Machine Design May 2014 PDF

machinedesign.
com
MAY 8, 2014
WORLDS BIGGEST
CABLE CARRIER p. 16
SOFTWARE SEES
VIBRATIONS BEFORE
THEY HAPPEN p. 36
COOL AND SMOOTH:
HOW TO POLISH 3D-
PRINTED PARTS p. 40
BY ENGI NEERS FOR ENGI NEERS
GEARING UP FOR AN
INDY
SPEED RECORD
p
|
32
Digital Edition Copyright Notice
The content contained in this digital edition (Digital Material), as well as its
selection and arrangement, is owned by Penton. and its affliated
companies, licensors, and suppliers, and is protected by their respective copyright,
trademark and other proprietary rights.
Upon payment of the subscription price, if applicable, you are hereby authorized
to view, download, copy, and print Digital Material solely for your own personal,
non-commercial use, provided that by doing any of the foregoing, you
acknowledge that (i) you do not and will not acquire any ownership rights of any
kind in the Digital Material or any portion thereof, (ii) you must preserve all copyright
and other proprietary notices included in any downloaded Digital Material, and (iii)
you must comply in all respects with the use restrictions set forth below and in the
Penton Privacy Policy and the Penton Terms of Use (the Use Restrictions), each
of which is hereby incorporated by reference. Any use not in accordance with, and
any failure to comply fully with, the Use Restrictions is expressly prohibited by law,
and may result in severe civil and criminal penalties. Violators will be prosecuted
to the maximum possible extent.
You may not modify, publish, license, transmit (including by way of email, facsimile
or other electronic means), transfer, sell, reproduce (including by copying or
posting on any network computer), create derivative works from, display, store,
or in any way exploit, broadcast, disseminate or distribute, in any format or
media of any kind, any of the Digital Material, in whole or in part, without the
express prior written consent of Penton. To request content for commercial use or
Pentons approval of any other restricted activity described above, please contact
the Reprints Department at (877) 652-5295. Without in any way limiting the
foregoing, you may not use spiders, robots, data mining techniques or other
automated techniques to catalog, download or otherwise reproduce, store or
distribute any Digital Material.
NEITHER PENTON NOR ANY THIRD PARTY CONTENT PROVIDER OR
THEIR AGENTS SHALL BE LIABLE FOR ANY ACT, DIRECT OR INDIRECT,
INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT
OF THE USE OF OR ACCESS TO ANY DIGITAL MATERIAL, AND/OR ANY
INFORMATION CONTAINED THEREIN.
Mz0lzsl-0kz0c0
Pt0l0cl|00f00t
I|tslPt|0t|l.
High-strength safety screens from Lee.
Protect critical hydraulic components with screens tough enough to take on
severe transients and complete clogging. Lee Hi-Bar
safety screens wont

burst or collapse at pressures up to 7,500 psid in either flow direction.
Make Lee your first choice for last-chance protection.
Call 1-800-LEEPLUG or visit www.TheLeeCo.com today.
One-piece construction from
solid bar stock
Hole sizes from 35 to 1,200
microns
7,500 psid pressure capability
Flange, Boss or Fitting mount
Bidirectional flow
Custom design capability
Westbrook London Paris Frankfurt Milan Stockholm
The Lee Company
2 Pettipaug Road
Westbrook, CT 06498 USA
See us at AUVSI, Booth #2149
NEWS
16 GIANT CABLE CARRIER
KEEPS SLUDGE MOVING
DEPARTMENTS
4 ON MACHINEDESIGN.COM
10 LETTERS
14 WHATS INSIDE
Low-cost servomotors include
encoder, drive, and controller
Electronic latch resists corrosion
and the outdoors
27 SENSOR SENSE
Wirelessly send power and
signals
42 DISTRIBUTION
RESOURCE
56 PUZZLES, MYTHS,
AND CURIOSITIES
FEATURES
32 2014 INDY 500: A YEAR OF TRANSITION
Rules and regulations are being tailored for faster
races in the upcoming years.
36 SOFTWARE TECHNIQUES PREDICT
TORSIONAL VIBRATION
Lumped-mass models can be combined with experimental
measurements for vibration analysis. By applying such
models using a tool such as MapleSim, designers can
address a wide variety of vibration problems.
40 HOW TO SMOOTH 3D-PRINTED PARTS
Sanding, bead blasting, and vapor smoothing are the most
widely used methods for smoothing plastic 3D-printed parts.
COLUMNS
8 EDITORIAL
If Starbucks
behaved like a
manufacturer
12 COMMENTARY
Paperless
manufacturing:
This time, not a false alarm
28 THE FORENSIC ENGINEER
What you dont know
about critical speed failures
can hurt you
30 INTERVIEW
The other four-year degree
46 PRODUCT DEVELOPMENT
Top 5 R&D-Product
Development Metrics
ON THE COVER: The Rahal, Letterman, Lanigan race teams No. 15 National Guard Honda
at the Firestone Grand Prix of St. Petersburg.
PRODUCTS
48 PRODUCT SPOTLIGHT
Engineered Materials
49 LITERATURE EXPRESS
52 NEW PRODUCTS
54 AD INDEX
2 05.08.14 MACHINE DESIGN
Printed in U.S.A., Copyright 2014. Penton Media, Inc. All rights reserved. MACHINE DE-
SIGN (ISSN 0024-9114) is published monthly except for an extra issue in May, November,
and December by Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66212.
Paid subscriptions include issues 1-14. Issue No. 15 (OEM Handbook and Supplier Di-
rectory) is available at additional cost. Rates: U.S.: one year, $139; two years, $199;.
Canada/Mexico: one year, $159; two years, $239; All other countries: one year, $199;
two years, $299. Cost for back issues are U.S. $10.00 per copy plus tax, Canada $15.00
per issue plus tax, and Intl. $20.00 per issue. OEM Handbook and Supplier Directory,
$50.00 plus tax. Prepaid subscription: Penton Media (MACHINE DESIGN), P.O. Box 2100,
Skokie IL 60076-7800. Periodicals Postage Paid at Shawnee Mission, Kans., and at ad-
ditional mailing offices.
Can GST #R126431964. Canadian Post Publications Mail Agreement No. 40612608.
Canada return address: IMEX Global Solutions, P.O. Box 25542, London, Ont., N6C 6B2.
Digital subscription rates: U. S.: one year, $69; two years, $99;. Canada/Mexico: one year,
$79; two years, $119; All other countries: one year, $99; two years, $149.
POSTMASTER: Send change of address notice to Customer Service, MACHINE DESIGN, P.O.
Box 2100, Skokie, IL 60076-7800.
32
40
36
In This Issue
MAY 8,

2014
|
VOLUME 86, ISSUE 5
the #1 value in automation
0tuet 1ouay, 5uIps 1ouay!
* See our Web site for details and restrictions. Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.
1-800-633-0405
0-more
around your pIantI

Practical, Powerful and Priced Right
Check out the powerful yet easy-to-use conguration
software by downloading a demo version at:
http://support.automationdirect.com/demos.html
C-more
EA9 series
touch panel
family
6-|ach IlI
A0-I60l-k
(No theraet)
6-|ach IlI
A0-I60l
8-|ach IlI
A0-I80l
10-|ach IlI
A0-I100l
12-|ach IlI
A0-I120l
15-|ach IlI
A0-I150l
$
400
$
000
$
1,200
$
1,700
$
1,000
$
600
Research, price, buy at: www.automationdirect.com/c-more
AII-new nardware at
Iower prIcesI
ALL EA9 6ERlE6 c-M0RE PANEL6 lNcL00E:
setial couuunications intet|ace
One us8 A-type and one us8 8-type pott
su ueuoty catd slot |ot data loin
F0LL-FEA10RE0 M00EL6 A00:
1o/1oo8ase-1 Ltbetnet couuunications
1wo additional setial potts
huul output pott and additional su ueuoty catd slot
on 1z- and 1s-incb uodels
REM01E AccE66 AN0 c0N1R0L B0lL1-lN
1be c-uote euote Access |eatute tesides in all
panels witb Ltbetnet suppott, and tequites no option
uodules. Access teal-tiue data ot initiate an action
on a conttol systeu |tou anywbete, any tiue.
c0NNEc1 10 c0N1R0LLER6 Wl1R 0RlVER6 F0R:
All Autouationuitect ptotauuable conttollets
Allen-8tadley - conttolLoix, coupactLoix,
uictoLoix Ltbetnet, sLc seties, llexLoix,
sLc s/os Ltbetnet
uodbus 1u and 1cr/lr Ltbetnet
CL sNrx
Outon host Link Adaptet
(czoo/csool, llNs setial
and Ltbetnet
selected uitsubisbi lx seties
and seties
sieuens s1-zoo rrl and s1-zoo/1oo
Ltbetnet (lsO ovet 1cr/lrl
New C-more EA9 series touch panels in 6 to 15
screen sizes are a practical way to give plant
personnel easy access to controls and data.
- tastet 8ooMHz tocessot
- incteased toject memoty, u to 8zMs
- z setiaI otts fot mote connectivity
- cIeat 1t1 sk coIot tD disIays
Our C-more remote HMI application, for iPad,
iPhone or iPod touch, is available on the App Store
for $4.99. It provides remote access and control to a
C-more panel for mobile users who have a wi- or
cellular connection.
3-pin RS485
Communications port
Built-in SD Card port
USB Port-B
10/100 Base-T Ethernet
Serial Communication ports
Audio Line in
Audio Line out
USB Port-A
HDMI Video out
EA9-T12CL
panel shown
RJ12 RS232
Communications port
9
5
6
7
8
1
2
3
4
10
starting at:
EA9-T6CL-R
serial communications
$
499.
00
u.s.
6" 1F1 1ouch Panel
1
Quick-disconnect fttings simplify and speed
fuid line assembly without leaks and spills.
Heres a review of the different types and
design considerations.
T
h
e
b
a
s
ic
s
o
f
Q
U
I
C
K

D
I
S
C
O
N
N
E
C
T
S
Presented by
Sponsored by
Quick-disconnect fttings (often abbreviated as QDCs or QDs) provide fast and easy connection
and disconnection of fuid lines. Tere are a myriad of quick-disconnect ftting types for low-pressure
liquids, high-pressure hydraulics, air, and other gases and even vacuum and they are found in virtu-
ally every industry that must handle fuids.
Fitting fundamentals
Tese fttings, also known as quick connects or quick-release
couplings, typically are operated by hand. Tey often are used to
replace screw-on or bolt-on ftting connections which require tools
and, therefore, take more time to assemble and disassemble. Tus,
quick disconnects greatly improve the end users experience by sim-
plifying connections/disconnections without fuid leaks and spills.
Engineers can use quick disconnects to enhance the serviceability
of their designs and add to the value of their products. Te design
engineer will also fnd the ease of connection and disconnection
will save valuable time during development and testing.
To ensure top-notch performance, many design considerations
need to be taken into account before specifying a quick disconnect.
Because these fttings have a number of components in the fuid
path, they often have higher pressure drops than simpler fttings.
Before specifying a quick disconnect, make sure it meets your fow
requirements.
Quick disconnects can also have pressure limitations, so be sure
the specifed ftting can handle the maximum service pressures in
the application including transient pressure spikes. Material selection is vitally important. All materi-
als of construction must be compatible with the working fuid. Te same goes for temperature compat-
ibility.
Other important questions to ask prior to specifying a quick disconnect include:
Does the ftting need to operate one handed?
Is a shut-of mechanism needed in either or both ends of the connector?
Is a QD with no shut of mechanism preferred, to maximize fow capacity when connected?
Is dry breaking (discussed later in this tutorial) required?
BESW
ICK QUICK DISCONNECTS PROVIDE FAST
AND SIM
PLE TUBE CONNECTIONS AND
DISCONNECTIONS IN A SPACE SAVING PACKAGE.
lnternal
Lxternal
ln this standard single
shut-off quiok disoonneot,
only the internal half of the
oonneotor oontains a valve that
prevents 1uid from esoaping.
ENGINEERING TV
INSIDE THE RECALLED
GM IGNITION SWITCH
The Chevy Cobalt ignition is one of those included in the recent
GM recall of 1.6 million vehicles. Machine Design editors
picked up a 2007 Cobalt steering-column assembly from a
local junkyard and disassembled the ignition assembly. View
this short video to get an up-close and personal view of the
part causing all the controversy. www.engineeringtv.com/video/
Inside-the-Recalled-GM-Ignition;Only-Engineering-TV-Videos
THE BASICS
OF QUICK
DISCONNECTS
Quick-disconnect couplings provide fast and easy connec-
tion and disconnection of fuid lines while preventing leaks
and spills. This guide, sponsored by Beswick Engineering,
reviews the different types of quick-disconnect fttings avail-
able for low-pressure liquids, high-pressure hydraulics, air
and other gases, and even vacuum, and discusses major design
considerations. Download a copy at http://machinedesign.com/
cables-connectors-enclosures/basics-quick-disconnectors.
EDITORS WEB PICKS
METAL-INDUSTRY SITES
Metal production and processing are rough on machinery.
To address their unique needs, Altra Industrial Motion has
launched two new Web sites, www.AltraMetalProducers.com
and www.AltraMetalProcessing.com. They cover a range of
heavy-duty products, including U-joints, spindles, geared mo-
tors, clutches, brakes, couplings, torque limiters, and gear and
belt drives. Applications include furnaces and mills, as well as
casting, heat treating, coating, slitting, and forming.
SMART-MOTOR GUIDE
The new Class 5 SmartMotor DMX Guide is now available
from Moog Animatics at http://tinyurl.com/animatics-DMX-
Users-Guide. It explains SmartMotor support for the Digital
MultipleX (DMX) communications protocol, and describes
the major concepts that must be understood to integrate a
SmartMotor into a DMX network. The combination can be
used for motion control or other operations, communication
with other devices, and to synchronize motion between motors
for electronic camming and gearing.
MOTION APP
MICROMOs new MOTION app is
a dc-motor calculator for iPhone and
Android devices. Engineers can calculate
motor-performance data using speed,
torque, and catalog data; or voltage,
torque, and catalog data. Users input a
minimum of one and a maximum of nine
variables, and pick from 13 equations
related to speed or voltage to generate the
desired results. Learn more at www.micromo.com.
SHAFT-GROUNDING HANDBOOK
Electro Static Technologys 36-page Aegis Shaft Grounding
Ring Motor Handbook covers best practices for protecting mo-
tor bearings from electrical damage. The book explains how to
diagnose bearing damage caused by variable-frequency drives
and inverters, and how to prevent it in motors of various sizes
and power ratings. Download a free copy at www.est-aegis.
com/bearing.
on
join us online
The Truth About Compressed Air!
Compare these Blowoffs
Tere are a variety of ways to blow the water from the bottles shown in the photo below, but
which method is best? To decide, we ran a comparison test on the same application using
four dierent blowo methods: drilled pipe, at air nozzles, Super Air Knife (each using
compressed air as a power source), and a blower supplied air knife (using an electric motor
as a power source). Each system consisted of two twelve inch long air knives. Te following
comparison proves that the EXAIR Super Air Knife is the best choice for your blowo,
cooling or drying application.
Te goal for each of the blowo choices was to use the least amount of air possible to get the
job done (lowest energy and noise level). Te compressed air pressure required was 60 PSIG
which provided adequate velocity to blow the water o. Te blower used had a ten horsepower
motor and was a centrifugal type blower at 18,000 RPM. Te table at the bottom of the page
summarizes the overall performance. Since your actual part may have an odd conguration,
holes or sharp edges, we took sound level measurements in free air (no impinging surface).
Drilled Pipe
Tis common blowo is very inexpensive
and easy to make. For this test, we
used (2) drilled pipes, each with (25)
1/16" diameter holes on 1/2" centers.
As shown in the test results below, the
drilled pipe performed poorly. Te initial
cost of the drilled pipe is overshadowed
by its high energy use. Te holes are
easily blocked and the noise level is
excessive - both of which violate OSHA
requirements. Velocity across the entire
length was very inconsistent with spikes
of air and numerous dead spots.
Flat Air Nozzles
As shown below, this inexpensive air
nozzle was the worst performer. It is
available in plastic, aluminum and
stainless steel from several manufacturers.
Te at air nozzle provides some
entrainment, but suers from many
of the same problems as the drilled
pipe. Operating cost and noise level are
both high. Some manufacturers oer
at air nozzles where the holes can be
blocked - an OSHA violation. Velocity
was inconsistent with spikes of air.
Blower Air Knife
Te blower proved to be an expensive,
noisy option. As noted below, the
purchase price is high. Operating
cost was considerably lower than the
drilled pipe and at air nozzle, but
was comparable to EXAIRs Super
Air Knife. Te large blower with its
two 3" (8cm) diameter hoses requires
signicant mounting space compared
to the others. Noise level was high
at 90 dBA. Tere was no option for
cycling it on and o to conserve energy
like the other blowos. Costly bearing
and lter maintenance along with
downtime were also negative factors.
EXAIR Super Air Knife
Te Super Air Knife did an exceptional
job of removing the moisture on one
pass due to the uniformity of the laminar
airow. Te sound level was extremely
low. For this application, energy use was
slightly higher than the blower but can be
less than the blower if cycling on and o
is possible. Safe operation is not an issue
since the Super Air Knife can not be dead-
ended. Maintenance costs are low since
there are no moving parts to wear out.
The Super Air Knife is the low cost way to blowoff, dry, clean and cool.
If you think compressed air is too expensive and noisy - read this. The facts will surprise you!
Blowof Comparison
Comp. Air
Horsepower
Required
Sound
Level
dBA
Purchase
Price
Annual
Electrical
Cost*
Approx. Annual
Maintenance
Cost
First
Year
Cost Type of blowof PSIG BAR SCFM SLPM
Drilled Pipes 60 4.1 174 4,924 35 91 $50 $4,508 $920 $5,478
Flat Air Nozzles 60 4.1 257 7,273 51 102 $208 $6,569 $1,450 $8,227
Blower Air Knife 3 0.2 N/A N/A 10 90 $5,500 $1,288 $1,500 $8,288
Super Air Knife 60 4.1 55 1,557 11 69 $550 $1,417 $300 $2,267
*Based on national average electricity cost of 8.3 cents per kWh. Annual cost refects 40 hours per week, 52 weeks per year.
Facts about Blowers
Energy conscious plants might think a
blower to be a better choice due to its slightly
lower electrical consumption compared
to a compressor. In reality, a blower is an
expensive capital expenditure that requires
frequent downtime and costly maintenance
of lters, belts and bearings. Here are some
important facts:
Filters must be replaced every one
to three months.
Belts must be replaced every three to
six months.
Typical bearing replacement is at least once
a year at a cost near $1000.
Blower bearings wear out quickly due
to the high speeds (17-20,000 RPM)
required to generate eective airows.
Poorly designed seals that allow dirt and
moisture inltration and environments
above 125F decrease the one year
bearing life.
Many bearings can not be replaced in the
eld, resulting in downtime to send the
assembly back to the manufacturer.
Blowers take up a lot of space and often
produce sound levels that exceed OSHA
noise level exposure requirements. Air
volume and velocity are often di cult to
control since mechanical adjustments are
required.
To discuss an application, contact:
EXAIR Corporation
11510 Goldcoast Drive
Cincinnati, Ohio 45249-1621
(800) 903-9247
Fax: (513) 671-3363
email: techelp@exair.com
www.exair.com/45/423a.htm
See the Super Air Knife in action.
www.exair.com/45/akvideo.htm
EDITORIAL
CONTENT DIRECTOR: LELAND TESCHLER leland.teschler@penton.com
EXECUTIVE EDITOR: KENNETH J. KORANE ken.korane@penton.com
SENIOR EDITORS: ELISABETH EITEL elisabeth.eitel@penton.com,
STEPHEN J. MRAZ stephen.mraz@penton.com
ASSOCIATE EDITOR: LINDSEY FRICK lindsey.frick@penton.com
CONTENT PRODUCTION DIRECTOR: MICHAEL BROWNE michael.browne@penton.com
PRODUCTION EDITOR: RICHARD GAWEL richard.gawel@penton.com
PRODUCTION EDITOR: JEREMY COHEN jeremy.cohen@penton.com
PRODUCTION EDITOR: DENISE GRECO denise.greco@penton.com
ASSOCIATE CONTENT PRODUCER: ILIZA SOKOL iliza.sokol@penton.com
ASSOCIATE CONTENT PRODUCER: SARAH MANGIOLA sarah.mangiola@penton.com
INDUSTRY COVERAGE:
AUTOMOTIVE, PACKAGING, MEDICAL STEPHEN J. MRAZ
CAD/CAM, MANUFACTURING ELISABETH EITEL, LINDSEY FRICK
FASTENING & JOINING, MATERIALS LINDSEY FRICK
FLUID POWER KENNETH J. KORANE
MECHANICAL ELISABETH EITEL, LINDSEY FRICK, KENNETH J. KORANE
ART DEPARTMENT
ART DIRECTOR: RANDALL L. RUBENKING randall.rubenking@penton.com
CREATIVE DIRECTOR: DIMITRIOS BASTAS dimitrios.bastas@penton.com
SENIOR ARTIST: JIM MILLER james.miller@penton.com
GROUP DESIGN DIRECTOR: ANTHONY VITOLO tony.vitolo@penton.com
PRODUCTION
GROUP PRODUCTION DIRECTOR: CAREY SWEETEN carey.sweeten@penton.com
PRODUCTION COORDINATOR: COURTNEY DENISON courtney.denison@penton.com
AUDIENCE MARKETING
AUDIENCE DEVELOPMENT DIRECTOR: BRENDA ROODE brenda.roode@penton.com
AUDIENCE DEVELOPMENT MANAGER: DEBBIE BRADY debbie.brady@penton.com
ONLINE MARKETING SPECIALIST: DAN KRAFT dan.kraft@penton.com
FREE SUBSCRIPTION/STATUS OF SUBSCRIPTION/ADDRESS CHANGE/MISSING BACK ISSUES:
HALLMARK DATA T | 847.763.9670 F | 847.763.9673 hydraulicspneumatics@halldata.com
ONLINE
ONLINE SALES & MARKETING MANAGER: VIRGINIA GOULDING virginia.goulding@penton.com
COMMUNITY LEADER: RYAN MALEC ryan.malec@penton.com
CLIENT SERVICES COORDINATOR: JOANN MARTIN joann.martin@penton.com
SALES & MARKETING
BRAND DIRECTOR: PAUL MILNAMOW T|312.840.8462 paul.milnamow@penton.com
REGIONAL SALES REPRESENTATIVES
AZ, CA, ID, OR, NV, UT, WA, BRITISH COLUMBIA, ONTARIO: PAUL MILNAMOW, paul.milnamow@penton.com
T|312.840.8462 F|913.514.3957
AL, AR, FL, GA, KS, LA, NM, MS, MO, NC, OK, SC, TX: FRANNY SINGLETON franny.singleton@penton.com
T|678.947.8563 F|913.514.6884
CO, IA, KY, MN, MT, NE, ND, SD, TN, WI, WV, WY: PAUL MILNAMOW paul.milnamow@penton.com
T|312.840.8462 F|913.514.3957
IL, IN, MI: MELINDA HURLEY melinda.hurley@penton.com T|847.784.9825 F|913.514.6625
DE, DC, MD, NJ, NY, OH, SC, PA, VA: BRANDY BISSELL brandy.bissell@penton.com T|919.773.1875 F|913.514.6357
CT, ME, NH, MA, RI, VT, QUEBEC: LIZ STOTT, liz.stott@penton.com T|857.636.9737 F||913.514.6914
INTERNATIONAL SALES REPRESENTATIVES
UNITED KINGDOM, SCANDINAVIA, FRANCE, SPAIN, PORTUGAL: STUART PAYNE stuart.payne@husonmedia.com
T|+44 0)1932 564999 F|+44 0)1932 564998
Belgium, Netherlands, Luxemburg: RODRIC LEERLING rodric.leerling@husonmedia.com
T|011.31.229.841882 M|31.683.232625
Germany, Austria, and Switzerland: CHRISTIAN HOELSCHER, christian.hoelscher@husonmedia.com T|011.49.89.95002778
F|011.49.89.95002779
Italy: CESARE CASIRAGHI Casiraghi Pubblicit Estera T|011.390.31.261407 F|011.390.31.261380
Tokyo, Japan: YOSHINORI IKEDA Pacific Business, Inc. T|011.81.03.3661.6138 F|011.81.03.3661.6139
DESIGN ENGINEERING & SOURCING GROUP
VICE PRESIDENT & MARKET LEADER: BILL BAUMANN
GROUP DIRECTOR OF EDITORIAL CONTENT: NANCY FRIEDRICH
GROUP DIRECTOR OF OPERATIONS: CHRISTINA CAVANO
GROUP DIRECTOR OF MARKETING: JANE COOPER
RESEARCH MANAGER: JULIE RITCHIE
MARKETING & EVENTS SPECIALIST: ADRIAN PIAZZA
PENTON MEDIA INC.
CHIEF EXECUTIVE OFFICER: DAVID KIESELSTEIN david.kieselstein@penton.com
CHIEF FINANCIAL OFFICER: NICOLA ALLAIS nicola.allais@penton.com
SENIOR VP, DESIGN ENGINEERING GROUP: BOB MACARTHUR bob.macarthur@penton.com
1166 AVENUE OF THE AMERICAS, 10TH FLOOR
NEW YORK, NY 10036 T | 212.204.4200 |
Electronic Design | Machine Design | Microwaves & RF | Medical Design | Source ESB | Hydraulics & Pneumatics | Global Purchasing | Distribution Resource | Power
Electronic | Mobile Dev & Design | Defense Electronics | Auto Electronics | Electronic Design Europe | Engineering TV
MAY 8, 2014
So many combinations-
it might blow your mind.
| n|roJuc| ng |ne Dbje|500 Connex3 |rom 3|ra|asys, the worlds only full-color and
multi-material 3D printer. Select from incomparably brilliant and consistent
colors, plus a full palette of transparent colors the only 3D printer to
offer such a wide array. And its the only 3D printer that prints flexible
materials in a broad range of shore values. All with ultra-fine detail creating
the most true-to-life modeling possible. Stratasys is the proven leader
in multi-material 3D printing. or wna| ever your m| nJ
can | mag| ne, v| s| | s| r a| asys. com/Dbj e| 500Connex3.
[COLOR
+
RUBBER
+
TRANSPARENT
+
RIGID]
2014 Stratasys, Ltd.
7+5($'(' ,16(576
)25 3/$67,&6
+LJK WRUTXH UHVLVWDQFH
+LJK SXOORXW UHVLVWDQFH
+LJK UHVLVWDQFH WR
SODVWLF FUHHS
$FFRPPRGDWHV ZLGH
KROH WROHUDQFHV
5HXVDEOH WKUHDGV
63,52/ ,QVHUWV DOORZ
GHVLJQHUV WR UHSODFH
PDFKLQHG DQG FDVW PHWDO
FRPSRQHQWV ZLWK SODVWLF
WR DFKLHYH VLJQLFDQW
FRVW DQG ZHLJKW VDYLQJV
ZLWKRXW DQ\ ORVV RI MRLQW
VWUHQJWK
Create a
strong joint
that wiII not
degrade
over time
Editorial
LELAND TESCHLER
|
Content Director
P
ity me. Ive just learned I must sit through six online management-train-
ing courses every quarter. I just finished my first experience with this new
requirement and it has lived up to my worst expectations.
Authors of online management courses seem to suffer from the same
problems that earn criticism for authors of pop-culture management books: Primarily
they tend toward platitudes like, Leaders are focused on people, a favorite phrase in the
course I just plowed through.
Worse, course authors often point out what they claim are management best practices
only by citing policies of companies that are doing well financially. But they have no con-
trol group for comparison. In other words, they seem never to have darkened the doors
of companies turning in mediocre results. Thus, they have no way to tell whether average
performers handle employees in ways worse than those of companies held up as being
successful because of people-management skills.
This lack of a valid yardstick yields management courses that make questionable sup-
positions, such as Companies with satisfied employees are also the ones that deliver the
best overall results, and Anyone can learn to be a leader.
Even so, one might say the insights course authors seem to glean from high perform-
ers are at best unspectacular. Many of them could be put in the category of common
sense masquerading as business advice, such as Employees want a nice, comfortable
work environment Sometimes it takes working side by side to properly show someone
how to accomplish something If you are teaching a subordinate how to do something,
sometimes that is a good use of your time.
OK, Captain Obvious.
Still, I must admit I learned something important from my management studies,
though not about management: Starbucks, one of the companies often lionized by
management writers, hires people off the street to be baristas and puts a lot of thought
into training them. This fact only becomes significant by envisioning what this company
might do if it behaved like a manufacturer.
If Starbucks behaved like a manufacturer, it wouldnt train anybody. It would try to
hire baristas with five years of experience. It likely wouldnt find enough of these people
to run its stores. So its top managers would write op-eds in business publications claim-
ing there was a barista shortage. They would also insinuate that the dearth of experi-
enced baristas proves there are serious shortcomings in the American education system.
Starbucks CEO would then testify before Congress claiming the dearth of baristas will
hamper U. S. economic growth. He would also plead for immigration reform that would
let experienced baristas from foreign countries work in the U. S.
Oddly, my management courses have so far said precious little about training people
who arent managers. The message seems to be that day-to-day employee skill training
doesnt have much to do with leadership. That might explain why there are so few com-
panies like Starbucks.
If Starbucks
behaved like a
manufacturer
05.08.14 MACHINE DESIGN
The round thing has to go
into the rectangular thing.
The engineers choice
These space-saving centrifugal module packages include our new
RadiCal impeller design for the best aerodynamic efciency and acoustics.
The square packages range in size from 6.5 (165mm) to 11.8 (300mm)
with performance up to 940 CFM or 3 static pressure. Modules are plug and
play, can be mounted in any orientation and are completely maintenance-
free. Available with PSC motors or energy efficient GreenTech EC
motors in 2-speed or fully speed controllable versions.
For more information, visit info.ebmpapst.us/RadiCal.
IN PRAISE OF
APPRENTICESHIPS
Tere are 398,000 apprentices in the
USA and 1.5 million in Germany. And
while Germanys economy is built on
manufacturing, ours is increasingly
built on degree infation and a service
economy (i.e., burger fipping).
We have tremendous numbers of
workers retiring from manufactur-
ing, an incredible opportunity for our
youth. Yet the workplace is chang-
ing rapidly and the next generation
may not be prepared for the future.
Nanotech, 3D printing, and Big Data
are all examples of the game-changers
that mean the new workforce must be
extremely adaptable and constantly
retraining.
Instead, we send 19 million kids to
college. Some will consider dropping
out to join the burger fippers. Let our
next generation enjoy the fun of manu-
facturing through the perspective of
hands-on-apprenticeships the other
four-year degree.
Timothy Pearsons
TAKING MECHATRONICS
TOOFAR?
Every electronic device has a me-
chanical analog and vice versa. As Max
Planck pointed out, for example, the
atom can be represented as either an
electronic device or mechanical system.
We also know electronic/mechanical
analogs can be derived from one an-
other. So the next step will be deriving
a mechanical model of the atom from
the existing electronic model based on
Plancks atom. Perhaps this could be a
turning point for mechatronics.
I would go one step further and
suggest mechatronics in the future will
analyze atoms and molecular actions
in all felds, including chemistry. Te
hydrogen atom consists of two electri-
cal particles: an electron and proton.
It is amazing how a system of only two
components can be so complex and dif-
fcult to analyze. Tis approach could
unite the felds of electronics, mechan-
ics, physics, and computing in many
areas of scientifc investigation.
Weldon Vlasak
WHAT BIG SALARY?
I appreciated the recent editorial
(Happy Engineering Week 2014!
Feb.4). But reason number six as to
why I should love my engineering ca-
reer, Earn a big salary, seems fawed.
Tis may be the rule in the public
sector and some large corporations but,
in medium to small companies, it just
isnt so.
Based on my experience, it should
read:Wear many hats, work lots of
hours, and earn a salary.
Unfortunately, earning a big salary
these days is relegated to politicians,
lawyers, managerial public employees,
and teachers.
But hey, we appreciate the recognition.
Thomas D. Moore
PHOTOS MIGHT NOT LIE,
BUTTHEY CAN MISLEAD
Your article on bearing failure (Bear-
ing Killers: Preventing the Top Causes
of Bearing Damage, Feb. 10), brings
to mind a situation I encountered in
a gearbox, a double-reduction unit
with 1,800 rpm in and 64 rpm out. It
drove a mixer in a large tank. Te tank
contained hydrogen and the motor and
gearbox were purged with nitrogen
to prevent an explosive mixture from
building up.
From start-up of the equipment, we
had issues with the intermediate bear-
ings. Te high-speed input bearings
and low-speed output bearings were
all right, but the intermediates looked
like the tops of the roller bearings were
ground of, just like the photo of the
bearing starved of lubrication.
Afer fve bearings, the gearbox
manufacturer suggested we replace
nitrogen with air. It stated that in the
absence of oxygen, the friction curve
shifs down and we were going from
a 0.01 friction factor to a 0.1. (Tey
cited work by NASA and Shell Oil in
vacuum service.)
We replaced the nitrogen with
instrument air and the bearing failures
went away.
Te moral of the story: Failures are
not always what they seem, and de-
pending on photos of typical failures
can cause problems.
John Weaver
Letters
BRINGING BACK
MANUFACTURING
A reader makes a point that U. S. blue-collar
workers are retiring and we have no quali-
ed younger people to replace them.
He suggests that bringing back ap-
prenticeships might bring back U. S.
manufacturing. Another reader
isnt buying the idea that engi-
neers should be happy for their
big salaries. Most of them dont
have big salaries, according to him.
LETTERS TO THE EDITOR:
Please include your name, address, and day-
time phone number. Letters may be edited for
brevity and to focus on essential points.
Mail: Letters, MACHINE DESIGN, 1300 E. 9th St.,
Cleveland, OH 44114-1503, Fax: 216-621-8469
E-mail, Editorial: mdeditor@penton.com
For Industrial Automation and Control, we have the products
& solutions you need from the most trusted brands.
newark.com | 800.463.9275
INDUSTRIAL
ELECTRONICS
Your one-stop source for
Featured product:
Mini Overload Relay
(51M9250)
" I get what I need to keep my line
running, when I need it.
It's great to be an engineer."
Commentary
LINDSEY FRICK | Associate Editor
lindsey.frick@penton.com
Paperless manufacturing:
This time, not a false alarm
M
anufacturers of all sizes are adopting
manufacturing-information technolo-
gies, which eliminate a lot of paperwork.
They have been around for decades,
though, so why are manufacturers seeing value in them now?
Product lifecycle management (PLM) is a manufacturing
information technology that is a case in point. Siemens, Austin,
one of the biggest names in the PLM industry, has 7 million
licensed seats and more than 71,000 customers worldwide.
Arena Solutions, Foster City, Calif., also a provider of PLM,
boosted its customer base by 77% and tripled its average deal
size in just one year. Those numbers are hard to ignore.
Steve Chalgren, vice president of product management and
strategy at Arena, reports that the companys growth spurt came
partly because it took a leap from small-sized manufacturers
to midmarket and large enterprises. Companies that want to
be flexible enough to move operations to any factory location
adopt PLM. In addition, product cycles in the industrial sector
are starting to mimic those of high tech and high tech has
always had strong PLM adoption, he says.
DRIVING THE SHIFT
Connecting multiple factories is becoming more important
in the global economy. Also, the concept of opening up mini-
factories is starting to take hold because efficiency can be
tracked more closely with information technologies. Chemi-
cal plants are already turning modular. A recent report from
Frost & Sullivan states that smaller, more-modular plants
are replacing large-scale chemical production plants. The
expected result of these mini-factories is a 30% improvement
in efficiency.
Efficiency, government regulations, and customer demand
have always been major drivers in the ongoing reach for continu-
ous improvement. But improvements are getting more difficult
to come by with goals such as zero waste, stricter fuel economy,
and, as one manufacturer shared at the PackExpo packaging
technology show, enabling you to jump when Walmart tells you
to. He explained that connecting plant-floor data throughout
the enterprise is one of the only ways to survive when a buyer like
Walmart decides frozen-fish packaging must change from a box
to a stand-up pouch in less than one year.
Yet manufacturers have a reputation for keeping information
technologies out of the lineup of strategies used to address these
issues. In fact, over 90% of manufacturers still use paper forms
and Excel spreadsheets to create reports. So why are manufac-
turers now open to information technologies like PLM? Are
we at a tipping point where manufacturers need information
technologies just to survive?
One obvious reason for recent widespread adoption is acces-
sibility and affordability through the cloud. Legacy PLM is
stuck in the large enterprises, says Chalgren. The unneces-
sary complexity and science-project toolkit methodology is
being destroyed by PLM software companies that offer agility.
More CFOs and other execs are adopting the notion of rent-
ing SaaS (software as a service) software for immediate ROI
(return on investment) and opportunity cost benefits.
THE ROLE OF MES
Julie Fraser, principal of the consulting firm Iyno Advi-
sors, Cummaquid, Mass., says while the PLM industry has
jumped from desktop to cloud, the uptick in business is mainly
because the software has taken on new functions. PLM has
been around for 20-some years and is primarily about design-
ing products effectively. But in recent years, it has also helped
design the processes to make those products, she explains.
What were seeing is a convergence of manufacturing exe-
cution systems (MES) and PLM.MES focuses on how you
execute in production.So in the case of high tech, where
changes are frequent, these two systems need to work together
well. Siemens and Dassault Systmes, Waltham, Mass., have
taken the lead on this type of convergence by acquiring MES
providers, Fraser says.
However, manufacturers themselves, as well as other soft-
ware providers, are already beginning to make information
flow between PLM and MES for real-time changes and updates
of product information throughout the life cycle. This integra-
tion is finally beginning to fulfill the promise of the end-to-end
product lifecycle management vision, she adds.
800 453 6202
>> Accelerate your productivity at ni.com/embedded-platform
2013 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments.
Other product and company names listed are trademarks or trade names of their respective companies. 12118
Smarter Embedded Designs,
Faster Deployment
The combination of NI LabVIEW system design software and recongurable I/O
(RIO) hardware helps small design teams with varied expertise develop demanding
embedded applications in less time. Using this graphical system design approach,
you can take advantage of the same integrated platform to program embedded
processors and FPGAs for faster application development in industries ranging
from energy to transportation, manufacturing, and life sciences.
LabVIEW system design
software offers ultimate
exibility through FPGA
programming, simplies
code reuse, and helps
you program the way you
thinkgraphically.
QUIET
The Quietest
Brush Motor
on the Market
Up to 24,000 Hour Service Life
High-Efciency
IP65 Protection Standard
with up to IP69K Available
20 dBA Sound Isolation Booth
Whispered Conversation
Articial Respirator
Rain
Ofce Environment
30 dBA
40 dBA
50 dBA
60 dBA
Download a 24-page brochure
with specications, drawings,
and performance curves at
www.crouzet.com
For additional information
800.877.5311
CRZ-NA.Motors@crouzet.com
Low-cost servomotors
include encoder,
drive, and controller
CLEARPATH SERVOMOTORS FROM Teknic Inc., Rochester, N. Y. (www.teknic.com),
combine a high-performance servomotor, optical encoder, brushless sine-wave
servodrive, and motion controller into a compact package. Combining the components
into a single device eliminates failure-prone cables. It is priced so that it can be used
where ac-induction, dc-brush, and stepper motors were used in the past.
Whats Inside
The device comes in a wide range of NEMA-23 and 34 frame sizes, with peak
power from 100 to 1,000 W (1.3 hp). Prices for the NEMA-23 systems start at $254,
while those for NEMA-34 units begin at $290.
The MC Series of ClearPath servomotors have a built-in motion controller with jerk-
limited profiles that let users precisely control position, velocity, or torque using simple
digital inputs such as switches, pushbuttons, and PLC outputs. The SD Series have
high-speed step-and-direction interfaces, letting it be used with motion controllers as
drop-in replacements for stepper motors and digital servos. The units can operate in
any of 11 modes. (To see the unit operating under each of them, go to www.teknic.
com/clearpath.)
Edited by Stephen J. Mraz
Skewed stator laminations and
windings overlap several stator teeth
to minimize torque ripple.
USB port
for easy
programming
and diagnostics
also provides
access to 11
position, torque,
and velocity
operating
modes
Shatterproof
encoder disc
made of a
vibration-
damped
composite of
polyester, steel,
and aluminum.
Thermal sensor
and rms torque
algorithm
protect against
motor burnout.
DSP controls sine-wave commutation,
vector torque engine, and adaptive
position/velocity servo algorithm.
Phasing PWB configures
stator winding for a wide
range of input voltages.
Anodized-aluminum
housing does not chip
or peel.
Rare-earth magnets
are sintered, not mixed
with resin, creating
maximum magnetic
energy.
Constant-force
wave spring extends
bearing life
Wire insulation exceeds Class H
specs to reduce premature heat-
aging failures.
SMART
Intelligent
Motion
Control
Integrated Speed
and/or Motion Control
Intuitive Software
Interface for Plug
and Play Startup
Compact Size
Easy Installation
Easy Selection of
64,000 Proportional
Positions for any
Application
Download a 20-page brochure
with specications, drawings,
and performance curves at
www.crouzet.com
For additional information
800.877.5311
CRZ-NA.Motors@crouzet.com
Electronic latch
resists corrosion
and the outdoors
THE R4-EM OUTDOOR Electronic Rotary Latch from Southco,
Concordville, Pa. (www.southco.com), has a sealed actuator
and stainless-steel or plated-steel housing, making it rugged
enough to withstand outdoor use and resist corrosion. The
electromechanical actuator within the latch is sealed to IP56
for protection against water and dust and can withstand
temperatures from 40 to 80C. It is powered by 12 to 24 Vdc
with minimal current consumption, and has a simple optional
mechanical override. The microcontroller inside the latch accepts
control inputs from any access-control device. It also has the
power to open or close against heavy mechanical loads. It can be
supplied with a sealed or nonsealed connector or no connector at
all. An optional internal microswitch provides a latch-status signal
for remote monitoring.
Edited by Stephen J. Mraz
GO TO MACHINEDESIGN.COM
Stainless-steel
plated housing
Versatile rotary
mechanism
Mounting holes
simplify installation
Optional internal
microswitch for
monitoring latch
status
Sealed connector
Dc-motor actuator
sealed to IP56
T
he worlds largest plastic
cable carrier has been
installed in Belgiums Antwerp
Mechanical Dewatering, Recycling,
and Application of Sludge (Amoras)
plant to help process 550,000 lb of
sand, silt, and water dredged each
year from Antwerp harbor.
Energy Chain cable carriers are
modular devices that bend and flex
while protecting hoses or cables.
Developed by igus inc., East Provi-
dence, R. I., they are used on the
first major section of the plant: a
1,150-ft-diameter circular holding
basin. The multilink carriers pro-
tect hoses that run from two high-
power pumps mounted on either
side of the 560-ft dredging bridge
that stretches from the center of
the basin to the perimeter. The
bridge can swing 360 to get to any
of the basins four sections while the
pumps are independently moved
along the bridge from the center of
the basin to the perimeter to reach
different areas of that section.
When a pump moves toward the
center, the carrier holds and sup-
ports the extra hose, preventing
it from kinking and protecting it
GIANT CABLE CARRIER
KEEPS SLUDGE MOVING
The Energy Chain, a plastic, multilink cable carrier, resembles a bicycle chain. It supports
and protects the hose that flexes to remain connected to a sludge pump as it moves along a
bridge above a holding basin.
Plastic links
protect hoses
connected to
traveling pumps.
TINY BATTERY LETS
RESEARCHERS
TRACK
SALMON
ARMY CORPS OF Engineers
researchers in Washington
State have been surgi-
cally implanting battery-
powered transmitters into
salmon to track and moni-
tor their moments through
rivers and the ocean. But
those batteries were too
big and weak to meet some
of the researchers goals.
So engineers at nearby
Pacific Northwest National Laboratory downsized
the battery.
The engineering team used carbon and lithium
chemistry to create a laminated combination of
carbon fluoride (the cathode), a separating mate-
rial, and lithium (the anode). They rolled up and
encapsulated the layers of material to cut down its
size. Rolling it up also let them have a large active
surface area in a smaller package. The increased
surface area, in turn, keeps the batterys impedance
from being too high, a traditional problem with
small batteries.
The new battery is only 70 mg, less than half the
previous batterys weight at 135 mg, and measures 6
3 mm. The smaller size lets researchers inject the
battery and track younger fish whose movements
are crucial to the studies. And injections are faster,
easier on the fish, and less costly.
The battery has an energy density of about 240W/kg,
which compares to about 100 W/kg for commercially
available silver-oxide button batteries. This lets the bat-
tery power an acoustic signal strong enough to be heard
in fish-tracking studies despite the sound of nearby
dams. It can send these 744-msec signals out every
3sec for three weeks, or about every 5 sec for a month.
The batterys chemistry is also better in cold water
than currently used batteries, sending clearer signals at
lower temperatures.
RESOURCES:
Pacific Northwest National Laboratory, www.pnl.gov
from abrasion. Each link of the chain measures 3-ft
long and 14-in. wide, with the hose running inside.
The links are large enough to give the hoses room to
expand and contract with changes in temperature
and internal pressures. And to further minimize
abrasion and wear, and extend the life of the hose
and chain, igus added rollers made of iglide J, a self-
lubricated plastic, inside the links to support the
hose while letting it move and shift.
The cable carrier has proven capable of sup-
porting the hoses while they carry sludge at up to
2,000ft
3
/hr, or about 70 lb/ft of Energy Chain. The
carrier is also light enough that structural engineers
on the project could use smaller motors to move
the sludge pumps and to rotate the dredging bridge.
Project managers are also confident the Energy
Chain will last the estimated 15-year lifespan for the
processing plant.
RESOURCES:
igus inc., www.igus.com
Sand, silt, and water dredged from Antwerp harbor first get
dumped in a circular holding basin at the Amoras plant. A rotating
bridge with two pumps that move from the center to the perimeter
can be positioned to reach any area of the basin and its four sub-
divisions.
The microbattery, which will
be injected into salmon to
track their movements, sits
amid grains of rice.
17 GO TO MACHINEDESIGN.COM
F
1
l
8
1
l
0
O ~ 1.O MFa (O ~ 145 FS)
ressure ranqe
Fressure unit on dislay
Four ressure unit
conversions. MFa, kql/
cm
2
, bar, FS
Accurate readout and
wide viewinq anqle
Relaceable CR2O82
battery last u to 8 years
FG5 dust and slash
rool enclosure
ac00m type
8ack IIht
1/4" port [88FI, 8FI &
88FF)
Digital Pressure Gauge
Email: sales@adsens.net
www.adsens.net
18310 Bedford Cir., Industry, CA 91744-5971 USA
TEL: 626-854-2773 FAX: 626-854-8183
NEW AVAILABLE OPTION:
News
MAKING LADEE LAST
RECENTLY, NASA CLEARED its Lunar Atmo-
sphere Dust and Environment Explorer
(LADEE) craft for a 28-day mission exten-
sion so it can gather more information
about the moons atmosphere. The
launch-vehicle performance and orbit-
capture burns using LADEEs onboard
engines were extremely accurate, so
the spacecraft had significant propellant
remaining to conduct more research,
says Butler Hine, LADEE project manager
at NASAs Ames Research Center, Moffett
Field, Calif.
Part of LADEEs life-extending compo-
nents include an avionics controller that
gathers data from a star tracker, an iner-
tial-measurement unit, and sun sensors
to drive the spacecraft into orbit positions
through connections with power circuitry
controlling the crafts thruster valves. The
13.8-lb avionics unit (IAU) is 9.90 x 8.26
x 4.68 in. Its sturdy enough to withstand
the extreme temperatures and radiation
of space partly because engineers of
Moog Inc., Huntsville, Ala., and Moog
Broad Reach Engineering, Tempe,
Ariz., designed its electronics with silicon
coatings to resist ionization and eliminate
the need for protective shields or metal
enclosures.
Moog engineers designed LADEEs four
bipropellant 5-lbf thrusters 12 years ago.
Each thruster has an injector and platinum-
LADEEs integrated avionics unit (IAU) has
multiple circuit boards and is powered by a
solar-charged battery.
propellant to the thrusters) or closed (for
a leakproof storage of the propellants). An
electrical signal prompts valve actuation
through a microswitch. The valves control
the flow of both oxidizer and fuel to the
thrusters with a single actuator, which
reduces the component count and overall
mass and cost.
LADEEs 5.5-lb valve-driver unit, a
stand-alone switch-extension platform
from Moog measuring 5.6 7.9 3.5 in.,
controls and monitors the valves. The unit
serially communicates commands and
status updates with the IAU.
Moog also made LADEEs Spacecraft
Energization and Power Interfacing unit, a
1.5-lb safety power circuit that isolates the
battery and solar-array power from LADEE
until the spacecraft separates from the
launch vehicle. It has extra connectors that
let engineers power the spacecraft through
umbilical cables during ground testing.
A flight-control computer in the IAU, a
RAD750 from BAE Systems Inc., Arling-
ton, Va., runs the algorithms that control
the spacecraft and manage two streams of
data communications. The first is data to
and from ground stations. The second is
with subsystems on LADEE itself, including
those for operating the spacecraft as well
as four instrument sets, including a lunar-
dust experiment, a UV/visible spectrom-
eter, a neutral-mass spectrometer, and a
lunar-laser communication demonstration.
The car-sized LADEE has been orbiting
the moon since last October at an altitude
of 8 to 37 miles to record cyclical changes
in the moons tenuous atmosphere. It was
scheduled to crash into the moon on or
around April 21.
RESOURCES:
Avionics units, www.broadreachengineer-
ing.com/products/spacecraft-avionics-
system
Software used to design LADEE hull,
machinedesign.com/cad/software-lets-
spacecraft-carry-heavier-loads
Video of Moog turret, www.moog.com/
products/turret-test-systems
alloy combustion chamber to mix the
hypergolic propellants (which ignite on con-
tact, without an electric or thermal igniter).
The combustion chamber resists oxidation
and withstands temperatures exceeding
2,600F. The injector controls the fuel and
oxidizer propellant impingement angles
and velocities for a perfect mix.
The thrusters first flew on a microsat-
ellite-technology experiment mission in
2006, and their first commercial flight was
in 2009 on the launch of the Telstar-11N
communication satellite. In fact, an array
of commercial and civil craft for telecom-
munications and space exploration now
uses more than 200 of the thrusters.
Two flow-control valves for LADEE
meter propellants into the injectors. The
torque-motor-actuated valves stay mag-
netically latched open (to allow flow of
This NASA photo shows the LADEEs two
thrusters and avionics controller (called the
IAU). A spectrometer on the LADEE scans
the lunar atmosphere for atoms. So far, its
detected three noble gases, tides of sodium
and potassium, and regular dust clouds
kicked up by a constant rain of meteoroids.
Valve-
driver
unit
Integrated
avionics unit
Latch
valve
5-lbf
thruster
5-lbf
thruster
Latch
valve
More and more original equipment manufacturers are specifying
Lubriplate Lubricants for their machinery. Why? With 143 Years
of Lubrication Experience, they know Lubriplate has the Quality
Products and Services to meet their needs, the needs of their
equipment and the needs of their customers.
The Brand OEMs Can Trust
When Specifying Lubricants.
Lubriplate Lubricants
Contact: EIIen Girard / OEM AnaIyst / 973-465-5731 / egirard@IubripIate.com
For Equipment Recommendations and Lubricant Specications
To visit us on Facebook, Twitter or LinkedIn, go to
www.IubripIate.com and cIick on the desired icon.
Plant Surveys
Tech Support
Software
Machine Tags
Training
Oil Analysis
A Dedicated OEM Department
For Complete OEM Technical Support
Full Range of Quality Products
Synthetic, Petroleum and H-1 Food Grade
Worldwide Distribution Network
Ensures Availablity Regardless of Location
Backed By:
ESP
Lubriplate
Extra Services Package
Lubriplate
News
SOLAR MODULES FOR
BEAMING POWER TO EARTH
A RESEARCHER AT the Naval Research Laboratory has constructed a module
designed to be put in orbit around Earth and collect solar power, trans-
form it into microwaves, and transmit them to Earth where they would
be converted to usable electricity. The military wants to use the technol-
ogy to power remote bases and for
humanitarian purposes.
In the Navy design, the module
receives solar energy on a photovol-
taic panel on one side; electronics
in the middle convert the direct
current into a radio frequency
(RF); and the backside has an
antenna that beams the power to
Earth. The module is four times
more efficient than any previous
device for turning solar energy to
RF. To get rid of the heat built up by
the sun and electronics, the module
unfolds into a zig-zag pattern. It lets
the module radiate heat more effi-
ciently and, thus, receive greater
The solar modules can be folded for trans-
port then unfolded in space to efficiently
radiate excess heat away.
News
thinner solar panels, a flatter and lighter anten-
na, and converting the chunky prototyped RF
boards into a monolithic microwave integrated
circuit, putting the entire PCB onto a chip.
RESOURCES:
Naval Research Laboratory, www.nrl.navy.mil
concentrations of sunlight without
overheating.
To make the module economical,
robots would assemble a horde of
them to form an array more than
half a mile, or nine football fields in
diameter. (The largest object cur-
rently in orbit is the International
Space Station, which stretches a
little more than a football field from
end to end.) The array would also
include large solar reflectors to
boost the amount of sunlight falling
on the modules.
There are concerns about shoot-
ing a concentrated beam of power
through the atmosphere. Several
precautions are being considered.
The module would only send ener-
gy to specified receivers that sig-
naled they wanted it. Using micro-
waves to send the power to Earth
should be much safer than using
high-energy lasers. The modules
could use a lower frequency, thus
reducing the power concentration.
But this would mean larger trans-
mitters and receivers. It would,
however, yield a side benefit: Power
could be sent to Earth regardless
of the weather. At 2.45 GHz, the
researcher says he could beam
electricity through a monsoon.
There are also plans to reduce the
modules weight to lower the costs
of placing them in orbit. To this
end, the Navy will experiment with
To get the most out of the
solar modules in a geostation-
ary orbit, (the smaller circle),
they would be accompanied
by reflectors (funnel and dish)
that concentrate sunlight on
the photovoltaic cells.
News
AS PART OF its plan to double the efficiency of its 6,000-truck
fleet, Walmart Corp., Bentonville, Ark., worked with several
companies to build the Walmart Advanced Vehicle Experience
(Wave). It is a testbed of cutting-edge technologies that might
show up in the next generation of trucks and trailers used to
deliver goods across the country.
The futuristic Wave truck includes several improvements, courte-
sy of partners Capstone Turbine, Great Dane Trailers, Peterbilt,
and Roush Engineering. On the outside, the truck sports LEDs for
most lighting needs. This cuts weight and power requirements. And
the truck is put together using advanced
high-strength adhesives rather than rivets.
This simplifies assembly and cuts inventory
costs. Other features include:
Aerodynamics: Engineers redesigned
the cab and trailer using CFD to cut aero-
dynamic drag by 20% compared to the
newest conventional trucks on the road.
The wheelbases have also been shortened
by mounting the cab over the engine. This
reduces the trucks weight and improves its
maneuverability.
Hybrid powerplant: The trucks
engine, a range-extending series-hybrid,
uses much smaller and lighter batteries
than pure electric trucks. The engines are
well suited to the shorter trips and lower
speeds that characterize most Walmart
deliveries (Walmart distribution centers
are now closer to metropolitan areas so
final-delivery trucks make shorter trips.)
These shorter trips also create more
opportunities to recover energy through
regenerative braking. The generators and
energy-storage devices on the truck are
scalable to the needed range.
Microturbine power: A small turbine
on the hybrid engine improves fuel econ-
omy and gives the truck a greater range.
WALMART TESTS TRUCK OF THE FUTURE
The Wave truck from Walmart houses a host
of efficiency-oriented features such as com-
posite body panels. The panel on the roof of
the trailer, for example, is 53 ft long.
without the need for aftertreatment. Turbines
also have few moving parts which reduces
maintenance requirements and weight.
Charge mode: In this mode, sensors
determine the batteries state of charge
and start charging using the turbine if
needed. Drivers can select charge mode if
they want to top off the batteries prior to
shutting down.
Electric-vehicle mode: The truck runs
on electric power alone, usually on urban
streets, until the battery charge drops to
50%. At that point, the turbine starts and
begins charging the batteries.
Hybrid-electric mode: For maximum
range, the turbine runs continuously, only
shutting down if the batteries run out.
Component electrification: The truck
uses scaled-up versions of automotive
subsystems powered by electric motors
instead of hydraulics. They include power
steering and air conditioning.
Trailer: The vehicles trailer is built almost
exclusively from carbon fiber, including
one-piece panels for the roof and sidewalls,
saving nearly 4,000 lb compared to tradi-
tional designs. The trailers convex nose
also improves aerodynamics while provid-
ing storage space inside the trailer. Other
features include low-amperage LED lighting
strips, composite trailer skirts, aerodynamic
wheel coverings, a posi-lift suspension,
and a one-piece, fiberglass-reinforced floor
panel with a 16,000-lb forklift rating.
Cab: the drivers compartment has
a lightweight sliding door and a simpli-
fied dashboard with fewer controls and
displays. Instead, customizable LCDs
let drivers keep clutter to a minimum.
Theres a also a full-sized sleeper with a
fold-down bed.
RESOURCES:
Walmart Corp., www.walmart.com
The hybrid powertrain lets the turbine spin at its most-efficient
speed, while the electric motor/energy-storage device handles
acceleration and deceleration. Trucks scheduled for longer trips
would be outfitted with larger turbines and smaller energy-storage
devices.
Fuel neutrality: Turbines can use a wide variety of fuels, includ-
ing diesel, natural gas, and biodiesel, while generating few emissions
Drivers face much less clutter on the redesigned Wave dashboard
compared to the control panels of conventional trucks. Drivers have the
option to customize the LCDs to show just the information they need.
51 Parmenter Road, Hudson, MA 01749
(800) 258-0110 | www.boydcoatings.com/MachD
COATED
AEROSPACE
DEVICE
The Leader in Coating Aerospace,
Medical, and Industrial Components.
News
small enough to fit in the confined area
under the hull.
ECM imported measurements into a
CAD package that can construct features
and surfaces from point data. For this par-
ticular case, one of the four blades was fit-
ted with complex surface geometry (Nurbs
surfaces). The other three blades were
created by rotating the initial CAD-rendered
blade every 90 to form four identically
shaped blades in the model. As a quality
check, actual measurements for the other
three blades were compared to the engi-
neered surface of the main blade to find
disparities and any deformations.
ECM converted the propeller model into
STL and IGES CAD files. This data can
be used to generate CAD drawings and
surface definitions for molding replicas of
the Harmony propeller or to generate a
five-axis NC machine program for cutting
propellers from metal.
RESOURCES:
ECM Global Measurement Services,
www.eastcoastmetrology.com/index.html
dimensions so they could be replicated on propellers powering
other ships in its fleet.
ECM Global Measurement Services, Topsfield, Mass.,
did the data capture. The main challenge was measuring the
propeller while it was mounted on the ship driveshaft under the
hull. The laser tracker, able to scan up to 1,000 points/sec, was
A LASER TRACKER helped measure a 25-year-old propeller in just a
few hours as a means of generating a CAD model from which cop-
ies could be made.
The propeller was on a successful commercial fishing vessel
named Harmony. Boat owner Atlantic Trawlers had no draw-
ings of the four-bladed prop but wanted to capture the propeller
PROPELLER GETS IMMORTALIZED IN DIGITAL DATA
A digitizer captured the dimensions of one
of the propeller blades on the fishing vessel
named Harmony.
Engineered to improve performance.
Designed to reduce costs.
(952) 927-1400
www.mnrubber.com
Minnesota Rubber & Plastics
High tolerance components and assemblies are
what we work with everyday at Minnesota Rubber
and Plastics. Our experience in design, sealing and
manufacturing complex devices has made us the
preferred partner for industry leaders throughout
North America, Europe and Asia. The next time
your component or assembly seems impossible,
there's no one better to partner with than Minnesota
Rubber and Plastics. We'll make your tough
application a reality.
We Mold Solutions
To Your Problems.
A prcducl cf wcrd-cass accuslc
cngnccrng cxpcrlsc, Pcppcr+Fuchs
ulrascnc scnscrs arc ccmpclcy
unacclcd by dusl, cccr varalcns,
gcss, cr lransparcncy. wlh sub-mmclcr
prccscn, scflwarc ccngurably, and
dclcclcn rangcs frcm , nch lc cvcr
3u fccl, ulrascncs arc dca fcr bclh
swlch-pcnl and anacg ccnlrc cf cbjccls
as dvcrsc as bcllcs, rcfusc ccnlancrs,
wccdcn pacls, slcc ccs, and fccds.
Pcppcr+Fuchs, lnc.
33u./86.uuu1
www.pcppcr-fuchs.us
'RZQORDG IRXU DSSOLFDWLRQ
UHSRUWV WKDW VKRZ \RX KRZ
WR HDVLO\ XVH XOWUDVRQLF
WHFKQRORJ\
www.sensing.net/ulse
Scan. Lcarn Mcrc.
THE PULSE OF AUTOMATION
WerIds Largest 5eIectien ef bItrasenic 5ensers
Sensor Sense
Wirelessly send
power and signals
MANY SENSORS NEED to send power and control signals through barriers, between
stationary and movable equipment, and over rotating or exchangeable machine
sections.
Consider a conveyor that moves parts through an assembly plant. One common
setup is to have trays (called carriers) on the conveyor containing parts needing work at
various plant stations. When the conveyor parks a part-filled carrier at a given station, a
robot jumps into action and performs a task on the parts. But first, controls must verify
the parts are positioned properly. For this job, engineers often fix sensors to the carriers
that send position confirmations to the controls.
Its common for engineers to use mechanical connections
such as slip rings, high-flex cabling, and high-density
connectors to get power and signals to and from these kinds
of traveling sensors. But these options have drawbacks.
Sometimes they dont fit into a machines geometry. Plus
many slip rings are prone to contact wear. Cables tend to flex
and snag. High-density connections are costly and possible
sources for contact failure.
Inductive coupling is a more versatile option for
transmitting power and signals between mobile sensors and
stationary controls.
Inductive coupling is noncontact electromagnetic
transmission that uses current flow through coils of wires on one side of the setup
to induce voltage in coils of wires on the other side of the setup. In this way, this
transmission lets machine controls wirelessly transfer primary-system side power and
signals to exchangeable or movable secondary sides. Inductive coupling also lets users
leverage all the benefits of wireless signal transfer by reducing wiring for maintenance-
free, cost-effective connections.
To make inductive coupling an option for sensors, some manufacturers offer
exchangeable cartridges with two transmitters that pass electrical signals across an air
gap usually to the control-system auxiliary or main control panel.
Inductive couplings can make single or multisensor connections across air gaps.
Two caveats: Inductive coupling makes for simple power and signal transfer without
using batteries, but transmission elements must be within 20 mm of one another. In
addition, the elements must be stationary when signals go from the secondary element
to the primary.
Pepperl+Fuchs (www.pepperl-fuchs.us) provided information for this column.
Edited by Elisabeth Eitel
Channel 1
Channel 2
Channel 3
Status
Power on
PRIMARY SIDE SECONDARY SIDE
Power
Air gap
Signal
Sensor 1
Sensor 2
Sensor 3
0slancc-bascd phclc scnscrs
addrcss mcrc chacngng
appcalcns by ncl jusl
dclcrmnng f an cbjccl s
ThLkL, bul asc whLkL l s
ccalcd. Thrcc mclhcds havc
cmcrgcd as frcnl runncrs lc
shcw ycu whcrc:
ackgrcund Supprcsscn
Mul-Pxc Array
Pusc kangng Tcchnccgy

hew yeu have
a cheice:
1here er Where
Pcppcr+Fuchs, lnc.
33u./86.uuu1
www.pcppcr-fuchs.us
0cwncad cur c-bcck lhal cxpans hcw
lhcsc lcchnccgcs w wcrk fcr ycu.
www.sensing.net]where
0istonce-boseJ hete sensers will
hove yeur stonJorJ hete senser
nerveusly leeking ever its sheulJer.
Scan. Lcarn Mcrc.
www.masterbond.com
Hackensack, NJ 07601 USA
+1.201.343.8983
main@masterbond.com
Extraordinarily high
shear and peel strength
Room temperature curing
Superior electrical
insulation properties
Adhesive for
High Performance
Structural Bonding
Epoxy EP31
be
strong
The Forensic Engineer
DR. CIRO RAMIREZ
cramirez@trengineer.com.
T
wo men were test running a rebuilt pickup truck in a home garage when
an unexpected failure caused the truck to catch fire. The ensuing inferno
burned one of the men while destroying the garage and truck. An examina-
tion of the truck showed the fuel tank had been punctured. Leaking gasoline
had been ignited either by hot exhaust components or sparks from a broken driveshaft.
The tubular-steel driveshaft had just been replaced as part of the rebuild. When it
failed, it shattered into three pieces and flailed around until the engine stopped, making
it more difficult to determine what damage happened before and during the failure.
Possible causes included improperly installed fasteners, metallurgical defects, design
problems, and fabrication errors. Investigators found no loose or broken fasteners, and
the cardan or U-joints at the ends of the driveshaft were secure and intact. They there-
fore quickly ruled out joint failure and fastener-installation problems.
Metallurgical analysis revealed the unexpected presence of zinc on some of the frac-
ture surfaces. Investigators chalked up its presence to postfailure impacts between the
shaft fragments and other zinc-plated parts under the truck. The fractures lacked the
characteristic appearance of fatigue failures, and the driveshaft had only been running
for a few minutes when it failed. The fracture surfaces had the appearance of ductile
rupture. The failures were in the body of the driveshaft, not at welded seams. The failed
driveshaft had flattened sections typical of buckling failures.
As it turned out, the truck rebuild was not a simple reconditioning effort. The men
had replaced the engine with a larger displacement V8, and the manual transmis-
sion had been replaced with a three-speed automatic not sold with this vehicle. These
modifications altered the geometry of the driveline and necessitated fabricating a new
driveshaft. The new shaft, specified by the owner but fabricated by a local shop, was
slightly longer and built with tubing having a smaller diameter than the original. These
modifications proved to be disastrous.
Critical speed failures are a familiar concern for engineers who design rotating
machinery. The general public is mostly unaware of this risk. A critical speed failure
happens when the rotational speed of the component approaches one of its natural
frequencies, usually the lowest. Bending vibrations of the component are excited by the
rotation and can quickly build up to amplitudes high enough to cause structural failure.
In this case the shaft modifications lowered the natural frequency of the unit and
allowed a critical speed failure. A contributing factor was the lack of a speed limiter on
the V8 engine. The engine could easily exceed redline as the owner revved it. Because
the truck was supported on jack stands, the driveline was also unloaded and more
susceptible to overspeed. The modifications to the driveline design created an unrecog-
nized hazard, which led to the failure.
Had the individuals involved understood the effects of the modifications on the criti-
cal speed, this failure could have been avoided.
What you dont know
about critical speed
failures can hurt you
Together, we can drive your profits
in the automotive industry.
www.parker.com/general 1 800 C-Parker
What do auto manufacturers need to run reliably and profitably? Everything. Which is why
Parker is built to be your one-source solutions supplier. In Asia alone, Parker has 40
manufacturing facilities and 8,000 employees. So you can reduce the number of purchase
orders, cut shipping costs and streamline the engineering and completion process.
Visit www.parker.com/general. And give your automotive plant the ultimate tune-up.
Interview
TIMOTHY PEARSON
|
President
Great Glen Solutions, Cleveland Heights, Ohio
A
ccording to manufacturing consultant Tim
Pearson, there is a drastic imbalance in the
way the United States prepares future genera-
tions to compete in the global job market. And
in no sector is the divide more apparent than manufacturing.
Whats the problem?
The reality is that too many kids are heading for college and
missing out on a much-more rewarding and financially
advantageous alternative: skilled apprenticeships. Students
who waste enormous sums on tuition, sitting in classrooms to
learn nonproductive skills, could better use their time playing
an active role in the fascinating, rapidly evolving, engaging,
and personally rewarding world of manufacturing. After com-
pleting a four-year apprenticeship, a newly trained worker can
immediately contribute to Americas future economic success.
Why apprenticeships?
Manufacturing workers of the future are not the line workers
of the past. Today, they are part of a networked world collabo-
rating with suppliers, engineers, and customers. The impacts
of emerging technologies like nanotech, 3D printing, and big
data are rapidly changing the norm, so manufacturers need
highly skilled, educated, and adaptable workers willing to con-
stantly retrain and upgrade their skills to keep pace with an
ever-changing world.
Arent apprenticeships offered now?
We do have an infrastructure addressing this need at the state
level. In Ohio, for example, there are 86 apprenticeship options
from accordion maker to combination welder. In Northeast
Ohio, the production of fabricated metal parts and machinery
involves 86,000 of the regions 264,000 manufacturing-sector
employees. There are 45 sponsors for tool-and-die apprentice-
ships and 16 sponsors for machinist apprenticeships in Cleve-
land and Cuyahoga County alone.
But more is needed?
We can make further progress using the demonstrated success
of the German model. Sixty percent of young people in Germany
enter the dual-education system where they earn a company
salary while the government pays for technical college. This
drives the lowest youth unemployment rate among developed
countries, a mere 7 to 8% about half that of the U. S.
The 398,000 apprenticeships in the U. S. are dwarfed by the
deadweight of 19.9 million college students, whose advanced
The other four-year degree
degrees are devalued by the sheer number of graduates.
Germany, on the other hand, has 1.5 million apprentices and
only about 2 million university students a significantly more-
effective use of their human resources. Their resultant output
contributes to a trade surplus through exports of vehicles and
vehicle parts, machinery, chemical products, computer and elec-
trical products, and other highly engineered goods. One quarter
of all German jobs are a direct result of exports, one consequence
of the incredibly productive apprenticeship model.
How do manufacturers benefit?
Businesses can and must do more to support and encourage
such a system. Investing in more apprenticeships can help com-
panies at the technological forefront of manufacturing resolve
their persistent complaints about skilled labor shortages. And
the lack of qualified workers is only getting worse as a growing
proportion of our manufacturing workforce approaches retire-
ment. Replacing retiring workers represents both a challenge
for the economy and an opportunity for the next generation.
Apprenticeship programs also contribute to needed change in
societys inadequate respect for the historical and future linchpin
of the American economy, the skilled manufacturing technician.
But responsibility lies not only at the corporate level. If your
child girl or boy is about to leave high school, consider the
apprenticeship alternative. You may find that those spatial skills,
seriously neglected in rote classroom exercises, are more suited
to making things than taking notes.
Just as important, apprenticeships and the resulting degrees
can serve as a way for the economically disadvantaged to get
ahead and out-achieve university students handicapped by
core curriculum courses that teach them little that is applicable
to a modern economy. Some of the very best engineers in my
career, involving everything from medical devices to missiles,
airplanes, and trucks, are those who gained the deeply practical
knowledge of an apprentice, and then layered on theory with a
technical degree.
You and your company dont have to contribute to degree
inflation, where college graduates begin their independent
lives with exorbitant debt and no career. Or worse, drop out
and end up in mindless, low-skill burger-flipping jobs that
make poor use of their talents, spatial skills, and potentially
vast productive capacity. Encourage apprenticeships, the other
four-year degree!
Call 1-888-WASHERS
1-888-927-4377 sales@bokers.com
612-729-9365 FAX 612-729-8910
FREE CATALOG & BROCHURE
WASHERS &
STAMPINGS
WWW.BOKERS.COM/MD
SLICK?
(maybe)
SLICK?
DEFINITELY.
Introducing the new SLIC PIN
with a Self-Locking
Implanted Cotter. Its a pin and a cotter all in one.
COST SAVING. QUICK-LOCKING. SECURE.
If youre using labor intensive pins, cotters or clips,
try something SLIC!
WELL SUITED FOR AUTOMATED ASSEMBLY
FREE SAMPLES
U.S. Patent No. 6,872,039
& 7,147,420
Foreign Patents Issued
ALTERNATE PLUNGER DESIGN
FEATURES ROUNDED TOP
FOR EASY REMOVAL
NEW!
800-222-2231
www.pivotpins.com
HUSTISFORD, WI
CLEVIS PINS, COTTERS, QUICK RELEASE PINS & DEVICES, STEEL LANYARD ASSEMBLIES AND MORE!
2014 INDY 500:
A year of transition
The design of the cars is slowly being upgraded and standardized in pursuit
of higher speeds while keeping safety paramount.
T
he 2014 IndyCar racing season is one of transition.
Officials are checking on past changes, making
some new ones to the chassis and engines, and get-
ting ready for aerokits that could reduce drag and
(hopefully) bump up speeds. They are also monitoring their
only tire supplier, Firestone (a subsidiary of Bridgestone), to
see if the tires will continue to stay ahead of the curve.
The transition is aimed at the 2016 race, the Indys 500
100th running. Thats the season in which officials hope at
least one racer sets a new speed record for the four-lap quali-
fying runs. The current record, 236.986 mph, was set by Arie
Luyendyck in 1996. Officials and teams see higher speeds as a
surefire way to increase interest in IndyCar racing.
PREPPING FOR AEROKITS
Officials will let teams use aerokits from suppliers other
than Dallara this year, but only at the Triple Crown tracks
Indianapolis, Pocono, and Fontana. The rest of the year, race
teams will field Dallara DW12 chassis, bodies, and aerokits.
IndyCar managers will be watching to see how the kits affect
STEPHEN J. MRAZ
|
Senior Editor
stephen.mraz@penton.com
Indy 500
Even the 500-mile Indianapolis race can come down
to how fast and precise the pit crew performs. 32
HONDA PROVIDES MORE THAN JUST
ENGINES: SAFETY
FIRES IN THE pit-lane areas and injuries attributed to cars
leaving the pit too quickly, even before crews can remove the
refueling hose, should be as rare as hens teeth at this years
Indy 500, thanks to the Refueling Safety Interlock. It was
developed at Honda Performance Development Inc. (HPD),
the subsidiary of Honda that designs IndyCar engines and
a host of components for other race series. The interlock
includes a fuel-probe sensor and corresponding electronics in
the engine-control unit (ECU) and gearbox-control unit (GCU).
It prevents first gear from being engaged by the paddle shifter
on the steering wheel while the refueling hose is still attached
to the car.
The interlock was designed for both IndyCars and endur-
ance sports-car racing, and is now mandatory on Indy racers.
The fuel-probe sensor, installed in the refueling buckeye
or inlet valve on an IndyCar chassis, detects the pres-
ence of the refueling nozzle. Software in the ECU signals the
GCU to place, or hold, the transmission in neutral. This pre-
vents drivers from leaving the pit before the refueling hose is
detached from the car.
While the interlock was being developed, engineers at
HPD discovered they would have to modify the sen-
sor to ensure it could survive the harsh
operating environment of an IndyCar.
For example, they replaced all of the
wire leads and resoldered all joints.
They also added heat-
resistant shrink-
wrap to soldered
joints, as well as
thermal insulation
and a motorsports connec-
tor to the leads and a fuse to
eliminate electrical shorts.
HPD has offered to pro-
vide the design of its inter-
lock, free of charge, to other
racing series that want it. The
only hardware prerequisite
is that the cars gearbox must
have an electronic paddle-shift
mechanism.
handling and speeds, as well as the conditions of IndyCar
racing. The hope is that the kits will counter some of the
problems with the relatively new Dallara DW12 chassis. Offi-
cials suspect the bottom or undertray of the current chassis is
too large and smooth. They base their suspicions on the fact
that some Indy racers tend to roll after side impacts on ovals.
IndyCar engineers and technicians have already tried solving
the problem by reducing the undertrays surface area, and they
hope the aerokits will not cause the problem to reappear or
get worse. The goal is to ensure the cars are stable
before adding power that could push speeds
to new records.
The kits will likely include side pods,
engine cover, and front and rear wings.
Currently, all teams use the kits that come
Hondas twin-turbocharged
V6, the HI14RTT, meets Indy-
Cars techni cal regul a-
tions that limit engines to
a maximum of six cylinders
and 2.2 liters. Cylinder bore is
restricted to 95 mm or less, but
stroke is unlimited. RPMs are lim-
ited to 12,000 or less. In addition to
using direct fuel injection and two
Borg-Warner turbochargers, other
features include drive-by-wire
throttle technology and a series-
spec McLaren Electronics Engine
Control Unit.
This years dual-turbocharged Chevy engines are built to be durable
and powerful, as well as easy to maintain. Its said a crew can switch
out entire engines on an Indy racer in under 45 min. The 250-lb engine
puts out 650 hp at 12,000 rpm
Indy 500
could get sidetracked. In 2011, for example, race teams asked
for and got a delay in the aerokits introduction when the
costs for the new DW12 chassis went over budget. Then in
2012, racers felt they had fast, competitive cars and races and
had no need for the kits, or their high costs, so the introduc-
tion got put off again.
Team owners likely wanted one more delay, but Indy-
Cars technical staff has set out a road map for the technical
development of the championship, one that includes keeping
costs down. Their goal is that new aerokits will improve per-
formance and, thereby, extend the life of the DW12 chassis.
This would save teams the cost of buying a new chassis and
make their original purchase of the DW12 a more-econom-
ical investment. (The current chassis originally sold for
$349,000, or as a complete car for $385,000.) IndyCar offi-
cials also felt a further delay would upset fans, the ultimate
customers for Indy racing.
IndyCar management also hopes the kits will visually differ-
entiate the cars. In an odd note, cars will be named based on the
with the Dallara chassis. But for this years Triple Crown
tracks, kits will be designed and built by new two teams: Pratt
& Miller partnering with GM Racing for cars with Chevy
engines; and Wirth Research working with Honda Perfor-
mance Development for racers with Honda engines. And in
2015, when kits are allowed for all races, Lotus and a few other
companies could join Honda and Chevy as suppliers. Dallara
will stop making aerokits because it would take too much time
and money for the Indianapolis company to build different
kits, according to Andrea Toso, the head of R&D for Dallaras
IndyCar project.
Kit manufacturers will likely supply two kits, one with speci-
fications suited to road and street courses, as well as short
ovals, and another set with specs for superspeedways.
The kits will cost no more than $75,000 (which will not
include the cost for fasteners), and each team has the option
to use two of them during the 2015 and following seasons.
Upgrades after that are limited in price to $15,000.
As is often the case with IndyCar rules, these regulations
INDYCAR MANAGEMENT WANTS to
keep costs down for its racing teams,
and using the same chassis for the next
decade or more is key to that effort. But
they also want to increase speeds, which
means introducing aerokits, new tires, and
possibly new engines. Heres their plans
for tackling these possible changes in the
upcoming years.
2013: Changed smooth underbody to
make the car more stable and prepared
for aerokits.
2014: Engine upgrades and adjustments
to downforce to improve overtaking and
safety.
2015: Aerokits and changes to underbody.
2016: Possible changes to tires and
increases to engine power.
2017: Possible upgrades to engines and
aerokits.
2018: Competition enhancements based
on performance of 2017 package.
2019: Review body and chassis for poten-
tial upgrades or changes.
2020: Competition enhancements based
on performance of 2019 package.
2021: Possible upgrade to aerokits.
Firestone is the sole provider of tires to IndyCar teams, and it will remain the only supplier through
the 2018 season. The companys Firehawk tire, which is used by Indy race teams, is said to borrow
tread pattens and other technology from the companys top-line consumer tire, the Firehawk Wide
Oval Indy 500. While front tires weigh in at about 18 lb, the wider back ones tip the scales at 23 lb.
Racing is tough on tires, as this image
shows. Thats why teams get up to 33
sets for the Indianapolis 500 race alone.
At an estimated $2,600 per set, that can
mean an $85,800 bill for tires. And used
tires must go back to Firestone, which
studies them for future improvements.
TIMELINE FOR TECHNOLOGIES
These images show the Rahall Letterman Lanigan #15 car in its 2014 colors.
COMPARING RACER CARS
INDYCAR RACER FORMULA 1 NASCAR SPRINT CUP
TOP
SPEED
230 mph 225 mph 200 mph
ENGINE Turbocharged 2.23-liter V6 Normally aspirated 2.4-liter V8 Normally aspirated 5.7-liter V8
POWER 550 to 700 hp, depending on boost 750 hp 865 hp
GEARBOX Assisted six-paddle shifter, with reverse Semiautomatic with four to seven gears Manual four speed
FUEL E85 Unleaded racing gas
E-15, a blend of ethanol and
unleaded racing gas
TIRES Firestone Firehawk (ungrooved racing slicks) Ungrooved racing slicks Ungrooved racing slicks
WEIGHT
1,575 lb (road/street/short oval tracks)
1,545 lb (speedways)
1,415.37 lb, including driver (minimum) 3,400 lb, including driver and fuel
Indy racers hold the speed record over Spring and Formula 1 cars. Thats a lead IndyCar management wants to maintain.

let the cars generate 22.5 in. of boost for road courses, 20.3
for ovals, and only 18.9 for superspeedways. Each team is also
allowed 10 driver-chosen 15 to 20-sec boosts that increase the
pressure to 23.2 psi. Officials are still unsure how much advan-
tage these boosts will give to teams.
Indy officials also say that it was always difficult, if not
impossible, to equate the different allowable boost levels when
teams have either one or two turbo units. Making all engines
carry two of the same turbochargers eliminates the problem.
The 7163 EFR turbos have been upgraded for racing.
Weight was cut and the end housings were redesigned for
IndyCar engines. But like stock EFR turbos built for per-
formance cars, the turbine wheels and shaft are construct-
ed of strong, lightweight gamma titanium-aluminum alloy
for quicker response. And ceramic ball bearings increase
the thrust capacity and durability while improving effi-
ciency at low expansion rates. The cast-stainless-steel
housing also contributes to efficiency and durability.
Another change, one that pushes teams to focus on engine
durability, penalizes teams that change engines before
2,500 miles. Last year, they could change engines after
2,000miles without incurring a penalty.
IndyCar officials will continue to make certain engine
components and configurations mandatory as it proceeds
through what they call the homogolation process. Over the
next two years, they will specifically look to standardize con-
necting rods, though the turbos wastegates and valve springs,
and spark plugs could also be standardized. Items that teams
can still change include the cylinder heads and valve angles,
port locations and shapes, combustion-chamber shapes, and
spark-plug and fuel-injector locations, as well as the ducting
for the turbos and camshafts. Some of these parameters have
limits teams must respect. The valve angles, for example, can
be from 60 to 90.
aerokit supplier. For example, if Honda supplies, the
kit, it will be a Honda car. If a traditional aerospace
firm such as Lockheed makes the kit, a hope of
IndyCar officials, the car will be a Lockheed racer.
EQUALIZING ENGINES
While Honda engines were equipped with only
one turbocharger last year, Chevy engines had the
advantage of carrying two. Thats one reason some
racing enthusiasts say Chevy-powered cars domi-
nated the 2013 season (even though Chevy won
only one more race than Honda, and Honda won
Indy). To end that dominance, IndyCar officials
say all cars must carry two Borg-Warner turbo-
chargers. Honda is confident that Chevys two extra
years of experience with twin turbos will not be a
disadvantage.
These engineered for racing (EFR) turbos will
This is a 3D model of a four-cylinder engine in MapleSim software
from Maplesoft. The software lets designers use symbolic and numer-
ic techniques to diagnose vibration issues on machines powered by
unsteady inputs such as internal-combustion engines.
Software techniques
predict torsional vibration
I
ts no secret that minimizing machine vibrations
improves reliability, quiets operation, and boosts end-
user satisfaction. But all rotating and reciprocating
equipment vibrates. Its sometimes difficult to predict
these vibrations, partly because any given machine exhibits
unique vibration signatures during start-up, shutdown, and
normal continuous operation. In fact, nondescript machine
noise and coupling wear are often the only evidence that a
machine has a vibration problem. Left unaddressed, such issues
can eventually allow high-amplitude vibrations that wear gears
and even cause gear-tooth failures and bent or broken shafts.
Now new software helps designers prevent such problems by
evaluating the torsional response on any machine with rotat-
ing components. Such software makes lumped-mass models,
which are idealized one or two-dimensional representations of
machines composed of rigid masses jointed by massless springs
and dampers. Lumped-mass models generated in software
are good for vibration analysis because they can identify the
sources of vibration, modes of vibration, paths that vibrations
take through a machine, and ways a designs vibrations might be
effectively damped.
After analysis with lumped-mass models, the designer can
finish the vibration analysis with experimental measurements.
Lumped-mass models (also called lumped-parameter sys-
tems) outperform distributed-parameter models and finite-
element analysis (FEA) when a machines physical objects have
dimensions that are small relative to the direction of vibration.
Thats because compared to distributed-parameter systems,
lumped models are simpler and allow faster simulation. For
example, a long shaft with torsional vibration or bending is a
good candidate for lumped-parameter analysis.
A lumped models accuracy increases with its degrees of free-
dom, defined by its number of mass-spring-damper submodels.
Some software can make lumped-mass models quite sophisti-
cated, even placing models in realistic vibration-analysis envi-
ronments when needed.
Using symbolic techniques for model simplification and
order reduction as well as numeric techniques for solving the
equations with simulation software designers can diagnose
and solve myriad vibration issues.
DR. THANH-SON DAO
|
Application Engineer
Maplesoft of Waterloo Maple Inc., Waterloo, Ontario
CAD
Software can generate lumped-mass models with symbolic and
numeric inputs to predict whether machines will propagate or
damp vibrations.
Propeller
Mass
Transmission
Flywheel
V4 IC engine
Pump
This diagram of a ship driveline
shows how vibration-analysis
software simplifies models.
This template lets
designers quickly
model engines to
see if they exhibit
unacceptably large
vibrations. Then a
simulation (bottom)
generates plots of
deflection (left) and
propeller torque (right)
for all the engine
orders.
ROOT CAUSES OF FAILURE
In industrial environments, the most common cause of
machine breakdowns is bearing failure. Mechanical problems
that can damage bearings but cant be seen directly include
unbalance, misalignment, mechanical looseness, bent shafts,
resonance excitation, as well as problems with belts, gears,
aerodynamics, and electrical connections.
Consider a passenger-vehicle powertrain. Most vibration
on the driveline comes from power-input fluctuations, par-
ticularly when a combustion engine provides the mechanical
power. Other vibrations on automobile drivelines come from:
Forced responses of periodic excitation from fluctuating
engine torque
Transient responses of the driveline to impulses from gear
shifting
Clutch-judder phenomena during clutch engagement
Excitation of the drivelines natural frequencies to avoid
coincidence of engine-torque harmonics
Such a machines vibrations also couple with movements of
the machine structure. For example, a vehicle in heavy urban
traffic must frequently stop and start. During acceleration,
rotary vibrations in the drivetrain temporarily couple with the
cars vertical and horizontal motions. The forces associated
with these motion inputs complicate the vibration analysis of
the designs mechanical structures.
TWO TECHNIQUES
In general, there are two approaches to analyze these vibra-
tions. The first technique is FEA, which models mechanical
structures as thousands of discretized and idealized elements.
A designer then analyzes the relationships between the ele-
ments to construct the mass, stiffness, and damping matrices
and determine the natural mode shapes and frequencies of
the structure during vibrations. Before FEA-based analy-
sis, though, a meshing technique discretizes the object into
thousands of basic elements. This approach has advantages
for objects having complex geometries. However, analysis of
a machines vibrations using FEA-based elements means the
software must solve huge systems of thousands of linear equa-
tions. That makes vibration analysis with FEA time consum-
ing and expensive.
An alternative for analyzing machine vibrations, particu-
larly on relatively simple rotary shafts and drivetrains, is to use
lumped-mass models and experimental measurements. For
example, to model a long shaft with multiple diameters and
properties, the designer uses the software to divide the shaft
into many segments defined by masses and inertias, springs,
and damper components. The nonlinearity of the spring stiff-
ness and damping incorporates easily using a mathematical
representation or a lookup table based on experimental data.
Then the designer can add gears, clutches, and other compo-
nents (including backlash values) to complete the model.
The driveline vibrates during an engine run-up test from 100 to 3,000 rpm, and this graph identifies contributions of vibration harmonic orders to
maximum shear stress between cylinders one and four. Note the 24 orders in the plots for integers and half orders of a four-stroke engine. These
plots indicate which orders contribute the most to the overall vibration (the red dotted curve).
CAD
The engine produces gas pressure for torque pulses that
repeat after every complete working cycle. A four-stroke,
single-acting engine has an interval of 4 or two crankshaft
revolutions. A two-stroke engine has an interval of 2. Due
to this harmonic nature, the gas torque is usually represented
as a Fourier series:
T
g
(t) T
o
c
k
cos(kt) s
k
sin(kt)
k
h
o
k
h
o
k = 0.5, 1, 1.5, ... for four stroke cycle

k = 1, 2, 3, ... ... for four stroke cycle
where h
o
= maximum number of required harmonic orders;
and T
o
= constant function of the cylinder firing angle,
crankshaft radius, nominal power, and other constants.
Notice how this gas-torque equation consists of a steady
part, T
o
, that doesnt excite vibration and a fluctuating part
that does.
In engine-vibration theory, the harmonic order is the num-
ber of excitations during one crankshaft revolution. The fourth
order repeats twice in a four-stroke engine, so the harmonic
orders are half multiples , 1, and
3
/
2
. The fourth order
repeats four times each revolution in a two-stroke engine, so
there are no half-orders and the orders are integer multiples.
In the above gas-torque equation, the sine and cosine terms
represent the harmonic orders and half-orders. The parameter
h
o
is the maximum number of required harmonic orders, typi-
cally with a value from 8 to 12.
In some software, designers can define the harmonic orders
for the engine (including half-orders for four-stroke engines)
through symbolic equations using Modelica or custom com-
ponent code. First determine the amplitudes of the sine and
cosine terms for each harmonic order in the series from simu-
lation or experimental data. Then enter these amplitudes into
a model as 2D lookup tables (to represent the strength of all
The source of excitation is one of the most important parts
of a lumped model. Later in this article, well explore two
application examples: In one, the source is an internal-com-
bustion engine that induces vibrations via reciprocating piston
and slider-crank mechanism movements. In another, its a
turning ship propeller cutting through ice and water.
The first step is to use the software to create a 1D physical
model of the design focusing on the machines mechanical
linkages. The model consists of springs, dampers, masses, and
rotational inertias, as well as force and moment components
for either the torsional or translational domain. All other
motions are ignored to keep the model simple.
Next, use table-lookup components to incorporate
experimental data into model elements, which define
behavior in terms of nonlinear springs and dampers. Some
software also integrates custom-component data on spring
forces, damping forces, and moments from Excel spread-
sheets. That lets designers edit component equations to fit
the application.
Once a lumped model with vibration excitation source is
set up, the software executes vibration analysis numerically in
both time and frequency domains (based on the simulation
results) or analytically (based on the mass and stiffness matri-
ces extracted from the model).
ENGINE EXCITATION MODEL
Consider the internal-combustion engine. Its predominant
vibration source is variations in gas-pressure torque, related to
the cylinder gas pressure by the slider-crank geometry:
T
g
P
g
ARsin(1cos)
where Tg = engine gas-torque, Nm; P
g
= cylinder gas
pressure, MPa; A = lateral piston area, mm
2
; R = radius of the
crank shaft, mm; and = rotation of the crank shaft, degrees
This is another ship-driveline model (in MapleSim). It shows a
pump at one end of the shaft and a flywheel attached to cylin-
der one that works as a damper for the engine.
the harmonic orders over a range of the engines mean effec-
tive pressure).
For a four-cylinder engine, the designer must determine gas
pressure for different speeds and load conditions. The usual
practice is to test several engine prototypes on a test bed with a
pressure transducer fixed inside the combustion chamber. The
transducer measures gas torque in the chamber and integrates
that collected data into the lumped model.
Excitation also varies with the rotational shaft speed, which
directly influences the vibrational frequency, so the designer
must analyze the machine vibrations over a range of engine rpm.
Likewise, to model a multicylinder engine, assume that all
the cylinders have the same outputs, so the gas torque is the
same for all of them. The only caveat is that theres a phase dif-
ference between the fluctuating torques in the cylinders. (Any
more detail about the model is beyond the scope of this article.)
Some software has vibration-analysis templates to let
designers execute all vibration analysis in one software envi-
ronment. It lets designers linearize nonlinear models for con-
trol design or modal analysis. For example, the designer can
extract any driveline models dynamic equations in symbolic
form, extract stiffness and damping matrices, and plot the
mode shapes. That way, plots can reveal machine behaviors so
designers can remedy the weakest parts.
TORSIONAL VIBRATION IN A SHIP DRIVELINE
Consider a large ship moved by a propeller through water.
The driveline that powers the propeller needs torsional-
vibration analysis. In fact, this is a good application
to explore because it has driveline elements common to
myriad machines.
The propeller-driveline model consists of a four-cylinder,
four-stroke internal-combustion engine, a propeller that pro-
duces the thrust to push the ship forward, and shaft sections
modeled as inertia components with spring-stiffness and
damping properties.
Assume that the propel-
ler and engine connect
through a simple reduc-
tion-gear transmission.
Assume that theres a
pump at one end of
the shaft. Also assume
that theres a flywheel
attached to cylinder one
for damping vibrations
and smoothing output
motion by leveraging
Newtons first law.
The two most signif-
icant sources of vibra-
tion in this case are the engine and the propeller. Therefore,
we need highly detailed models for these components.
The driveline is structurally simple because there are no
translational parts, so a 1D lumped-mass model is sufficient.
Both engine and propeller subsystem models contain for-
mulations that account for the fluctuation torques that excite
vibrations.
To evaluate the engine design, load the cylinder gas-exci-
tation torque data generated from real experiments into the
simulation software using 2D lookup tables. Then model the
propeller torque as a second-order sinusoidal function that
describes the vibration as a function of rotational speed and
the number of propeller blades.
EIGENVALUE AND ORDER ANALYSIS
Software built on symbolic mathematical computation
lets designers extract dynamic equations for entire models or
individual components. One command from within the soft-
ware extracts differential equations to describe the driveline.
Another command yields a stiffness matrix with the models
eigenvalues and eigenvectors (natural frequencies) and mode
shapes. Where available, linearization templates yield stiffness
and damping coefficient matrices for nonlinear systems.
A more visual and common technique for investigating
vibrations and sounds from rotating machines is order analy-
sis. Its strength is that it generates a plot that clearly shows
discrete peaks in vibration signals for excited machine subsys-
tems. Designers use order analysis to test devices ranging from
gearmotors to gas turbines and even dental tools.
For the continuation of this feature and full explanation of how to use
order analysis, visit machinedesign.com and search for Thanh-Son.
RESOURCES:
Maplesoft, maplesoft.com/industries/automotive/noise_vibration
Many high-quality parts produced
on 3D printers can be sanded by
hand to eliminate layer lines and
produce a smooth finish.
How
to Smooth
3D-printed Parts
T
heres a misconception that 3D
printing cannot make the kind of
smooth and polished parts avail-
able from traditional manufac-
turing technologies. But finishing techniques
can address such concerns, and they are
widely available. For example, RedEye, one of
the worlds largest providers of 3D-printing
services, offers finishing services for parts
printed from fused-deposition modeling
(FDM) and PolyJet machines.
The ability to use each finishing tech-
nique depends largely on part geometry and
the material. These two factors determine
what type of aesthetics can be achieved,
as well as a parts function because differ-
ent methods allow for different textures and
appearances. Some methods are better for
prototypes, display models, or end-use parts,
says Bill Camuel, project engineering super-
visor at RedEye, Eden Prairie, Minn.
RedEye offers several finishing techniques,
but the company usually gets requests for sanding, bead blasting, and a technique
using vapor smoothing.
SANDING
Though FDM systems are engineered to produce high-quality parts right off the
machine, the layer lines can be visible, and they often deter customers from using
them in end-use applications where aesthetics are a priority. The sanding process
alleviates the concern and can be used for display models, sales or concept samples,
form-fit-function prototypes, or end-use parts.
The process of sanding is exactly as it sounds. FDM plastic parts can be sanded by
hand or with belt sanders, like wood or automotive parts. Sanding is an inexpensive,
effective, and proven method to reach a smooth finish. It is consistently the most
widely used finishing technique for 3D-printed parts.
Sanding works on all but the tiniest parts. Parts can never be too large, but manu-
ally reaching small undercuts or drafts is difficult. Also, the process is relatively
LINDSEY FRICK | Associate Editor
lindsey.frick@penton.com
3D printing
Sanding, bead blasting,
and vapor smoothing
are the most-popular
methods for achieving
smooth plastic
3D-printed parts.
Bead blasting
sprays tiny, plas-
tic particles at
a part inside a
closed chamber
to produce a
smooth finish in
about 5 to 10 min.
Finishes can vary based on the approach.
From bottom to top, RedEye shows the fin-
ishes of raw FDM, Ready Part glossy, and
Ready Part matte. Ready Part is the name of
RedEyes vapor-smoothing process.
quick for standard-finish parts. Standard-
finish parts from an FDM machine usually
have stair-stepped surfaces. Sanding removes
stair-stepping on a part roughly the size of a
television remote in about 15 min. However,
getting a part of the same size ready for paint
takes as much as 2 hr because of additional
steps like priming and drying time.
When parts must hit benchmarks for accu-
racy and durability, its important to keep
in mind how much material sanding will
remove. Removing too much could force
adjustments in part design and wall thick-
ness before printing. Benchmarks will also
help determine which sanding technique to
use hand sanding or power sanding
and which tools to employ.
BEAD BLASTING
The second most-commonly used fin-
ishing process is bead blasting. Here,
an operator holds a nozzle that sprays
tiny beads of media at a part to remove
layer lines. Its quick, taking about 5 to
10min to complete, and the process
leaves products with a smooth finish that
looks like a uniform matte finish.
Bead blasting is flexible, as it works with most FDM mate-
rials. It also can be used on parts throughout their product
development and manufacturing life cycle, from prototyping
to production. The versatility comes from the media, typically
small, plastic particles that are composed of finely reground
thermoplastic particles. RedEye most
commonly employs these plastic bead
media, which are durable and offer an
abrasiveness that ranges from mild
to harsh, for spraying. Baking soda
also works well because its not too
aggressive, though it can be messier
than plastic.
One of the limitations of bead
blasting is part size. Because the pro-
cess takes place in an enclosed cham-
ber, the maximum part size is 24
32 32 in. And, given that parts are
bead-blasted by hand, they are fin-
ished one at a time and, thus, can-
not be mass finished.
VAPOR SMOOTHING
Rounding out the top three is
a finishing method called vapor smooth-
ing. The part is dipped into a vapor tank containing liquid at
the base that is brought to boiling point. The vapor rises and
melts away about 2 m of the part surface, leaving it smooth
and shiny after only a few seconds. Once polished, the finished
parts can withstand upwards of 100F. Those who prefer a
matte finish can bead blast the part after smoothing, which
subdues the surface tension and camouflages layer lines.
Because it provides an even surface finish, vapor smoothing
is widely used in consumer, prototype, and medical applica-
tions. The method does not significantly affect part accuracy.
And, when bead blasted, the matte finish makes the part ready
for filming, coating, and plating layers. These coatings are
typically applied to stronger, high-performance materials.
Unfortunately, like bead blasting, vapor smoothing presents
some size restrictions. Because materials are dipped into a
tank, the largest part size is 3 2 3 ft. Unlike sanding and
bead blasting, vapor smoothing has material restrictions as
well. Instead of accommodating the full spectrum of FDM
materials, vapor smoothing can only service ABS and ABS-
M30, which are common durable thermoplastics. These mate-
rials are economical and strong enough to perform much like
the final product.
RESOURCES:
RedEye, www.redeyeondemand.com
MAY 8, 2014
f r om
gl obal purchasi ng. com
VICTORIA FRAZA KICKHAM | DISTRIBUTION EDITOR victoria.kickham@penton.com
IF THERE IS A consensus among some of
the largest distributors in the industrial
marketplace, it is that the economy has
improved but in a slow-yet-steady pace.
Also, this past winter while harsh and
damaging at times to many companies
should not be used as an excuse for
declines in cold-weather business. Mark
Simon, vice president of sales at Allied
Electronics, called 2013 a reasonably
good year and one that improved
somewhat over time.
Things started to pick up pretty
steadily [with] moderate increases along
the way, he explained. As we moved
into 2014, it has continued.
Simon also pointed out that the over-
all economy seemed to be on an uptick
along with the various industries Allied
Electronics serves.
The economy itself has just done
better, he said. Medical has done fairly
well. Automotive has come back over the
last couple of years and been pretty sta-
ble, which has allowed a lot of the smaller
companies which serve that particular
vertical to do quite well.
Tim Breen, president and chief operat-
ing officer at Motion Industries, agreed
with Simon on the economy, but he did
so cautiously.
I believe that the economy is get-
ting better. We are seeing some signs
of opportunity, explained Breen. But
I do think it will be a challenging 2014
for everybody.
Breen spoke of anticipating the prod-
uct needs of the factory of the future,
one with more automation and related
technologies. But nonetheless, he said
Motions leaders know the company cant
completely reinvent the wheel as far as its
business plans are concerned.
Bearings, the PT business, fluid pow-
er, and hoses are steady products all these
years and we continue to stay focused on
them to make sure were maximizing our
opportunities, Breen explained.
Both Breen and Simon agreed on the
impact this past difficult winter had on
their respective companies. Simons com-
pany, Allied Electronics, is headquar-
tered in Fort Worth, Texas.
From a sales perspective, it hurt us
for several weeks. There were delays in
getting materials, said Simon. But weve
seen a very strong backlog, so I think that
for the most part weve rebounded
quite nicely.
JOE NOWLAN | CONTRIBUTING EDITOR jcnowlan@gmail.com
Six of the largest distributors serving industrial markets
today point to improving end markets and acquisitions as key
growth opportunities this year.
2014: A Year of Growth,
Say Top Distributors
The economy itself has just done better,
said Mark Simon, vice president of sales at
Allied Electronics. Medical has done fairly
well. Automotive has come back over the
last couple of years and been pretty stable,
which has allowed a lot of the smaller com-
panies which serve that particular vertical to
do quite well.
Allied Electronics, Inc 2014. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.
1.800.433.5700
The most trusted brands in Power, all under one roof.
HEU||MAE HOU5E
c||ede|ec.cem/PowerHouse
Headquartered in Birmingham, Ala.,
Motion Industries faced similarly dif-
ficult stretches of bad weather.
It impacted most businesses, Breen
agreed. You have branches closed, and
we had plenty of those [closed] in Janu-
ary and February. Several thousands of
hours [were] lost because of the weather.
But he was quick to add that this year
wasnt the first time winter weather has
affected Motion Industries.
Thats a challenge every year. Some-
times it is worse than others and this year
weve had kind of a rash of it, Breen said.
You deal with that the best you can and
try to recover as fast as you can and get
ready for the next day. We dont use it as
an excuse.
David Mayer, vice president of mar-
keting and services at Kaman Indus-
trial Technologies, described how his
company also lost some business this
past winter when harsh weather caused
some branches to remain closed as
employees could not get to their respec-
tive locations.
We had a number of our branches
that were affected by winter weather,
Mayer said. I would say we were cer-
tainly impacted in the early part of the
first quarter of 2014 by winter weather,
largely on the eastern seaboard and the
east coast.
On a positive note, housing was
among the industries that showed signs
of improvement for Kaman in 2013.
Durables, housing materials, lum-
ber, shingles, roofing, asphalt all had
a very strong year for us, Mayer said.
And metals did well last year, too. Most
of the end markets to which we sell
were strong.
In remarks made during an earnings
conference call this past January, Wes-
co president, chairman, and CEO John
Engel was somewhat optimistic about the
overall economy for 2014.
We expect macroeconomic condi-
tions to show improvement over 2013
with a strengthening recovery in non-
residential construction this year,
Engel said during the call. Wesco ben-
efited from the increasing demand for
new lighting products as well as overall
data communications.
Solid growth in lighting, driven by
LED and retrofit applications, and con-
tinued growth in data communications
were the catalysts for the second half [FY
2013] improvement, Engel explained.
We are pleased with the strength of our
utility business in delivering ongoing
above-market sales growth.
Some top distributors made key acqui-
sitions in 2013. Mayer discussed a few
that Kaman made Western Fluid
Components, Ohio Gear & Transmis-
sion, and Northwest Hose & Fittings.
All of [the 2013 acquisitions] have
done well. Were pleased with the results,
Mayer said. For the most part, we leave
the [acquired] businesses alone. We like
the approach of keeping the local people
and the entrepreneurial spirit. The three
that we did in 2013 were all good strategic
fits, both from the geographic standpoint
and from a product-mix standpoint.
In late February, Kaman announced
its intent to acquire B.W. Rogers, a
fluid-power distributor. Mayer, who said
he expects that acquisition to be final-
ized in the second fiscal quarter of 2014,
described it as the biggest acquisition in
Kamans history.
Motion Industries also made some
acquisitions, including Paragon Service
& Supply in 2013 and, in early 2014,
Commercial Solutions Inc. Breen antici-
pates more on the horizon.
Acquisitions are certainly a key focus
for us in terms of our long-term growth,
he said. [Those] appear to have been
very nice acquisitions for us so far. And
were working on others. We are optimis-
tic about additional acquisition activities
during 2014.
Erik Gershwind, president and CEO
at MSC Industrial Supply, referred to a
soft market environment [that] persisted
in the fiscal fourth quarter of 2014 when
speaking on an earnings conference call
last October. However, he said he was
confident about what calendar-year 2014
will hold for MSC.
We are in the midst of building a
foundation that will support the next leg
of our growth story, he said during the
call. Our actions will ensure that we not
only continue to outgrow the market as
we have in the current low-growth envi-
ronment, but accelerate our growth.
Like many in distribution, Gershwind
said he has seen customers become bet-
DistributionResource|GlobalPurchasing
Durables, housing materials, lumber, shin-
gles, roofing, asphalt all had a very strong
year for us, said David Mayer, vice president
of marketing and services at Kaman Indus-
trial Technologies. And metals did well last
year, too. Most of the end markets to which
we sell were strong.
Just getting out there and being in front of
the customer so that when they do have an
opportunity to buy something, our companys
name is top of their mind. Thats what were
trying to do, said Tim Breen, president and
chief operating officer at Motion Industries.
COMPANIES DEVELOPING SOME of the
newest sensor products tout their ability
to improve overall long-term stability
and the benefits of their ultra-compact
forms. The DLVF series digital output
sensor from All Sensors, Honeywell
Sensing & Controls TSC TruStability
pressure sensors, and STMicroelectron-
ics LPS25H digital barometer micro-
electromechanical-systems (MEMS)
pressure sensor are a few examples.
All Sensors DLVR series mini digital
output sensors are based on the com-
panys CoBeam2 technology, which
reduces package stress susceptibility,
resulting in improved overall long-term
stability. The technology also improves
position sensitivity compared to single-
die devices, the company says. Applica-
tions include heating, ventilation and air
conditioning; medical breathing; indus-
trial controls; environmental controls;
and portable, handheld equipment.
The suppl y voltage options are
designed to ease the integration of the
sensors into a wide range of process con-
trol and measurement systems, enabling
direct connection to serial communi-
cations channels. The sensors also can
enter very low-power modes between
readings to minimize load on the power
supply in battery-powered systems.
According to the company, these cali-
brated and compensated sensors provide
accurate, stable output over a wide tem-
perature range. They are intended for
use with noncorrosive, non-ionic work-
ing fluids. A protective parylene coating
is optionally available for moisture and
harsh media protection.
Honeywel l Sensing & Controls
TruStability TSC and NSC pressure
sensors eliminate the need for system
calibration over temperature and offer
reduced part-to-part variation. They
measure differential or gauge pressures
and are intended for use with noncor-
rosive, non-ionic gases. Numerous
package styles and mounting options
are available. Both series are piezo-
resistive silicon pressure sensors that
offer a ratiometric analog output for
reading pressure over the specified full-
scale pressure span and temperature
range.
The TSC series is temperature com-
pensated and unamplified. Compensa-
tion makes it easier to integrate into a
system by eliminating the need to cali-
brate the system over temperature. It also
offers reduced part-to-part variation.
STMicroelectronics LPS25H ultra-
compact absolute piezoresistive pressure
sensor includes a monolithic sensing ele-
ment and an IC interface that can take
the information from the sensing ele-
ment and provide a digital signal to the
external world.
The sensing element consists of a sus-
pended membrane realized inside a sin-
gle mono-silicon substrate. It can detect
the absolute pressure and is manufac-
tured with a dedicated process.
DistributionResource|GlobalPurchasing
ter educated and more technologically
sophisticated, particularly when it comes
to inventory management.
A smart use of inventory manage-
ment tools can help manufacturers
create leaner, less complicated supply
chains and increase efficiency, Gersh-
wind said in an interview prior to
addressing the Ariba LIVE conference
in Las Vegas this past March.
Today, businesses are more connect-
ed and have access to more information
than ever, which creates opportunities
for greater collaboration. Were seeing
how working closer with customers can
improve the efficiency of their industrial
supply chains, reduce costs, and drive
greater value across their business,
Gershwind continued.
Applied Industrials president and
CEO Neil Schrimsher said he is confident
as his company celebrates its 90th anni-
versary this year.
Applied has a strong foundation, and
we have solid momentum heading into
fiscal 2014, Schrimsher said in the annu-
al report.
He went on to cite the goals Applied
Industrial has set, among them, Grow-
ing sales in our core business as well as
in targeted industries [while] expanding
our value-add with existing customers
Driving product expansion beyond
our base offering with opportunities
across all of our product groups [And]
utilizing our strong financial position to
accelerate acquisitions.
Another issue on which there is gen-
eral agreement is that the value that a suc-
cessful distributor brings to customers
will be what continues to make them suc-
cessful and profitable. Simon could well
have been speaking for many of his col-
leagues when he emphasized the service
he believes Allied Electronics brings to
customers, over and above price.
Selling at a low price is easy to do. Its
easy to hand out a low price, he said. But
to deliver and to service a customer in the
way that they need to be serviced, so they
can make their deliveries to their clients,
is another thing.
Sensor Technologies Improve
Products from Honeywell, STMicroelectronics, and All
Sensors boast long-term stability and ultra-compact forms.
Honeywell Sensing & Controls TruStabil-
ity TSC pressure sensors eliminate the need
for system calibration over temperature and
offer reduced part-to-part variation.
GO TO MACHINEDESIGN.COM 45
BRADFORD L. GOLDENSE
|
President
Goldense Group Inc. (GGI)
Needham, Mass.
in sales. That is still the case today,
with customer satisfaction being
a close second. What was miss-
ing was a metric that specifically
measured new product sales, the
force that sustains the lifeblood of
most companies. Ah, but things
are never easy. What exactly is
new? And, doesnt new differ
by industry? Certainly so. That
is why you see the variable N in
the metric. The matter of defining
new is more complex.
Across industries, N ranges
from one to seven years. The most
common N is 3. After three years,
products are no longer new. Indus-
try averages are hard to come by, but figures ranging from
25% to 32% are generally accepted to be industry averages for
N = 3. If your company has less than 25% of its sales in any
year from new products, there is generally an opportunity to
improve the new-product development engine.
The fourth metric is pretty straightforward: Patent produc-
tion. Like R&D spending, which is a required metric, patents
are registered with governments and they are tracked as a
matter of compliance. No surprise here, regardless of whether
there is a great deal or little patent activity.
The fifth metric is New products released. Product
releases are big events in every company and nearly all
employees have responsibilities associated with new product
releases. Product releases start the meter for counting the
revenues associated with new products, in support of the third
ranked metric.
Top-5 R&D Product-
Development Metrics
F
ive metrics affect every
member of the R&D and
product -devel opment
communities, regardless
of their level of responsibility. GGI
surveyed manufacturers about met-
rics in 2013 and has done so regularly
since 1998. Interestingly, our research
showed no change in these top five
metrics throughout the great recession.
The top five metrics fall into two
categories, input and output. The
first two metrics are input metrics,
R&D spending and R&D head-
count. Each year, management deter-
mines how much to reinvest into R&D.
R&D spending is typically measured
as a percentage of sales. Some industries reinvest 1 to 2%, oth-
ers 20 to 25%. The right amount depends on ones industry, the
company strategy, and what the competition is spending. You
cannot judge the figure alone as either good or bad.
Headcount is a key metric for R&D. In operations, the unit
of production capacity is generally a piece of equipment
assisted by people. In R&D, however, the unit of production
capacity is generally people assisted by a piece of equip-
ment. An R&D organizations capacity is best measured by its
people. Appropriately, these are the top two metrics.
Why doesnt everyone measure R&D spending? Public
companies are required to disclose this figure and private
companies are not. Headcount is more of a judgment call.
Most firms measure it because people are the largest cost in
the vast majority of R&D budgets and a key consideration for
product-development capacity.
The third metric has a long name, The percentage of the
current years sales due to new products released in the prior
N years. A shorter name would be New product sales, or the
Vitality Index. Unlike the first two metrics, the third metric
did not exist until 1988 when 3M introduced it to the world.
It immediately resonated. For decades, the corporate metrics
that best resonated with every employee were sales and growth
BRADFORD L. GOLDENSE, NPDP, CMfgE, CPIM, CCP, presi-
dent of Goldense Group Inc. (GGI) (www.goldensegroupinc.
com), has advised over 300 manufacturing companies on four
continents in product management, R&D, engineering, product
development, and metrics. GGI is a consulting, market research,
and executive education firm founded in 1986.
Goldense on R&D-Product Development
0
10
20
30
40
50
60
70
80
R
&
D

s
p
e
n
d
i
n
g

a
s

p
e
r
c
e
n
t
a
g
e

o
f

s
a
l
e
s
R
&
D

h
e
a
d
c
o
u
n
t

P
e
r
c
e
n
t
a
g
e

o
f

c
u
r
r
e
n
t

y
e
a
r
s

s
a
l
e
s

d
u
e

t
o

n
e
w

p
r
o
d
u
c
t
s

r
e
l
e
a
s
e
d

i
n

t
h
e

p
a
s
t

N

y
e
a
r
s
N
u
m
b
e
r

o
f

p
a
t
e
n
t
s

l
e
d
/
p
e
n
d
i
n
g
/
a
w
a
r
d
e
d
/
r
e
j
e
c
t
e
d

N
u
m
b
e
r

o
f

n
e
w

p
r
o
d
u
c
t
s

r
e
l
e
a
s
e
d

P
e
r
c
e
n
t
a
g
e

o
f

c
o
m
p
a
n
i
e
s

t
h
a
t

u
s
e

t
h
e

m
e
t
r
i
c
TOP-5 R&D PRODUCT-DEVELOPMENT METRICS
79%
67%%
62%
61%
58%
^^^JLU[YPJP[`UL[ZHSLZ'JLU[YPJP[`UL[
EZ INDEXER
,HZ` [V 0U[LNYH[L 9VI\Z[ *VUZ[Y\J[PVU 5V 4HPU[LUHUJL

>L N\HYHU[LL V\Y WYVK\J[Z TLL[ `V\Y ZWLJPMPJH[PVUZ7,906+
RISK is a four letter word
...so eliminate it!
:25/' /($'(5 ,1
6HUYR,QGH[HUV
&XVWRP5RWDU\7DEOHV
+RUL]RQWDO&DURXVHOV
+L&DSDFLW\5RWDU\3ODWIRUPV
/LQHDU6HUYR6\VWHPV
Cast Iron Right Angle Gear Reducers:
WorldWide Electric Corporation
1-800-808-2131 www.worldwideelectric.net
CALL NOW FOR
THE LOWEST
MARKET PRICES!
+,*+ 48$/,7< *($5 5('8&(56 $1' 027256 )25 7+( 32:(5 75$160,66,21 ,1'8675<
SPEED REDUCERS
x HeIicaI inIine
x Cast iron right angIe
x AIuminum worm gear
x Shaft mount reducers
N0fl0NL00 ll0FlfLF 00f#0f8lL0
1800808Z1J1 l NNN.N0fl0NL000l0FlfLF.0l
MOTORS
x Permanent magnet DC
x NEMA T & TC-frame
x 56C-frame AC
x StainIess steeI
0ll 80N f08 18l l0Nl$1
N8.l1 F8l0l$
$0 Nllll08 N0818 0f
l8l8108f
Polyurethane for seals
A NEW polyurethane has been developed that is more resistant to water
and withstands major temperature uctuations. Polyurethane, primarily
known as foam for door
frames and mattresses
and frequently used in
paints and adhesives,
is important for seals
that perform tasks
under especially severe
conditions. Along with
excellent resistance to
ozone, it has four times
the robustness of elas-
tomers and effectively
withstands exposure to
mineral uids.
A specic modica-
tion of the polyure-
thanes components responsible for temperature characteristics lets it
handle temperatures of 40 to 120C. Seals made from the material stay
exible at low temperatures and sufciently stable at high temperatures.
The material offers excellent performance in heat and cold, can be used
in mineral hydraulic uids at up to 120C, and is safe from damage due to
hydrolysis even when used in water heated to 80C.
FREUDENBERG-NOK SEALING TECHNOLOGIES, 47690 East Anchor Court,
Plymouth, MI 48170, (800) 533-5656, www.fst.com
Heat/light-stabilized copolymer
HLS HEAT and
light-stabilized
polyether block
amide (PEBA)
copolymers resist
oxidation and
degradation
during storage.
Manufactured
from medical-
grade Pebax
polymers and USP
VI additives, the
copolymer is for
use in medical devices such as vascular catheters.
PEBA copolymers degrade due to oxygen, moisture, heat, and ultra-
violet light, causing a loss in material properties and reduced function-
ality. A targeted stabilizer system decomposes and neutralizes the free
radicals these conditions create, extending the reliable functionality of
these devices.
FOSTER CORP., 45 Ridge Rd., Putnam, CT 06260, (860) 928-4102,
www.fostercomp.com
Spotlight_
Engineered
Materials
Polysulfone foam
A HIGH-PERFORMANCE polysulfone
foam, Udel P-1703 NT, provides low-hal-
ogen content and low-smoke perfor-
mance for wire and cable applications.
The material passes NFPA 262 smoke and
ame test for plenum applications.
The resin offers lower specic gravity
(1.24) and higher foam rate (50 to 60%)
over comparable resins such as uori-
nated ethylene propylene. Its high-foam
rate has a low dielectric constant (1.8 to
2) to meet cable electrical requirements
without the need for signicant modica-
tions to existing constructions.
The material is chemically foamed
using a FCB-8 foaming masterbatch, or
it can be foamed with physical foaming
gases such as nitrogen. A ratio of 97% wt
of P-1703 NT resin to 3% wt FCB-8 master-
batch is typically used to achieve 50%
foaming.
SOLVAY SPECIALTY POLYMERS USA LLC,
4500 McGinnis Ferry Rd., Alpharetta, GA
30005, (770) 346-0583. www.solvay.com
Moldable silicone
MS-1001 MOLDABLE silicone, for
LED lighting applications, delivers a
Shore D 25 hardness after cure for LED
lighting designs that demand high-
hardness optical parts, ner details,
and excellent reproduction of mold
features.
The silicone can be injection
molded into complicated geometric
shapes, thicker or bigger parts with
reasonable molding cycle times.
The materials high-heat and
photothermal stability allows optics
to withstand close proximity and
alignment with high-brightness LED
dies, which is not possible with optics
manufactured from plastics.
DOW CORNING CORP., Corporate
Center, Box 994, Midland, MI 48686,
(800) 248-2481, www.dowcorning.com
LITERATURE
E
x
p
r
e
s
s
BY ENGI NEERS FOR ENGI NEERS
machinedesign.com
MAY 2014
Smalleys new catalog combines existing Spirolox Retaining Ring and Smalley
Wave Spring selections with series recently released from Smalley including Met-
ric Hoopsters and Laminar Seal Rings. For 50
years Smal l ey has been the i ndustry l eader i n
qual i ty, servi ce and product i nnovati on. Over
10,000 standard parts in carbon and stainless
steel; free samples available. Specials manufac-
tured with No-Tooling-Costs from .200-120.
Smalley Steel Ring Company
(847) 719-5900
Email: info@smalley.com
Web: www.smalley.com/getcatalog
NEW 50TH ANNIVERSARY PARTS AND ENGINEERING CATALOG
Astro Met, Inc.
Cincinnati, OH
(513) 772-1242
Fax: (513) 772-9080
Email: fgorman@astromet.com
Web: www.astromet.com
Astro Mets unique advanced ceramics provide cost effective solutions to material
performance problems in a wide range of demanding applications. Amalox 68 a
99.8% alumina ceramic and Amzirox 86 an yttria
stabilized zirconia provide superior wear resistance,
corrosion resistance, high temperature stability,
low thermal expansion, high stiffness to weight ra-
tio, biocompatibility and high dielectric strength.
ADVANCED CERAMIC SOLUTIONS
Deublin Company
2050 Norman Drive West
Waukegan, IL 60085
Phone: (847) 689-8600
E-mail: info@deublin.com
Web: www.deublin.com
Deublin, the leading manufacturer of rotating unions,has a new, updated 56-page catalog that
includes complete information for selecting unions for a variety of applications, from water and
steam, to air and hydraulic, oil and coolant. Both operating data and dimensional specifica-
tions are provided in one comprehensive catalog, along
wi th i nstal l ati on and servi ce i nformati on. Thi s refer-
ence catalog provides detailed information on over 50
application categories and over 500 models. The cata-
log is available free via reader response, phone or email.
DEUBLIN ROTATING UNION CATALOG AVAILABLE
Hercules Sealing Products
Clearwater, Fl
Phone: (888) 525-0094
Fax: (800) 759-6391
Online Ordering Available Now:
www.HerculesUS.com/machinedesign/litreview
The 2014 Seal Catalog contains almost a 1000 pages of Inch and Metric seals in the most popular styles. Each
part listing includes seal material, temperature, speed, pressure specifications and a cross-sectional drawing.
A color index is available with enlarged profiles for ease of identification. The easy to use format enables you to
quickly locate your specific part. New products for 2014 include:
Rod U-Seals, Piston Seal Assemblies, Wear Rings, Oil Seals, O-
rings, Wipers and a wide variety of repair accessories. A complete
list of custom manufactured seal products (Seals on Demand) can
be found in the front of the new 2014 Seal Catalog. Custom seal
orders placed by 3 pm EST are shipped the same day guaranteed
(some restrictions apply). To order this free catalog or to place your
order online, visit www.HerculesUS.com/machinedesign/litreview
SEAL CATALOG
Fabco-Air, Inc.
(352) 373-3578 or
www.fabco-air.com
Shipping in 2 days with Adjustable air cushions both ends Magnetic
pistons 303 Hard chrome plated piston shaft Stainless steel tie rods
Special bushings self lubricate piston rods
Anodized aluminum end caps Factory
lubricated with Magnalube-G
3D CAD
drawings. Request Catalog #FCQN-OEM.
OEM-PRICED NFPA AIR CYLINDERS
RACO International L.P.
Bethel Park, PA
(888) 289-7226, (412) 835-5744
Fax: (412) 835-0338
Email: raco@racointernational.com
Web: www.racointernational.com
RACO Electric Linear Cylinders with ballscrews or acme screws are an environmentally safe
and low maintenance replacement for hydraulic or pneumatic cylinders. Thrusts to 200,000
lbs., speeds to 30/second, and strokes to 20 ft. Mod-
ular system allows custom built units using the spe-
ci al hi gh torque RACO actuator motor or servo and
stepper motors. Cylinders are built for heavy duty indus-
trial applications. Other types of cylinders are available
for high speed, high positioning accuracy applications.
ELECTRIC CYLINDERS
ACE Controls Inc.
Farmington Hills, MI
(800) 521-3320 (248) 476-0213
Email: shocks@acecontrols.com
Web: www.acecontrols.com
ACE Controls Main Catalog now includes its largest range of industrial and safety shock
absorbers, as well as models for the PET & GLASS industries. Additional catalog products
include: Gas Springs, Hydraulic Dampers, Velocity and Feed Controllers. ACE shock
absorbers provide superior motion control and deceleration to prevent impact damage,
dampen noise, increase cycle speeds and improve product performance. Typical
applications include aerospace, automotive, amusement, automation, defense, glass,
machine tool, material handling, medical, packaging,
and more. Made in USA
ACE CATALOG EXPANDS OFFERING
OKeefe Controls Co.
(800) 533-3285
Email: sa@okcc.com
Web Site: www.okccbo.com/1
20,000 Precision Orifices are included in the 72 page 2014 catalog. Orifices in
sizes from .0003 to .125 diameter are made of brass, stainless steel or sap-
phire. Connections include barbs, compression
styles, press-in inserts, set screw threads, and
pipe sizes 1/8, 1/4, 3/8 and 1/2 NPT. Catalog
also includes inline screens, check valves and
fixed flow controls.
NEW CATALOG PRECISION ORIFICES
Floyd Bell Inc
(614) 294-4000
Fax: (614) 291-0823
Email: sales@oydbell.com
Web: www.oydbell.com
ULTRA LOUD PIEZOELECTRIC ALARMS
Ultra Loud selection of piezoelectric whoops, warbles, sirens, beeps and
more offers 100Hz lower frequency than industry counterparts. Available
i n vari ety of vol tages and output up to
108dB! Rugged panel mount products are
IP68 and NEMA 4X when used wi th op-
ti onal gasket I SO 9001:2000 regi stered
company all products made in the USA.
Floyd Bell Inc
(614) 294-4000
Fax: (614) 291-0823
TURBO LIGHT WATERPROOF LED PANEL INDICATORS
Tiny (approx.1x1) LED Panel Indicators provide BRIGHT output with super-
sleek design. Available in variety of voltages and output up to 14,500 cd/m2! Rug-
ged, tamper-proof, lo-profile panel mount de-
sign is IP68 and NEMA 4X. Available in 5 colors
and 3 brightness levels. ISO 9001:2000 regis-
tered company all products made in the USA.
P39L
800.663.4509
Floyd Bell Inc
(614) 294-4000
Fax: (614) 291-0823
AUDIOLARM II PIEZOELECTRIC ALARMS
The industrys largest selection of piezoelectric whoops, warbles, si-
rens, beeps and more. Available in variety of voltages and output up to
103dB! Rugged panel mount products are
IP68 and NEMA 4X when used with op-
tional gasket. ISO 9001:2000 registered
company all products made in the USA.
Floyd Bell Inc
(614) 294-4000
Fax: (614) 291-0823
TURBO MINIATURE PIEZOELECTRIC ALARMS
Tiny (approx.1x1) piezoelectric alarms provide LOUD output with a super-
sleek design. Available in variety of voltages and output up to 103dB! Rug-
ged, tamper-proof, lo-profile panel mount
desi gn i s I P68 and NEMA 4X. Opti onal
manual volume control offers increased at-
tenuation. ISO 9001:2000 registered com-
pany al l product s made i n t he USA.

BEIs Industrial Encoders
for Dummies
Visit www.beisensors.com/dummies
for your free copy today
HOTWATT, INC.
Danvers, MA
(978) 777-0070
Fax: (978) 774-2409
Email: sales@hotwatt.com
Web: www.hotwatt.com
Hotwatt, made in USA, manufactures cartridge, air process, immersion, strip and
finned strip, tubular and finned tubular, band, crank-
case, foil, flexible glasrope and ceramic heaters.
We are a quality supplier to OEMs in the indus-
trial, medical, commercial, packaging, instrumen-
tation, aviation, transportation and military fields.
ELECTRIC HEATING ELEMENTS, CUSTOMIZED
AND STOCK FOR 60+ YEARS
Connectable (PC) Belts available in diameters ranging from .093 through .562.
CUSTOM MADE IN INCH, METRIC & O-RING SIZES
Very Clean in Operation Eliminates Tensioning Devices
Exceptional Abrasion Resistance
Line Shaft Conveyor Belts - Original Equipment & Connectable
www.pyramidbelts.com
(P) 641.792.2405 E-mail: sales@pyramidbelts.com
522 North Ninth Avenue East, Newton, IA 50208
AN ISO 9001
CERTIFIED COMPANY
COLORS AVAILABLE
Round, Flat and Connectable Polyurethane Belts
Allows for accurate, non
destructive measurements on
o-ring and belt inside
diameter (ID) or inside
circumference (IC).
Available in Standard and
Metric Sizes.
DIAMETAPE BELT
MEASURING TOOL
Samples available at little or no cost
POWER TRANSMISSION-PART CONVEYING
PYRATHANE

BELTS
With Lifetime Warranty Against Manufacturing Defects
Laboratory
homogenizers
HMG-10 SERIES
of laboratory
homogenizers has
a 144-W, high-torque
motor with a variable-
speed adjustment, sepa-
rate on/off switch, and is
constructed of 316 stain-
less steel. The generators
probes quickly lock into
a special adapter to pro-
vide hands-free ejection
of the probe, minimizing
the chance of accidental
contamination.
OMEGA ENGINEERING,
One Omega Dr., Stam-
ford, CT 06907, (203)
359-1660, www.
omega.com
Products
Direct-drive radial-piston motor
THE HYDRE-MAC direct-drive radial-piston mo-
tor handles variable-speed applications. The
low-speed, high-torque motor, featur-
ing a cam-lobe design, employs a
MacTaggart Scott heavy-duty
motor design. The motor in-
creases component life with
two inlet and outlet ports
that reduce pressure drops
at high power; generating
less heat overall. A sym-
metrical 18 piston/roller
assembly eliminates piston
side loading and reduces
wear and tear. Hydre-MACs
repairable wear surfaces in-
clude shaft seals, wear rings, piston
seals, and bearing pads that can be
replaced on-site.
EATON CORP., HYDRAULICS GROUP USA,
14615 Lone Oak Rd., Eden Prairie, MN 55344,
(888) 258-0222, www.eaton.com/hydre-mac
SchemaLics PN Codes DescripLions
Search OTTO Lnineerin aL Lhe Apple App sLore or Lhis Free Download
www.ottoexcellence.com 847.428.7171
OTTO Controls Catalog App
Free Easy Access to
CopyrihL 2014 OTTC Lnineerin, Inc. OTTC and Lhe OTTC LxpecL Lxcellence loo are reisLered Lrademarks o
OTTC Lnineerin, Inc. All rihLs reserved. 2014-16
Designed, Manufactured
and Precision Tested
in the U.S.A.
4(+, 05 <:(
FeaLures Specs Drawins
Self-lubricating
rod-end bearings
THE WN 648 self-lubricating rod-end
bearings,now available in inch sizes,
are for control and link mechanisms
in all types of machines. These RoHS-
compliant bearings are designed for
high-load, low-speed applications
with hanging angles, requir-
ing linear, rotational, or
oscillatory motions. Avail-
able in both tapped and
threaded-stem versions,
the bearings are made of
zinc-plated low-carbon steel,
with right or left-hand threads.
The ball socket is low-carbon,
zinc-plated,
case-hard-
ened steel.
The external ring is
a special oil-impreg-
nated bronze material,
which makes the rod
ends self-lubricating and
maintenance-free.
J.W. WINCO, 2815 S.
Calhoun Rd., New
Berlin, WI 53151, (800)
877-8351, www.jwwinco.com
sumption coils, allowing operation
directly from a PLC without interface
relays. The 35-mm, DIN-rail mount-
able contactors come in three and
four-pole models and have IP20-rated
housings, self-lifting pressure plates,
and coil voltage indication.
AUTOMATIONDIRECT, 3505 Hutchin-
son Rd., Cumming, GA 30040, (770)
889-2858, www.automationdirect.
com/motor-controls
Miniature contactors
THE CWC Series of miniature contactors, for switch-
ing and controlling motors, take up less space inside
electrical enclosures while still offering 15 hp @ 460 V.
Dimensions of the 7 to 16-A contactors are the
same for ac or dc coil voltages, making panel design
and assembly easier. The dc models feature low-con-
P39
Ad Index
Advertiser . . . . . . . . . . . . . . . . . . . . . . . Page
Adsens Technology . . . . . . . . . . . . . . . . . . . 18
Allied Electronics. . . . . . . . . . . . . . . . . . . . . 43
Altech Corp. . . . . . . . . . . . . . . . . . . . . . . . .IFC
Automationdirect.com . . . . . . . . . . . . . . . . . . 3
Balluff Inc . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bokers Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 31
Boyd Coatings Research Co. Inc . . . . . . . . . . 24
Centricity Corp.. . . . . . . . . . . . . . . . . . . . . . 47
Crouzet Motors . . . . . . . . . . . . . . . . . . . 14, 15
Dura-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . 55
EBM-Papst . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exair Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fineline Prototyping. . . . . . . . . . . . . . . . . . IBC
Intech Powercore Corp. . . . . . . . . . . . . . . . . . 6
Lee Company, The . . . . . . . . . . . . . . . . . . . . . 1
Lubriplate Lubricants Co. . . . . . . . . . . . . . . . 20
Master Bond Inc. . . . . . . . . . . . . . . . . . . . . . 28
Metal Powder Ind Federation . . . . . . . . . 21, 23
Minalex Corp.. . . . . . . . . . . . . . . . . . . . . . . 18
Minnesota Rubber & Plastics. . . . . . . . . . . . . 25
Nachi America Inc . . . . . . . . . . . . . . . . . . . 55
National Instruments . . . . . . . . . . . . . . . . . . 13
Newark . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Nordson. . . . . . . . . . . . . . . . . . . . . . . . . . . BC
Otto Engineering Inc.. . . . . . . . . . . . . . . . . . 53
Parker Hannifin. . . . . . . . . . . . . . . . . . . . . . 29
Pepperl+Fuchs. . . . . . . . . . . . . . . . . . . . 26, 27
Pivot Point Inc . . . . . . . . . . . . . . . . . . . . . . . 31
Precision Paper Tube Co. . . . . . . . . . . . . . . . 47
Pyramid Inc. . . . . . . . . . . . . . . . . . . . . . . . . 52
Reell Precision Manufacturing. . . . . . . . . . . . 31
Smalley Steel Ring Co. . . . . . . . . . . . . . . . . . 22
Spirol Intl. Corp.. . . . . . . . . . . . . . . . . . . . . . 8
Stratasys. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Trim-Lok Inc. . . . . . . . . . . . . . . . . . . . . . . . . 54
Visumatic . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Worldwide Electric . . . . . . . . . . . . . . . . . . . 47

While every effort has been made to ensure the
accuracy of this index, the publisher cannot be
held responsible for any errors or omissions.
At EngineeringTV.com
users can browse
video libraries using
technology-based
navigation to focus
on specific technology
topics. They can also
browse by company
brand, trade show, or
by publication-specific
video playlists.
From tutorials to
trade-show coverage,
Engineering TV is
the video site for
design-engineering
professionals.
Dura-Bet
800-770-2358 614-777-0295
Fax: 614-777-9448 www.durbeI.com

1
%
v
ir
g
in
u
r
e
n
e
n
o
r
e
g
r
in
d
w
s
e
)m
k
e
s
s
o
n
g
e
r,
Io
n
g
e
r
I
s
in
g
b
e
Is
.
LONG-LFE BELT8 MOVE HEAVY LOAD8
When a competitor`s belts Iailed aIter only nine months
service in a large postal distribution center, Dura -Belt's
Long-Life HT belts replaced them. Nine yers
later, HT belts are still going strong -- moving your mail
on conveyors that run 24 hoursday, 7 daysweek.
Even though some postal tubs have soIt bottoms and
carry over-weight loads, HT belts take the punishment
and keep the mail moving. Over are in service
on powered-roller conveyor systems. For longer-liIe and
heavier loads, try time-tested HT (high tension) O-ring
belts -- the only ones colored "Post Office Blue".
8u|dIhePer|ecI
8ecsIe|c|ne
With Visumatic
Robotic Fastening
t FeSPcPuT peS|PSmBOce
t meEe|yOH EuSBbMUy
t 5pMUmcSPO BccuSBcy
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
HE NEW 8kEED OF
EkkOkFkEE kO8O|C5
V | 5 U .A | C . C O. t 8 5 . 2 5 5 . 7 0 7
Feed & Drive Tooling Package
FOR SCARA ROBOTS
Puzzles, myths, and curiosities
THE DAYLIGHT SAVINGS EFFECT
ON ENERGY AND TRAINS
THE U. S. government continues to claim that Daylight
Savings Time (DST) saves the country energy. And
while some studies show a small drop, less than 0.5% of
electrical use, the overall energy demand actually jumps
by 4%, according to a recent Dept. of Energy study.
With the extra daylight from DST, people tend to
do more things go to the park, golf,or shop and
Americans being American, they drive to get to those
events. Thats why the fuel industry lobbied to reintro-
duce DST after two short-term experiments using DST
to save energy during World Wars I and II. The fuel
industry knows full well that DST has led to higher gas
consumption.
Similarly, the people who own golf courses say
that the additional month of daylight translates into
$400million more in revenue. The barbecue grill and
charcoal-business groups also notice a bump in sales
during the extra month of sun $200 million.
That last time DST was extended, going from seven to
eight months in 2005, the change was part of the Energy
Policy Act. But the extension had nothing to do with
energy, according to Michael Downing, author of Spring
Forward, The Annual Madness of Daylight Savings
Time. He says the National Association of Convenience
Stores pushed hard for the change because it wanted
Halloween to fall during DST. It would give kids more
time to collect candy, which many people buy at con-
venience stores. The association also knows that about
80% of Americans buy gas at convenience stores, and it
calculates that the extra hour of daylight translates into
a $1 billion increase in sales.
Electric utilities say the extra light of DST, which
now stretches eight months, does lower the amount of
electricity that goes for powering indoor lighting, but
thats more than offset by higher use of air conditioning
Name that GADGET
Be the first to identify this gizmo from a past
issue of MACHINE DESIGN and win a fabulous
prize, along with the honor of seeing your
name in an upcoming issue. E-mail entries
to stephen.mraz@penton.com and put
Gadget in the subject line.
time to get crops in and to market. They used their lob-
bying power to stave it off until 1966 when their num-
bers and influence shrunk and President Johnson then
signed the legislation.
DST also affects Amtrak trains. When we turn our
clocks back an hour in October, any Amtrak train run-
ning on time stops at 2:00 a. m. and waits an hour before
getting underway again. This keeps the trains on time,
according to Amtrak. Passengers on these stopped trains
get to enjoy the local nighttime scenery and an extra
hour of travel time. Why the trains cant keep chugging
along and at least stop at the nearest station, thus deliv-
ering some passengers and cargo early, is an Amtrak
mystery. In the spring, when clocks go back at 2 a. m.,
trains instantaneously become an hour behind sched-
ule. They then struggle to make up the lost hour.
A minor but persistent DST myth: It was first pro-
posed by Benjamin Franklin. While Franklin talked
about a time shifting scheme that would give Parisians
more daylight to enjoy themselves, he was being satiri-
cal. In fact, the first serious proposal came from George
Vernon Hudson of New Zealand in 1895. He was an
entomologist (a scientist who studies insects). Shifting
the clock would let him do his insect collecting in the
daylight.
MYTH:
at offices, factories, and
shopping malls.
Another DST myth
is that the practice
was established
to help farmers.
In fact, farmers
strongly resisted
DST because it
gave them an hour less
Prepared for Takeoff.
Create production-quality parts with
additive manufacturing and our new
high-performance materials.
FineLine has added Cobalt-Chrome, Titanium and
Inconel to its growing lineup of Direct Metal Laser
Sintering materials. This means aerospace companies
can now quickly and accurately test the properties
of actual parts before making a major investment in
full-scale, in-house production. So give us a call today.
Well help your business soar.
919-781-7702
nelineprototyping.com
Lets Talk
info@nordsonefd.com 800-556-3484
Fast and easy programming to reduce setup time
Lets Talk
about
Throughput
We know you're busy, so we'll mention three
words: accuracy, repeatability and speed. The
very things we've been obsessed with since
1963. You'll see them in every detail of the
Nordson EFD dispensing robots.
Theyre accurate
0.01 mm precision in all axes
Theyre consistent
Optional height sensors, cameras and needle
adjusters mean uniform resultseven after
tip changes
They're fast
Operating speeds of up to 800 mm/second
Easily integrated into existing assembly lines
Its been a great talk. And we know the
results will speak for themselves.
SEE IT IN ACTION AT
www.nordsonefd.com/robots-md

Machine Design May 2014 PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Machine Design May 2014 PDF

Uploaded by

Copyright:

Available Formats

machinedesign.

safety screens wont

around your pIantI

Pusc kangng Tcchnccgy

k = 0.5, 1, 1.5, ... for four stroke cycle

,HZ` [V 0U[LNYH[L 9VI\Z[ *VUZ[Y\J[PVU 5V 4HPU[LUHUJL

You might also like