iQs
could be around a long,
long time.
The car costs about
$17,500, and comes in
only one well-thought
out trim level. There are
a few options: an aero
kit for the exterior, and
some floor mats, cargo
nets, and a seven-color
special lighting kit for
the interior. You can
also get alloy wheels,
some tricked out sus-
pension components,
and a navigation sys-
tem. Stephen J. Mraz
Navigating Mars with Morse Code
Curiosity, NASAs
Martian rover, peri-
odically checks to see
how much its drive
wheels are slipping in
loose gravel or sand
by comparing the dis-
tance it actually trav-
els to how far it has
been told to move.
To do this, the rover
checks dozens of
nearby features, such
as nearby pebbles and
shadows on rocks.
NASA engineers have
ensured Curiosity can
carry out this visual
odometry even if
there arent any distin-
guishable landmarks.
NASA designers
etched the Morse
Code letters J-P-L (for
Jet Propulsion Laboratory) in all six wheels so that they leave a distinctive pat-
tern in the sand as the rover moves. Curiositys cameras can discern the pattern
and use it for measurements. If Curiosity determines theres
a significant position error from wheel slip, it recalculates the
path to its next target. This should let the rover get to targets
more quickly and directly. MD
Resources:
NASA Curiosity
rover, www.nasa.gov/
mission_pages/msl
Curiosity leaves a pattern of distinct lines in the tire marks it
leaves behind in the Martian soil. They are actually the letters
JPL in Morse Code (J: --- P: -- L:-). They let the rover determine
if its wheels are slipping in gravel or sand.
RS# 120
Phone 1-888-260-7466 Fax 516-771-6444
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REPORTERS NOTEBOOK
LOOKING BACK
10 YEARS AGO 2002
Cat latches: Heavy-duty compres-
sion latches from Southco, Con-
cordville, Pa., help Caterpillar secure
inspection panels while meeting
more-stringent noise regs.
Caterpillar's small and medium-
sized tractors and large track loaders
use a modified version of Southcos
Vise Action Compression Latch.
The latch was tweaked so it installs
quickly and easily, fits flush with panels,
has a folding handle for easy opening,
and locks with a key.
The lockplugs pawl is fully adjust-
able and its shaft was shortened by
10mm to reduce inside protrusion. An-
tivibration washers eliminate potential
loosening of the pawl during equip-
ment operation.
30 YEARS AGO 1982
High-angle helical gears from metal
powders: Helical gears with angles
as high as 41 can now be made from
metal powders on a production basis,
reports Dixon Sintaloy Inc. The gears
were previously produced from metal
powders
with angles
up to
around 30,
except as
experimen-
tal or spe-
cialty items.
However,
the company claims to have perfected
a new technique that allows volume
production of metal-powder helical
gears with angles approaching the 45
limit. The technique is applicable to all
commonly used metal-powder alloys.
50 YEARS AGO 1962
Recovering big boosters in a pillow-
like structure is proposed by Philip
Bono and John Hayes of Douglas
Aircrafts Missile and Space Systems
Div. The Roost (Reusable One-stage
Orbital Space Truck) would be used
with a 50-ft-diameter, 273-ft-long sin-
gle-stage booster
capable of carrying
a 160-ton payload.
After separation of
the payload, liquid
hydrogen (left over
from the launch)
would inflate two
heat-resistant fabric
bags, protecting
the booster with
a conical structure 327 ft in diameter
at the base. The blunt cone structure,
designed to withstand 1,800F, limits
reentry temperature to 1,500F. Air re-
sistance should allow Roost to land at
the gentle rate of 1 mph. MD
Latch
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RS# 121
REPORTERS NOTEBOOK
COMPANY NEWS
EDUCATION CENTER
In a joint effort, Agilent Technolo-
gies, Santa Clara, Calif., Concilium
Technologies, Republic of South
Africa, and the department of elec-
trical, electronic, and computer
engineering at the University of
Pretoria, South Africa, have devel-
oped one of the largest electrical
engineering training laboratories
in the world.
The Agilent-Computer Aided
Education Center is an undergrad-
uate laboratory with 144 worksta-
tions, each fitted with an Agilent
DSOX2002A digital oscilloscope
with a built-in function generator,
a U3401A 41/2 digit dual-display
digital multimeter, an E3630A triple-
output dc power supply, and various
RF design and analysis software
programs.
CAPABILITIES EXPANDED
Sil-Pro, Delano, Minn., has pur-
chased 60 to 100-ton Sodick
Plustech thermoplastic injection-
molding machines and converted a
5-ton liquid-silicone rubber machine
back to thermoplastics to handle in-
creased demands for thermoplastics
molding.
Sil-Pro is a contract manufacturer
specializing in molded and extruded
silicone, thermoplastics, and full-
service medical-device contract
manufacturing and assembly.
ACQUISITION
The Drives & Motion Div. of Yas-
kawa America Inc., Waukegan, Ill.,
has acquired Wermac Electric Ltd.
in Calgary, AB, Canada. Wermac
has been an innovator in applying
variable-speed drives and electrical
controls in the oil and gas industry.
The new division, Yaskawa Wer-
mac, will reside at the former Wer-
mac Electric facility in Calgary, AB,
and is now a division of Yaskawa
Motoman Canada, a subsidiary of
Yaskawa America Inc. The Drives &
Motion Div. manufactures industrial
automation equipment, including
include industrial ac drives, com-
mercial HVAC drives, spindle drives
and motors, servosystems, motion
controllers, and low-voltage indus-
trial control switches.
Pecora Corp., Harleysville, Pa., a
manufacturer of weatherproofing
products, has acquired the deck-
coating product line of Carlisle
Coatings and Waterproofing Inc.,
Wylie, Tex.
PERSONNEL
Brent Ekiss, technical sales represen-
tative with Fabrico, Kennesaw, Ga.,
will now pursue LED market oppor-
tunities in North America. Fabrico
offers design and manufacturing
services for flexible materials.
RS# 122
Get the Original from
Avago Technologies!
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Avago has been making encoder modules
previously used in US Digital kit encoders
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If you have been using US Digital
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RS# 123
REPORTERS NOTEBOOK
COMPANY NEWS
ciples and physics behind of each
type of motor is included as well
as applications and commercially
available products with drawings
and technical data.
The piezomotor brochure can be
downloaded at: www.piezo-motor.
net/pdf/PI_Brochure_Piezomo-
tor_Piezo_Motor_PiezoWalk_Ultra-
sonic_Actuator.pdf
EMPLOYER OF YEAR
FINALIST
Mouser Electronics Inc., Mansfield,
Tex., an electronic-component dis-
tributor, which employs nearly 1,000
people, is a top-five finalist to be the
2012 Texas Employer of the Year. The
Texas Workforce Commission will
announce the winner at its annual
conference Nov. 28-30.
If chosen, it would be the sec-
ond award Mouser receives at the
conference the other is the Local
Employer of Excellence Award for
Tarrant County, nominated by the
Workforce Solutions for Tarrant
County.
FREE COMPILER
Microchip Technology Inc.,
Chandler, Ariz., is offering the free
MPLAB XC32++ Compiler with
unlimited code generation. The
MPLAB XC32++ supports all of
Microchips 32-bit PIC32 microcon-
trollers and lets designers develop
and reuse C++ projects by making
all of Microchips C language exten-
sions available in an environment
that is compliant with the majority
of C++98 and C++2003 ANSI stan-
dards. The compiler also includes
Dinkumware standard C, C++, and
template libraries.
The compiler can be downloaded
at www.microchip.com/get/10E7. MD
three types of piezomo-
tors inertial motors,
often referred to as stick-
slip motors; ultrasonic
motors; and stepping
(walk) type motors.
Background information
on the operating prin-
PIEZOMOTOR
TECHNOLOGIES
A 70-page brochure
from PI (Physik Instru-
mente) Inc., Auburn,
Mass., a manufacturer
of piezo-positioning
equipment, covers
RS# 124
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COMMENTARY
Whats up with
model-based
engineering?
Model-based engineering (MBE) seems to mean dif-
ferent things to different people. But according to CAD
validation specialist Doug Cheney of ITI TranscenData
in Milford, Ohio (www.transcendata.com), the model-based approach repre-
sents the future of product development because machines not humans
will read the data and validate models. A good model-based approach drives
design decisions based on a companys engineering and business rules. It
should significantly slash costs by flagging design errors early on, when they
are relatively inexpensive to fix. The main MBE tenet is that data is created
once and directly reused by all downstream consumers.
Cheney says high-end OEMs use model-based approaches to reduce the
number of drawings, or even do away with them all together. As industry
leaders such as Daimler and Boeing lead the way into MBE, they are pushing
CAD vendors to fully support 3D annotation, an important attribute of 3D
product and manufacturing information (PMI). PMI conveys nongeomet-
ric attributes in 3D CAD that are needed for manufacturing. It can include
GD&T, surface finish, and material specifications. Cheney also says its in-
teresting that midrange packages such as SolidWorks and Solid Edge already
support 3D PMI.
MBE means that OEMs and smaller companies no longer have to manually
check drawings but process owners should plan on using the latest tools for
automatically checking models. Hand in hand with this technology change,
its necessary to plan for model defect resolution processes during the CAD-
model-creation stage. Otherwise, a companys MBE scheme will fall flat on
its face, says Cheney.
So what kind of technical roadblocks do companies face in moving to
a model-based enterprise? Cheney say nontechnical issues include limited
budgets and the natural human resistance to change. Technical issues include
incomplete CAD software functionality, digital data variation, and lagging
regulations.
There are several types of digital-data variation. They fall under the head-
ings of Can it be manufactured? (i.e., no unrealistic features such as walls
with zero thickness); Is it equivalent? (i.e., no data loss in migration or
translation from CAD A to CAD B); and, Is it correct and clear? (i.e., no
unintentional or undocumented changes).
To manage variation in model-based enterprises, it is necessary to auto-
mate the checking of data to ensure consistent structures, complete content,
and realistic features. It is also critical to automate translation validation to
eliminate data loss or degradation. Lastly, companies should automate ECO
validation so that no unintentional changes get through and all intentional
changes are clearly documented.
Cheney adds that STEP is an important part of MBE. Companies can col-
laborate in a few ways. They can give external suppliers access to their PLM
systems. Or, they can publish models in various visualization formats. An-
other way is to share models through the latest version of STEP, AP242.
According to Cheney, some engineers predicted the death of STEP when
visualization formats arose. But STEP has enough intrinsic value and sup-
porters in the government and large aerospace/defense OEMs that its still an
important part of companies strategies, especially for the long-term preser-
vation of their MBE models. The real value of STEP is in preserving models
when the authoring systems have disappeared into the wind. MD
Leslie
Gordon
Senior Editor
RS# 126
NOVEMBER 22, 2012
TRANSPORTATION INDUSTRY FOCUS
Traditional snowmobiles are large enough to carry
two passengers, travel on dual skis up front and
a single track in back, and weigh 400 to 600 lb.
They are powered by two or four-stroke engines
cranking out 80 to 160 hp and cost $8,000 to
$13,000 or more. Several companies make snow-
mobiles for trails and off-road mountain trek-
king, as well as multiperson touring versions, but
they all have the same basic layout and design.
Until now.
A small California-based company, Sierra Snow
in Granite Bay, has designed and built a new kind of
powered snow bike they call the PSV Snow Runner
(Personal Snow Vehicle). Driving one is said to be a
cross between riding an off-road motorbike, jet ski,
and snowboard. They are more maneuverable, run
cleaner, and cost less than traditional snowmobiles.
PSV targets
The Snow Runners started as clean-sheet de-
signs, but they borrow technology from motorcy-
cles, racing karts, mountain bikes, and snowboards.
This is likely due to the fact that the developer Jim
Wade, has extensive experience designing and
racing motorcycles and karts, and enjoys biking,
snowboarding, and snowmobiling.
Wade started with a list of requirements for his
new take on powered travel over snow. His PSVs
would be:
Lightweight, high power, and made using off-
the-shelf technology.
Snow runners combine
technology from motorcycles,
snowmobiles, mountain bikes,
and snowboards.
Authored by:
Stephen J. Mraz
Senior Editor
stephen.mraz@penton.com
Resources:
Sierra Snow, www.sierra-snow.com
Snow Runner video, tinyurl.com/9apof3v
Sno-Runner info, snorunner.com
Sno-Runner Promo video, tinyurl.
com/9ngm8qd
Rethinking
the
SNOWMOBILE
The SR-125 Snow Runner from Sierra
Snow is a small, easy to handle mini-
snowmobile designed for just one rider.
With power from a 30-hp, two-stroke
engine, it is said to be easy enough to ride
for beginners but offers the power and
performance to thrill off-trail enthusiasts.
explaining his choice to install hydraulic disc brakes on his
Snow Runners. Often on snow, the best you can do is lock
up the drive track and use the drag of the paddles to stop.
The small hydraulic disc brakes used on mountain bikes
have the power to do just that.
For both the SR-85 and 125, the engines and drive
tracks mount in a common high-strength, lightweight
frame made of TIG-welded (tungsten-inert-gas) 4130
tubular steel, a design feature used on go-karts. Snowmo-
biles use a heavier steel and aluminum chassis.
Wade and his engineering team redesigned the seat for
Small enough to fit inside a midsized SUV, minivan, or
pickup-truck bed.
Rigid yet simple, with a chassis along the lines of racing
karts and motorcycles.
Easy, stable, and safe to ride for all age groups and
abilities.
Environmentally friendly: low emissions and minimal
noise.
A range of sizes small to large.
And less expensive than full-sized snowmobiles.
Gas-powered PSV
The first Snow Runner designed was the
SR-85. Its 18hp comes from a two-stroke
85-cc engine fueled by a gas-oil mix. The
second Snow Runner, the SR-125, has a
larger 125-cc engine that burns the same
fuel but cranks out 30hp. Wade plans on
upgrading these engines soon to cleaner-
burning four-stroke engines. This should
make the PSVs environmentally friendlier
and let the vehicles avoid current and future
restrictions against two-stroke vehicles in
places like Yellowstone National Park.
Snow Runners are expected to drive
through powdered snow over 3-ft deep, so
the design had to ensure the radiators for
the liquid-cooled engines had access to air-
flow. Riders have been known to block the
radiators with snow. Company engineers
are working on a fix for that problem.
The engines put their power through
five or six-speed manual transmissions, just
like motorcycles. The transmission then
turns the 10-in.-wide drive track, a feature
lifted from snowmobiles. It is studded with
paddles that push Snow Runners through
the snow. The SR-125, however, has a longer
drive track with larger paddles to take full
advantage of its 30 hp.
As you can imagine, braking on snow
is tough. The PSVs are all equipped with
hydraulic brakes based on those used on
mountain bikes.
Snow is so variable, its always a little bit
of a crapshoot how the stopping aspect of
the design is going to work, says Wade in
Jim Wade, the inventor
of the Snow Runner,
envisions it being used
by law enforcement and
rescue personnel in snowy
areas. This image depicts
a SR-125 decked out with
storage space, a radio, and
emergency-red body panels.
Many experts said it was
impossible to build an electric
version of the Snow Runner,
and even if you could, it
would be impractical
and too expensive. But
after some research
and experimentation,
Jim Wade built one
that works well on
battery power
despite the cold
temperatures.
Now hes ready to
take it to market.
TRANSPORTATION INDUSTRY FOCUS
The Original Sno-Runner
Although Jim Wade designed the Sierra Snow Run-
ner starting from scratch, he did have a bit of inspira-
tion: the Sno-Runner. It was a small, personal snow-
mobile designed, manufactured, and sold by Chrysler
through its Outboard Marine Div. from 1979-81. They
originally built the vehicle for the U.S. Marine Corp, but
it didnt perform well in powder snow, so the Marines
passed. The Marines did, however, pay Chrysler for the
design and tooling.
Sno-Runners were powered by a 134-cc Power Bee
engine that generated 7 hp. The vehicle was small, sim-
ple, and light enough to be broken down and packed
in the trunk of a car.
Chrysler was nearing bankruptcy in the late 70s and it decided to market the
Sno-Runner to the public in the hopes of generating some much-needed profts.
When prototypes were introduced at a snowmobile exposition in Alaska, dealer-
ships and the press fell in love with it. Unfortunately, Chrysler hurried the fnal de-
sign and cut some corners, resulting in a 30% loss of power. To make matters worse,
engineers hadnt accounted for the fact many Sno-Runner owners would use their
snow bikes in mountains where thin air sucked away another 30% of the power.
Still, they sold about 28,000 of them before demand cratered. Chrysler liquidated
its stock, selling it to C.O.M.B. Liquidators. C.O.M.B. rebranded the vehicle as the
Sno-Rabbit and sold them of.
There are still Sno-Runner enthusiasts out there and several sites on the Web sell
parts and upgrades.
SR-125
roughly the same power as the SR-125.
There were several unknowns about the power re-
quirements and what kind of battery works best for a small,
electric, snow vehicle, says Wade. Several consultants of-
fered to run power simulations, but they wanted to charge
more than it would cost to just make an educated guess
the SR-85 and SR-125 to save weight,
which freed up space underneath for a
high-performance exhaust system.
Gas tanks on both PSVs hol d
enough fuel for about 1.5 hr of riding
time. Wade is confident he can find
space for a larger fuel tank that will
double the fuel capacity and give Snow
Runners a 3-hr range.
One of the more-difficult engineer-
ing challenges was building a front
end that supported the Snow Runner,
provided a comfortable ride for the
driver, and gave it crisp steering in both deep snow and
on groomed winter trails. The initial design used a single
snowmobile ski attached to a fork and shocks similar to
those on mountain bikes. The design went through sev-
eral different combinations of ski sizes and steering ge-
ometries. While performance improved, Wade was not
satisfied.
Fortunately, Wade had one
of those inspirational Aha mo-
ments, and the solution came to
him: use a ski shaped more like a
snowboard, make it as wide as the
rear drive track, and add fins on
the bottom for control and stabil-
ity. So Wade built and patented a
10-in.-wide ski, the same width as
the drive track, and added fins to
the bottom. After some trial and
error in sizing the ski, they got the
desired stability and handling.
The Electric Snow Runner
When the engine supplier
for the SR-125 backed out on an
agreement, Wade and his com-
pany ended up with time on their
hands. Wade used this time to
develop a battery-powered Snow
Runner, the SR Electric, with
But it was
then sold to
the public
as a mini-
snowmobile
or snow bike.
Chryslers Sno-
Runner was
built back in
the late 1970s
as a possible
military vehicle.
SR-Electric
the SR Electric V 2.0 longer run times.
The current pod will survive over 5,000 charging cy-
cles, which Sierra Snow estimates should last over 5 years
(assuming it is used every day over four winter months).
The pod weighs 70 lb and costs about $1,000. But battery
costs keep coming down, so its hard to put a fixed price
on the pod right now, says Wade.
Motor speed is ultimately determined by the driver
working a motorcycle-type twisting electric throttle,
which sends a signal to an off-the-shelf motor controller.
The motor turns a chain drive with gear ratios chosen to
give the PSV a speed range appropriate for trail riding.
Wade plans on upgrading the next-generation of SR Elec-
trics to use a quieter and lighter timing-belt
drive instead of a chain.
The added weight of the battery, which
had the PSV pushing 200 lb, had practically
no effect on handling or ride after Wade ad-
justed the spring rates and shocks on the front
and rear suspensions, The flat torque curve
of the motor gives the SR Electric plenty of
off-the-line acceleration and the power to
pull itself and a rider through handlebar-deep
snow.
Wade came up with an innovative so-
lution to the twin problems of recharging
batteries and getting consistently good per-
formance from them despite frigid tem-
peratures. The battery cells are packaged
in a pod that users can remove from the
frame in less than 3min. The pod and its
transfer cart slide into a charging/condi-
tioning station designed at Sierra Snow.
Less than 35 min later, the pod is ready to
be slid back into its mount on the PSV with
enough power to provide 70 to 80min of
thrills and chills to the next rider. The sta-
tion also monitors and adjusts the charge
while keeping battery temperatures above
50F and conditioning them for maximum
output. So ideally, riders would always re-
move the pod from the charger and install
it in a Snow Runner right before going out
for a ride. Afterwards, they would return it
to the station until the next ride.
Battery-powered PSVs should be fine for
traveling around known areas and trails. And
its quiet and clean operation makes it suitable
for the most pristine of parks. The silent op-
eration is also drawing interest from the mili-
tary, which is looking for stealthy vehicles.
Wade has almost everything he needs to
take his Snow Runners to market including
the completed plans and engineering details,
sourcing for parts, business plans and finan-
cials, and a long line of interested customers.
The only thing lacking is investors who can
help him make it happen. MD
and build one. So we decided to skip the simulations.
The team selected a 30-hp pancake motor based on its
power and torque ratings being close to those of the 125-cc
engine in the gas-powered PSV. The 48-V battery pod they
designed uses 16 LiFePO
4
cells, which have good power
but slightly less energy density than the LiCoO
2
batteries
typically found in consumer electronics. But LiFePO
4
bat-
teries offer longer lifetimes and faster discharge rates. And
they are less susceptible to heating problems due to over-
charging. Fortunately, the battery pod could be sized to fit
under the seat where the exhaust system was mounted on
other Snow Runners. The next version of the SR Electric
will likely have a battery pod with a higher voltage, giving
Tech specs
SR-125 SR-Electric
Engine Water-cooled, two-cycle Pancake motor
Power 30 hp (stock), 35 hp (racing trim) 25 hp
Batteries N/A 16 LiFePO
4
cells
Displacement 125-cc N/A
Cylinders One N/A
Clutch Manual None
Transmission Manual six-speed Direct chain drive
Brakes Hydraulic disc
Front shocks Fork-style, double-adjustable
Front travel 7 in.
Rear shocks Dual, double-adjustable coil-over
Rear travel 8 in.
Track (short) 78 10 1 in. N/A
Track (long) 98 10 1 in. 98 10 1 in.
Dry weight 140 lb (short track) N/A
155 lb (long track) 95 lb
Length 7 ft
Width 25 in. (at handlebars)
Height 32 in.
Price
$5,850 (short track) N/A
($6,995 (long track) $6,850
ELECTRICAL/ELECTRONIC
aircraft, but in industrial equip-
ment of all kinds. One often en-
counters industrial applications
where hundreds of amps switch
within a microsecond. Examples
include motor drives, IGBT power
circuits, SCR trigger circuits, and
power contactors. Such current
switching radiates large magnetic
and electric fields, creating electri-
cally noisy conditions. Fortunately,
optical fiber links can remedy such
problems. For example, polymer
optical fiber (POF) is steadily re-
placing copper cabling in many in-
dustrial RS-485 and Fast Ethernet
communication schemes. Unlike
copper cables that can act as an an-
tenna, glass and plastic fibers are
dielectric materials and, thus, im-
mune to the stray EM fields com-
mon in motors drives, ac/dc power
inverters, and power-distribution
systems. These fibers can even sit
Smaller price tags
now make plastic
fiber-optic cables
more practical for
thwarting big spikes
of electrical noise.
Authored by:
Markus Wirsing
Industrial Fiber Product Div.
Avago Technologies Ltd.
San Jose, Calif.
Edited by Leland Teschler
leland.teschler@penton.com
Key points:
Recent developments in plastic optical cable
have brought down prices.
Optical fiber can be an economical way
of warding off problems caused by
electromagnetic interference.
Resources:
Avago Technologies Ltd., www.avagotech.com
For another feature on
cables and how to use
them, scan this code or go
com/article/analysis-helps-
subsea-cables-survive-0809
Better economics
for
INDUSTRIAL
FIBER OPTICS
SFH-Series or connectorless
transmitters and receivers
have 650-nm fiber-optic
components that work with
unconnectorized POF that
need no polishing. The user
simply cuts the fiber to the
desired length, inserts it in
the active component ports,
and tightens the built-in
locking mechanism. HFBR-
453XZ Series connectors are
an enhanced version of the
HFBR-4501Z and HFBR-4503Z
connectors for POF. This design
uses a simple, snap-together
concept that eliminates the
need for crimping, thereby
greatly reducing labor and tool
costs as well as potential yield
loss from installation error.
Researchers at NASAs Langley Research Center got
some alarming results when they looked at how elec-
tromagnetic interference could potentially affect flight
navigation and communication systems. Interference
from some ultrawide-band signals, for example, could
suddenly silence aircraft radios with no warning. EMI
could also lead radio-navigation systems to give erro-
neous readings. Distance-measuring equipment could
be influenced by EMI as well, in some cases reading
out distances that were off by a full nautical mile.
Perhaps most worrying, sufficiently bad EMI could
knock airplane images completely off displays of air-
traffic collision-avoidance systems.
Such are the difficulties EMI can cause not just in
Industrial communication links must also reject com-
mon-mode noise and be designed to avoid ground loops.
One common means of realizing these goals is to use an
optocoupler. It can place up to 15 mm of galvanic insu-
lation between the data source (P, UART, etc.) and the
copper transceivers driving twisted-pair cable. (Galvanic
insulation distance is the maximum distance between the
input and the output based on the maximum physical di-
mensions and limits on package stability.)
This insulation can prevent common-mode noise from
propagating into sensitive receiver decision circuits, which
can cause errors in the data transmission. However, the
transmitter and receiver in couplers are in close proximity,
so close that stray capacitance across the isolation barrier
can be an issue. So optical coupling is effective only to the
extent that this capacitance is minimized. Typical parasitic
capacitance of optocouplers is 0.4 pF. POF links have a
parasitic capacitance that is directly proportional to link
length about 1 pF/m, i.e., essentially zero. And a fiber
link with a standard length of several meters produces an
isolation barrier measured in meters, not millimeters. All
in all, POF eliminates any pathway for common-mode
noise.
The benefits of fiber links dont always come at a sub-
stantial cost penalty. To illustrate this point, consider two
bills of materials (BOMs) for equivalent industrial link
designs, one for a 10-m RS-485 copper link, the other for a
10-m plastic optical fiber (POF) link. As the requirements
for shielded/certified cables rise, so do the associated costs.
In contrast, POF costs remain the same regardless of the
application environment.
One reason the cost of POF links compares more fa-
vorably with copper in recent years is better integration.
It is now possible to find fiber transmitter and receiver
packages that include driver ICs. For example, the AFBR-
1624Z transmitter integrates a 650-nm LED source with
optics and a driver IC for use with 1-mm POF. Similarly,
in a duct along-
side high-voltage
power cables with-
out concern for
cross talk.
Opti cal fiber
al so compl etely
eliminates ground
loops and their po-
tential noise and
safety issues. Fiber
is a candidate for
monitor and con-
trol functions in
high-voltage ap-
plications and ex-
cels at connecting
control triggers to
high-current/volt-
age switching cir-
cuits through an
isolation barrier.
Nevertheless, many design engineers have been reluc-
tant to build fiber optics into data and control networks.
Reasons include a perceived cost disadvantage, concerns
about ease of use and installation, or simply a greater fa-
miliarity with copper and its infrastructure. But recent
developments in fiber-optic transmitters and receivers
now make fiber an economical alternative to copper links.
Moreover, the new devices can be easier to use and install
than copper lines.
Galvanic isolation
Designers must sometimes go to great lengths to gal-
vanically isolate copper wiring to prevent dc-current flow.
Typical measures include differential line receivers; RF,
magnetic, capacitive or optical coupling; and transform-
ers. However, these precautions can prove inadequate in
the presence of extremely large switching currents and
voltages as arise from variable-frequency motor drives,
utility-scale wind turbines, or beefy dc-to-ac inverters.
Unlike copper wiring, optical fibers need neither rig-
orous grounding rules to avoid ground-loop interference
nor termination resistors to avoid reflections. Properly
used, optical transceivers and fiber cables can prevent
lightning strikes from catastrophically damaging equip-
ment and can safely isolate outdoor and tower-mounted
electronics.
IEC 664-1:1992 is the international insulation standard
for low-voltage equipment. It dictates that even in the
worst possible environment (i.e., outdoors) the minimum
standard distance for a working voltage of 10 kV is 45 cm,
a little less than 18 in. A plastic optical fiber this long is
considered an ultrashort link. The average installation
length of plastic fiber is 10 m. At this length, the possible
working voltage exceeds the standard by 20 times, an illus-
tration of why the galvanic isolation properties of optical
fibers work well for harsh industrial environments.
Ofce (Pollution degree 1)
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0 2,000 4,000 6,000 8,000 10,000
Minimum creepage, IEC664-1:1992
M
i
n
i
m
u
m

c
r
e
e
p
a
g
e
,

c
m
Working voltage, Vdc
Outdoors (Pollution degree 4)
Polluted (Pollution degree 3)
Industrial (Pollution degree 2)
The IEC 664-1:1992
standard gives
recommended
minimum creepage
distances. For example,
if the application entails
working voltages of
10 kV outdoors, the
standard recommends
at least 64 cm
between energized
conductors and any
conductive material.
For impulse voltages,
IEC 664-1:1992 calls for
0.55mm/kV clearance
to prevent arcing.
ELECTRICAL/ELECTRONIC
Amplifer
TEM cell
EMI
feld
Cable loop
Field probe
Tx
Rx
Field sensor
POF cable
EMI test setup
BERT
50 Mbyte/sec PRBS7
Rx app board
Tx
24 dBm POF attenuator
the AFBR-2624Z receiver consists of an IC with an
integrated photodiode to produce a logic-compat-
ible output. Designers can connect TTL, LVTTL,
PECL, LVDS logic signals to the inputs and need
little or no knowledge of optical drive circuits.
Clearly, the copper cable itself dominates the
cost of a copper link. Since the beginning of 2009
when copper dipped to $2,000/metric ton, the
price of copper has risen to over $10,000/metric
ton and is now sitting at about $8,400/metric ton.
Thus, copper prices can be volatile. In contrast, the
cost of plastic in POC is quite stable and may po-
tentially drop as sales volumes rise. Such price dy-
namics favor the economics of plastic fiber. This is
especially true for conservative or high-reliability
designs. Here, most engineers will choose a well-
shielded, high-quality cable to help prevent noise
ingress and egress. Fiber easily competes on cost
in such cases. The cost of the copper cable drops in
applications that can get by with less shielding (i.e.,
CAT5) or shorter links, on the order of 10 m. For
longer cables, however, POF runs about $0.20/m
800
700
600
500
400
300
200
100
0
0 500 1,000 1,500 2,500 2,000 3,000
EMI efect, 1-m unshielded twisted pair
E

f
e
l
d
,

V
/
m
Frequency, MHz
1-m unshielded twisted pair
LEGEND
E-feld maximum
Mobile bands
800
700
600
500
400
300
200
100
0
0 500 1,000 1,500 2,500 2,000 3,000
EMI efect, fber only
E

f
e
l
d
,

V
/
m
Frequency, MHz
1-m unshielded twisted pair
LEGEND
E-feld maximum
Mobile bands
A test setup demonstrates the degree to which
copper cable can be susceptible to EMI. Here, a
POF transmitter and receiver sit inside a transverse
electromagnetic (TEM) test cell. An amplifier sweeps
across a range of frequencies from 0 to 3GHz and
beams its signal at the POF Tx/Rx pair as a source
of EMI. Meanwhile, a 50-Mbytes/sec pseudo-
random bit stream (PRBS7) signal is fed to the POF
transmitter. It gets sent back through the POF link
to the receiver board and to a bit-error-rate tester
(BERT) for measurement. The accompanying plot
shows what happens when the data passes through
a 1-m-long unshielded twisted-pair cable sitting in
the TEM cell. Red lines depict departures from the
generated signal that the test equipment measured.
Predictably, the resulting signals are unusable in
this noisy environment. The situation is different
when the copper cable is removed to leave only
the fiber-optic transmitter and receiver devices
with a direct loop-back path on a PCB, The results
showed no bit errors. In this configuration, the POF
link withstood an electrical field exceeding 150 V/m
across the entire frequency range of 0 to 3 GHz.
tions for the inevitable rise of communication data rates.
For example, fiber links can transmit 125 Mbytes/sec Fast
Ethernet (100BASE-FX) signals up to 2 km, while equiva-
lent copper links (100BASE-TX) are limited to 100 m.
Moreover, optical fibers are thinner and weigh less than
equivalent lengths of copper cable. So a given installation
space can hold more optical than copper links and the op-
tical links will be easier to handle. MD
compared $1/m for cop-
per without connectors.
Terminating fibers
Typi cal l y, i t t akes
more time to terminate
glass fibers than to con-
nect twisted-pair wire be-
cause these fibers require
end polishing and ep-
oxy. The relatively large
1-mm polymer core in
POF, however, makes this
kind of fiber much easier
to handle. Today vendors
offer connectorless and
crimpless style connec-
tors that let POF cables
terminate more easily
than shielded twisted-
pair cables.
Connectorless trans-
mitters and receivers have
650-nm fiber-optic com-
Typical POF link,
discrete components
Typical POF link,
integrated components
SN74LVC26125
SN75451BD
RX
HFBR-25x1/2/4Z
HFBR-15x1/2/4Z
TTL output
TTL input
AFBR-1624Z
AFBR-2624Z
RXout
TXin
The Avago AFBR-1624Z transmitter integrates a 650-nm
LED source and optics with a driver IC for use with 1-mm
POF. The AFBR-2624Z receiver consists of an IC with an
integrated photodiode to produce a logic-compatible output.
Designs using the AFBR-1624Z/2624Z Versatile Link fiber-optic
transmitter/receiver use less board space, consume less power,
and cost less than links handled with separate components. This approach also
reduces the signal trace length which improves the EMI performance of the parts.
Comparing typical BOMs for copper RS-485 and POF links
Copper RS-485
Component Quantity
Unit cost
(at 5,000)
Subtotal
DB9 connector 2 $1.80 $3.60
DB9 twisted-pair cable 10 m $2.70/m $27
Line driver 2 $1.50 $3.00
Resistor 2 120 $0.02 $0.04
Resistor 4 10 k $0.02 $0.08
Ceramic cap 10 V 2 10 F $0.12 $0.24
Total $33.96
POF link
Duplex POF assembly 1 $14.56 $14.56
Tx/Rx link 2 $9.78 $19.56
Inductor 4 1 H $0.20 $0.80
Resistor 2 4.7 k $0.02 $0.04
Capacitor 4 0.1 F $0.05 $0.20
Ceramic cap 10 V 4 10 F $0.12 $0.48
Total $35.64
Heres how the bill of
material for an Avago
industrial POF link using
the AFBR-1624Z/2624Z
Versatile Link fiber-optic
transmitter/receiver
compares with that of a
typical copper link. The pair
operates any type of signal
from dc to 50Mbytes at up
to 50m with 1-mm POF.
The AFBR-2624Z receiver
combines an IC with an
integrated photodiode to
produce a logic-compatible
output. Note the cost of the
copper cable dominates
the cost of the copper link.
This is why POF links cost
less per meter than copper
equivalents for longer cable
runs.
ponents that work with unconnectorized POF that needs no
end polishing. The user simply cuts the fiber to the desired
length, inserts it in the active component ports, and tight-
ens a built-in locking mechanism. Another design uses a
simple, snap-together concept that eliminates the need for
crimping, thereby greatly reducing labor and tool costs as
well as potential yield loss caused by installation errors.
Optical fiber is also a way of future-proofing applica-
MATERIALS
The dark days of energy-hogging, poorly toler-
anced cast parts are over. A new casting method
dampens vibration and uses less energy during
production. The technology is called cast-to-
tolerance (CTT) synthetic-quartz-composite
casting and the magic lies in the mixture.
CTT synthetic-quartz composite is a pre-
cisely formulated mixture of high purity quartz
aggregates, liquid-polymer resin, and various
air release and wetting agents. Depending on
the degree of tolerance required for the finished
casting, the size of quartz particles in the mix-
ture range from a fine powder to 10-mm grains. Cast-
ings can be made for specific applications by blending in
different types of liquid-polymer resins with the quartz
aggregates.
When liquid resin Bisphenol-F epoxy is used in the
mixture, it produces a casting that resists chemicals, mak-
ing it a good alternative to stainless steel. CTT castings
do not rust or deteriorate from exposure to aggressive
coolants.
CTT castings commonly go into vibration-dampening
applications. To make castings that dampen vibration,
liquid resins such as Bisphenol-A epoxy, Methyl methac-
rylate, or rigid urethane are used in the mixture. Machines
that use this type of casting include those for inspection,
prepress plate setters, and pick-and-place equipment. Re-
duced vibration lets these machines operate faster and
Authored by:
Terry Capuano PE
Precision Polymer Casting LLC
Mentor, Ohio
Edited by Lindsey Frick
lindsey.frick@penton.com
Key points:
CTT synthetic-quartz castings can be cast in color,
eliminating painting or plating.
Specific types of liquid resin blend with quartz
aggregates to produce castings that will satisfy
different applications.
Compared to cast-iron parts, CTT synthetic-quartz
castings typically consume 85% less energy to be
produced.
Resources:
Precision Polymer Casting LLC, www.castinite.com
Its all in the mix.
Quartz aggregates range from a fine powder to
3/8-in. particles. The flourlike aggregates on the
right are used for CTT.
with greater accuracy. For cutting machinery, these cast-
ings extend cutting-tool life by one-third.
Heat transfer and electrical conductivity are two prop-
erties to keep in mind when using CTT castings. The CTT
material does not transfer heat well or conduct electricity
thoroughly. This is a benefit when casting machine tools
because the machine base will not easily move when heat
builds during machining. The application of a conductive
Cast-in
custom
components
like threaded
inserts create
castings that
can mount to
hoses, attach
to other
components,
or act as
mounting
surfaces.
Casting
with QUARTZ
Polymer composite bar
Cast iron bar
0 0.01 0.02 0.03 0.04 0.05 0.06
0
0.001
0.0005
0
0.0005
0.001
0.001
0.0005
0
0.0005
0.001
0.01 0.02 0.03 0.04 0.05 0.06
50% of initial bending
Mode decay: 0.006 sec
50% of initial bending
Mode decay: 0.064 sec
This turbine-blade inspection base was
originally made from granite pieces. It
was CTT cast to 0.0003-in. flatness on
the top and front surfaces and 0.0005in.
perpendicularly between the top and
front. Foam core was cast internally to
reduce weight by 70% compared to granite.
gel coat on the casting will make it conductive, as will plac-
ing wiring into the mold prior to casting.
Tolerance in the tooling
Tooling for the CTT mixture must be machined to
closer tolerances than the desired finished tolerances on
the casting. Steels used to make the tooling must have
good wear qualities, but the tooling does not need heat
treatment. Proper tool design and construction is critical
to holding precise tolerances. And as any designer knows,
tolerance costs money.
Luckily, the CTT technology offers a poor-mans tool-
ing option. When a high-precision top surface of a casting
is required (bottom of the mold), only the mold base
is machined. Then low-cost sheet steel can be used
to create the sides and cores. It is even possible to
use wood sides with a precision steel-base mold.
Typical mold tolerances are 0.0005-in./ft flatness,
0.001-in. total indicator reading (TIR) for surfaces,
and 0.0001-in. diameters. The finished part dimen-
sions often exactly match the mold, but not consis-
tently enough to say every casting will be to tolerance.
For routine production, assume the finished part toler-
ances will be one-half of the mold tolerances. CTT cast-
ings can, therefore, be cast to 0.001-in./ft flatness,
0.002-in. TIR surfaces, and 0.0002-in. diameters.
Closer tolerances are possible, but at some point,
the cost of the tooling exceeds the value.
One of the biggest issues to keep in mind
with high-precision casting is inspection. When
trying to qualify close-tolerance surfaces, the
inspection technique must be agreed upon prior
to production. Although 0.0002-in. flatness
should be the same regardless of the inspection
technique, it often is not. The technique used
to qualify dimensions will affect the readings
so it is important to find an inspection tech-
nique that both the vendor and customer have
available.
Energy and cost saving
Finished CTT castings typically consume
85% less energy during production than similar
cast-iron parts. One reason is that CTT almost
A small
inspection base
was originally
made from cast
iron and then
machined. The
inspection base
above is made from
a mixture of quartz
aggregates and a liquid-polymer resin. This base
dampens vibration 10 times faster than the cast-
iron base. Vibration tests comparing a bar of
the same material versus a bar of cast iron show
similar results.
This
machine
base is
made
with
cast-in
hydraulic
holes, air
lines, and
electrical
wiring to
reduce
machine
assembly
time.
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MATERIALS
to reduce air voids and to fill every recess in the tooling.
Some castings are consolidated by applying a vacuum
depending on the formulation of the mixture, size of the
casting, and its cure time. Overall, the method of cast-
ing a synthetic-quartz-composite mixture produces fin-
ished parts that need little to no inspection as the feature
placement, color, and tolerance stay consistent from part
to part. MD
eliminates all secondary operations. Once the CTT tool-
ing has been produced and qualified, the casting process
consists of assembling the tooling and installing inserts
that replace the need for machining. For example, steel or
stainless-steel threaded inserts are cast-in to create stan-
dard tapped holes. Other types of inserts like foam can be
cast-in as the structural core of the casting, which reduces
weight and cost. CTT castings can also be cast in color.
This means secondary operations like painting or plating
can be eliminated.
Unlike cast iron, CTT mixture can be blended and
poured into the mold at room temperature. Vibration
and/or mechanical pressure then compacts the mixture
6,000 years later
Casting: A 6,000-year-old process where a material in
liquid form is poured into a mold to produce a harder part
called a casting.
Cast-to-tolerance (CTT) synthetic-quartz-composite
casting: A technology involving an exothermic pour ma-
terial made of quartz aggregates and liquid resin. The
mixture is poured into the mold at room temperature
and compresses to match tolerances with the assistance
of vibration, mechanical pressure, or a vacuum.
This 22-ft-long grinder base weighs in at 45,000 lb. It was
machined to 0.0005 in. overall. It is possible to cast parts
up to 50,000 lb. The only limitation is the ability of the
factory to pour and vibrate the mixture within an 8-hr
day. Formulation changes also need to be made to adjust
the exothermic reaction.
RS# 128 RS# 127
CAD/CAM/CAE/FEA
Its no secret that
carmakers are under
a lot of pressure to reduce
the number, size, and weight of
engine components for better fuel
economy. In one case, we were tasked with
designing a smaller and more-efficient heat
sink to thermally regulate the electronic
components in Toyota hybrid vehicles.
Instead of using typical analytical design
methods and trial-and-error physical prototyping, we first used mul-
tiphysics software to design and test possible prototypes.
Hot under the hood
Toyota hybrid vehicles have sophisticated electrical systems in
which many power diodes and power semiconductors such as in-
sulated-gate bipolar transistors handle power conversion and other
applications. These components are standard planar silicon devices
measuring a few centimeters on each side. The devices mount on alu-
minum heat sinks, or cold plates, with channels in which a water-and-
How Toyota designed
a small, efficient heat
sink to cool electronic
components in its
future hybrid vehicles
Authored by:
Ercan (Eric) Dede
Principal Scientist
Toyota Research Institute of North America
Ann Arbor, Mich.
LeslieGordon
Key Points:
Engineers designed a smaller and more-
efficient heat sink to thermally regulate the
electronic components in future Toyota hybrid
vehicles.
Numeric simulations generated an optimal
cooling channel topology with fluid streamlines
in branching channels.
The dual configuration prototype provided
higher-performance cooling in an ultracompact
package.
Resources:
Toyota Research Institute of North America,
http://tinyurl.com/8kdkq3r
MULTIPHYSICS SOFTWARE
builds a
better heat sink
These
isometric
views show the
derived hierarchical
microchannel cold plate
without a jet plate (top)
and with a jet plate
shown transparent for
clarity (bottom).
CAD/CAM/CAE/FEA
between Comsol and Matlab.
The aspect ratio of the channels (i.e., ratio of height to
width) was important, but to simplify the numerical simu-
lations we assumed a thin 3D structure and then further
flattened it. Once we derived an initial channel topol-
ogy, we investigated the height of the fins that separate the
cooling channels and performed a separate parametric
sizing study. We had already done similar studies, so our
assumptions were well informed.
Our numeric simulations generated an optimal cool-
ing channel topology with fluid streamlines in branch-
ing channels. Because the channels efficiently distributed
exits. One answer was to combine jet impingement with a
peripheral channel to boost the area-average heat transfer.
Comsol Multiphysics CFD and Heat Transfer Modules
were essential to the numerical simulations at the heart
of our work. And Comsols LiveLink for Matlab also let
us work with the multiphysics simulations in a high-level
scripting language to automate the process of improving
the cold plates topology.
We examined how the topology influenced variables
such as steady-state convection-diffusion heat transfer
and channel fluid flow. We used well-established material-
interpolation techniques and a special optimizer, iterating
The images show
the prototype
aluminum cold
plates with (top)
and without
(bottom) the
hierarchical
microchannel
topology.
Toyotas numeric simulations produced an optimal cooling channel topology
with fluid streamlines in branching channels (left); normalized temperature
contours (center); and normalized pressure contours (right).
glycol-coolant mixture flow.
In earlier model years, the
cold plate featured a fluid inlet
on one side and an outlet on
the other side. The long chan-
nels in between were mostly
straight. They provided ad-
equate heat transfer but at
the cost of a significant pres-
sure drop across the plate. We
needed a much smaller and
more-efficient design, but this
meant that thermal manage-
ment would be more difficult.
It might seem reasonable
to simply redesign the cold
plates so more coolant could
flow through them. But that
would require more pump-
ing power. The limited space
in the engine compartment
meant that using a larger,
more-powerful pump or an
additional pump was unac-
ceptable. Therefore, we had
to reengineer the cold plate to
simultaneously get optimum
heat transfer and negligible
additional pressure drop.
Jets not enough
Interestingly, many re-
searchers have identified jet
impingement as an attrac-
tive way to cool surfaces. But
while jet impingement per-
forms well with respect to
heat dissipation close to the
jet, it doesnt work well further
away from the orifice. Thats
because most heat transfer
happens close to the jet en-
trance where the fluid is the
coolest and flows fast. Much
of the heat-transfer capability
is lost by the time the coolant
coolant throughout the plate, we used the fractal-like to-
pology to guide the design of a cold-plate prototype. We
set the size of the plate to 60 45 mm, with a middle cool-
ing zone of 25 15 mm to match a specific heat source. We
assumed the plates base substrate thickness to be 1 mm.
Real-world performance
After using Comsol and Matlab to improve optimize
the channel topology, we then used the final channel con-
cept to design and evaluate a prototype using Comsols
LiveLink for SolidWorks. LiveLink lets users actively link
to CAD, and it was easy to import various designs from
SolidWorks back into Comsol to verify pressure drop and
heat transfer. This capability lets users quickly establish a
reasonable starting point and progress from there quickly.
Last, we fabricated two physical prototypes based on
the SolidWorks designs using standard micromachining
techniques. One prototype was a dual jet/hierarchical mi-
crochannel version and the other used jet impingement of
a simple flat plate.
We tested the prototypes to see whether the dual con-
figuration would indeed provide higher-performance
cooling in an ultracompact package. On average, it did dis-
sipate 12.8% more heat than the flat-plater version. With
regard to pressure drop, both cold plates demonstrated
similar results, but the dual version performed slightly bet-
ter at higher flow rates. MD
Toyota performed other numerical topology
optimization simulations to study the fluid
flow of a cold-plate inlet manifold comprising
a single fluid inlet and six outlets. The manifold
could feed fluid to multiple multipass cooling
cells. The image shows the streamlines colored
with velocity magnitude. The curvy sidewall
manifold shape was generated through Comsol
fluid-flow topology optimization studies, where
the goal was to minimize the pressure drop
across the manifold while balancing the flow
rate to each outlet nozzle.
RS# 129
High-end AWM-style cables are
making a comeback in machine
wiring providing over 20 years
of reliable performance.
If you find electrical safety standards confusing, youre not alone. Many
machine builders recently grappled with an ambiguous round of changes to
NFPA-79. This is the National Fire Protection Association code that outlines
electrical standards for industrial machinery that protects operators, equip-
ment, and facilities from fire and electrical hazards. NFPA-79 is cited exten-
sively in the National Electrical Code (NEC) that governs the electrical wiring
of industrial machines.
The standard cuts a broad swath across the industrial machinery landscape.
It applies to a comprehensive range of machines everything from machine
tools and injection-molding presses to testing machines and packaging lines. It
encompasses all of a machines electrical and electronic elements operating at
600 V or less. This means that a vast majority of machine power, control, and
lighting circuits fall under the scope of NFPA-79.
Machine builders complied with the dictates of NFPA-79 for years. But ear-
lier this year the standard underwent revisions that make it more difficult to
specify compliant electrical cabling.
Appliance wire OKd
The key change to NFPA-79 for 2012 involves the ability to use appliance
wiring material (AWM), which had been banned since 2007. AWM can be an
economical wiring choice compared to higher-performing UL-listed machine-
tool wire (MTW). But there were several sound reasons behind the AWM ban.
For one, some contractors were using AWM incorrectly as part of the build-
ing infrastructure. The NEC does not recognize AWM for this type of use.
Also, not all AWM products are created equal when it comes to the quality
of their insulation layer. The insulation thickness of low-quality commodity
cabling varied such that the wire, while meeting its electrical insulation require-
ments, was not sufficiently flame resistant for use in industrial machines.
Its important to stress that not all AWM suffers from these quality issues.
Lapp and other reputable cable manufacturers can and do produce AWM prod-
ucts whose insulation wall thickness is both consistent and adequate for the
voltage rating of the cable. High-quality AWM can pass the specified vertical
flame tests (FT 1) and can safely be used in industrial machines. Keep in mind,
however, that AWM lacks the extra layers of PVC-nylon insulation found in
Appliance wire
is back, but
regulations may
limit its use.
Authored by:
Rick Orsini
Senior product manager
Lapp USA
Florham Park, N.J.
Edited by Robert Repas
Key points:
NFPA-79 outlines electrical standards for
industrial machinery to protect operators,
equipment, and facilities from fire and
electrical hazards.
Banned in 2007, AWM may now be used in
machine wiring, restrictions permitting.
New permissions may let MTW products that
carry a UL TC-ER listing slash installation costs,
even over AWM.
Resources:
Lapp USA, www.lappusa.com
NFPA 79 Standard, bit.ly/Rbblbv
UL Wire and cable flammability testing, bit.
ly/TxHTv2
For a white paper on the NFPA 79 electrical
code, scan this code or go
com/whitepaper/
understanding-the-
electrical-code-to-be-
compliant-0501
Safety standard
gives
APPLIANCE WIRE
a new lease on life
AWM and NFPA compliance
One company successfully navigating the shoals of the recent
NFPA-79 revisions is Krones Inc., Franklin, Wis., a manufacturer
and integrator of packaging lines for food and beverage compa-
nies. The companys engineering team recently found that com-
pliant AWM usage does require a bit of extra efort compared to
the automatic compliance found with UL-listed MTW.
Whenever you must implement changes because of an elec-
trical-code change, theres defnitely an engineering-labor factor,
says Mike Nelson, the Krones engineer charged with NFPA-79
compliance.
Some of that engineering labor went into researching spe-
cifc AWM products to see whether they meet the compliance
restrictions. Even proper jacket labeling doesnt answer every
compliance question regarding AWM. You cant tell whether a
product complies just by looking at the cable, says Nelson. And
even more engineering labor went to NFPA-79s documentation
requirements.
In all, Nelson estimates that Krones has spent more than 150
engineering man-hours complying with the requirements relat-
ed to AWM use. And that fgure represents just the work done to
formulate a compliance strategy. It does not include the technical
documentation and drawing changes needed to incorporate the
wire into each and every machine.
NFPA restrictions. In the case of extremely large machines
such as bottling lines, machine builders and installation
contractors can spend dozens of engineering hours and
thousands of dollars complying with the documentation
requirements.
These documentation needs, while not insurmount-
able, must be factored into the cost of wiring the machine.
In some cases, the added documentation costs can erode
the minor price advantages of some AWM cables.
One way around the concern of documentation is to
favor listed MTW. Because it inherently complies with
NFPA-79, MTW cabling alleviates the documentation
requirement and eliminates any residual confusion over
whether a given AWM product is approved and properly
labeled. MTW also has a host of technical advantages that
derive from its superior flexibility and resistance to flame,
MTW. This extra insulation allows some types of MTW to
pass flame tests (FT 4) more rigorous than those for even
the best AWM.
Reversing the AWM ban reflected the realities of the
global machinery marketplace in which AWM remains a
widely used cabling choice. The restrictions imposed by
the new NFPA standard attempts to negate the potential
drawbacks of AWM.
The first restriction states that the AWM must be iden-
tified as suitable for the application at hand and must be
used in accordance with the machine-manufacturers in-
structions. Other restrictions detail cable construction in-
cluding minimum conductor count, flame resistance, and
wall thickness. Compliant AWM cable must carry a jacket
print legend that spells out the AWM style number, volt-
age, temperature rating, and flame rating.
The reversal on AWM
usage also requires more
documentation. For ex-
ampl e, manuf act urers
must provide field-instal-
lation information related
to the AWM wi re with
each machines technical
documentation.
Easy compliance
Given all the cable runs
on and around todays com-
plex industrial machines,
t he need to document
AWM usage for each and
every machine represents
the most onerous of all the
Exposed cable runs for fast installation
Another change in the 2012 NFPA-
79 standard allows exposed cable runs
along the structure of the equipment or
in the machine chassis. As long as the ex-
posed cables closely follow the surface
and structural members of the machine,
the installation does not require conduit,
raceways, or any special hardware. Thanks
to reductions in installation time and la-
bor, exposed cable runs can reduce costs
dramatically compared to traditional in-
stallation methods that need conduit or
special mounting hardware.
Certain UL-listed cables meet exposed
run (-ER) specifcations, which provide an
additional level of protection for these
types of applications. Cables meeting -ER
requirements are subjected to the same
crush and impact tests as armored-type
or metal-clad (MC) cables, that lets cables
leave the machine area and enter a cable
tray without conduit.
Keep in mind, though, that not all UL-
listed cables meet NFPA requirements,
especially lower-priced commodity and
rigid products.
A Krones technician documents the use of AWM in
compliance with NFPA-79.
This diagram shows where
the different wire classes apply for
plant and machine wiring as detailed by
the NEC and NFPA-79 code.
oil, chemicals, and mechanical stresses.
Some MTW products carry a UL
TC listing for use in tray cables and may
be rated for use in exposed runs. These
broadly certified MTW cables adapt to
the widest range of application require-
ments, and their use in exposed runs can
slash installation costs.
MTWs technical edge notwithstand-
ing, there are times when AWM may be
the best choice. For example, AWM may
win out in overseas markets for supply-
chain reasons.
If you do go with AWM, make sure
the product you buy is of a high quality
designed to withstand all of the abuse
found in an industrial environment.
Most importantly, buy only from repu-
table suppliers that can help you comply
with the complex labeling, documenta-
tion, and application hurdles imposed by
NFPA-79. MD
Common electrical-compliance questions
With both UL requirements and NFPA standards holding
sway over diferent aspects of electrical compliance, its al-
ways been tough to fgure out whether a given cable choice
will pass regulatory muster.
The job of picking compliant cables recently became
even tougher when the latest version of NFPA 79, the main
standard governing the electrical safety of industrial ma-
chines, drastically changed the compliance picture.
Here are some of the most commonly asked compliance
questions and answers:
Is NFPA-79 a law?
No. NFPA-79 is the key electrical safety standard accepted
by machine builders, installers, and buyers in the U. S. It is
also used as a reference by the National Electric Code.
Must a machine comply with NFPA-79?
In most cases, yes. The need for NFPA compliance ulti-
mately depends on the application details and whether the
machine is being installed in a building. When in doubt, its
a good idea to comply with NFPA-79 to maximize safety and
avoid potential litigation.
Will machine builders and buyers standardize on the
new edition of NFPA-79?
Yes. Concerns about safety and liability issues will force
compliance with the new 2012 edition of the NFPA standard.
Buyers of industrial equipment are unlikely to purchase non-
compliant machines that could increase the potential for
litigation.
Who decides which cables can be installed in the
feld?
Engineers may assume that UL dictates cable choice, but
the real authority falls with electrical inspectors who deter-
mine compliance with the National Electrical Code. How-
ever, UL does control the electrical, physical, and environ-
mental-testing requirements and approvals that, in practice,
determine cable usage in the feld.
Are UL listed cables always allowed for use on a
machine?
Not necessarily. There are machines that use UL-listed
cordage incorrectly. For example, some listed cables are only
intended for temporary applications. Other listed cables
may not meet the minimum stranding requirements needed
for NFPA-79 compliance.
Whats special about MTW approval?
Machine-tool-wire (MTW) approval requires that the
cable be fexible and ofer a high degree of mechanical du-
rability. These qualities let it perform under the challenging
conditions surrounding industrial machines.
Are all MTW cables oil resistant?
Yes, all compliant MTW cables minimally meet the re-
quirements of the UL Oil Res I test. For applications requir-
ing more-severe exposure, the more-rigorous Oil Res II test
is also a permitted option.
Can I run MTW cable into building infrastructure?
No, not unless it is dual marked with the appropriate UL
Listing. Cables marked TC ofer the high fammability rat-
ing needed for installation in building infrastructure. The
MTW requirements mandate that a cable only meet the
minimal fame test known as VW1.
Can cables be left exposed when going from the ma-
chine to the cable tray?
In most cases, no. Cables designed for exposed runs must
have TC-ER approval.
Communication cables, tray cables,
and exposed-run applications
NEC-336, 392,
501, AND 800
NFPA-79 Machinery area
Cordage NEC-400
NFPA-79 UL
MTW or AWM
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or visit www.hofmanonline.com/excelerate
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ORR ON ENGINEERING
The death of e-mail?
People are already rejecting e-mail as their main form of
communication in their social lives and are starting to do
so at work. What does this mean for engineering organiza-
tions and why should you care?
Consider the twenty-something now entering the
workforce who mostly communicate via Facebook, Twit-
ter, and text messaging. They are why engineering or-
ganizations should introduce software such as Yammer,
Jive, or Tibbr. These enterprise social systems provide
companies with a better way to communicate than the
point-to-point networks of e-mail. Engineers dont have
to search e-mail and sort through a swamp of irrelevant
information.
Yammer and Jive still allow person-to-person commu-
nications and all the features users look for in e-mail. But
everything happens inside the enterprise firewall. Enter-
prise social systems are thus more secure than e-mail. The
applications also make it more clear that the contents of
your communications belong to the company and can be
accessed by management. Of course, this is true of corpo-
rate e-mail, though that may not be obvious to everyone.
Yammer is said to let users collaboratively create, edit,
and publish content with coworkers right from a browser.
Users can display team goals, compile notes, and draft
documents together online, viewing
character-by-character changes in real
time as others make edits to a page.
Jive is said to let users follow people, projects, and con-
tent critical to their jobs. And Jive doesnt flood them with
irrelevant updates. Its smart enough to pick out just what
you really need to know. Away from your computer? You
can access all your Jive conversations and colleagues from
a smartphone or tablet. Browsing the Web? Jive brings
social collaboration to every Web site and app. Using
Microsoft Office or Outlook? Jive lets users share, collabo-
rate, and participate from these familiar programs.
Lastly, Tibbr is said to let users filter and organize in-
formation to match the way they work. Most engineers use
about nine different applications a day, making it hard to
find just the right piece
of information to com-
plete a task. Tibbr helps
users boil everything
down by letting them,
say, approve expense
reports or order more
inventory.
Joel Orr
Resources:
Joel Orr, Copywriter, www.
joelwritescopy.com
(650) 336-3937
Edited by Leslie Gordon,
LeslieGordon
RS# 130
Farmington Hills, Ml 48335
tel: 800-521-3320 / fax: 248-476-2470
e-mail: shocks@acecontrols.com
www.acecontroIs.com
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SOFTWARE REVIEW
Every year, software companies
introduce new versions, prom-
ising new features and
exciting improvements.
SolidWorks 2013 up-
holds this tradition. In
addition, you may have
heard rumblings about
features that users have
been wanting for years.
SolidWorks is at least
listening.
For example, its a no-
brainer for big companies
to keep up with constant
software updates, even
though this is an expen-
sive proposition. But for
small businesses, its a
different story. So what
do they do? They dont upgrade
every version. But then these small
shops get files they cant open or
they get dumb solids through a
translator.
To address this issue, users have
begged SolidWorks to act more
like Microsoft Word, which has a
downloadable compatibility pack-
age that opens newer versions.
Until now, SolidWorks has stead-
fastly refused to provide this capa-
bility. But SolidWorks 2013 at least
works with previous releases. This
means that from this release on,
if you have service pack 5 of a re-
lease, you will be able to read the
very next versions files. You wont
be able to do much with them. You
can add to them and subtract from
them. But you wont be able to di-
rectly access the feature tree. Its a
nod to what users want and better
than nothing.
That said, other improvements
to the software make modeling
easier. Youve been able to save
user-defined views for a long time
by right-clicking in the graphics
area and selecting the telescope
icon. But you had to rotate or
otherwise orient the model, an
inaccurate process. You have an
isometric view, but how about get-
ting a reverse isometric view? The
new version lets users orient mod-
els quickly and easily. The nice part
is that you can save views to use in
other documents. You can also add
more than one exploded view to
a configuration. And you can copy
and paste exploded views.
In another example, building an
assembly could get pretty tedious
in previous versions of SolidWorks.
If users didnt pin the dialog, they
would have to restart the Insert
Component command each and
every time they wanted to insert
something. Even when users
pinned the dialog, they could only
insert one component at a time.
SolidWorks 2013 lets users select
multiple components and insert
them all at once. Users can even
select multiple components and
place them sequentially. These ca-
pabilities are great timesavers.
And a nice enhancement is the
center-of-mass (COM) point. It is
reference geometry that tells you
at a glance where your assemblys
balance point will be. And its live.
It updates with any changes to
the model. Thats good for people
making devices that must be
SolidWorks 2013 makes
3D modeling easier
By selecting faces,
edges, or corners on
the View Selector,
users can look
at models from
different angles
more easily than
ever before.
RS# 131
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they can right-click an existing set
and pick Add To Baseline. When
the cursor changes, users select
any new items they want dimen-
sioned. It couldnt be much easier.
Another new feature I like is the
ability to import and link tolerance
and precision data from the model
onto the drawing. So when users
change the value in a model, the
drawing updates. Users can even
specify that they want to import
only dimensions that have toler-
ances. Slick!
Last, when Autodesk pur-
chased MoldFlow, injection-mold-
ing analysis ceased to be part of
SolidWorks. That has been an an-
noyingly large gap in the software.
Third-party applications attempt
to fill the need, but nothing works
in SolidWorks. Fortunately, Version
2013 fills the gap with SolidWorks
Plastics. I am told there will likely
be a pared down Plastics Xpress
included for free in future versions.
Mike Hudspeth
Why would users want to do that?
There are times when a subassem-
bly must be replaced with a single
part or vice versa. SolidWorks lets
you go through all of the steps to
select and confirm a replacement
but then it tells you, You cant do
that. The new version does lets
users create swept cut features in
assemblies and then propagate
them to the component part files.
In addition, users can now
control models materials via a
design table. Youve been able to
configure dimensions and color
but not materials until now. Say
youre a bullet manufacturer, for
example, with special clientele.
Each customer wants 45 bullets,
but one wants them in lead, one
wants steel, and one wants silver.
Now you can do that.
Other helpful new features:
SolidWorks 2013 lets users add
new dimensions to an existing set
of baseline dimensions. Previously,
users had to add a new set. Now
balanced like swords, guidance
systems, and even tennis racquets.
Users can even mate to the COM of
a component in an assembly (but,
interestingly, not to the COM of
the assembly itself ).
Another enhancement: The
Replace Component command
lets users replace a component
with another of the same name
and type from another folder.
SolidWorks hasnt previously let
users do that. This will be well
received by designers who have
had to update models from, say,
outside vendors. Unfortunately,
the capability to replace a com-
ponent with a different type of
component is not yet available.
LeslieGordon
Resources:
Mike Hudspeth is a designer with more than
two decades of experience, a lifelong artist, and
an avid model builder.
The software comes from Dassault Systmes
SolidWorks Corp., www.solidworks.com
RS# 426
RS# 132
SPOTLIGHT ADHESIVES & FASTENERS
Ceramic fasteners
A range of
ceramic nuts,
bolts, and
washers handle
applications
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Standard products includes alumina
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Adhesives
Line of adhesives complements the Raychem brand
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The new
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The closures are both touch and press
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The transparent closures come in widths
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devices are available in multiple resins and
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RS# 447
Standoff fasteners
PEM unthreaded Keyhole and Snap-Top standoff
fasteners mount and detach PC boards, panels, or
components without tools or hardware. Both fasten-
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or eliminate the risk of loose hardware damaging
internal circuitry, and allow screwless designs of
subassemblies.
Keyhole Type SKC stainless-steel self-clinching
standoffs let PC boards or panels be slipped quickly
into place and removed from an assembly by simply
sliding the board
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a single threaded
standoff further
improves security.
Snap-Top Types
SSA, SSS, and SSC
aluminum, steel,
and stainless-steel
standoffs clinch
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and Type KSSB
brass standoffs
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hold boards and panels securely, while allowing quick attach-
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All install permanently in sheets or panels as thin as
0.040in./1 mm by squeezing them into a properly sized hole.
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RS# 448
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Loctite 3193T delivers high adhesion to plastic, while
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LOCAs provide better adhesion and reliability than
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Henkel Corp., Engineering Adhesives, One Henkel
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kelna.com/loca RS# 450
Loctite Liquid Optically Clear Adhesives (LOCA) in-
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RS# 136
RS# 135
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or excessive wear of the
bearings and compo-
nents in the machinery
or the engine supplying
fluid to the filter assembly.
Inspection can be done
without draining, leaking,
or losing any fluid or oil, and
See-through
filter assembly
See-through filter
assemblies let us-
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fluid or oil pumping
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determine fluid condi-
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element and contaminants/
particles that have been filtered out of
the fluid system. Users can determine
if the particles are from normal use
without unbolting or loosening any
fasteners or fittings. The filter element
comes in micron mesh and can be
cleaned and reused.
Clear View Filtration, 7320 North
Regal St., Spokane, WA 99217, (509)
467-7584, www.clearviewfiltration.com
RS# 467
Programmable linear-
position sensors
The LS1 Series of noncontact linear
position sensors. are insensitive to
magnetic fields and have no mechani-
cal sensor track. Models are available
with and without a return spring.
The unit features programmable
end-points that are set using push-
buttons on top of the sensor. Pro-
gramming is through a signal proces-
sor and two LED programming status
indicators. An output range can be
programmed either the same as, or in-
dependent of, actual travel length by
setting minimum and maximum out-
put levels. Current or voltage output
levels can be programmed separately
from position programming.
Key specifications include a 25
to 100-mm measurement range for
the return spring version and 25 to
200 mm for rod-only version. Resolu-
tion is to 0.05 % and repeatability to
less than 0.05%. Four output options
are available: 0.1 to 10 V, 4 to 20 mA,
10 to 0.1 V, and 20 to 4 mA. Sensor life
is >100 million movements.
Novotechnik U.S. Inc., 155 North-
boro Rd., Southborough, MA 0177,
(508) 485-2244, www.novotechnik.
com/ls1 RS# 468
RS# 137
NOVEMBER 22, 2012 MACHINE Design.com 58
B&B Electronics is a global source
for rugged, reliable,
edge-to-backbone wired and
wireless networking.
Backed by strong technical
support, B&Bs Ethernet, USB,
Wireless and Serial solutions are
known for being easy to use, easy
to install and easy to order.
Contact:
B&B Electronics
Tel: 888.948.2248
Email: orders@bb-elec.com
URL: http://www.bb-elec.com
Download B&Bs latest white papers:
http://bb-elec.com/technical_library.asp
RS# 255
Stainless Steel
Tube Fittings
20-page catalog (#74-H) describes
these Mark VIII O-SEAL stainless steel
tube fittings that will not shake loose.
Unique leakproof sealing system al-
lows easy slip-in, slip-out connections
matched to your system. O.D. tube
sizes from 1/4 to 2. Reliable to 6,000 psi for liquids and gases.
Available in steel, bronze, monel, and titanium. Call 888-278-
5449, Web: www.cpvmfg.com
CPV Manufacturing Inc., Philadelphia, PA
POSITAPE
Tape Extension Position Sensors

utilize the functional principle of the
Cable Extension Position Sensors.
Constructed with a specially designed stainless steel
tape they are perfectly suited for applications that re-
quire pulleys due to tight locations.
ASM Sensors, Inc.
650 W. Grand Ave., Unit 205
Elmhurst, lL 60126, USA
(630) 832-3202
info@asmsensors.com
www.asmsensors.com
Brushless DC and Intelligent Servo Motors
Dunkermotor releases its 2012
Low Voltage Brushless DC and
Intelligent Servo Motors catalog.
Expanded catalog includes
specifcations on custom confg-
urable BLDC motors, controls,
gearheads, brakes, encoders
and accessories. Available for
complimentary download at
Dunkermotor website or email
request for hard copy.
Dunkermotor
Email: info@dunkermotor.com
Web: www.dunkermotor.com/2012_BLDC_catalog
Get Your 2012/2013 Cable & Wire Catalog Today!
Wondering if we carry a cable that meets your needs? Then the 2012/2013
HELUKABEL
Cables and Wires Catalog is a must have item for your office.
Inside the 2012/2013 Cables and Wires Catalog:
Spec Sheets for 30,000+ Line Items
Cable and Wire Selection Tables
Over 100 Pages of Cable and Wire
Technical Information
Available in hard copy or on CD
With the 2012/2013 Cables and Wires Catalog
on your desk, the solution to your cable and
wire problem is only an arms length away!
847-930-5118
cables@helukabel.com
www.helukabel.com
New Shock Absorption and Vibration
Dampening Catalog
ACEs SLAB product is designed
to absorb shock loads and insulate
vibrations for machines, crane rails,
hydraulic crushers, presses, and more.
Reduce impact forces and noise.
Extend machine life. Made of
visco-elastic PUR materials and
manufactured to a patented formula.
Available in a variety of densities,
thicknesses and dimensions.
ACE Controls Inc.
Farmington Hills, MI
(800) 521-3320 (248) 476-0213
Email: shocks@acecontrols.com
www.acecontrols.com
Multi-Purpose Pneumatic Tools
Hand or bench models
improve productivity. Make
plumbing assemblies; splice
cable and wire rope; crimp,
swage, stake, punch, pierce,
fare, seal, emboss,
and notch.
Fabco solves problems
Let us help!
FABCO-AIR, Inc.
Gainesville, Florida
Helical Products Co., Inc.
COUPLINGS, U-JOINTS
and MACHINED SPRINGS
Helicals 28-page catalog
features miniature fexible
couplings, u-joints, power
transmission couplings and
machine springs. Quick-
reference, product summary
chart highlights features and
technical data. Easy-to-use part
number builders make ordering
easy.
Visit: www.heli-cal.com
RS# 251
RS# 260
RS# 263
RS# 254
RS# 256
RS# 259
RS# 262
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2013 Washers Catalog
The complimentary 2013
Washer Catalog illustrates
Bokers 27,000 non-standard
fat washer sizes, wide range
of outside diameters, from
0.080 to 5.140, variety of
inside diameters and
thicknesses, as well as its
over 2,000 materials. With
its extensive selection and
custom capabilities, Bokers
provides endless washer
possibilities and manufactures
solutions to your exact
specifcations. ISO 9001:2008
Registered
www.bokers.com/mdds
Clamps and Tooling
Components
This 688-page, illustrated
catalog includes toggle
clamps, pins, hoist rings,
knobs, modular fxturing,
supports, jig and fxture
bases, drill bushings and
power workholding devices.
Full specs included. Online
version at carrlane.com.
Carr Lane Mfg. Co.
St. Louis, MO
www.carrlane.com
DATA FILE LITERATURE ADVERTISING
Website to quickly find and
RS# 257
RS# 264
RS# 258
RS# 253
New tutorials and podcasts on Learn Web site
What is a PLC plus many more
topics on industrial control prod-
ucts including new videos and
podcasts on AutomationDirects
free self-service learning site.
Visit http://learn.automationdirect.com
to watch these and other tutorials
on a range of industry topics.
HAZARDOUS LOCATION SERVO INDEXERS
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CENTRICITY CORPORATION
www.centricity.net 330-545-5624
New BEI Sensors Selection Guide Covers Products,
Environments and Technology for Motion Control
BEI Sensors product selection guide
explains the fundamentals of various
speed and position sensing technolo-
gies and how to choose which is best
suited to a particular application.
BEIs extensive line of rugged products
include rotary encoders, rotary and
linear potentiometers and rotary
Hall effect sensors, all of which are
displayed in easy-to-read charts that
summarize the most critical specifca-
tion criteria side-by-side.
www.beisensors.com/guide
RS# 252
RS# 261
RS# 250
MACHINE Design.com 59
POWER TRANSMISSION STRETCH BELTS
Pyramid Inc. has manufactured round and flat
Pyrathane
belts for over 40 years.

Pyrathane
belts are used in a wide variety of

low and fractional horsepower drive
applications such as live-roller conveyor
systems, as well as transport devices for paper,
currency and small parts. Pyrathane
belts are
manufactured to our customers specifications
and are of the highest quality with exceptional
abrasion resistance and durability.
Pyramid Inc.
522 N. 9th Ave. E. Newton, IA 50208
Phone: 641-792-2405 Fax: 641-792-2478
E-mail: sales@pyramidbelts.com
Website: www.pyramidbelts.com
Cross-referenced to metal
cam followers for
easy replacement
Only our patent pending iCamFollowers
offer all these advantages: plastic tire elimi-
nates rail wear; no lubrication is required in
the bearing or on the rail; reduce noise up
to 10dB; absorb shock and vibration; high
load capacity; ball bearings permit higher
linear speeds; lighter weight reduces inertia;
are suitable for use in clean rooms; wash
downs; work well in subzero temperatures
(-40F). For load ratings and sizes go to
www.intechpower.com/icam.
Intech Corporation, 201-767-8066
Over 15,000 products +
everything you need to know
about
Order your free copy today at: www.orientalmotor.com
- Stepping Motors
- Servo Motors
- AC Motors
- Brushless Motors /
AC Speed Control Motors
- Linear & Rotary Actuators
- Cooling Fans
Encoders
for OEMs
Orders placed
before 11 A.M. PST,
ship same day.
Order Today,
Get It Tomorrow
usdigital.com
360.260.2468
sales@usdigital.com
NOVEMBER 22, 2012
New Safety Sensing and Signaling Catalog
New Tapeswitch Corporation
safety, sensing, and signaling
product guide features machine
guarding and personnel protec-
tion, including a complete line of
switches, ribbon switches, safety
and sensing mats, edges, and
bumpers, light curtains, safety
interface controllers, custom
products, power isolation and
access trapped key interlocks,
and non-contact interlocks for
hard guard and enclosure safety.
Order Free Catalog Today.
www.tapeswitch.com
Smalley Steel Ring Company
New Smalley Engineering
& Parts Catalog
Smalleys new catalog combines
existing Spirolox Retaining Ring
and Smalley Wave Spring selec-
tions with series recently released
from Smalley. Now a single catalog
includes new: Hoopster Rings, Met-
ric Wave Springs, Constant Sec-
tion Rings and more. Over 10,000
standard parts in carbon and stain-
less steel; free samples available.
Specials manufactured with
No-Tooling-Costs from .200-120.
(847)719-5900 info@smalley.com www.smalley.com/getcatalog
www.masterbond.com
Epoxy Impregnant Seals Metals And Non-Metals
tight security
One Component EP19HT
Chemically resistant
Resists up to 400F
Seal Master Corp., Kent, OH
SEALS, ACTUATORS,
GRIPPERS AND BAGS
Solve difficult closure prob-
lems with custom-built, fab-
ric-reinforced, fully molded
elastomeric Seal Master
infatable seals. With close
tolerance capability and re-
sistance to compression,
theyre ideal for imaginative production and processing
applications too. Engineered specialties include fabric-
reinforced bags, bladders, plugs and other custom rubber
products. Design assistance offered.
RS# 273
RS# 269
Taylor Devices Inc.
TAYLOR DEVICES UNI-SHOK
Taylor Devices offers the Uni-Shok industrial
shock absorber for high-speed, au-
tomated machinery. Available in
14 models, Uni-Shok provides
up to 5000 in-lbs. of
capacity. Patented,
self-adjusting fuidic
metering system eliminates adjustment down-time. Features
stainless steel piston rod, internal coil spring reset, bronze
bearings, silicone fuid and threaded body for mounting ease.
Contact: Taylor Devices Inc., 90 Taylor Dr., N. Tonawanda, NY
14120-0748.
Phone: 716.694.0800 Fax: 716.695.6015
Web site: www.taylordevices.com
RS# 267
RS# 276
RS# 272
RS# 265
RS# 268
RS# 271
RS# 275
SELF-LUBRICATING GEAR
SOLUTIONS CALCULATED FOR LIFE
The Intech Power-Core gears are precision
machined and offer solutions to applications
in which lubrication, wear, noise, vibration,
inertia, shock load, moisture and chemicals
present a problem for nylon, Delrin or metal
gears. Metal Core provides for a secure at-
tachment to the shaft and higher torque trans-
mission. Gear design and sizing is backed
by durability calculation using proprietary
software.
Intech Corp., 250 Herbert Ave., Closter, NJ
07624. (201) 767-8066; Fax: (201) 767-7797.
www.intechpower.com
The DPGM409 covers the full spectrum in pressure measurement with Gage,
Sealed Gage, Absolute, Compound Gage, Vacuum, and Barometric pressure
ranges. Its core is a highly stable micromachined silicon sensor with a very high
0.08% accuracy. Each unit is supplied with a 5-point NIST traceable calibration
certicate and is tested to industrial CE standards. A user selectable analog
output of either 0 to 5 Vdc, 0 to 10 Vdc or 4 to 20 mA is standard on all models
and a built-in wireless transmitter option is also available.The electronics are
enclosed in a stainless steel and ABS housing that is washdown rated and has
a unique magnetic stylus system for programming that prevents accidental
programming changes.The display has large 25.4 mm (1 in) digits plus a 0 to
100% bargraph. MIN/MAX/AVG readings are front panel programmable and free
data logging and charting software is included. A wireless transmitter option
is available to transmit the readings to a receiver in your control room. Power
comes from a long life lithium battery (included) with a typical life of 4 years.
Price Starts at $695
OMEGA Introduces DPGM409 Pressure Gauge with Metric
Fittings and Ranges
Omega | Stamford, CT USA | www.omega.com
Email: info@omega.com | Twitter: @OmegaEng
Facebook: http://www.facebook.com/pages/Omega-Engineering/121219014465
Phone: 1-800-TC-OMEGA or 203-359-1660
Nomex
Insulating Tubing & Bobbins

Nomex
is a calendered, aramid
insulation paper that, when wound
into an insulating tube with appro-
priate binders, offers superior high
temperature resistance and high
dielectric strength in insulating
tubing and bobbins Nomex also
possesses excellent mechanical
toughness, resilience and high
mechanical strength. Full PDF Lit
fle available at www.pptube.com.
Precision Paper Tube Co., Inc
The Original - Since 1934
847-537-4250
www.pptube.com
sales@pptube.com
Nomex is a registered trademark of the DuPont Co.
Trim-Lok Inc., Buena Park, CA
Vinyl & Rubber Extrusions
Trim-Lok Inc. releases a brand new
FREE Catalog 500 featuring How
to Order steps for the frst time
customer, along with an expanded
line of complete trims and seals.
FREE samples may be requested.
Latest additions include our Flap
Seal, Fire Retardanct Trim, adn
Hatch Seal. Contact us toll fee at
1-888-874-6565, e-mail us at info@
trimlok.com or visit us on-line at
www.trimlok.com
RS# 274
RS# 279 RS# 278
RS# 282
RS# 281
RS# 277
RS# 280
RS# 266
RS# 270
Powerful,
clean, efcient.
High performance
drum motors
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SHOCK
& VIBRATION
SOLUTIONS
Celebrating 30 Years
Of Providing Custom
Engineered Solutions
& Standard Products
www.sorbothane.com
800.838.3906
MADE IN
THE U.S.A.
Depiction of
Frequency Waves
Depiction of
Frequency Waves
BUSINESS INDEX
This index includes all significant references to
parent companies mentioned in feature editorial
material within this issue of MACHINE DESIGN. It doesnt
cite companies listed solely in the Products and
Lit Section. Page numbers listed refer to the pages
where the articles begin.
Sil-Pro. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Simrit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SolidWorks . . . . . . . . . . . . . . . . . . . . . . . . . .47, 52
Sony . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Southco. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TE Connectivity. . . . . . . . . . . . . . . . . . . . . . . . . 54
techfortrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Texas Workforce Commission . . . . . . . . . . . 30
Tibbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Tolomatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Toshiba . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Toyota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Toyota Research Institute of
North America . . . . . . . . . . . . . . . . . . . . . . 45
Twitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
U. S. Naval Research Laboratory . . . . . . . . . 22
University of Pretoria . . . . . . . . . . . . . . . . . . . 28
Velcro USA Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 54
Virginia Tech University . . . . . . . . . . . . . . . . . 21
W.L. Gore & Associates Inc. . . . . . . . . . . . . . . 18
Wermac Electric Ltd. . . . . . . . . . . . . . . . . . . . . 28
Workforce Solutions for Tarrant County . . 30
Yammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Yaskawa Motoman Canada . . . . . . . . . . . . . 28
Yaskawa Wermac . . . . . . . . . . . . . . . . . . . . . . . 28
Google. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Henkel Corp., Engineering Adhesives. . . . 55
ITI TranscenData. . . . . . . . . . . . . . . . . . . . . . . . 33
Jive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Kollmorgen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Krones Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Lapp USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
MICROMO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Microchip Technology Inc. . . . . . . . . . . . . . . 30
Microsoft. . . . . . . . . . . . . . . . . . . . . . . . . . . .51, 52
MoldFlow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Mouser Electronics Inc. . . . . . . . . . . . . . . . . . 30
NASA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12, 25
NASA Jet Propulsion Laboratory. . . . . . . . . 25
NASA Langley Research Center. . . . . . . . . . 38
National Fire Protection Association. . . . . 48
National Instruments . . . . . . . . . . . . . . . . . . . . 6
OTTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Panasonic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PennEngineering. . . . . . . . . . . . . . . . . . . . . 6, 54
PI (Physik Instrumente) Inc.. . . . . . . . . . . . . . 30
Precision Polymer Casting LLC. . . . . . . . . . . 42
Precora Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Purdue University . . . . . . . . . . . . . . . . . . . . . . 23
Rethink Robotics . . . . . . . . . . . . . . . . . . . . . . . . 6
Rittal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Samsung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Sierra Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Advanced Technology Labs of Adobe Inc.23
Agilent Technologies . . . . . . . . . . . . . . . . . . . 28
Ansys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Autodesk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Avago Technologies Ltd. . . . . . . . . . . . . . . . . 38
BMW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Boeing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Bosch Rexroth. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CNBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
C.O.M.B. Liquidators . . . . . . . . . . . . . . . . . . . . 36
Carlisle Coatings and Waterproofing Inc.. 28
Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Chrysler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Comsol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Concilium Technologies . . . . . . . . . . . . . . . . 28
Daimler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dixon Sintaloy Inc. . . . . . . . . . . . . . . . . . . . . . . 26
Douglas Aircrafts Missile and
Space Systems Div. . . . . . . . . . . . . . . . . . . 26
Drives & Motion Div. of
Yaskawa America Inc. . . . . . . . . . . . . . . . 28
Eaton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fabrico. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 28
Facebook . . . . . . . . . . . . . . . . . . . . . . . . . . .12, 51
Faulhaber Group . . . . . . . . . . . . . . . . . . . . . . . 16
Freudenberg and NOK Group . . . . . . . . . . . 21
General Motors Corp. . . . . . . . . . . . . . . . . . . . . 8
Gibbs Sports Amphibians Inc. . . . . . . . . . . . 20
Goodfellow Corp. . . . . . . . . . . . . . . . . . . . . . . . 54
RS# 139
RS# 138
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With Visumatic
Robotic Fastening
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All of these dene
Visumatics automatic
fastening components.
Ready to drop in place,
congured to your specs,
AND every Visumatic
product is backed with our
unmatched Human Touch
customer service.
Smarter Machines
from Creative Engineers
for Smart Customers
C O N 5 | D E k
TheViperMBC
Rise of the
Machines
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FOR SCARA ROBOTS
ADVERTISER INDEX
RS# . . . . COMPANY. . . . . . . . . . . . . .PAGE
143 . . . . . Absopulse Electronics Ltd. . . . 63
131 . . . . . Ace Controls. . . . . . . . . . . . . . . . . . 52
147 . . . . . Airfloat . . . . . . . . . . . . . . . . . . . . . . . 56
113 . . . . . Alcoa Fastening Systems . . . . . 15
104 . . . . . Allied Electronics . . . . . . . . . . . . . . .5
101 . . . . . Altech Corp. . . . . . . . . . . . . . . . . . IFC
126 . . . . . ASM Sensors . . . . . . . . . . . . . . . . . 33
103 . . . . . Automationdirect.com. . . . . . . . .3
123 . . . . . Avago Technologies U.S. Inc. . 29
102 . . . . . Avnet. . . . . . . . . . . . . . . . . . . . . . . . . . .1
136 . . . . . Bokers Inc. . . . . . . . . . . . . . . . . . . . 56
127 . . . . . Centricity Corporation . . . . . . . 44
146 . . . . . Clippard Instrument
Laboratory, Inc. . . . . . . . . . . . . . . . BC
137 . . . . . Dunkermotor . . . . . . . . . . . . . . . . 57
133 . . . . . Forest City Gear . . . . . . . . . . . . . . 55
117 . . . . . Gortrac, Division of
A&A Mfg. Co., Inc.. . . . . . . . . . . . . 19
125 . . . . . Helical Products
Company, Inc. . . . . . . . . . . . . . . . . 31
142 . . . . . Hernon Manufacturing. . . . . . . 63
139 . . . . . Interroll Automation, Llc . . . . . 60
141 . . . . . Linx Technologies . . . . . . . . . . . . 62
121 . . . . . Master Bond, Inc. . . . . . . . . . . . . . 27
109 . . . . . MITRPAK. . . . . . . . . . . . . . . . . . . . . . 10
111 . . . . . NB Corp . . . . . . . . . . . . . . . . . . . . . . 13
114 . . . . . Newark/Element 14. . . . . . . . . . 17
132 . . . . . Nexen Group Inc . . . . . . . . . . . . . 53
108 . . . . . Oasis Materials Company Lp . 10
. . . . . . . . . Ondrives.us. . . . . . . . . . . . . . . . . . . 26
110 . . . . . Penn Engineering . . . . . . . . . . . . 11
130 . . . . . Pentair Technical Products . . . 51
145 . . . . . Proto Labs, Inc. . . . . . . . . . . . . . . IBC
118 . . . . . Rittal Corporation . . . . . . . . . 22-23
112 . . . . . RJS Corporation . . . . . . . . . . . . . . 14
107 . . . . . Rollon . . . . . . . . . . . . . . . . . . . . . . . . . .9
129 . . . . . Rotor Clip Company. . . . . . . . . . 47
124 . . . . . SAB Associated Wire Products 30
115 . . . . . Servometer . . . . . . . . . . . . . . . . . 18
122 . . . . . Smalley Steel Ring Company. 28
138 . . . . . Sorbothane Inc. . . . . . . . . . . . . . . 60
While every effort has been made to ensure the
accuracy of this index, the publisher cannot be
held responsible for any errors or omissions.
106 . . . . . Spirol International
Corporation . . . . . . . . . . . . . . . . . . . .8
135 . . . . . Stock Drive Products . . . . . . . . . 56
128 . . . . . Techno Inc. . . . . . . . . . . . . . . . . . . . 44
116 . . . . . Techno Omil. . . . . . . . . . . . . . . . . . 18
144 . . . . . U.S. Tsubaki Incorporated . . . . 64
. . . . . . . . . UBM Cannon. . . . . . . . . . . . . . . . . 32
119 . . . . . Veljan Hydrair Ltd. . . . . . . . . . . . . 24
120 . . . . . Veljan Hydrair Ltd. . . . . . . . . . . . . 25
134 . . . . . Vesco Plastics Sales. . . . . . . . . . . 55
140 . . . . . Visumatic. . . . . . . . . . . . . . . . . . . . . 61
105 . . . . . ZERO-MAX . . . . . . . . . . . . . . . . . . . . .7
Website to quickly find and
RS# 140
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RS# 141
BACKTALK
Engineering
failures/disasters
The field of engineering evolves daily.
The marvels of engineering far out-
weigh the failures/disasters. These fail-
ures and/or disasters result when engi-
neers and designers push boundaries by build-
ing taller buildings, longer bridges, or reach-
ing further out into space. After such an event,
changes are made and regulations introduced
until further developments outstrip them.
A Web site, Engineering Failures Case
Studies in Engineering (engineeringfailures.
org), contains case studies in engineering de-
sign, construction, operation, maintenance, management, and interface with
nonengineering organizations and personnel.
Examples of such disasters include the Soyuz 11, Tacoma Narrows Bridge,
FDIV Bug in Pentium, a freight train carrying ethanol derailing in Illinois, three
injured in a North Dakota oil-well explosion, Sayano-Shushenskaya Hydro-
electric power-station accident in Khakassia, Russia, and the Hyatt Regency
walkway collapse in Kansas City, Mo.
The sites intent is to let readers reflect on what led to the failures and use
the knowledge to advance engineering. MD
Coolest
tech toys
for 20121
Accor di ng
t o CNBC,
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f or 2012
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Samsung
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The Worlds Slimmest
Digital Camera
Continued on page 64
RS# 143
RS# 142
BACKTALK
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Note with S Pen, LG
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RS# 144
T H E U L T I M A T E P O W E R T R A N S M I S S I O N C O M P O N E N T P A C K A G E
Tsubaki cubed.

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2011 U.S. Tsubaki Power Transmission LLC , . All Rights Reserved.
211MADB64_rev_1.indd 1 11/8/12 4:24:14 PM
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RS# 146

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November 22, 2012

A Penton Media Publication

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